SERVICE MANUAL FOR 6535 SERIES TWO TON HIGH EFFICIENCY PACKAGED HEAT PUMPS
TABLE OF CONTENTS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Accessibility Of Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Unit Dimensions And Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. ACCESSIBILITY OF APPLIANCE The accessibility of this appliance will vary from one installation to another. It shall be left to the service technicians. judgement, the best method of attaining access to perform service. 3. UNIT DIMENSIONS AND SPECIFICATIONS PACKAGE HEAT PUMP MODEL NUMBER BREAKDOWN FOLLOWS: 6 5 3 5 Revision Letter Model Series X 7 1 6 - Panasonic Compressor(s) 7 - Sanyo Compressor(s) 8 - Tecumseh Compressor(s) 4.
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6. GENERAL INFORMATION This packaged heat pump mounts below the floor of the vehicle. The innovative design makes it possible to maintain a smooth, free-flowing roof line for the vehicle. It also relocates all noise and condensate drainage off the roof to below the floor of the vehicle. 1st stage (the first compressor and refrigeration circuit), will operate when: 1) The thermostat is demanding cooling or electric heating, The heat pump contains a dual compressor system.
DEFAULT MODE: WHEN THE THERMOSTAT IS SWITCHED TO HEAT AND ELECTRIC HEAT IS SELECTED ON THE SUB-BASE, AND THE OUTDOOR TEMPERATURE FALLS TO A POINT AT WHICH THE HEAT PUMP SHUTS DOWN (USUALLY BETWEEN 25 - 40 DEGREES), THE SUB-BASE WILL AUTOMATICALLY ALSO CALL FOR GAS FURNACE OPERATION IF THE INDOOR TEMPERATURE DROPS TO 45 DEGREES. GAS FURNACE OPERATION WILL SHUT OFF AT 60 DEGREES. THE USER SHOULD SWITCH THE SUB-BASE TO GAS HEAT IF THIS OCCURS.
6535-3451 Thermostat Wiring The thermostat operation switches the 12VDC + to all output terminals 7B. THERMOSTAT - 6535-3351 COLEMAN-MACH SERIES THERMOSTAT 6335-3351 THERMOSTAT OPERATION The display indicates room temperature and the word ROOM is shown on the LCD until the temperature selector is pressed; at which time the display temporarily indicates the setpoint temperature and the word SET is shown on the LCD. Each time the UP arrow is pressed, the setpoint will increase.
6535-3351 Heat Pump Thermostat Example To Bring On Gas Furnace as 2nd Stage Heat Setpoint 70 \\\ Indoor Temp.
6535-335 2-stage Heat Pump Thermostat Operation Table Mode Switch Fan Mode Switch Fan Speed Switch Calling 1 Cool Auto Lo No 2 Cool Auto Lo Stage 1 1° Above Set ID fan low, compressor #1 and OD blower low cycle as needed 3 Cool Auto Lo Stage 2 2° Above Set ID fan low, compressors #1 & #2 and OD blower high cycle as needed 4 Cool On Lo No 5 Cool On Lo Stage 1 1° Above Set ID fan low continuous, compressor #1 and OD blower low cycle as needed 6 Cool On Lo Stage 2 2° Above S
8. A TYPICAL COOLING CYCLE OF THE HEAT PUMP Begins with a call from the wall thermostat for High or Low fan (customer choice). Compressor 2 starts, the outdoor fan goes off (subject to available 115 volt power supply). Indoor fan starts on the selected speed. Outdoor fan starts again 2 seconds later (High Speed). Within a few seconds the thermostat will call for cooling. Both systems operate to satisfy the thermostat. Compressor 1 starts. Both compressors shut off at setpoint temperature.
10A. WIREBOX COMPONENT CHECKOUT 6535 “-” Model Unit Note: The drawing above depicts a typical control box for the 6535 “-” Model Heat Pump only. Heat Pump control boxes beginning with the “A” model do not have a high pressure switch. The Heat Pump Printed Circuit Board has changed from time to time, the terminal designations and board components as noted above may have changed locations on the board. Use the above drawing only as a reference.
10B.
11. SERVICE PROBLEMS AND POSSIBLE SOLUTIONS COOLING MODE Problems Possible Solutions 1. Nothing Runs - Cooling Mode No A/C Voltage, No 12 VDC, Thermostat, Wiring, P.C. Board, High Pressure Switch Open 2. IDFM* Runs, No Compressor, No ODFM* Cooling Freeze Thermister - (Insufficient Indoor Air Flow), Thermostat, Wiring, Compressor, Contactor, P.C. Board 3. IDFM* Runs, ODFM* Runs, No Compressor Insufficient Voltage To Unit, Run Capacitor, Start Device, Overload, Wiring, Compressor 4.
12. ELECTRICAL DIAGNOSTIC FLOW CHARTS 6535 SERIES With the use of these flow charts, you will be able to quickly identify a non-working problem. Determine if the problem is high or low voltage and then solve the problem. To use these flow charts, start at the top left corner. Check what is indicated in that box. If the answer to what is indicated is No, work horizontally until you find the problem. When the answer is Yes or OK, work the chart downward until you locate the problem.
12A.
12A.1 No Cooling; Cooling Mode No Green L.E.D. light F/FY Circuit Open to The Thermostat Note: The green light on the board has some new functions on the 6535 “A” model. If the light is on solid, everything is OK. If the light is blinking slowly, the unit is in a 3 minute time delay. If the light is blinking fast, there is either no line voltage to Circuit 1 or one of the thermisters are open. If the light is not on at all there is no 12VDC power to the thermostat or the PC Board.
12A.2 No Indoor Blower Low Speed; Cooling Mode Thermostat Set To Low Cool Note: All operating functions subject to thermostat time delays. Important Notice: If the unit is equipped with a high pressure switch and this switch opens, it Opens the 12 VDC (-) negative circuit from the thermostat to the P.C. Board and all heat pump functions are dead. Be sure to correct the root problem causing the high head pressure. If any heat pump function operates, the switch is OK.
12A.3 No Indoor Blower High Speed; Cooling Mode Thermostat Set To High Cool Note: All operating functions subject to thermostat time delays. Important Notice: If the unit is equipped with a high pressure switch and this switch opens, it Opens the 12 VDC (-) negative circuit from the thermostat to the P.C. Board and all heat pump functions are dead. Be sure to correct the root problem causing the high head pressure. If any heat pump function operates, the switch is OK.
12A.4 Compressor #1 Checkout; Cooling Mode Thermostat Calling For Cooling Note: All operating functions subject to thermostat time delays Important Notice: If the unit is equipped with a high pressure switch and this switch opens, it Opens the 12 VDC (-) negative circuit from the thermostat to the P.C. Board and all heat pump functions are dead. Be sure to correct the root problem causing the high head pressure. If any heat pump function operates, the switch is OK.
12A.5 Compressor #2 Checkout; Cooling Mode Thermostat Calling For Cooling Note: All operating functions subject to thermostat time delays. Important Notice: If the unit is equipped with a high pressure switch and this switch opens, it Opens the 12 VDC (-) negative circuit from the thermostat to the P.C. Board and all heat pump functions are dead. Be sure to correct the root problem causing the high head pressure. If any heat pump function operates, the switch is OK.
12B.
12B.1 No Heating; Electric Heat Mode (Green L.E.D. Light Circuit) F/FY Circuit Open to The Thermostat Note: The green light on the board has some new functions on the 6535 “A” model. If the light is on solid, everything is OK. If the light is blinking slowly, the unit is in a 3 minute time delay. If the light is blinking fast, there is either no line voltage to Circuit 1 or one of the thermisters are open. If the light is not on at all there is no 12VDC power to the thermostat or the PC Board.
12B.2 No Indoor Blower; Electric Heat Mode Note: Only High Fan Speed Is Energized In The Heating Mode. All Operating Functions Subject To Thermostat Time Delays. Important Notice: If the unit is equipped with a high pressure switch and this switch opens, it Opens the 12 VDC (-) negative circuit from the thermostat to the P.C. Board and all heat pump functions are dead. Be sure to correct the root problem causing the high head pressure. If any heat pump function operates, the switch is OK.
12B.3 Compressor #1 Checkout; Electric Heat Mode Note: All Operating Functions Subject To Thermostat And P.C. Board Time Delays. Thermostat or Sub-base Must Be In The Electric Mode.
12B.4 Compressor #2 Checkout; Electric Heat Mode Note: All Operating Functions Subject To Thermostat And P.C. Board Time Delays. Thermostat or Sub-base Must Be In The Electric Mode. Important Notice: If the unit is equipped with a high pressure switch and this switch opens, it Opens the 12 VDC (-) negative circuit from the thermostat to the P.C. Board and all heat pump functions are dead. Be sure to correct the root problem causing the high head pressure.
12B.5 No Reversing Valve Operation Electric Heat Mode Note: All Operating Functions Subject To Thermostat And P.C. Board Time Delays. Thermostat and/or Sub-base Must Be In The Electric Mode. Note: If the Compressors or Fan Motors are not Running, Refer To Proper Checkouts. Important Notice: If the unit is equipped with a high pressure switch and this switch opens, it Opens the 12 VDC (-) negative circuit from the thermostat to the P.C. Board and all heat pump functions are dead.
12C. OUTDOOR BLOWER MOTOR; HEATING OR COOLING MODE 12C.
12C. OUTDOOR BLOWER MOTOR; HEATING OR COOLING MODE 12C.
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