Haier AC-8888-107, Service Manual

Page 1: ...1 HAIER COMMERCIAL AIR CONDITIONER Service Manual Part AC 8888 107 HAIER TRADING COMPANY LLC www haieramerica com ...

Page 2: ... compressor design Haier Hi Efficiency fin and copper tube design Compact design of outdoor unit Convenient for installation and maintenance Heat pump 10SEER Manual code SYJS AM 004 05 Rev 2 Edition 2005 03 22 Mode HR18A1VAR HR24A1VAR HR30A1VAR HR36A1VAR HR42A1VAR HR48A1VAR HR60A1VAR ...

Page 3: ...ELECTRICAL SPECIFICATIONS 5 3 SAFETY PRECAUTION 9 4 SYSTEM COMPONENTS AND FUNCTIONS 9 5 ELECTRICAL CONTROL DEVICES 11 6 APPLICATION 12 7 REFRIGERANT DIAGRAM 13 8 INSTALLATION INSTRUCTIONS 14 9 MAINTENANCE INSTRUCTIONS 31 10 SERVICE AND TROUBLESHOOTING 32 11 WIRING DIAGRAMS 43 12 EXPLOSIVE DIAGRAM AND SPARE PARTS LIST 44 ...

Page 4: ...iprocating compressors This gives the air conditioning a much more durable compressor needing less external protection while increasing the unit efficiency in cooling mode 1 2 NOMENCLATURE FOR MODEL NUMBE Example H C 24 A 1 V A R Haier System type Nominal capacity in 1000 Btuh SEER designation Design series Electric Designation Body style Reserved Brand symb ol H Haier C Air Conditioner R Heat Pum...

Page 5: ...N This deep drawn and sturdy base keeps the bottom of the coil out of harms way The base has weep holes to allow the water from rain to flow away from the unit Fig 1 4 ACCESSORIES LOW AMBIENT CONTROL This allows low temperature operation in the cooling cycle down to 0 outdoor temperature This control should be installed in units that operate in cooling in outdoor ambient temperatures below 65 and ...

Page 6: ... 0 3 1 3 0 3 1 3 3 3 4 3 2 Heating HSPF 7 0 7 0 7 0 7 0 7 0 7 0 7 0 Total Input Watts Heating 1740 0 2000 0 2581 0 3160 0 3594 0 3989 0 4800 0 Outdoor Airf low Rate CFM 1850 1850 1950 1950 2700 2900 2900 Voltage Phase Frequency Hz 208 230 1 60 208 230 1 60 208 230 1 60 208 230 1 60 208 230 1 60 208 230 1 60 208 230 1 60 Minimum Circuit Amps 10 1 12 9 16 2 19 4 21 2 31 9 37 6 The Maximum Fuse Size ...

Page 7: ... 5 5 5 8 8 Cabinet color White White White White White White White Top cov er Stamped sheet metamped sheet metamped sheet metamped sheet metamped sheet metamped sheet metamped sheet met Basepan Deep Drawn Elev at eep Drawn Elev at e ep Drawn Elev a t eep Drawn Elev at eep Drawn Elev at eep Drawn Elev at eep Drawn Elev at Serv ice panel Easy Access Easy Access Easy Access Easy Access Easy Access Ea...

Page 8: ...5 8 5 8 3 4 7 8 7 8 7 8 7 8 Max Ref rigerant Line Length Ft 115 115 115 115 115 115 115 Outdoor abov e Indoor Unit 70 70 70 70 70 70 70 Indoor abov e Outdoor Unit 50 50 50 50 50 50 50 Serv ice Valv es Re usable Re usable Re usable Re usable Re usable Re usable Re usable Ref rigerant Connection Ty pe Sweat Sweat Sweat Sweat Sweat Sweat Sweat Orif ice 074 059 Orif ice 078 068 Orif ice 078 068 Orif i...

Page 9: ... compressors but all use electricity to turn an electric motor to drive a pump Air conditioners use two types of compressors The first is the enhanced reciprocating compressor It operates with an offset crankshaft and pistons and resembles an internal combustion engine The driving force is supplied by an electric motor turning the crankshaft and forcing the pistons into the cylinders where valves ...

Page 10: ...assembly Fig4 3 METERING DEVICES Flow Check Pistons One air conditioning metering device is the flow check piston It has two functions First it acts as a refrigerant metering device controlling refrigerant flow into the evaporator Second it acts as an open check valve when refrigerant flows in the opposite direction When refrigerant enters the device from the nut end the piston seats and forces al...

Page 11: ...perate continuously by setting the thermostat subbase fan switch to the ON position PROTECTION DEVICES Protection for the unit begins with the installation of appropriate fuses or circuit breakers by the installing contractor Breaker or fuse size is governed by local codes and the National Electrical Code Current requirements for each unit are found in the unit specifications OVERLOADS AND LIMITS ...

Page 12: ...time for system pressure to equalize before re starting the compressor This relay user solid state circuitry to measure the time since the power was interrupted It is set for up to 3 minutes It is not field adjustable It is a delay on break timer Compressor relay PCB Fig 5 1 START KITS OPTIONAL This special relay uses the EMF generated by the compressor start windings to take a start capacitor out...

Page 13: ...living space Select the indoor and outdoor equipment combination based on the manufacturer s engineering data After the proper equipment combination has been selected satisfying both sensible and latent conditioning requirements the system must be properly installed Only then can the unit provide the comfort the manufacturer built into it There are several factors that installers must consider Out...

Page 14: ...upply ducts pays dividends in increased system capacity and lower operating costs Effective duct insulation is essential to prevent loss of capacity and sweating ducts in the cooling mode Duct systems installed in the conditioned space can be left uninsulated but a dense 1 2 fiberglass duct liner reduces blower and air noises and prevents sweating ducts when humidity levels are high Supply and ret...

Page 15: ...ER Cooling SERVICE VALVE SERVICE PORT DISCHARGE TEMP SENSOR INDOOR COIL DISTRIBUTOR SERVICE VALVE OUTDOOR COIL COMPRESSOR SERVICE PORT ACCUMULATOR HIGH PRESSOR LOW PRESSOR DEFROSED SENSOR CHECK VALVE ORIFICE DRYER Heating REVERSING VALVE CONDENSER EVAPORATOR REVERSING VALVE CONDENSER EVAPORATOR CHECK VALVE ORIFICE SERVICE PORT SERVICE PORT CHECK VALVE ORIFICE DISTRIBUTOR DISTRIBUTOR Commercial Air...

Page 16: ...llow these instructions may result in improper installation adjustment service or maintenance possibly resulting in fire electrical shock property damage personal injury or death This product is designed and manufactured to permit installation in accordance with National Codes It is the installer s responsibility to install the product in accordance with National Codes and or prevailing local code...

Page 17: ...leaner may be used several times a year to remove matter that will not wash off with water The best protection is frequent cleaning maintenance and minimal exposure to contaminants 8 3 INSTALLATION These units are designed for outdoor installations They can be mounted on a slab or rooftop It is important to consult your local code authorities at the time the first installation is made Check follow...

Page 18: ...sequent damage to the tubing or wiring In more confined application spaces such as corners provide a minimum of 10 clearance on all air inlet sides For service access to the compressor and control box allow 18 minimum clearance Ensure top is unobstructed If units are to be located under an overhang there should be a minimum of 36 clearance and provision made to deflect the warm discharge air out f...

Page 19: ...e installed in a cement slab as this limits access to the refrigerant should a leak be suspected To ensure good oil return to the compressor it is important to pitch the horizontal suction line toward the compressor approximately 1 2 for every 10 of line 8 6 Line Insulation Suction line requires insulation in order to prevent condensation from forming on the piping and to prevent heat gain caused ...

Page 20: ...en indoor and outdoor units are illustrated in Fig 8 2 A and Fig 8 2 B It s 70 when the indoor unit is below the outdoor unit Fig 8 3 A and 50 when the indoor unit is above the outdoor unit Fig 8 2 B To ensure good oil return to the compressor when the indoor unit is below the outdoor unit suction line oil trap should be used as illustrated in Fig 8 2 A Tubing Connections CAUTION Use extreme cauti...

Page 21: ...to 500 microns or less for a minimum of 30 minutes Close the valve to the vacuum pump and wait 15 minutes Vacuum should not rise above 800 microns If unable to obtain 500 microns or vacuum rises above 800 microns over 15 minutes period discontinue evacuation pressurize and check for leaks Repair any leaks found and repeat the step 2 3 Close valve to the vacuum pump and stop pump 4 When sure of a t...

Page 22: ...efective insulation exceeding the permissible current etc Perform electrical work according to the installation manual and be sure to use an exclusive circuit If the capacity of the power circuit is insufficient or there is incomplete electrical work it could result in a fire or an electric shock Ground the unit Do not connect the ground to a gas pipe water pipe lighting rod or telephone ground De...

Page 23: ...on the proper size for this application and the proper procedure for disconnecting power service to the unit The condensing unit control wiring requires a 24 Volt minimum 25 VA service from the indoor transformer as shown on the wiring diagram Copper Wire Size AWG 1 Voltage Drop Supply Wire Length Ft Supply Circuit Ampacity 50 100 150 200 15 14 10 8 6 20 12 8 6 4 25 10 8 6 4 30 10 6 4 4 35 8 6 4 3...

Page 24: ...Commercial Air Conditioner Model heat pump 10SEER UNITS 23 8 9 INDOOR UNIT INSTALLATION UNIT DIMENSIONS a For HB M20 air handler Fig 8 3 ...

Page 25: ...NDENSATE DRAINS UPFLOW 3 4 NPT FEMALE 1 2 54 cm 1 188 3 02 cm J INLET RIGHT SIDE VIEW LIQUID LINE SUCTION LINE A B E 0 83 2 12 cm 12 2 31 cm 0 83 2 12 cm 0 83 2 12 cm A B C D E F G H J K 53 35 22 9 23 54 25 18 9 06 83 46 5 79 22 64 19 86 3 56 135 5cm 56 1cm 59 8cm 64 0cm 23cm 212cm 14 7cm 57 5cm 50 4cm 9 05cm For HB3600VC1M25 A B C D E F G H J K 59 45 22 9 23 54 25 18 9 06 83 46 5 79 22 64 19 86 3...

Page 26: ...in an area visible to the owner This secondary drain pan is required in the event that there is a leak or main drain blockage Closed cell insulation should be applied to the drain lines in unconditioned spaces where sweating may occur Appliances installed in garages warehouses or other areas where they may be subjected to mechanical damage must be suitably guarded against such damage by installing...

Page 27: ...pan assembly with horizontal drain pan on the right side Remove oval gasket from horizontal pan drain and also remove the plastic drain cover from the lower left access panel Fig 8 5 3 Relocate horizontal pan on the left hand side of the A coil assembly 4 Knockouts are located within the drain assemblies Carefully remove only the correct knockouts using a hammer and screw driver for each applicati...

Page 28: ...o over torque screws Snap in the drain cover on the right lower service panel 7 The Air handler can now be placed in its left horizontal position as shown in Fig 2 The Air handler must be leveled and then pitched 1 4 toward drain side Important Drain pan must be tested for proper drainage by pouring water into the pan Traps must be installed on the primary drain and on the secondary drain if used ...

Page 29: ...off Then remove the horizontal and vertical drain pans The horizontal pan is not required for downfolw application 2 After removing the coil turn the Air Handler to the downflow position and relocate the 8 brackets which include 1 tie bracket 1 rear channel bracket 2 zee coil supports 2 stiffener brackets and 2 3 2 flat insulation retaining brackets In effect brackets coil and 2 lower access panel...

Page 30: ...condensate removal pump is permitted when necessary This condensate pump should have provisions for shutting off the control voltage should a blocked drain occur A trap must be installed between the unit and the condensate pump Important The evaporator coil is coated with oils that will dissolve Styrofoam and certain types of plastics Therefore a removal pump or float switch must not contain any o...

Page 31: ...to service and troubleshoot a air conditioning system a service technician must understand the unit s sequence of operation this is the order of events the system undergoes to cycle itself on and off Knowing how the units operate properly aids in determining where to start troubleshooting when the unit doesn t operate properly Where the system varies from its normal sequence is a major clue to any...

Page 32: ...s 7 This ends the 24 voltage signal to the indoor blower relay and this indoor blower strips 8 The system is now off 9 MAINTENANCE INSTRUCTIONS FILTERS WARNING DISCONNECT MAIN ELECTRICAL POWER TO THE UNIT BEFORE ATTEMPTING ANY MAINTENANCE 1 Keep the air filters clean A new home may require more frequent filter attention until dust from the construction is removed 2 Replace glass fiber filters when...

Page 33: ...NANCE ON THIS EQUIPMENT OTHER THAN THOSE PROCEDURES RECOMMENDED IN THE USER S MANUAL A FAILURE TO FOLLOW THIS WARNING COULD RESULT IN POSSIBLE DAMAGE TO THE EQUIPMENT SERIOUS TO THE EQUIPMENT SERIOUS PERSONAL INJURY OR DEATH The HVAC industry like the auto industry is faced with increasing government imposed efficiency regulations New and more sophisticated mechanical means for achieving higher ef...

Page 34: ...cian must be certificated under an approved program Failure to properly handle refrigerant may cost technician s job and also a stiff fine Up to 25 000 may be charged for a pattern of disregards concerning this very important federal law WARNING FOR YOUR OWN PROTECTION ALWAYS HAVE A RECOVERY RECYCLING DEVICE PRESENT WHEN DOING REFRIGERANT SERVICE TEST EQUIPMENT The following test equipment is reco...

Page 35: ...ns Auxiliary drain pan installed in horizontal applications Auxiliary condensate line installed in horizontal application CAPACITOR ELECTRICAL CHECK WARNING ANY CAPACITOR SHOWING SIGNS OF LEAKS OR BUDGING MUST BE REPLACED IMMEDIATEDLY DO NOT OPERATE THE COMPRESSOR WITH A CAPACITOR SHOWING THESE SIGNS Single phase compressors require a run capacitor connected to the run and start windings This puts...

Page 36: ...ce of speeds with indoor products Use an Ohmmeter to troubleshooting motors Indicator Fig 10 3 ELECTRICAL CHECKS 1 Be sure power is off to the motor 2 Disconnect the motor wires 3 Place one ohmmeter lead on common and the other on start The meter should show continuity 4 Place one ohmmeter lead on common and the other on run The meter should show continuity with less resistance 5 Leave one meter l...

Page 37: ...an ohmmeter to show open or closed contacts Fig 10 5 ELECTRICAL CHECKS 1 BE SURE ALL THE ELECTRICAL POWER IS OFF TO THE COMPONENT BEING CHECKED 2 Remove at least one wire from the component being checked 3 Measure the resistance of the holding coil with an ohmmeter A A special resistance indicates a good holding coil B Infinite resistance indicates a relay with an open holding coil REPLACE this re...

Page 38: ...e two windings are called start and run The start winding has the higher resistance and is connected in series with the capacitor The run winding has the lower resistance and connects directly to the power supply from the compressor contactor The design use a protective device called an internal overload if it detects either dangerously high amperages or temperatures in the compressor motor it ope...

Page 39: ...stem Bearing and valve failure is almost always caused by liquid refrigerant COMPRESSORS CAN ONLY PUMP REFRIGERANT VAPOR Liquid refrigerant damages the valves by deforming or breaking slugging them It damages the bearing by diluting the lubricating oil SYSTEM PUMP DOWN This procedure tests the compressor valves It can indicate internal refrigerant leaks such as through the liquid line service valv...

Page 40: ...00 90 80 70 60 50 40 35 29 4 29 1 28 5 27 7 26 6 25 1 23 0 20 2 16 6 11 9 6 1 0 6 2 6 30 25 20 15 10 5 0 5 10 15 20 25 30 4 9 7 5 10 2 13 2 16 5 20 1 24 0 28 3 32 8 37 8 43 1 48 8 54 9 35 40 45 50 55 60 65 70 75 80 85 90 95 61 5 68 5 76 1 84 1 92 6 101 6 111 3 121 4 132 2 143 7 155 7 168 4 181 8 100 105 110 115 120 125 130 135 140 145 150 196 1 210 8 226 4 242 8 260 8 278 0 297 0 316 7 337 4 359 1...

Page 41: ...mild burn out Oil with a test number greater than 0 05 indicates a serve burn out Some oil test kits indicate severity by color charge As a guide burn out classifications are as follows oil clear no color Possibly no burn out mechanical failure oil clear slight color Possibly a mild burn out oil very dirty strong odor test 0 05 severe burn out Note Dispose of any contaminated refrigerant oil in ac...

Page 42: ...rrect thermostat setting Set thermostat correctly Dirty filters Clean replace Indoor air blockage Check supply registers and return grills for blockage Blocked outdoor coil Clear away leaves and other debris Improperly sized unit Recalculate load Improper airflow Check should be 400CFM Ton Incorrect refrigerant charge Charge correctly per instruction Air non condensable or moisture in system Recov...

Page 43: ...ction in liquid line metering device or filter drier Replace defective components Flowrator piston size too small Change to correct size piston High head Low vapor pressures Incorrect capillary tubes Change coil assembly Blocked outdoor coil Clear away leaves and other debris Refrigerant overcharge Correct system charge Condenser fan not running Repair or replace High head High or normal vapor pre...

Page 44: ...D BCR 3 1 4 NO NC 2 60Hz 1PH L1 BK 208 230V BK 1 9 BR RD BK BL PU 1 1 2 2 4 4 5 5 3 3 WH 6 6 BR 3 4 BL PU WH 6 5 SW 2 ODA COOL LED RHS 2 HEAT COOL OFF OFF HEAT AUTO RHS 1 ON FAN CA TS HA SW 1 LINE VOLTAGE FACTORY STANDARD FIELD INSTALLED OPTIONAL LOW VOLTAGE FACTORY STANDARD FIELD INSTALLED Heat Pump Wiring Diagram H STRLY YL S RD C H C RCAP 5 S M R BR BR 6 OFM FL RD FL ELECTRIC HEATER KIT BK L2 R...

Page 45: ...Commercial Air Conditioner Model heat pump 10SEER UNITS 52 Sincere Forever Haier Group Haier Industrial Park No 1 Haier Road 266101 Qingdao China http www haier com ...