Applied Companies TM 55360 120

TM-55360-120
Operation &
Maintenance Manual
Rev -
16 MAY 2011
ENVIRONMENTAL CONTROL APPLIED COMPANIES

UNIT, HORIZONTAL W/ VERTICAL 28020 AVENUE STANFORD
INTAKE & DISCHARGE
VALENCIA, CA 91355-1105
120,000 BTU/HR COOLING
CAPACITY (661)257-0090
12 KW TOTAL HEATING (661)257-3770
208 VOLT, 3 PHASE, 50/60 Hz E-Mail:info@appliedcompanies.net
REFRIGERANT – R-407C CAGE Code: 54080
TABLE OF CONTENTS
LIST OF FIGURES ................................................................................................................ iv

LIST OF TABLES ....................................................................................................................v
1. INTRODUCTION ............................................................................................1
1.1 Forward .............................................................................................................1
1.2 Notice to User ...................................................................................................1
1.3 Safety Summary................................................................................................1
1.4 Warnings and Cautions .....................................................................................2
2. GENERAL INFORMATION ...........................................................................7
2.1 Equipment Description .....................................................................................7
2.2 Design Features ................................................................................................7
2.2.1 Operational .......................................................................................................7
2.2.2 Physical Characteristics ....................................................................................7
2.3 Special Features ................................................................................................8
2.3.1 Salt Spray Protection ........................................................................................8
2.3.2 Maintenance Features .......................................................................................8
2.3.2.1 Sight Glass ........................................................................................................8
2.3.2.2 Service Valves ..................................................................................................8
2.3.2.3 Diagnostic Lamps .............................................................................................8
2.3.3 Safety Features..................................................................................................9
2.3.3.1 Low/High Pressure Switches ............................................................................9
2.3.3.2 Overheat Safety Switch ....................................................................................9
2.4 Major Components ...........................................................................................9
2.4.1 Electrical Control Box and Control Panel ........................................................9
2.4.2 Evaporator Compartment................................................................................10
2.4.3 Condenser Compartment ................................................................................10
2.4.4 Filters ..............................................................................................................10
2.4.5 Lifting Eyes ....................................................................................................10
2.4.6 Flexible Air Ducts Assembly..........................................................................10
2.4.7 Power Cable Assembly ...................................................................................10
3. FUNCTIONAL DESCRIPTION ....................................................................16
3.1 Introduction.....................................................................................................16
3.2 Principles of Operation ...................................................................................16
3.3 Operational Description ..................................................................................16
4. INSTALLATION ...........................................................................................18
4.1 Environmental Control Unit Leveling ............................................................18
4.2 Ducting Installation ........................................................................................18
4.3 D-Pak Retrofit Installation ..............................................................................23
4.3.1 12” D-Pak Installation ....................................................................................23
TM-55360-120 i
Operations & Maintenance Manual
16 MAY 2011
4.3.2 18” D-Pak Installation.................................................................................... 23
5. OPERATION ................................................................................................. 24
5.1 General ........................................................................................................... 24
5.2 Controls and Indicators .................................................................................. 24
5.2.1 Electrical Control Box ................................................................................... 24
5.2.2 Control Panel ................................................................................................. 25
5.2.3 Sight Glass ..................................................................................................... 25
5.3 Operational Procedures .................................................................................. 26
5.3.1 Sequence of Operation ................................................................................... 26
5.3.2 Shutdown Procedure ...................................................................................... 26
5.3.3 Emergency Shutdown Procedure ................................................................... 27
6. TROUBLESHOOTING ................................................................................. 28
6.1 General ........................................................................................................... 28
6.2 Diagnostic Checks ......................................................................................... 30
6.2.1 Power Supply Check ...................................................................................... 30
6.2.2 Unit Voltage Check........................................................................................ 31
6.2.3 Scroll Compressor Check .............................................................................. 34
6.2.4 Use of Sight Glass.......................................................................................... 34
6.2.5 Checking Refrigerant Charge ........................................................................ 35
6.2.6 Icing or Frosting of Evaporator Coil .............................................................. 36
7. MAINTENANCE .......................................................................................... 37
7.1 Maintenance Instructions ............................................................................... 37
7.2 Cleaning Procedures ...................................................................................... 40
7.2.1 Evaporator Coil Cleaning .............................................................................. 40
7.2.2 Condenser Coil Cleaning ............................................................................... 40
7.3 Repair Procedures .......................................................................................... 40
7.3.1 Major Overhaul .............................................................................................. 41
7.3.2 Field Repairs .................................................................................................. 41
7.3.2.1 Leak Detection ............................................................................................... 41
7.3.2.2 Leak Repair .................................................................................................... 43
7.4 Attaching Manifold Hose to Schrader Valve ................................................. 45
7.5 Evacuation Procedure .................................................................................... 45
7.6 Charging Procedure ....................................................................................... 46
7.6.1 Preliminary Charging Steps ........................................................................... 46
7.6.2 Charging the System by Weight .................................................................... 47
7.7 Component Replacement Procedures ............................................................ 48
7.7.1 General ........................................................................................................... 48
7.7.2 Compressor .................................................................................................... 49
7.7.2.1 Compressor Burn-Out Cleanup Procedure .................................................... 50
7.7.3 Thermostat Knob ........................................................................................... 51
7.7.4 System ON/OFF Switch S1 HEAT/FAN/COOL Switch S7 ......................... 51
7.7.5 Indicator Lamp, Green ................................................................................... 52
ii TM-55360-120
16 MAY 2011
7.7.6 Switch, Thermostat S8 Switch, Safety Thermostat .......................................52
7.7.7 Switch, High Pressure S3 Switch, Low Pressure S4 ......................................53
7.7.8 Timer TM1, TM2............................................................................................54
7.7.9 Socket, Timer ..................................................................................................54
7.7.10 Contactors K1 to K4 .......................................................................................55
7.7.11 Relays, Time Delay TD1 to TD4 ....................................................................55
7.7.12 Relay, DPDT R1 .............................................................................................56
7.7.13 Transformer T1 ...............................................................................................56
7.7.14 Terminal Block TB1 .......................................................................................57
7.7.15 Terminal Block TB2 .......................................................................................57
7.7.16 Indicator Lamps, Green, Amber and Red .......................................................57
7.7.17 Switch, Fan Cycle S2......................................................................................58
7.7.18 Switch, Differential Pressure S10 ...................................................................59
7.7.19 Switch, Head Pressure ....................................................................................59
7.7.20 Switch, Current Sensing Relay .......................................................................60
7.7.21 Heater HR1 .....................................................................................................60
7.7.22 Valve, Service Port and Cap P1, P2 ...............................................................61
7.7.23 Filter/drier F1 ..................................................................................................62
7.7.24 Receiver, Refrigeration FC1 ...........................................................................62
7.7.25 Sight Glass D1 ................................................................................................63
7.7.26 Valve, Thermo Expansion TXV1 ...................................................................64
7.7.27 Coil, Condenser ..............................................................................................64
7.7.28 Coil, Evaporator E1 ........................................................................................65
7.7.29 Motor, Evaporator Fan B2 Motor, Condenser Fan B3 ...................................66
7.7.30 Filter, Return Air ............................................................................................67
7.7.31 Filter, Fresh Air ..............................................................................................68
8. PARTS LIST ..................................................................................................69
9. APPENDIX.....................................................................................................85
9.1 Appendix Contents .........................................................................................85
TM-55360-120 iii
16 MAY 2011
LIST OF FIGURES
Figure 2-1 Major Components (Curbside)............................................................................ 11

Figure 2-2 Major Components (Roadside, Forward)............................................................ 12
Figure 2-3 Major Components (Roadside, Aft) .................................................................... 13
Figure 2-4 Major Components (Fresh Air Filter) ................................................................. 14
Figure 4-1 Duct Attachment, Open ....................................................................................... 19
Figure 4-2 Duct Attachment, Closed .................................................................................... 20
Figure 4-3 Typical Duct Deployment (ECU Shown Mounted On a Trailer) ....................... 21
Figure 4-4 Correct Bending of Ducts.................................................................................... 22
Figure 6-1 Power Distribution Block TB1 ........................................................................... 30
Figure 6-2 Contactor K1 ....................................................................................................... 32
Figure 6-3 Transformer T1 ................................................................................................... 33
Figure 8-1 Compressor Compartment Components ............................................................. 73
Figure 8-2 Condenser Side Components, Forward ............................................................... 74
Figure 8-3 Condenser Side Components, Aft ....................................................................... 75
Figure 8-4 Evaporator Side Components, Aft ...................................................................... 76
Figure 8-5 Evaporator Side Components, Aft, Detail........................................................... 77
Figure 8-6 Evaporator Side Components, Forward .............................................................. 78
Figure 8-7 ECU Roadside ..................................................................................................... 79
Figure 8-8 Electrical Control Box......................................................................................... 80
Figure 8-9 ECU Control Panel.............................................................................................. 81
Figure 8-10 ECU Control Panel Box (Panel Removed) ....................................................... 82
iv TM-55360-120
16 MAY 2011
LIST OF TABLES
Table 2-1 Environmental Control Unit and Accessories ........................................................ 9

Table 2-2 Safety and Control Components Description ....................................................... 15
Table 6-1 Troubleshooting ................................................................................................... 28
Table 6-2 Troubleshooting (Continued) ............................................................................... 29
Table 7-1 Preventive Maintenance Checks and Services (PMCS) ....................................... 38
Table 7-2 Preventive Maintenance Checks and Services (PMCS) (Continued) .................. 39
Table 8-1 Environmental Control Unit Parts List................................................................. 69
Table 8-2 Environmental Control Unit Parts List (Continued) ............................................ 70
Table 8-3 Electrical Control Enclosure Assembly Parts List ............................................... 71
Table 8-4 GETT 1C Electrical Control Box Assembly Parts List........................................ 72
Table 8-5 Flexible Air Ducts Assembly, Base 25’ Set Parts List (PN 51983-1).................. 72
Table 8-6 Flexible Air Ducts Assembly, Add On 25’ Set Parts List (51983-2) ................... 72
Table 8-7 Recommended Common Support Tools and Equipment ..................................... 83
Table 8-8 Expendable and Durable Items List ..................................................................... 84
Table 9-1 Refrigerant Temperature/Pressure Chart .............................................................. 86
TM-55360-120 v
16 MAY 2011
1. INTRODUCTION
1.1 Forward
This air conditioner system is a custom environmental control unit (ECU) designed for
installation on a mobile utility trailer. It will provide years of trouble-free service if installed,
operated, and maintained in accordance with this manual. This manual provides user level
maintenance information for operation, servicing, troubleshooting, and repair of the system.
Damage to the unit from improper installation, operation, or maintenance is not covered by
the warranty.
Study the instructions contained in this manual. They must be followed to avoid difficulties.
Spare parts are available from Applied Companies and it is the responsibility of the user to
maintain the recommended inventory of spare parts to insure continuous unit operation.
Using substitute parts, or bypassing electrical or refrigeration components is not
recommended and will VOID THE WARRANTY.
1.2 Notice to User
This is an Environmental Control Unit (ECU); it incorporates several self-contained safety

and control features that are factory set and MUST NOT BE ADJUSTED. ANY
ADJUSTING OF CONTROL DEVICES WITHOUT APPLIED COMPANIES’
APPROVAL WILL VOID THE WARRANTY. Due to the extended range of operating
temperatures, this ECU incorporates a compressor unloader. Air temperature is controlled
via the monitoring of the return air temperature, which in turn controls the unloading of the
compressor. Safety thermostat switches are installed to prevent icing on the evaporator coil
in the event the return air falls below a predetermined set point. These safety switches do not
affect the normal operation of the ECU, and the factory settings must not be altered. The
ECU’s manually adjusted thermostat provides a limited range of operator adjustment and
must not be forced beyond its stop. This ECU uses R-407C refrigerant; the refrigerant
charge is based on weight and must not exceed the weight specified on the ECU data plate.
Paragraph 5.2.3 and Paragraph 6.2.4 provide an explanation of how a sight glass functions
and how it helps the user determine if the ECU’s refrigerant charge is accurate.
1.3 Safety Summary

Thoroughly read all instructions in this manual prior to operating or servicing this ECU.
Carefully read and understand all notes, cautions, and warnings contained in this manual that
pertain to the intended task.
TM-55360-120 1
16 MAY 2011
WARNING
This note alerts the operator of hazardous conditions that may result in injury or
death.
CAUTION
This note warns operator of situations that could result in damage to the equipment.
Never operate the ECU with any cover, screen, or panel removed unless specified by the
instructions in this manual. When required to operate the ECU with any cover, screen, or
panel removed, do so with extreme caution and follow all procedures as outlined in the
safety summary.
1.4 Warnings and Cautions

The following is a condensed list of WARNINGS and CAUTIONS that are noted
throughout this manual. All personnel operating, servicing, and maintaining this ECU
should read and understand these WARNINGS and CAUTIONS.
NOTE
Use of Term:
The following definitions apply to words “Must”, “Shall”, “Will”, and “May”:
 Must, Shall, and Will – Used to indicate mandatory requirements.
 May – Indicates an acceptable or suggested means of accomplishment.
WARNING
When possible, disconnect input power to ECU before performing any maintenance
to electrical system. Voltages used can be deadly. Shutting unit off at the control
panel DOES NOT disconnect power to various components of the ECU.
2 TM-55360-120
16 MAY 2011
WARNING
HIGH VOLTAGE is used in the operation of this equipment. Death on contact or
severe injury may result if you fail to observe safety precautions. Always disconnect
the ECU from the power source before working on it. Do not operate the ECU
without panels and grilles in place and tightly secured.
WARNING
REFRIGERANT UNDER PRESSURE is used in the operation of this equipment.
Death on contact or severe injury may result if you fail to observe safety precautions.
Never use a heating torch on any part that contains refrigerant. Do not let liquid
refrigerant touch you and do not inhale refrigerant gas.
WARNING
ROTATING FAN BLADES are used in this equipment. Severe injury on contact
may result if you fail to observe precautions. Always disconnect power source before
working on fans. Do not operate fans without panels and grilles in place and secured.
WARNING
DANGEROUS CHEMICAL, Refrigerant R-407C HCFC is used in this equipment.
WARNING
Do not allow anyone under equipment suspended from a sling device. Do not allow
unit to swing while suspended from a sling device. Failure to observe warning may
result in serious injury to personnel and damage to equipment.
TM-55360-120 3
16 MAY 2011
WARNING
DEATH OR SERIOUS INJURY may result if personnel fail to observe safety
precautions.
 Great care must be exercised to prevent liquid refrigerant, or refrigerant gas
discharged under high pressure, from coming into contact with any part of
the body. Extremely low temperature resulting from rapid expansion of
liquid refrigerant, or refrigerant gas discharged from under high pressure,
can cause sudden and irreversible tissue damage through freezing.
 All personnel must wear thermal protective gloves and a face shield or
goggles when working in any situation where refrigerant contact with skin or
eyes is possible. Application of excessive heat to any component in a charged
system will cause extreme pressure that may result in a rupture, possibly
explosive in nature.
 Exposure of certain Chlorofluorocarbon (CFC) and Halogenated

Chlorofluorocarbon (HCFC) refrigerants to extreme heat or a very hot
surface will cause a chemical reaction in the gas to form carbonyl chloride
(phosgene), a highly poisonous and corrosive gas.
 Generally, in their natural states, CFC and HCFC refrigerants are colorless,
odorless vapors with no toxic characteristics are heavier than air, and will
disperse rapidly in a well-ventilated area. However, in an unventilated area,
these refrigerants present a danger as an asphyxiate by displacing oxygen in
the area.
WARNING
Allow heaters to cool before touching. Severe burns can result from touching hot
elements.
WARNING
Compressed air used for cleaning purposes should not exceed 30 psig (2.1 kg/cm2).
Do not direct compressed air against skin. Use goggles or a full-face shield.
4 TM-55360-120
16 MAY 2011
WARNING
Heater elements present an ELECTRICAL SHOCK HAZARD, 120/208 VAC. Keep
hands away from heater coils when ECU is in the heat mode. Failure to observe this
warning could result in serious burns or death.
CAUTION
Do not use steam, open flame, heat gun, or any other source of concentrated heat to
thaw an iced evaporator coil. Thaw an iced coil by one of the following methods,
which best suits the conditions:
1. Operate the unit in a high heat mode (unless coil is more than 50% iced over).
Air must be able to circulate through the coil.
2. Use a lamp bulb of 75 watts maximum. Heat from the operating bulb will
thaw the coil. Protect the bulb and electrical connection from dripping water.
3. Use a commercial hair dryer or an electrical fan to blow air at the coil.
4. Shut the unit down until the ice has melted.
5. Run vent fan only until coil is defrosted
WARNING
Be sure the refrigeration system is fully discharged and purged by running dry
nitrogen through the system at a rate of not less than 1-2 cfm before brazing or
de-brazing operations.
CAUTION
Do not energize the ECU unless the condensate drains have been equipped with a
“p-trap” of at least 5 inches (20 mm) to prevent air, water, and other debris from
being drawn back into the ECU.
TM-55360-120 5
16 MAY 2011
CAUTION
Restrictive or kinked ductwork, high-pressure drop air filters, supply and return
vents blocked by equipment, diverters, etc. Will reduce air volume and cooling
capacity.
Placement of supply air vents too close to the return will cause cold air to feed
directly back through the return; this will cause the compressor to unload as it
senses the demand for cooling has been satisfied.
To insure proper operation and full capacity, the condenser air intake and discharge
openings must be completely free of obstructions.
Consult factory for no cost engineering assistance.
6 TM-55360-120
16 MAY 2011
2. GENERAL INFORMATION
2.1 Equipment Description

The ECU is a packaged system designed to operate on a mobile utility trailer, providing
conditioned air to a shelter via ducting. The ECU is controlled by a built-in control box on
the ECU. The ECU operates using 208VAC (180V to 255V), 3-phase, 50/60 Hz power
supplied by a trailer-mounted generator or shore power via an auxiliary power plug located
on the ECU. The refrigeration system uses R-407C refrigerant and has a cooling capacity of
120,000 Btu/hr. The heating system is comprised of a 10kW resistive-type heater. Fan motor
heat contributes an additional 2kW to the heat output.
2.2 Design Features
2.2.1 Operational
Capacity .................................................................................. 120,000 Btu/hr

Nominal Air Flow ................................................................... 3,800 CFM
Heating Capacity..................................................................... 12.00 kW, 208 VAC, 3 Phase
Maximum Design Ambient Temperature ............................... 131° F (55° C)
Minimum Design Ambient Temperature ................................ -40° F (-40 C)
Minimum Ambient Cooling.................................................... to +50° F (10 C)
Minimum Ambient Heating .................................................... to –40° F (-40 C)
Maximum Storage Temperature ............................................. 160° F (71 C)
Minimum Storage Temperature .............................................. –40° F(-40 C)
Refrigerant .............................................................................. R-407C, 12 lbs., 10 oz.
2.2.2 Physical Characteristics
Height...................................................................................... 39.00 (990.6 mm)

Width ...................................................................................... 78.00 (1981 mm)
Depth....................................................................................... 34.00 (863.6 mm)
Weight..................................................................................... 690 lbs (312.98 kgs)
Finish ...................................................................................... Polyurethane Chemical
Agent Resistant Coating
(CARC) Paint per
MIL-C-53039A
TM-55360-120 7
16 MAY 2011
2.3 Special Features
2.3.1 Salt Spray Protection

The cabinet is constructed of welded aluminum and aluminum alloy sheet, primed and
painted in accordance with (IAW) the specification. All external hardware and all internal
hardware are stainless steel or have been protected against corrosion IAW the specification.
The condenser coil is constructed from aluminum tubes and aluminum fins. The evaporator
coil is constructed from copper tubes and aluminum fins. Both the condenser coil and the
evaporator coil are coated with a protective TefloncoatingThe steel motor shafts are
coated with molycoat (molybdenum disulfide).
2.3.2 Maintenance Features
2.3.2.1 Sight Glass

A sight glass with a moisture indicator is provided to detect any contamination in the
refrigeration circuit and low refrigerant levels. This feature is located on the curb side of the
ECU. Refer to Paragraph 5.2.3 and Paragraph 6.2.4 for a detailed description of the sight
glass and how to use it.
2.3.2.2 Service Valves

Suction and discharge service Schrader valves have been provided to enable servicing of the
ECU. These features are located on the curb side of the ECU.
NOTE
All major components are easily accessible for ease of maintenance.
2.3.2.3 Diagnostic Lamps

The ECU is also equipped with a series of diagnostic lamps located on the electrical panel.
These are intended to assist the operator in quickly locating and correcting any potential
problems. Refer to Paragraph 5.2.1 for detailed information.
8 TM-55360-120
16 MAY 2011
2.3.3 Safety Features
2.3.3.1 Low/High Pressure Switches

Low and high-pressure switches are provided. They are factory set for the application. The
low-pressure switch will disengage control power to the compressor contactor if suction
pressure drops below a specific pressure. The high-pressure switch will shut off the
compressor if the discharge pressure rises above a specific pressure and requires a manual
reset of the safety switch. The manual reset switch is located in the electrical controls panel
of the ECU. These pressure switches are installed as safety devices and will help prevent
compressor failure or other serious damage to the system components.
2.3.3.2 Overheat Safety Switch

The ECU heater section is equipped with an overheat safety switch. If the temperature
should exceed the set point of the switch (140°F (60°C)), it will remove power to the heater.
2.4 Major Components

Major components for the ECU listed in Table 2-1 are detailed in Paragraph 2.4.1 through
Paragraph 2.4.7 and illustrated in Figure 2-1 through Figure 2-14. Safety and control
components are detailed in Table 2-2.
Table 2-1 Environmental Control Unit and Accessories
NOMENCLATURE PART NUMBER
ENVIRONMENTAL CONTROL UNIT 55360
FLEXIBLE AIR DUCTS ASSEMBLY, 50 ft OR 25 ft (15.24 or 51983 or 51983-1

7.6 m) SET
ECU MAIN POWER ASSEMBLY 52594
LOAD SHED CABLE ASSEMBLY 51865
2.4.1 Electrical Control Box and Control Panel

All of the major electrical control components are mounted in a control box on the end of
the ECU in the compressor compartment. A control box, located on the lower left rear
(evaporator end) is furnished with a hinged door for easy access, and is weather sealed. The
controls and electrical components are physically separated for safety.
TM-55360-120 9
16 MAY 2011
2.4.2 Evaporator Compartment
Contains the evaporator coil, expansion valve, motor, blower, and some refrigeration
components. Access to the compartment is gained by removing cover panels on the front,
rear, and/or top of the unit. Service access is provided by loosening ten (10) ¼-turn DZUS
fasteners securing the side access panel. The evaporator compartment cleanout drain plug is
accessed through this panel. The drain plug should be installed when operating the ECU.
2.4.3 Condenser Compartment

Contains the condenser fan, motor, compressor, and service features. Access to the
compartment is gained by removing cover panels on the end, sides, and/or top of the unit.
2.4.4 Filters
The air conditioner contains a return air filter located in the return air plenum. Access to the
return air filter is gained by removing the filter cover plate on the side of ECU return air
plenum. The ECU also contains a fresh air filter, located on the forward side of the
evaporator compartment. Access to the fresh air filter is gained by removing the fresh air
filter cover.
2.4.5 Lifting Eyes

The ECU is equipped with four (4) shoulder pattern lifting eyes, located at each corner. The
lifting eyes have a load rating of 1800 lbs (816 kg) each and are provided for vertical and
angled lifting applications up to a maximum of 45 degrees. Eyebolt shoulder must be
installed flush with the mounting surface. Workload limits are based on a straight vertical
lift and are to be used as a guide only. Lifting at an angle significantly reduces the workload
limit. Lifting at 45 degrees reduces the workload limit by 75% 450 lbs (205 kg) per lifting
eye).
2.4.6 Flexible Air Ducts Assembly

Supply (conditioned) and return air is provided to the shelter via a flexible ducting kit. The
ducts are provided in a 12-inch diameter by 25 ft (7.6 m) length for the supply air, and 18-
inch diameter by 25 ft (7.6 m) length for the return. The kit is made up of four (4) 12-inch
ducts and two (2) 18-inch (452.2 mm) ducts for a total ECU to shelter duct length of 50-feet
(15.24 m); Two (2) 12-inch (304.8 mm) duct covers; one (1) 18inch (452.2 mm) duct cover;
and a cover-net for the 18-inch (452.2 mm) return duct (to keep large debris out of the duct).
Each duct is equipped with an over-center clamping mechanism encased in the soft collar,
helical wear strips, and an integral storage bag with draw rope closure.
2.4.7 Power Cable Assembly

Main power to the ECU is provided via a weatherproof, jacketed cable with a Military
Standard (MS) connector.
10 TM-55360-120
16 MAY 2011
Figure 2-1 Major Components (Curbside)
TM-55360-120 11
16 MAY 2011
Condenser Air Exhaust
(On Top)
Supply Air Ducts

(Covered), 12”
Air Lift
Protection Skids
Condenser
Compartment
Evaporator
Compartment Return Air
Fresh Air
Flange, 18”
Filter
Return Air
Plenum
Return Air Filter
(Inside Plenum)
Figure 2-2 Major Components (Roadside, Forward)
12 TM-55360-120
16 MAY 2011
Figure 2-3 Major Components (Roadside, Aft)
TM-55360-120 13
16 MAY 2011
Fresh Air
Filter Cover
ECU Fresh Air

Retaining Filter
Screws
Fresh Air
Filter Bracket
Access Cover Return Air

Filter Access
Figure 2-4 Major Components (Fresh Air Filter)
14 TM-55360-120
16 MAY 2011
Table 2-2 Safety and Control Components Description
CONTROL FUNCTION
Filters impurities and absorbs moisture from liquid
FILTER/DRIER
refrigerant.
Provides means to monitor system charge,
SIGHT GLASS (S/G)
contamination, and operation.
High Pressure Switch (HPS) set to break on excess
HIGH PRESSURE SWITCH (HPS)
refrigeration system pressure (manual reset).
Shuts down the AC when refrigeration system
LOW PRESSURE SWITCH (LPS)
pressure falls too low. Equipped with automatic reset.
SOLENOID VALVE Cycle for temperature control.
COMPRESSOR UNLOADING VALVE For temperature control.
High Limit Trip Switch (HLS) set to break on electric

HEATER SAFETY SYSTEM
heater temperature rising above 140° F (60 C).
HIGH SIDE SERVICE VALVE To service unit.
LOW SIDE SERVICE VALVE To service unit.

System ON/OFF power switch,
HEAT/FAN/COOL mode selection switch,
CONTROL PANEL
LOADSHED ON/OFF
WARMER/COOLER temperature control knob.
TIME DELAY RELAY Prevents compressor from short-cycling.
TEMPERATURE CONTROL Thermostat.
THERMOSTATIC EXPANSION TXV set to maintain superheat of 10 – 15°F

VALVE (TXV) (-12 – -9.4°C).
COMPRESSOR Digital Scroll type.
Aluminum construction throughout, Teflon coated
CONDENSER COIL
for corrosion protection.
Copper tubing and aluminum fins, Teflon coated for
EVAPORATOR COIL
corrosion protection.
Works off system pressure to turn condenser fan ON
FAN CYCLE SWITCH
and OFF as required to maintain head pressure.
DIAGNOSTIC LAMPS Assist in operator identification of potential problems.
TM-55360-120 15
16 MAY 2011
3. FUNCTIONAL DESCRIPTION
3.1 Introduction
This chapter describes the functions of the ECU system in the cooling and heating modes, as
well as the operation of the refrigeration, heating, and electrical sub-systems.
3.2 Principles of Operation

The refrigeration system is a closed-loop circuit in which refrigerant is continuously
re-circulated by the pressure differential created by the compressor.
The compressor maintains high side condensing pressure, and the thermostatic expansion
valve separates the high-pressure side from the low-pressure side at the evaporator coil inlet.
The compressor is designed to increase refrigerant pressure (temperature) to a level high

enough for it to be cooled and condensed into liquid by the ambient air being drawn over the
condenser coil. The thermostatic (liquid) expansion valve is a pressure-reducing device
which meters high-pressure refrigerant into the low pressure evaporator coil at the amount
required. The high-pressure liquid refrigerant is forced out of the sub-cooler as a result of
the pressure differential created by both the compressor and the liquid expansion valve. It
flows through the sight glass, a device for visual inspection of the refrigerant, and continues
through the filter/drier, where moisture and other impurities are removed.
The liquid then flows through the thermostatic expansion valve, which meters the high
pressure liquid into the low pressure refrigerant circuit. The liquid then enters the low
pressure side of the circuit; it flows through the evaporator coil, boils by absorbing the latent
heat of vaporization at this low pressure, and evaporates into a low pressure (and low
temperature) gas. Heat from the surrounding air is extracted through the finned tubing of the
coil by the refrigerant. The gas then returns to the compressor, where it is compressed and
forced into the condenser coil. At this point, the high pressure (and high temperature) gas is
condensed into high pressure liquid. Ambient air drawn over the condenser coil extracts the
heat at the higher pressure from the refrigerant, causing condensation. The high pressure
liquid flows from the condenser coil, thus completing the cycle.
3.3 Operational Description

 Evaporator fan motor circulates air.
 Compressor starts after three (3) minute time delay. Time delay protects the
compressor from cycling on and off too quickly.
16 TM-55360-120
16 MAY 2011
 The Compressor takes low pressure, low temperature gas and compresses it to a
high temperature, high pressure gas.
 The refrigerant then flows to the condenser coil. The condenser fan draws outside
ambient air in and through the fins of the condenser coil. The high temperature,
high-pressure gas from the compressor is cooled by the flow of air over the
condenser coil and is changed into a lower temperature, high pressure liquid.
 The refrigerant then flows through the receiver and through the liquid/vapor sight
glass. This device indicates the presence of moisture and state of refrigerant in
the system.
 The refrigerant filter/drier removes moisture (water vapor) or impurities that may
be carried by the liquid refrigerant.
 The expansion valve senses the temperature of the refrigerant as it leaves the
evaporator coil. By use of a sensing bulb and an external equalizer line, the valve
constantly adjusts the flow of liquid refrigerant to the evaporator coil.
 As the liquid refrigerant leaves the expansion valve, it passes through a

distributor and distribution tubes and enters the evaporator coil as a low-pressure
saturated vapor. Warm air being drawn across the fins and tubes of the coil
causes the refrigerant to boil and change to a gas (vapor). The evaporator fan
draws the warm air from the conditioned space through the evaporator coil. As
the air from the conditioned space comes in contact with the evaporator coil, the
air is cooled and de-humidified.
 The refrigerant gas is then drawn back to the compressor and the cycle is
repeated.
TM-55360-120 17
16 MAY 2011
4. INSTALLATION
4.1 Environmental Control Unit Leveling

When preparing the ECU for operation, ensure the ECU is level within +/- 10 degrees.
4.2 Ducting Installation
CAUTION
Both sets of ducts must be in place before operating the ECU. Operating the ECU
without ducting may damage the equipment.
CAUTION
When installing flex duct, observe the following guidelines/precautions:
 Take care to avoid dips, sags, and bends as much as possible, since poorly
installed ductwork will reduce performance of the heating, cooling, or
ventilation system. This is particularly important with longer duct runs, as
flex duct has twice the resistance to air flow compared to rigid duct.
 Always opt for the minimum length of flexible duct. Any necessary bends
should be made with not less than one duct diameter centerline radius.
Ducting should extend a few inches beyond the end of a sheet metal
connection before bending. When bending the duct, be careful not to
compress it.
a. Attach ducting to the return and supply air flanges. As needed, adjust fit of duct
end over flange using duct clamp force adjustment screw.
(See
Figure 4-1 and Figure 4-2)
b. Stretch duct to its full length so air passages are as smooth as possible. Ensure
ducts are free of kinks and other obstructions, and are placed to prevent short-
cycling (air flowing directly from supply air into return air duct).
(See Figure 4-3)
c. Make all bends gradual—not less than one duct diameter centerline radius—so
air flow is not restricted. (See Figure 4-4)
18 TM-55360-120
16 MAY 2011
d. Make connections between sheet metal and flex ducts with metal or nylon
clamps.
e. Support flex duct so it does not sag (restricting airflow), using supports at least
one inch wide.
Figure 4-1 Duct Attachment, Open
TM-55360-120 19
16 MAY 2011
Figure 4-2 Duct Attachment, Closed
20 TM-55360-120
16 MAY 2011
Figure 4-3 Typical Duct Deployment (ECU Shown Mounted On a Trailer)
TM-55360-120 21
16 MAY 2011
Figure 4-4 Correct Bending of Ducts
22 TM-55360-120
16 MAY 2011
4.3 D-Pak Retrofit Installation
4.3.1 12” D-Pak Installation
a. Attach o-ring to duct.
b. Attach duct flange adapter. As needed, adjust fit of duct flange adapter over duct
flange using three (3) pan head screws, three (3) spring lock washers and three
(3) flat washers.
c. Attach duct adapter cover to adapter flange.
4.3.2 18” D-Pak Installation
a. Attach universal base. As needed, adjust fit of universal base over duct flange
using six (6) pan head screws, six (6) spring lock washers and six (6) flat
washers.
b. Attach o-ring to duct.
c. Attach duct adapter cover to adapter flange.
TM-55360-120 23
16 MAY 2011
5. OPERATION
5.1 General
This section will provide operational instruction for the 55360 120k Btu/hr Horizontal
Environmental Control Unit. Review and understand these instructions before operating the
unit.
5.2 Controls and Indicators
5.2.1 Electrical Control Box

Refer to Table 8-3 and Figure 8-8 for the arrangement and identification of the electrical
control components. The electrical control box contains the following indicators:
 COOL MODE TIME DELAY (Green) – ON when cooling system

(compressor) is in three (3) minute time delay. Time delay engages when
COOL mode is selected by mode switch (HEAT/FAN/COOL toggle). Time
delay allows pressure to equalize before energizing compressor. This is a
protection device for the compressor to prevent short-cycling. DOES NOT
INDICATE A FAULT.
 LOAD SHED ACTIVE (Green) – ON if refrigerant pressure at output of

compressor or overall current is too high. May indicate an over charge of
refrigerant or blocked condenser coil.
 HIGH PRESS FAULT (Red) – ON if refrigerant pressure at output of

compressor is too high. May indicate an over charge of refrigerant or blocked
condenser coil. High Pressure cut-out switch requires a manual reset.
 LOW PRESS FAULT (Red) – ON if refrigerant at input of compressor is too

low. Indicates a possible leak in the refrigerant system, iced evaporator coil, or
insufficient airflow (evaporator fan rotating backward). Lamp turns OFF when
pressure rises.
 AIR PRESS FAULT (Red) – Normally OFF, monitored by air differential

switch. ON indicates a fault resulting from: Fan rotating backward; restrictive
ductwork, including kinked air ducts or other blockage; or dirty air filter.
 LOW TEMP FAULT (Red) – Normally OFF, unless temperature falls below
56° F (13.3 C). Compressor will not start, and lamp illuminates. DOES NOT
INDICATE A FAULT.
24 TM-55360-120
16 MAY 2011
5.2.2 Control Panel
Refer to Table 8-4 and Figure 8-1 for the arrangement and identification of the ECU
controls. The ECU control panel contains the following switches and indicators:
 ON/OFF Switch - An ON-OFF toggle, this system power switch turns on power
to the ECU. In the ON position, all functions of the ECU will be available.
 SYSTEM ON Indicator (Green) – System power indicator is ON when power is

applied to the ECU.
 LOAD SHED ACTIVE (Green) – Senses available power with which to run the
air conditioner and places the air conditioner in a subordinate position to the
critical electronics by limiting its cooling performance during peak power
demands. It also reduces air conditioner power consumption.
 HEAT/FAN/COOL Switch- An ON-OFF-ON toggle, this switch selects the

operating mode for the ECU.
 Cool Mode - Compressor runs continually and the thermostat will cycle the
compressor solenoid valve for temperature control.
 Fan Mode - Evaporator fan will run continually for air circulation. No heating
or cooling will take place.
 Heat Mode - Thermostat will cycle the heater for temperature control.
 WARMER/COOLER Knob - This thermostat control knob allows user to control

air temperature from the ECU over a temperature range of 65° F to 100° F
(18.3 to 37.8 C).
5.2.3 Sight Glass

Refer to Table 8-1 and Figure 8-1 for part number and location of the sight glass. The sight
glass has a color-coded moisture indicator:
Green = Dry system
Yellow = Wet (water is present in the system)
The sight glass moisture indicator MUST be green before operating the system.
TM-55360-120 25
16 MAY 2011
5.3 Operational Procedures
CAUTION
Always ensure the top condenser air intake and exhaust panels are unobstructed
prior to operation. The ECU will not function if these mesh panels are obstructed
(refer to Figure 2-3).
CAUTION
Always verify proper phasing when applying power to the ECU (ABC).
5.3.1 Sequence of Operation

a. Verify ON/OFF switch is in the OFF position.
b. Verify 208 VAC, 3 Phase, 50/60 HZ power to air conditioner.
c. Select mode option for ECU.

 HEAT mode furnishes heat controlled by the thermostat.
 FAN mode circulates air without heating or cooling.
 COOL mode selects cooling as required by the thermostat. The compressor
will run continually.
d. Turn ON/OFF switch to ON.
NOTE:
The compressor is protected by a time delay relay and will energize after the three (3)
minute delay has been satisfied.
5.3.2 Shutdown Procedure

a. Turn ON/OFF switch to OFF.
b. Verify fan and compressor stop.
26 TM-55360-120
16 MAY 2011
5.3.3 Emergency Shutdown Procedure
a. Turn ON/OFF switch to OFF.
b. Disconnect ECU power cable or turn OFF power supply.
TM-55360-120 27
16 MAY 2011
6. TROUBLESHOOTING
6.1 General
The following table provides the technician with a basic guide to troubleshoot common
problems with the ECU. While this table is not intended to be all-encompassing, it does list
the more common problems that may be encountered along with the possible causes and the
suggested remedies. Refer to Paragraph 5.2.1 for use of diagnostic lamps.
Table 6-1 Troubleshooting
Symptom Possible Cause Remedy

ECU fails to Incorrect voltage. Correct voltage.
start.
Power failure. Check power source, power input,
and circuit breaker. Check control
cables and connections.
Compressor Defective contactor. Repair or replace. Check for
fails to start. overload.
Head pressure too high (high pressure Reset high pressure switch. Check
switch open). for condenser blockage. Check
condenser fan motor contactor (K2).
Loss of refrigerant (low pressure switch Repair leak, recharge system.

open).
Defective time delay relay. Replace relay.
Defective compressor. Replace compressor.

Noisy Worn or failed compressor bearings Replace compressor.
compressor. (indicated by excessive knocking).
Compressor running backward. Check line power phasing.

No condenser Overload trip. Determine cause and repair.
airflow.
Defective head pressure fan switch. Replace switch.
Defective Thermal cut-out switch Replace switch.

(TCO).
28 TM-55360-120
16 MAY 2011
Table 6-2 Troubleshooting (Continued)
Symptom Possible Cause Remedy

Head pressure Low condenser airflow (indicated by Open air passages. Clean coil. Check
too high. excessively warm air leaving the condenser fan(s).
condenser fan).
Air or other non-condensable gas in Reclaim system and recharge. Install

system. new filter/drier.
Over charge of refrigerant. Reclaim excess refrigerant from unit.

Head pressure Loss of refrigerant (indicated by Repair leak and recharge system.
too low. bubbles in the sight glass).
Cold ambient temperature. Pressure will come up as temperature

increases.
Suction Expansion valve stuck in the open Repair or replace valve.
pressure too position (indicated by abnormally cold
low. suction line).
Low charge, flash gas in liquid line Repair leak and recharge system.
(indicated by bubbles in the sight glass).
Clogged filter/drier.
Replace filter/drier.
Obstructed expansion valve (indicated
by loss of capacity). Replace valve.
Loss of control fluid from expansion

valve control head (indicated by Replace valve or control head.
bubbles in the sight glass).
Heater fails to Overload trip. Determine cause and repair.
operate.
Defective over-temp switch. Replace switch.
Defective contactor. Replace contactor.
TM-55360-120 29
16 MAY 2011
6.2 Diagnostic Checks
6.2.1 Power Supply Check

a. Ensure J1 (Figure 8-4) is connected to source power but ECU ON/OFF switch
is set to OFF (so power is supplied to unit but unit is not running while making
the following checks).
b. On the power distribution block (see Figure 6-1), use voltmeter and check for
proper voltage (208V +/- 10%) across:
L1 to L2
L1 to L3
L2 to L3
c. Check to see if there are any other switches or problems at main panel.
d. If no voltage, correct the problem.
Figure 6-1 Power Distribution Block TB1
30 TM-55360-120
16 MAY 2011
6.2.2 Unit Voltage Check
If there is a problem with a unit starting, or the compressor is cycling on its overload, the
trouble may be due to improper electric service being supplied to the unit. It will be
necessary to check the voltage in the unit power connections.
a. Shut off current by opening the circuit breaker.
b. Connect voltmeter to L1 and L2 terminals on contactor (K1) (see Figure 6-2).
c. Turn the thermostat so it does not call for cooling.
d. Turn on the disconnect switch.
e. Read the voltage (should be 208V +/- 10%). This is called “idle” voltage.
f. Turn the thermostat to call for cooling.
g. With unit running, read the voltmeter (should be 208V +/- 10%). This is called
“running voltage”.
h. Check idle and running voltage across L2 to L3 and L1 to L3 also (should be

208V +/- 10%).
TM-55360-120 31
16 MAY 2011
L1 L2 L3
Figure 6-2 Contactor K1
Some common causes of voltage drop include service transformers that are overloaded, and
service wiring that is too small, or too small a generator.
a. Check the main circuit breaker on the supply power line and the one on the
ECU and switch it OFF and back to ON.
b. Check the secondary side of transformer T1 for supply voltage (should be 25

VAC) (see Figure 6-3).
32 TM-55360-120
16 MAY 2011
SECONDARY SIDE (white wires)
PRIMARY SIDE (black wires)
Figure 6-3 Transformer T1
TM-55360-120 33
16 MAY 2011
6.2.3 Scroll Compressor Check
NOTE:
The following procedure must be performed by a journeyman, refrigeration
mechanic, or an air conditioning technician.
Scroll compressors do not have internal suction valves or dynamic discharge valves that can
be damaged, so it is not necessary to perform functional compressor tests where the
compressor is turned on with the suction service valve closed to check how low the
compressor will pull suction pressure. In fact, this type of test may actually damage a Scroll
compressor (and other types of compressors). The following diagnostic procedure should be
used to evaluate whether a Scroll compressor is functioning properly.
a. Verify proper voltage to the unit – If the compressor will not run, the normal
checks of motor winding continuity and short to ground should be made to
determine if the inherent internal overload motor protector has opened or if an
internal short to ground has developed. If the protector has opened, the
compressor must be allowed to cool sufficiently to allow it to reset.
b. Verify proper indoor and outdoor fan/blower operation (rotation) – With

service gauges connected to suction and discharge pressure fittings, energize
the compressor. If suction pressure falls below normal levels (see Table 9-1)
the system is either too low on charge or there is a flow blockage in the system
(refrigerant or air). If suction pressure does not drop and discharge pressure
does not rise to normal levels the compressor is faulty.
6.2.4 Use of Sight Glass

The sight glass provides a means to indicate low charge by showing continuous excess
bubbles of flash gas within the liquid line after the system has run for 30 minutes to
stabilize, which is helpful in determining if the system is adequately charged with
refrigerant. Although bubbles of flash gas in the glass are usually an indication of a low
refrigerant charge, this is not always the case. Other conditions that can cause bubbles to
appear are:
 A restriction in the liquid line upstream of the sight glass, such as a clogged
filter/drier.
 Erratic thermostatic expansion valve operation.
 Rapid fluctuation in discharge pressure.
 Low ambient conditions.
 Compressor operating in unloaded mode.
34 TM-55360-120
16 MAY 2011
The above conditions are often temporary or fluctuating. Prolonged observation (30 minutes
or more) of sight glass bubbles combined with other symptoms such as low suction pressure
and/or insufficient cooling are good indications that the system is low on refrigerant.
The sight glass also has a color-coded moisture indicator:

Green = Dry system
Yellow = Wet (water is present in the system)
The sight glass moisture indicator MUST be green before operating the system.
6.2.5 Checking Refrigerant Charge
WARNING
Adhere to the following precautions:
 Always wear safety glasses when working with refrigerant.
 Beware of refrigerant burn when removing hoses.
 Use caution when working with pressurized hoses.
 Use only hoses with side wall designed for high pressure.
a. Install gauge manifold to unit.
1) Turn ECU ON/OFF switch to OFF.
2) Put high-pressure hose on first.
3) Put low-pressure hose on second.
b. Turn the thermostat to call for cooling.
c. Turn ECU ON/OFF switch to ON.
d. Check the unit operating pressures at gauge manifold with the normal operating
pressure curve for this unit (see Table 9-1).
e. If the system is operating properly, disconnect gauge manifold, and reinstall all
gauge port caps and system service valve caps.
TM-55360-120 35
16 MAY 2011
6.2.6 Icing or Frosting of Evaporator Coil
A condition often encountered in the field is icing or frosting of the evaporator coil. Since
there are several causes for this condition, it can sometimes be difficult to diagnose. Icing
and frosting are two separate and distinct conditions:
 ICING - A covering of slick, smooth ice on the surface. This can be a very thin
coat or it may become quite thick. It may further build up over a fairly large
area.
 FROSTING - Has a snowy, crystal-like appearance. It is generally confined to

a very small area.
Generally the cause:

a. Low suction pressure.
b. Air volume through the evaporator coil is low.
c. Air filters restricted or plugged.
d. Small or restricted ductwork.
Occasionally the cause:

a. Refrigerant charge is low.
b. General restrictions.
c. Air stratification in conditioned space.
36 TM-55360-120
16 MAY 2011
7. MAINTENANCE
7.1 Maintenance Instructions

Preventive Maintenance Checks and Services (PMCS) are essential to ensure that the unit is
ready for operation at all times. They correct defects and deficiencies before they can cause
serious damage or complete failure of the equipment. Any effective preventive maintenance
program must begin with the indoctrination of operators to report all unusual conditions
noted during daily checks or actual operation to the appropriate maintenance personnel.
A system should be established to record all problems, defects, and deficiencies noted by
operators and discovered during maintenance inspections together with the corrective
actions taken.
A schedule for preventive maintenance inspection and service should be established

immediately after installation of the unit. Refer to PMCS Table (Table 7-1) for
recommended service intervals. When operating under unusually adverse conditions, such as
an extremely dusty, dirty, or sandy environment, it may be necessary to reduce the interval
to monthly or less depending on the severity of the environmental conditions.
Stand-by, non-operating units should be rotated on a last in, last out basis. Any unit not
operating for one (1) year should be tested. A walk-by, visual inspection should be done
monthly. Look for physical damage due to material handling and evidence of oil leakage
around the unit. Any unit that shows evidence of physical damage or oil leakage must be
tested.
The refrigerant compressor and its drive motor are hermetically sealed. The compressor
crankcase has a lifetime supply of oil and is pressure lubricated by an internal oil pump. If
compressor failure or motor burnout occurs, the compressor must be replaced. Refer to the
Parts List for the correct replacement part. The evaporator blower motor and the condenser
fan motor are permanently lubricated.
The PMCS Table (Table 7-1) lists the preventive maintenance checks and services that
should be performed at quarterly (or otherwise established) intervals. The PMCS items in
the table have been arranged in a logical sequence to provide for greater personnel
efficiency and least amount of required maintenance downtime.
TM-55360-120 37
16 MAY 2011
Table 7-1 Preventive Maintenance Checks and Services (PMCS)
SERVICE
COMPONENT PROCEDURES
INTERVAL
Return Air /  Remove, Clean, Inspect, and Service.

Monthly
Fresh Air Filters  Discard/replace damaged or unserviceable filter.
 Check for secure mounting. Secure as needed.

 Check for bent fins. Straighten with tongue depressor,
Evaporator and coil fin comb, or plastic sheet.
Quarterly
Condenser Coils  Clean coils as needed.
 Re-coat with Teflon spray suitable for refrigeration
coils. There are many commercially available products.
 Check outside surfaces for accumulations of dust, dirt,
Outside Surfaces Quarterly
or salt. Clean as required.
 Check for loose electrical connections. Secure as
needed. Semi-
Fan Motors
 Check for loose mounting hardware. Secure as needed. Annually
 Check for accumulated dust/dirt. Clean as required.
 Check for loose electrical connections. Secure as
needed. Semi-
Compressor
 Check for loose mounting hardware. Secure as needed. Annually
 Check for accumulated dust/dirt. Clean as required.
 Check for loose mounting. Tighten as needed.
 Check tubing attachments. Repair as needed.
 Inspect for bent or damaged equalizer tubing. Replace
Refrigeration Semi-
as needed.
Components Annually
 Check expansion valve bulbs insulation. Replace as
needed.
 Check insulation. Repair as needed.
 Check evaporator compartment for evidence of
moisture.
Condensate Drain Semi-
 Blow out drain line if necessary. (A quart of clean
Pan and Hoses Annually
water poured into the condensate pan provides a visual
check of the drain line condition.)
 Using the sight glass, inspect refrigerant while unit is
running in COOL mode and at high temperature (>100°
Refrigerant Semi-
F (>37.8°C)). The sight glass should be clear.
Charge Annually
 If low on charge, check for refrigerant leaks, recover
refrigerant, repair leak, and recharge system.
38 TM-55360-120
16 MAY 2011
Table 7-2 Preventive Maintenance Checks and Services (PMCS) (Continued)
SERVICE
COMPONENT PROCEDURES
INTERVAL
Electrical Panel /  Inspect for damaged insulation, broken connection to

Semi-
Interconnect lugs, and indications of deterioration. Replace and
Annually
Wiring repair as needed.
Brackets,
 Examine for loose or missing attaching hardware or Semi-
Mounts,
other obvious damage. Annually
Hardware, etc
 Clean the sight glass. Semi-
Sight Glass
 Inspect condition of glass. Replace if cracked. Annually
 Install all components and panels removed during
Reassemble PMCS. As Required
 Ensure all items are back in place and secure.
WARNING
De-energize the air conditioner by disconnecting the power cord from the power
source and removing the power cord from the power connector, as a first step to all
removal and replacement procedures. Lethal voltages are present even when the
ON/OFF switch is in the OFF position.
CAUTION
Air pressure not to exceed 35 psig (2.5 kg/cm2). Recommended pressure should be
between 25-35 psig (1.75-2.5 kg/cm2). Coil Cleaner such as Hydro Balance Corp
Enviro-Coil may be used. If coil cleaner is unavailable, mild soap and water may be
used.
TM-55360-120 39
16 MAY 2011
7.2 Cleaning Procedures
7.2.1 Evaporator Coil Cleaning

a. Remove panels.
b. Blow dirt from between fins with air nozzle pointing out.
c. Use coil cleaner where you can see foreign material left in the coil after being
blown out.
d. With damp cloth, clean debris from side filter compartment.
e. Reinstall removed panels.
f. Re-coat coil with Teflonspray suitable for refrigeration coils. There are many
commercially available products
7.2.2 Condenser Coil Cleaning

a. Remove panels.
b. Blow out debris between fins from inside – out, pointing the air nozzle up.
c. Use coil cleaner where you can see foreign material left in the coil after being
blown out.
d. Reinstall removed panels.
g. Re-coat coil with Teflonspray suitable for refrigeration coils. There are many
commercially available products.
7.3 Repair Procedures
NOTE:
All refrigeration work must be in compliance with EPA Section No. 608 and all
applicable local air quality standards.
40 TM-55360-120
16 MAY 2011
7.3.1 Major Overhaul
Under normal operating conditions and with the proper preventive maintenance, the unit
should provide excellent service for many years. After this time, the ECU should be returned
to the manufacturer or a suitably qualified depot for major overhaul and refurbishment. All
work must be performed by qualified refrigeration and electrical technicians and should
include replacement of compressors, motors, starters, contactors, bearings, and other
accessories as necessary.
NOTE:
REFER TO SAFETY SUMMARY SECTION OF THIS MANUAL. FAILURE TO
ADHERE TO THESE RECOMMENDATIONS COULD RESULT IN SERIOUS
INJURY.
7.3.2 Field Repairs

It may be necessary from time to time to perform field repairs on the refrigeration system. If
field repairs are necessary, the following procedures apply:
7.3.2.1 Leak Detection

a. Pressurize the system – In order to check a system for leaks it is necessary
that the system or portion of the system first be pressurized. This will
naturally be true of a new system prior to evacuating and charging, or an old
system that has lost its charge.
1) If the system has been in operation and has lost its entire charge, it is
desirable to pressurize the entire system to find the leak or leaks.
2) When the entire unit is to be pressurized, it is usually desirable to

pressurize the system through both the suction and discharge service
valves. In this manner, the pressure is supplied to both the high and low
sides of the system.
b. Refrigeration systems are commonly pressurized for purposes of leak

checking with refrigerant and dry nitrogen. Test pressures should be adjusted
to 10 psig or higher (max 150 psig). (Recover all refrigerant.)
 The advantages of the refrigerant/nitrogen mix are:

 It is less expensive than refrigerant.
 Nitrogen will leak approximately twice as fast as refrigerant from the
same size hole at the same pressure.
TM-55360-120 41
16 MAY 2011
 The valve and pressure gauge arrangement on a nitrogen bottle
provides an excellent means of checking if a leak exists.
 Nitrogen will not be absorbed by refrigerant oil, thereby causing a
misleading pressure drop.
 Test procedures are easier to obtain.
 Nitrogen is not ozone depleting.
 The advantages of refrigerant are:

 Refrigerant leaks can be detected with an electronic leak detector.
Nitrogen cannot be detected unless it is used with a portion of
refrigerant.
 Refrigerant may be more readily available for field repairs as it is
needed for the ECU in any event.
c. Test for leaks – Use one of the following two methods to leak test a system
charged with refrigerant.
 Electronic leak detector – An electronic leak detector is the preferred tool

for leak checking. It is highly sensitive and measures the electronic
resistance of gas samples.
1) Turn detector on and attach proper probe.
2) Pass probe along the lines going around the joints and connections.
Be sure to check all points.
3) Presence of a leak will be indicated by either a buzzing or beeping

sound.
 Soap Solution – Apply a solution of soapy water with a brush or sponge

to the joints and connections in the refrigeration line(s). A leak in the
lines will cause bubbles to form.
NOTE:
On existing systems which have been in operation, it is usually wise to make a visual
check of the system piping since a refrigerant leak will often be indicated by the
presence of oil. This is because some of the oil in the system will escape through the
leak with the refrigerant.
42 TM-55360-120
16 MAY 2011
7.3.2.2 Leak Repair
a. When a leak is located, properly reclaim the remaining refrigerant charge
before attempting repairs.
b. Adjacent piping must be thoroughly cleaned by removing all paint, dirt, and
oily film. Use a wire brush, sand cloth, or sandpaper and wipe the area with
clean, dry cloths.
c. Protect nearby parts from heat damage by wrapping with water-soaked

cloths.
d. For copper-to-copper (piping) repairs, use a 15%/80%/5%

silver/copper/phosphorous brazing alloy (Sil-Fos 15). No flux is required
with Sil-Fos 15. Silver solder (Stay-Silv #45) and flux are to be used on
copper-to-brass or copper-to-steel repairs. In an emergency, a 95%/5%
tin/antimony solder may also be used with flux for repairs. When repairs are
completed, remove all traces of flux.
e. After any repair, check for leaks prior to system use.
NOTE:
Damaged or leaking coils require replacement. The coils are supplied with factory-
installed copper stubs for integration into the refrigeration system. Aluminum coils
cannot be repaired in the field due to the high temperatures required to make
repairs.
TM-55360-120 43
16 MAY 2011
WARNING
DEATH or serious injury may result if personnel fail to observe the following safety
precautions.
 Great care must be exercised to prevent contact of liquid refrigerant or

refrigerant gas discharged under pressure, with any part of the body. The
extremely low temperature resulting from the rapid expansion of liquid
refrigerant, or refrigerant gas released under pressure, can cause sudden and
irreversible tissue damage through freezing.
 As a minimum, all personnel must wear thermal protective gloves and face
shield or goggles when working in any situation where refrigerant contact
with the skin or eyes is possible. Application of excessive heat to any
component in a charged system will cause extreme pressure that may result in
a rupture, possibly explosive in nature.
 Exposure of Refrigerant R-407C to extreme heat or a very hot surface will

cause a chemical reaction in the gas to form carbonyl chloride (phosgene), a
highly poisonous and corrosive gas.
 In its natural state, Refrigerant R-407C is a colorless odorless vapor with no

toxic characteristics. It is heavier than air and in a well-ventilated area will
disperse rapidly. However, in an unventilated area it will displace oxygen and
presents a danger as a suffocative.
CAUTION
Do not attempt to make any adjustments without the proper tools. Refer to
Table 8-7 for Recommended Common Support Tools.
44 TM-55360-120
16 MAY 2011
7.4 Attaching Manifold Hose to Schrader Valve
a. Remove cap from valve.
b. Make sure gauge manifold valves are closed.
c. If hose does not have an unseating pin, unseating coupler must be used. Make
sure coupler is lined up straight with Schrader valve. Screw coupler on to valve.
d. Open gauge manifold valve slightly and purge air from hose with refrigerant.
e. Read the suction pressure on compound gauge and head pressure on pressure
gauge.
f. To remove, push end of coupler tight against end of Schrader valve and hold in
place while quickly unscrewing coupler nut from Schrader valve. Remove
coupler from Schrader valve.
g. Reinstall cap on valve.
7.5 Evacuation Procedure
CAUTION
AT NO TIME USE THE COMPRESSOR TO EVACUATE THE SYSTEM OR
ANY PART OF IT.
NOTE:
A refrigeration system should be evacuated whenever the system has been open in
such a manner that there is a possibility that air and moisture could have entered the
system. The evacuation process is intended to remove non-condensable gases and
moisture from the portion of the system to be evacuated. The most important
contaminant to be removed is moisture. To remove moisture from the system, it
must first be boiled into vapor. Before water will boil at ordinary room temperature,
for example, at 70° F (21.1 C) the vacuum must be 29¼ inches of mercury at 30
inches of mercury barometric pressure. This means that the system must be within
¾ inches of mercury of absolute zero pressure. This low vacuum should be measured
by using standard commercial practices, an absolute pressure gauge, or an electronic
gauge. For this reason, a good vacuum pump must be used to accomplish good
dehydration.
TM-55360-120 45
16 MAY 2011
a. Evacuate the system to less than 500 microns, using a good vacuum pump and an
accurate high vacuum gauge. Operate the pump at 500 microns, or less, for
several hours and then allow the system to stand for several additional hours to
be sure the vacuum is maintained.
b. An alternate method of removing moisture and non-condensables from the

system is:
1) Evacuate the system to 29 inches mercury for ten minutes per ton of system.
Break the vacuum with refrigerant to be used for final charging of system and
vapor charge in system for a minimum of five (5) minutes.
2) Repeat Step 1) two more times.
3) Evacuate system to 29 inches mercury for twenty minutes per ton. Charge
system with the specified kind and quantity of refrigerant (charge into
vacuum).
c. Disconnect charging line at vacuum and connect to refrigerant supply. Crack

valve and purge charging line at center on manifold. Then close valve.
d. The system is now ready for the correct operating charge of refrigerant.
7.6 Charging Procedure
7.6.1 Preliminary Charging Steps

If the system has been open to the atmosphere, it should be first evacuated, and then proceed
as follows:
a. Attach a drum of proper, clean refrigerant to the center port of the charging
manifold with one of the charging hoses.
b. Attach a second charging hose to the suction gauge (low-pressure) side of the
gauge manifold.
c. Remove the cap from the suction line valve.
d. Loosely attach the suction gauge hose to the line valve. Open the valve on the
refrigerant drum and the suction valve on the charging manifold slightly to
purge the air from the manifold and hoses before tightening the fitting.
46 TM-55360-120
16 MAY 2011
e. Attach the third hose to the high pressure side of the manifold and the liquid
line valve. Repeat Steps c and d above.
7.6.2 Charging the System by Weight
a. Connect the manifold as instructed.
CAUTION
THE SYSTEM MUST BE CHARGED WITH LIQUID.
b. Place the refrigerant drum on a scale and determine exact weight of refrigerant
and cylinder or use a Charging cylinder. Refer to Data Plate for proper charge.
c. Insure refrigerant drum on a scale and determine exact weight of refrigerant

and cylinder or use a Charging cylinder. Refer to ECU data plate for proper
charge.
d. With manifold suction valve closed and manifold discharge valve open, open
refrigerant cylinder valve and allow pressure in system to balance with pressure
of cylinder.
e. When there is approximately a full charge (gas for R-407C), close the
discharge manifold valve and let the system stabilize for about five (5) minutes.
f. Start compressor by placing the SYSTEM switch to the ON position for the
ECU being serviced. Place the thermostat in the COOL position.
g. When the correct weight of refrigerant has been added to the unit, close
refrigerant cylinder valve and allow unit to run for 30 minutes. Check the
charge against the allowable head pressure as shown in Table 9-1
(REFRIGERANT TEMPERATURE/PRESSURE CHART) and correct if
needed.
h. Front seat gauge manifold valves, disconnect charging and gauge hoses, and
reinstall all valve caps.
TM-55360-120 47
16 MAY 2011
7.7 Component Replacement Procedures
WARNING
HIGH VOLTAGE is used in the operation of this equipment. Death on contact or
severe injury may result if you fail to observe safety precautions. Always disconnect
the ECU from the power source before working on it. Do not operate the ECU
without panels and grilles in place and tightly secured.
WARNING
ROTATING FAN BLADES are used in this equipment. Severe injury on contact
may result if you fail to observe precautions. Always disconnect power source before
working on fans. Do not operate fans without panels and grilles in place and secured.
7.7.1 General
Refer to the wiring diagram and refrigeration schematic in the Appendix of this manual for
the location of the system components and their relationship to each other. Refer to any
adjustments and settings that may be required before or after installation.
For copper-to-copper (piping) discharge or suction line, use a 15%/80%/5%

silver/copper/phosphorous brazing alloy (Sil-Fos 15). No flux is required with Sil-Fos 15.
Silver solder (Stay Silv #45) and flux are to be used on copper-to-brass or copper-to-steel
repairs. When repairs are complete, remove all traces of flux. After any repair, pressure-
check system with refrigerant, checking for leaks prior to recharging the system.
NOTE:
Damaged or leaking coils require replacement. The coils are supplied with factory
installed copper stubs for integration into the refrigeration system. Aluminum coils
cannot be repaired in the field due to the high temperatures required to make
repairs.
48 TM-55360-120
16 MAY 2011
7.7.2 Compressor
The compressor is the most important component of the air conditioner. Numerous safety
devices are provided to protect the compressor from contamination damage and burnout.
When replacing a burned-out compressor, it is mandatory that the refrigeration
system be thoroughly cleaned before operating the replacement compressor.
When a compressor burnout occurs, acid is created as a result of refrigerant-oil mixture
being exposed to the extreme high temperatures the motor burnout generates. The acid
diffuses throughout the refrigeration system and must be removed before a new compressor
is placed in service, or the acid will attack the windings of the new compressor motor. Any
dirt, scale, air, or water vapor also drastically shortens the operating life of the new
compressor.
NOTE:
The following procedure must be performed by a journeyman, refrigeration
mechanic, or an air conditioning technician.
a. Recover all refrigerant in the ECU.
b. Un-sweat suction and discharge lines from compressor.
c. Remove wires from compressor. Note where each wire is installed.
d. Remove and retain hardware that mounts compressor to ECU.
e. Remove compressor from ECU.
f. Install new compressor using hardware removed from defective compressor.
g. Braze suction and discharge lines.
h. Reinstall wires on new compressor per notes from removal step.
Replace liquid line filter/drier and add a suction line filter/drier

i. Purge system with dry nitrogen then add a holding charge of Refrigerant
R-407C. Refer to leak detection section of this manual (see Paragraph 7.3.2.1)
and perform leak check.
j. Once unit has passed leak detection test, evacuate refrigeration system to 500
microns of vacuum. Then break vacuum with R-407C refrigerant. Do this three
(3) times.
TM-55360-120 49
16 MAY 2011
k. Charge and operate unit.
l. After installation and start-up are complete, the following tests should be
performed on the replacement compressor and the information recorded.
1) Suction pressure
2) Discharge pressure
3) Amp draw
7.7.2.1 Compressor Burn-Out Cleanup Procedure

When a motor burnout occurs in the compressor, the resulting high temperature arc causes a
portion of the refrigerant/oil mixture to break down into carbonaceous sludge, corrosive
acid, and water. Contamination resulting from a burnout can result in repeat failures if the
contaminants are allowed to reach and remain in the crankcase of the replacement
compressor. This situation can be prevented by following the proper clean-up procedures
after a burnout. We recommend the filter/drier cleaning procedure. This involves the use of
approved filter/driers incorporating an adequate desiccant (not a filter only) in both the
liquid and suction lines.
WARNING
Use rubber gloves and safety glasses and ventilate the workspace. The oil from a
burnout could cause serious skin irritation and possibly burns. In some cases, the
fumes are toxic.
a. In order to avoid losing refrigerant to the atmosphere, you must recover

refrigerant using standard recovery procedures and equipment. At that point,
remove the inoperative compressor and install the replacement.
b. Since the normal color of refrigerant oil varies from oil to oil, take a sample of
oil from the replacement compressor and seal in a small glass bottle for
comparison purposes after the cleaning operation is complete. Suitable two-
ounce bottles are obtainable at any drug store.
c. Inspect all system controls such as expansion valves, solenoid valves, check
valves, reversing valves, contactors, etc. Replace any filter/driers previously
installed in the system, and clean or replace any filters or strainers. Install a
good quality moisture indicator if the system does not have one.
d. Install the recommended size filter/drier in the suction line, and an oversized
filter/drier in the liquid line. Charge unit with a fresh can of refrigerant. Do not
reuse contaminated refrigerant.
50 TM-55360-120
16 MAY 2011
e. Start the compressor and put the system in operation. As the contaminants in
the system are filtered out, the pressure drop across the filter/drier will increase.
Observe the pressure differential across the filter/driers for a minimum of four
(4) hours, preferably by means of one gauge and a manifold to eliminate gauge
error. If the pressure drop exceeds seven 7 psi, replace both filter/driers and
restart the system.
f. After the completion of Step e, allow the unit to operate for 48 hours. Check
the odor (warning: smell cautiously) and compare the color of the oil with the
sample taken in Step b. If an acid test is available, test for acid content. If the
oil is discolored, has an acrid odor, is acidic, or if the moisture indicator
indicates high moisture content in the system, change the filter/driers. The
compressor oil can be changed if considered desirable. Allow the system to
operate for an additional 48 hours, and recheck as before. Repeat until the oil
remains clean, odor free and the color approaches that of the original sample.
g. Replace the liquid line filter/drier with one of the normally recommended size.
Remove the suction line filter/drier and replace with a permanent type suction
line filter/drier.
h. After the cleaning procedure is completed, recheck in approximately two (2)

weeks to insure that the system condition and operation is completely
satisfactory.
7.7.3 Thermostat Knob

a. Use 1/16 Allen key to remove knob from control panel.
b. Install new knob using Allen key.
7.7.4 System ON/OFF Switch S1

HEAT/FAN/COOL Switch S7
a. Use 1/16 Allen key to remove thermostat knob from control panel.
b. Remove control panel from ECU by removing two Phillips screws.
c. Lift out control panel for access to switches and wires.
d. Remove leads from switch. Note where each lead is installed.
e. With 9/16 open-end wrench, loosen one of the thin nuts that hold switch to
panel. Remove outer nut and remove switch. Place to one side.
TM-55360-120 51
16 MAY 2011
f. Turn rear nut down on new switch. Install new switch in panel. Install front nut
and turn until five or six threads show above nut. Tighten rear nut to secure
switch.
g. Reinstall leads on new switch per notes from removal step.
h. Reinstall control panel.
i. Use Allen key to reinstall knob.
7.7.5 Indicator Lamp, Green

a. Use 1/16 Allen key to remove thermostat knob from control panel. Set knob
aside.
c. Lift out control panel for access to lamp and wires.
d. Pull female push-on terminals off back of lamp. Note where each is
installed.
e. Depress lamp retaining tabs and pull lamp out from front of control
panel. Set lamp aside.
f. Install new lamp into control panel. Verify retaining tabs are engaged
and lamp is secure.
g. Push female push-on terminals back on tabs per notes from removal
step.
h. Reinstall control panel.
i. Use Allen key to reinstall knob.
7.7.6 Switch, Thermostat S8
Switch, Safety Thermostat

a. Use 1/16 Allen key to remove thermostat knob from control panel. Set knob
aside.
52 TM-55360-120
16 MAY 2011
c. Lift out control panel for access to switches and wires.
d. Remove leads from switch. Note where each lead is installed.
e. Remove two screws (three for thermostat) holding switch to control panel.
f. Remove 18-inch return air duct (center bottom duct) and return air filter.
g. Trace capillary lead to switch’s sensing bulb located on mounting bar in front
of evaporator coil. This bar is accessible through the return air flange.
h. Cut cable ties and loosen clamp screw. Slide bulb out of clamp.
i. Retract capillary tube and bulb through grommets in filter frame. It may be
necessary to remove grommets to get bulb through. Grommets may be cut if
necessary.
j. Remove switch and its sensing bulb and set aside.
k. Feed capillary tube of new switch through filter frame grommets. If grommets
were removed, reinstall.
l. Insert bulb in clamp and tighten clamp screw. Check that bulb is securely held.
m. Install new switch.
n. Reinstall leads on new switch per notes from removal step.
o. Reinstall control panel.
p. Use Allen key to reinstall knob.
q. Reinstall filter and duct.
7.7.7 Switch, High Pressure S3

Switch, Low Pressure S4
a. Remove electrical control box cover and condenser aft side panel.
b. Remove two screws securing switch to electrical control box.
c. Remove electrical leads from switch. Note where each lead is installed.
TM-55360-120 53
16 MAY 2011
d. Trace capillary tube through electrical control box into condenser
compartment. Capillary tube expands to ¼ inch and is secured with a Schrader
valve fitting to another ¼-inch tube.
e. Remove capillary tube from Schrader valve fitting. Retract capillary tube
through grommets.
f. Remove switch and set aside.
g. Feed capillary tube of new switch through grommets.
h. Attach capillary tube of new switch to Schrader valve fitting.
i. Leak test in accordance with Paragraph 7.3.2.1.
j. If leak test is satisfactory, evacuate in accordance with Paragraph 7.5.
k. Charge in accordance with Paragraph 7.6.
l. Reattach leads to switch per notes from removal step.
m. Install new switch.
n. Reinstall electrical control box cover, condenser aft side panel, and service port
cover.
7.7.8 Timer TM1, TM2

a. Remove electrical control box cover.
b. Depress retaining clips securing timer to its socket and remove timer. Note
timer settings, then set timer aside.
c. Install new timer. Ensure retaining clips are engaged and timer is secure.
d. Set timer per notes from removal step.
e. Reinstall electrical control box cover.
7.7.9 Socket, Timer

54 TM-55360-120
16 MAY 2011
b. Depress retaining clips securing timer to socket and remove timer. Note timer
settings and set timer aside.
c. Remove wires from timer socket. Note where each wire is installed.
d. Insert flat head screwdriver into latch on bottom of socket and pull
down to disengage latch from DIN rail.
e. Lift up and then out to remove socket from DIN rail. Set socket aside.
f. Install new socket on DIN rail: hook socket on top of rail, then push
bottom of socket until it clicks onto rail. Ensure latch is engaged and
socket is secure.
g. Reattach wires per notes from removal step.
h. Reinstall timer. Ensure settings are correct per notes from removal step.
i. Reinstall electrical control box cover.
7.7.10 Contactors K1 to K4
b. Remove all wires from contactor. Note where each wire is installed.
c. Remove mounting screws. Remove contactor and set aside.
d. Install new contactor.
e. Reattach all wires per notes from removal step. Tighten screw as each set of
wires is reinserted.
f. Reinstall electrical control box cover.
7.7.11 Relays, Time Delay TD1 to TD4

b. Remove all wires from relay, including jumper wire connecting A1 and 15.
Note where each wire is installed.
TM-55360-120 55
16 MAY 2011
c. Insert flat head screwdriver into latch on bottom of relay and pull down to
disengage latch from DIN rail.
d. Lift up and then out to remove relay from DIN rail. Set relay aside.
e. Install new relay on DIN rail: hook relay on top of rail, then push bottom of
relay until it clicks onto rail. Ensure latch is engaged and relay is secure.
f. Reinstall wires, including jumper wire, per notes from removal step.
g. Ensure that all time delay settings are correct per notes from removal step.
h. Reinstall electrical control box cover.
7.7.12 Relay, DPDT R1

b. Pull female push-on terminals off bottom of relay. Note where each is installed.
c. Loosen bottom mounting screw. Remove top screw and remove relay. Set
aside.
d. Slide bottom tab of relay under washer on lower screw. Reinstall upper screw
and tighten both screws.
e. Push female push-on terminals back on tabs per notes from removal step.
7.7.13 Transformer T1
a. Remove electrical control box cover and condenser forward side panel.
b. Remove all wires from transformer. Note where each wire is installed.
c. Remove four screws and backing nuts securing transformer to electrical control
box. Backing nuts are located on back side of electrical control box.
d. Remove transformer and set aside.
e. Install new transformer.
56 TM-55360-120
16 MAY 2011
f. Reinstall all wires on new transformer per notes from removal step.
g. Reinstall electrical control box cover and condenser forward side panel.
7.7.14 Terminal Block TB1

b. Loosen setscrews in top of terminal block, and slide wires out of their recesses.
Masking tape may be used to hold wires in relationship to each other before
loosening screws. Note where each wire is installed.
c. Remove mounting screws and terminal block. Set terminal block aside.
d. Holding new terminal block in hand, look into recesses (holes) where wires are
inserted. Back out setscrews until screws clear holes.
e. Install new terminal block with mounting screws.
f. Insert wires into appropriate recesses per notes from removal step. Tighten
setscrew as each wire is inserted.
g. Reinstall electrical control box cover.
7.7.15 Terminal Block TB2

b. Remove screws down both sides of terminal block that have a terminal under
them. Masking tape may be used to hold wires in relationship to each other
before removing screws. Note where each wire is installed.
c. Remove mounting screws and terminal block. Set terminal block aside.
d. Install new terminal block with mounting screws.
e. Insert terminal block screws through terminal rings and reinstall on block per
notes from removal step.
7.7.16 Indicator Lamps, Green, Amber and Red

TM-55360-120 57
16 MAY 2011
b. If necessary, remove screws securing lamp plate to electrical control box and
lift out plate for access to lamps and wires.
c. Pull female push-on terminals off back of lamp. Note where each is
installed.
d. Depress lamp retaining tabs and pull lamp out from front of plate. Set
lamp aside.
e. Install new lamp into plate. Verify retaining tabs are engaged and lamp
is secure.
f. Push female push-on terminals back on tabs per notes from removal
step.
g. If removed, reinstall lamp plate.
h. Reinstall electrical control box cover.
7.7.17 Switch, Fan Cycle S2

a. Remove top grill panel, and electrical control box cover.
b. Trace and remove leads from electrical box. Note where each lead is installed.
c. Unscrew switch from service valve it is mounted on. There is a 5/8 hex on the
end of the switch’s capillary tube, where it screws on to service port. Use a
7/16 backing wrench when removing switch from Schrader valve. There is a
Schrader (tire) valve inside service port, which prevents refrigerant loss when
switch is removed.
d. Remove switch and set aside.
e. Install new switch on service port.
f. Reattach leads to new switch per notes from removal step.
g. Replace cable ties.
h. Reinstall condenser forward side panel or end panel, and electrical control box
cover.
58 TM-55360-120
16 MAY 2011
7.7.18 Switch, Differential Pressure S10
a. Remove evaporator aft side panel.
b. Remove two mounting screws and pull switch away from the panel on which it
is mounted.
c. Loosen screw retaining cover and remove cover.
d. Remove electrical leads. Note where each lead is installed.
e. Remove barbed fitting from switch with ½-inch open-end wrench. Set switch
aside.
f. Install barbed fitting on new switch and tighten to secure.
g. Reattach electrical leads to new switch per notes from removal step.
h. Reinstall cover on switch.
i. Install new switch onto panel.
j. Reinstall evaporator aft side panel.
7.7.19 Switch, Head Pressure

i. Remove top grill panel, and electrical control box cover.
j. Trace and remove leads from electrical box. Note where each lead is installed.
k. Unscrew switch from service valve it is mounted on. There is a 5/8 hex on the
end of the switch’s capillary tube, where it screws on to service port. Use a
7/16 backing wrench when removing switch from Schrader valve. There is a
Schrader (tire) valve inside service port, which prevents refrigerant loss when
switch is removed
l. Remove switch and set aside.
m. Install new switch on service port.
n. Reattach leads to new switch per notes from removal step.
o. Replace cable ties.
p. Reinstall condenser forward side panel or end panel, and electrical control box
TM-55360-120 59
16 MAY 2011
cover.
7.7.20 Switch, Current Sensing Relay

a. Remove electrical panel.
b. Remove leads. Note where each lead is installed.
c. Remove two screws securing switch to box.
d. Remove switch, note settings, and set switch aside.
e. Install new switch into box and secure with screws.
f. Ensure settings on new switch are correct per notes from removal step.
g. Reattach leads to switch per notes from removal step.
h. Reinstall electrical panel.
7.7.21 Heater HR1

a. Remove evaporator cover.
b. Remove nuts from terminals on side of heater and remove all leads. Also
remove push-on leads from top of heater. Note where each lead is installed.
60 TM-55360-120
16 MAY 2011
CAUTION
AT NO TIME USE THE COMPRESSOR TO EVACUATE THE SYSTEM OR
ANY PART OF IT.
c. Remove supply air plenum to access screws. Remove six screws securing
heater to ECU frame.
d. Remove heater and set aside.
e. Lower new heater into evaporator compartment. Reinstall screws securing

heater to ECU frame.
f. Reinstall supply air plenum.
g. Reinstall heater leads per notes from removal step.
h. Reinstall evaporator cover.
7.7.22 Valve, Service Port and Cap P1, P2

The valve and cap perform the same function with the refrigerant as the same valve and cap
do with automotive tires.
a. Remove service port cover.
b. Caps are unscrewed and removed to attach manifold gauge lines to service port
for service.
c. Valve problems are most likely to occur when attaching manifold gauges. If
refrigerant starts leaking from the service port, immediately insert Schrader
valve tool into service port and tighten valve.
d. If leak stops, no further action is required.
e. If leak does not stop, refrigerant will have to be recovered using standard
recovery procedures and equipment.
f. Using Schrader valve tool, unscrew valve. Loosen backing nut behind valve.
g. Un-sweat tube and pull valve straight out. Set valve aside.
TM-55360-120 61
16 MAY 2011
h. Remove Schrader core from new valve and set core aside. Install new valve
and braze onto tube. When done, reinstall Schrader core and tighten valve
backing nut.
i. Leak test in accordance with Paragraph 7.3.2.1.
j. Evacuate system in accordance with Paragraph 7.5.
k. Recharge system in accordance with Paragraph 7.6.
l. Screw caps onto service ports.
m. Reinstall service port cover.
7.7.23 Filter/drier F1
a. Recover refrigerant using standard recovery procedures and equipment.
b. Remove evaporator forward side panel.
c. Un-sweat tubes on either end of filter/drier.
d. Loosen clamp screw to remove filter/drier. Note direction of arrow on body of

filter/drier, then remove filter/drier and set aside.
e. Install new filter/drier with arrow pointing in same direction as noted in

removal step.
f. Insert tubes into inlets on both ends of filter/drier and braze tubes. Filter/drier
must be wrapped with a wet cloth while brazing. Do not overheat filter/drier.
Cool with wet cloth when done.
g. Leak test in accordance with Paragraph 7.3.2.1. Tighten clamp.
h. Evacuate ECU in accordance with Paragraph 7.5.
i. Charge in accordance with Paragraph 7.6.
j. Reinstall evaporator forward side panel and service port cover.
7.7.24 Receiver, Refrigeration FC1

62 TM-55360-120
16 MAY 2011
b. Remove condenser aft side panel and end panel.
c. Un-sweat tubes on side of refrigeration receiver.
d. Loosen clamp screw to remove refrigeration receiver. Note how refrigeration

receiver is oriented in condenser compartment, then remove refrigeration
receiver and set aside.
e. Install new refrigeration receiver. Ensure orientation is the same as noted

during removal step.
f. Leak test in accordance with Paragraph 7.3.2.1. Tighten clamp.
g. Evacuate ECU in accordance with Paragraph 7.5.
h. Charge in accordance with Paragraph 7.6.
i. Reinstall condenser aft side panel, end panel, and service port cover.
7.7.25 Sight Glass D1

b. Remove condenser end panel.
c. Remove two screws securing sight glass bracket and remove bracket.
d. Un-sweat top and bottom tubes on sight glass.
e. Remove sight glass and set aside.
f. Install new sight glass. Insert tubes into top and bottom inlets of sight glass and
braze tubes. Sight glass must be wrapped with a wet cloth while brazing. Do
not overheat sight glass. Cool with wet cloth when done.
g. Leak test in accordance with Paragraph 7.3.2.1. Reinstall sight glass bracket.
h. Evacuate ECU in accordance with Paragraph 7.5.
i. Charge in accordance with Paragraph 7.6.
TM-55360-120 63
16 MAY 2011
j. Reinstall condenser end panel and service port cover.
7.7.26 Valve, Thermo Expansion TXV1

b. Remove evaporator side panels.
c. Cut cable ties holding capillary tube, trace tubing to bulb, loosen clamp and
slide bulb out.
d. Un-sweat tubes going into valve. Remove valve and set aside.
e. Insert three tubes into new valve and braze tubes. Valve must be wrapped with
a wet cloth while brazing. Do not overheat valve. Cool with wet cloth when
done.
f. Leak test in accordance with Paragraph 7.3.2.1.
g. Evacuate ECU in accordance with Paragraph 7.5.
h. Charge in accordance with Paragraph 7.6.
i. Unwind capillary tube enough that bulb can be placed in its original position.
Tighten clamp.
j. Install cable ties to restrain capillary tube.
k. Reapply cork insulation.
l. Reinstall evaporator and service port covers.
7.7.27 Coil, Condenser

b. Remove condenser covers while unit is being evacuated.
64 TM-55360-120
16 MAY 2011
c. Remove brackets securing coil to ECU frame.
d. Un-sweat upper line of condenser coil and remove section of line with valve
body. A wet cloth must be used on condenser coil inlet/outlet. Do not overheat
aluminum fittings on condenser coil.
e. Un-sweat lower line of condenser coil at elbow. A wet cloth must be used on
condenser coil inlet/outlet. Do not overheat aluminum fittings on condenser
coil.
f. Tilt top of coil away from frame and lift out.
g. Reassemble new coil and refrigeration lines in reverse order. Braze with wet
cloths wrapped around aluminum fittings of condenser coil.
h. Leak test in accordance with Paragraph 7.3.2.1.
i. Evacuate ECU in accordance with Paragraph 7.5.
j. Charge in accordance with Paragraph 7.6.
k. Reinstall condenser and service port covers.
7.7.28 Coil, Evaporator E1

b. Remove evaporator side panels.
c. Remove return air plenum and supply air plenum.
d. Remove two front screws behind supply plenum securing evaporator fan
bulkhead. Lift evaporator fan bulkhead up and bend back out of the way.
e. Un-sweat thermo expansion valve from coil distributor. Valve must be

wrapped with a wet cloth while brazing. Do not overheat valve. Cool with wet
cloth when done.
f. Un-sweat suction line from coil.
g. Remove side brackets securing coil to angled frame.
TM-55360-120 65
16 MAY 2011
h. Push bulkhead back and remove coil through side of ECU.
i. Reassemble new coil and refrigeration lines in reverse order. Braze with wet
cloth wrapped around thermo expansion valve. Do not overheat valve. Cool
with wet cloth when done.
j. Leak test in accordance with Paragraph 7.3.2.1.
k. Evacuate ECU in accordance with Paragraph 7.5.
l. Charge in accordance with Paragraph 7.6.
m. Pull evaporator fan bulkhead back into position and reinstall screws behind
supply plenum.
n. Reinstall supply air plenum, return air plenum, and evaporator side panels.
7.7.29 Motor, Evaporator Fan B2

Motor, Condenser Fan B3
a. Remove evaporator or condenser side panels and electrical control box cover.
b. For evaporator motor only, loosen side screws on vertical panel in front of
blower wheel and pull panel away from blower wheel. Slide blower wheel off
cone in order to access motor.
c. Loosen two setscrews in fan hub with 5/32 hex key from hex key set. Take at
least two turns on setscrews.
d. Spray fan hub shaft interface with WD-40 or other penetrating oil if available.
Let set for 15 minutes. Pull fan off shaft. Retain square key.
e. Record distance from end of shaft to side of ECU.
f. Trace motor leads to contactor in electrical control box.
g. Remove leads from contactor. Note where each lead is installed.
h. Pull wires out of grommets etc. until they are hanging loose from motor.
i. Remove four bolts holding motor base to its support using ½-inch socket with
ratchet and ½-inch wrench.
j. Lift motor out of ECU. Set aside.
66 TM-55360-120
16 MAY 2011
k. Place new motor on the motor support and reinstall four (4) bolts.
l. Wrap leads with spiral wrap. Reinsert through grommets etc. to the electrical
control box.
m. Cut all leads to length. Strip ends ¼ inch.
n. Reinstall leads on contactor per notes from removal step.
o. Check bore of fan hub for burrs caused by removal. If burrs are found, remove
with round file or sandpaper wrapped around a dowel.
p. Reinstall fan on motor shaft. With the motor and inlet ring securely mounted to
the ECU place the key on the motor shaft keyway, and slide the fan wheel on
the motor shaft. Key should be flush with fan and fan should be distance from
side of ECU recorded in Step e. above.
q. Position the fan wheel so that there is a ¼ to 3/8 inch overlap of the fan wheel
to the inlet ring. Install the motor shaft set screw into the fan hub and tighten
securely. Spin the fan wheel to ensure that the fan wheel does not rub against
the inlet ring and a concentric clearance has been established.
r. Locate the setscrew hole adjacent to the keyway set screw previously installed.
Use a center punch to mark the center of the setscrew hole on the motor shaft.
If motor shaft length is excessive, mark the shaft so that excess maybe
removed. Note: The motor shaft is not to be recessed into the fan wheel hub.
s. Remove the fan wheel and using a 7/32 drill, drill a hole 3/16 inch deep.
Remove any excess motor shaft, if required. Coat the motor shaft completely
using #238 dry film lubricant or equivalent.
t. Install the fan wheel and key onto the motor shaft, aligning the fan wheel to the
inlet ring and the hole drilled for the setscrew. Lightly spin the fan wheel to
ensure proper engagement and that the fan does not rub the inlet ring.
u. Place Loctite No. 242 or equivalent on the setscrews. Torque the setscrews to
125-inch pounds. Cover the setscrews with anti-tamper paint or torque seal.
v. Reinstall all covers.
7.7.30 Filter, Return Air

a. Remove two thumbscrews securing side panel on return air plenum.
TM-55360-120 67
16 MAY 2011
b. Remove side panel.
c. Spring-load mechanism inside return air plenum should pop filter out as soon
as side panel is removed. If necessary, push in on filter and let go to release
springs. Remove filter.
d. Install new filter.
e. Reinstall side panel and tighten thumbscrews.
7.7.31 Filter, Fresh Air

a. Remove four screws securing fresh air filter door bracket to side panel.
b. Pull off bracket and door assembly.
c. Remove filter.
d. Install new filter.
e. Reinstall bracket and door assembly.
68 TM-55360-120
16 MAY 2011
8. PARTS LIST
ECU parts are listed in Table 8-1 through Table 8-6. See Figure 8-1 through Figure 8-10 for
illustration. (Fig No. column in Table 8-1 through Table 8-6 lists first figure occurrence
only.) Recommended common support tools are listed in Table 8-7.
Table 8-1 Environmental Control Unit Parts List
FIND FIG REF CAGEC PART DESCRIPTION QTY

NO. NO. NO.
1 8-7 N/A 54080 70726 FILTER, RETURN AIR 1
2R728 (ALTERNATE PART)
2 8-1 B1 54080 71563 COMPRESSOR, DIGITAL SCROLL 1
125K WITH SCREW ON TERMINALS
NOTE 1 ZRD125K (ALTERNATE PART)
C-TF5-250
3 8-1 FC1 54080 71662 RECEIVER, REFRIGERATION 1
4 8-1 C1 54080 72010 COIL, CONDENSER, ALUMINUM 1
5 8-4 E1 54080 72448 COIL, EVAP, 30.00 X 29.00 COPP 1
6 8-1 B2 54080 71836 MOTOR, 3HP, 208-3Ø-60HZ 10.4 AMP, 1
56Z, TEAO (CONDENSER MOTOR)
7 8-1 B3 54080 72371 FAN, PROP. 30” 7 BLADES, 25 1
DEGREES (CONDENSER FAN)
NOTE 2 30/7- (ALTERNATE PART)
7/25/PAG/
4ZR/5/8X3
/16A
8 8-4 B3 54080 71836 MOTOR, 3HP, 208V, 3Ø, 1725RP 1
(EVAPORATOR MOTOR)
9 8-4 B2 54080 71889 BLOWER WHEEL, 20” X 4.5” W/ 5/8” 1
SHAFT HUB (EVAPORATOR FAN)
62814 12-2060- (ALTERNATE PART)
6N CCW
10 8-4 HR1 54080 72230 HEATER, 10.0 KW, 208V 3Ø, SINGLE 1
STAGE
11 8-1 D1 54080 70072 SIGHT GLASS .625 1
NOTE 3 SA-15S (ALTERNATE PART)
12 8-1 P1, P2 54080 70823 VALVE, SERVICE, WITH BRAZED 2
1/4” COPPER TUBE
53104 CD3604 (ALTERNATE PART)
13 8-4 TXV1 54080 71425 THERMO EXPANSION VALVE 1
NOTE 3 SVE-10- (ALTERNATE PART)
GA
14 8-6 F1 54080 71087 FILTER DRIER, 5/8” X 5/8” ODF 1
NOTE 3 C-165-S (ALTERNATE PART)
15 8-1 S2 54080 71251 SWITCH, FAN CYCLE W/ SCHRADER 1
VALVE FITTING
TM-55360-120 69
16 MAY 2011
Table 8-2 Environmental Control Unit Parts List (Continued)
FIND FIG REF CAGEC PART NO. DESCRIPTION QTY

NO. NO.
16 8-1 S10 54080 73526 SWITCH, HEAD PRESSURE 1
17 2-1 H 54080 73487 HOURMETER 1
18 8-4 S9 54080 71525 PRESSURE SWITCH, SENSITIVE, 1
AIR DIFFERENTIAL, SPDT, ADJ.
NOTE 4 P32AC-1 SET POINT
(ALTERNATE PART)
19 8-4 J1 54080 MS3102A32-17P CONNECTOR, POWER INPUT 1
0B1C1 (ALTERNATE PART)
20 8-4 J2 54080 MS3102E18-10S RECEPTACLE, LOAD SHED 1
3FXU2 (ALTERNATE PART)
21 8-8 LS1 54080 71724 RELAY, CURRENT SENSING, 10- 1
0SFN7 CR4395-EH-240- 100
101-A-CD-ELR-R (ALTERNATE PART)
22 8-1 54080 52596 ASSEMBLY, ELECTRICAL BOX 1
ENCLOSURE
(See Table 8-3 for parts breakdown)
23 8-4 54080 52564 ASSEMBLY, ELECTRICAL 1
CONTROL BOX, GETT 1C
24 8-7 54080 50028 FILTER, FRESH AIR 1
25 8-7 54080 70200-4 EYEBOLT, 7/16-14 X 1 1/6”, 180 4
39428 3014T481 (ALTERNATE PART)
ACCESSORY PARTS:
26 none 54080 51983 FLEXIBLE AIR DUCTS 1
ASSEMBLY, 50’ SET
27 none 54080 51983-1 FLEXIBLE AIR DUCTS 1
ASSEMBLY, 25’ SET
NOTE: EITHER ITEM 26 –OR– ITEM 27 IS USED ON THE ECU, NOT BOTH ITEMS.
28 none 54080 52594 CABLE ASSY, MAIN POWER, ECU 1
29 none 54080 51865 CABLE ASSY, LOAD SHED 1
30 none 54080 70709 COVER, AIR DUCT, 12” DIA 2
31 none 54080 70710 COVER, AIR DUCT 18” DIA 1
32 none 54080 71676 COVER, NET, RETURN AIR DUCT 1
NOTES
1. Emerson Climate Technologies, P.O. Box 730020, Dallas, TX 75373-0020.
2. Multi-Wing America, Inc., P.O. Box 425, Burton, OH 44021.
3. Parker Hannifin/Sporlan Division, 13557 Collection Center Drive, Chicago, IL 60693.
4. Johnson Controls, P.O. BOX 93107, Chicago, IL 60673-3107.
70 TM-55360-120
16 MAY 2011
Table 8-3 Electrical Control Enclosure Assembly Parts List
FIND FIG REF CAGEC PART NO. DESCRIPTION QTY

NO. NO.
1 8-8 K1 54080 71126 CONTACTOR, 60 AMP, 3 POLE 1
2X175 CDP-C3P60- (ALTERNATE PART)
24
2 8-8 K2-K4 54080 72845 CONTACTOR, 40 AMP, 3 POLE 3
3EKU4 HCC- (ALTERNATE PART)
3XQ04CG
3 8-8 (P/O K3) 54080 72874 AUX CONTACT, 15A, NO-NC, 1
2X175 CDP-B- 24VAC
1SPDT (ALTERNATE PART)
4 8-8 TB1 54080 70001 BLOCK, POWER DISTRIBUTION, 1
71400 16220-3 175A
(ALTERNATE PART)
5 8-8 T1 54080 71001 TRANSFORMER, 150VA, 50/60HZ, 1
25.5V SECONDARY
6 8-8 TB2, TB3 54080 71233-10 TERMINAL BLOCK, 10 POLE, 2
DOUBLE ROW
71785 10-141 (ALTERNATE PART)
7 8-8 K5, K6, 54080 71007 RELAY, TIMED DELAY, D6M 3
K7 2X175 D6M (ALTERNATE PART)
8 8-8 K8, K9 54080 71716 TIMER 2
61964 H3CR-F8- (ALTERNATE PART)
24VAC/DC
9 8-8 K8, K9 54080 71717 SOCKET, TIMER 2
61964 P2CF-08E (ALTERNATE PART)
10 8-8 R1 54080 70227 RELAY, DPDT, 10 AMP, 24VAC 1
0PJN9 3-1393117-0 (ALTERNATE PART)
11 8-8 G 54080 71663-2 LAMP, GREEN 24V AC/DC LED 1
MINIATURE
8Z410 PF50CG5- (ALTERNATE PART)
0005
12 8-8 R 54080 71663-1 LAMP, RED 24V AC/DC LED 4
MINIATURE
8Z410 PF50CR5- (ALTERNATE PART)
0003
13 8-8 S3 54080 71677 SWITCH, HIGH PRESSURE, 1
MANUAL RESET, W/SCHRADER
VALVE, 480 PSI
14 8-8 S4 54080 52593 SWITCH, LOW PRESSURE, 1
AUTOMATIC RESET,
W/SCHRADER VALVE
TM-55360-120 71
16 MAY 2011
Table 8-4 GETT 1C Electrical Control Box Assembly Parts List
FIND FIG PART

REF CAGEC DESCRIPTION QTY
NO. NO. NO.
54080 70760 SWITCH, TOGGLE, ON-OFF
1 8-9 S1 1
3EKU4 7200019 (ALTERNATE PART)
54080 70761 SWITCH, TOGGLE, ON-OFF-ON
2 8-9 S7 1
3EKU4 73022 (ALTERNATE PART)
70009
54080 LAMP, GREEN, 28V
3 8-9 G 1090QC5 1
71744 (ALTERNATE PART)
-28V
70020
54080 KNOB, ROUND W/ INDICATOR LINE
4 8-9 N/A EH71- 1
23480 (ALTERNATE PART)
1C2S
5 8-10 S8 54080 70584 THERMOSTAT 1
6 8-8 LS1 54080 71724 CONTROLLER, LOADSHED 1
7 8-10 S4 54080 71522 SWITCH, SAFETY THERMOSTAT 1
8 8-10 S5 54080 71919 SWITCH, SAFETY THERMOSTAT 1
Table 8-5 Flexible Air Ducts Assembly, Base 25’ Set Parts List (PN 51983-1)
FIND FIG PART

NO. NO. NO.
1 N/A N/A 54080 70707 AIR DUCT, FLEXIBLE, 12” DIA X 25’ 4
2 N/A N/A 54080 70708 DUCT, INSULATED, 18” RETURN X 25’ 2
Table 8-6 Flexible Air Ducts Assembly, Add On 25’ Set Parts List (51983-2)
FIND FIG PART

NO. NO. NO.
1 N/A N/A 54080 70707 AIR DUCT, FLEXIBLE, 12” DIA X 25’ 2
2 N/A N/A 54080 70708 DUCT, INSULATED, 18” RETURN X 25’ 1
72 TM-55360-120
16 MAY 2011
Figure 8-1 Compressor Compartment Components
Item # Description Item # Description

1 Assembly, Electrical Control 7 Coil, Condenser, Aluminum
Enclosure
2 Switch, Fan Cycle 8 Receiver, Refrigeration
3 Switch, Head Pressure 9 Sight Glass, .625
4 Service Valve 10 Compressor, Digital Scroll
5 Motor, 3HP, 208-3Ø-60HZ 11 Solenoid, Compressor Unloading
10.4 AMP, 56Z, TEAO (inside junction box)
6 Condenser Fan, Prop
TM-55360-120 73
16 MAY 2011
Figure 8-2 Condenser Side Components, Forward
Item # Description Ref

1 Assembly, Electrical Control Enclosure -
2 Motor, 3HP, 208-3Ø-60HZ 10.4 AMP, 56Z, B2
TEAO
3 Coil, Condenser, Aluminum C1
4 Compressor, Digital Scroll B1
74 TM-55360-120
16 MAY 2011
Figure 8-3 Condenser Side Components, Aft

1 Motor, 3HP, 208-3Ø-60HZ B2
10.4 AMP, 56Z, TEAO
2 Assembly, Electrical Box -
Enclosure
3 Compressor, Digital Scroll B1
4 Receiver, Refrigeration FC1
5 Coil, Condenser, Aluminum C1
6 Condenser, Fan Shroud -
TM-55360-120 75
16 MAY 2011
WARNING
Heater Elements (Item 10 below) present an ELECTRICAL SHOCK HAZARD.
120/208 VAC and a BURN HAZARD. Keep hands away from heater coils when
ECU is in the heat mode. Allow heater to cool before touching. Failure to observe
this warning could result in serious burns or death.
Figure 8-4 Evaporator Side Components, Aft

1 Heater, 10.0 KW, 208V 3Ø, Single Stage HR1
2 Motor, 3HP, 208V, 3Ø, 1725RP B3
3 Blower Wheel, 20” X 4.5” W/ 5/8” Shaft Hub -
4 Coil, Evap, 30.00 X 29.00 COPP E1
5 Thermo Expansion Valve TXV1
6 Air Pressure Switch, Sensitive, Differential,
S9
SPDT, Adj. Set Point
7 Assembly, Electrical Control Box, GETT 1C -
8 Connector, Power Input J1
9 Receptacle, Load Shed J2
76 TM-55360-120
16 MAY 2011
Figure 8-5 Evaporator Side Components, Aft, Detail

1 Coil, Evap, 30.00 X 29.00 E1
Copper
2 Thermo Expansion Valve TXV1
TM-55360-120 77
16 MAY 2011
Figure 8-6 Evaporator Side Components, Forward

1 Blower Wheel, 20” X 4.5” W/ -
5/8” Shaft Hub
2 Motor, 3HP, 208V, 3Ø, 1725RP B3
3 Filter Drier, 5/8” X 5/8” ODF F1
4 Heater, 10.0 KW, 208V 3Ø, HR1
Single Stage
5 Coil, Evap, 30.00 X 29.00 COPP E1
78 TM-55360-120
16 MAY 2011
Figure 8-7 ECU Roadside
Item # Description
1 Eyebolt, 7/16-14 X 1 1/6”, 180
2 Heater, 10.0 KW, 208V 3Ø,
Single Stage
3 Filter, Fresh Air
4 Filter, Return Air
TM-55360-120 79
16 MAY 2011
Figure 8-8 Electrical Control Box
Item Description Ref Item Description Ref
# #
Contactor, 60 AMP, 3 Block, Power Distribution,
1 K1 9 TB1
Pole 175A
Contactor, 40 AMP, 3 Lamp, Green 24V AC/DC
2 K2,K3,K4 10 G
Pole LED Miniature
Terminal Block, 10
3 TB2 11 Ground Lug
Pole, Double Row
Aux Contact, 15A, NO- Lamp, Red 24V AC/DC
4 K3 12 R
NC, 24VAC LED Miniature
Relay, Timed Delay,
5 K5,K6,K7 13 Relay, Current Sensor LS1
D6M
Transformer, 150VA,
Switch, Low Pressure,
6 50/60HZ, 25.5V T1 14 S6
Automatic Reset, 10/32 PSI
Secondary
Switch, High Pressure,
7 Socket, Timer K8, K9 15 S7
Manual Reset, 500 PSI
Switch, Fan Cycle, 340/160
8 Timer, Socket K8, K9 16 S8
PSI
80 TM-55360-120
16 MAY 2011
Figure 8-9 ECU Control Panel

1 Switch, Toggle, HEAT-VENT-FAN S2
2 Switch, Toggle, ON-OFF S1
3 Lamp, Green, 24V G
4 Thermostat Control Knob None
5 Thermostat S3
TM-55360-120 81
16 MAY 2011
Figure 8-10 ECU Control Panel Box (Panel Removed)

1 Switch, Safety Thermostat, 56°F S5
2 Switch, Safety Thermostat, 62°F S4
3 Switch, Thermostat, Adjustable S3
82 TM-55360-120
16 MAY 2011
Table 8-7 Recommended Common Support Tools and Equipment
Item No. Description Type

1 Crimper, Multi-Purpose VACO 1900
2 Hex Key Set 5/64-/14, 12” Arms
3 Screwdriver Set, 6 Piece Slot 3/16x6, 3/16x3, 1/4x4,
5/16x6, Phillips #1x3, #2x4
Screwdriver Phillips #2x10

4 Socket Wrench Set 3/8 Drive ¼ to 7/8, 3” & 6”
Extension, Ratchet, Box
5 Wrench Set, Comb. 9 pc. ¼ to ¾ Allen 29013
6 Wrench, Adjustable (Crescent) 6”
10”
7 Meter, Analog Clamp-On VAO
Amprobe, ACD 12
Carrying Case, SV-12
Test Leads, DTL-12
8 Manifold Set (Gages) J/13 M7-5GY5
9 Meter, Phase Amprobe, PRM-1
10 Pump, Vacuum Dayton
11 Refrigerant Recovery Unit Yellow Jacket R60
12 Oxy-Acetylene Brazing Kit (without cylinders) Turbo Torch CWK-57
13 Drill Bit 7/32
14 Torque Wrench 5/32 hex, range to include
125-inch pounds
15 Electronic Refrigerant Leak Detector Johnson Controls RLD-
H10PM
TM-55360-120 83
16 MAY 2011
Table 8-8 Expendable and Durable Items List
Item No. Description U/I
1 Cloth, Cleaning (for cleaning external surfaces, wiping down internal components, AR
and wet-wrapping while brazing)
2 Sponge AR
3 Mild Soap (e.g. dish soap) AR
4 Compressed Air CN
5 Cleaner, Coil: Hydro-Balance Corp. Enviro-Coil Concentrate (CAGEC 0W3W7, CS
p/n H-EC01)
6 Bottle, Spray (for diluting Enviro-Coil) AR
7 Coil Fin Comb EA
8 Teflon Spray: Nu-Calgon Cal-Shield (CAGEC 0XX75, p/n 4148-32) QT
9 Brush, Wire EA
10 Sandpaper PG
11 Brazing Alloy, Copper-Phosphorous (for copper-to-copper brazing): Lucas- AR
Milhaupt Inc., Sil-Fos 15 (CAGEC 91874, p/n Sil-Fos 15)
12 Solder, Silver (for copper-to-brass brazing): J.W. Harris Co. Inc., Stay-Silv 45 AR
(CAGEC 27911, p/n Stay-Silv 45)
13 Flux (for copper-to-brass brazing) AR
14 1/4” Copper Tubing AR
15 Tape, Cork AR
16 Electrical Wire, 18 Gauge AR
20 R-407C Refrigerant AR
21 Dry Nitrogen AR
22 Bottle, 2oz glass (for oil samples) EA
23 Filter/Drier, Oversized (CAGEC 54080, p/n 70283) EA
24 Gloves, Rubber PR
25 Gloves, Thermal Protective PR
26 Goggles, Safety Eye EA
27 WD-40 CN
28 Spiral Wrap FT
29 Air Dry Solid Film Lubricant (CAGEC 34227, p/n 238 Dry Lube, or equivalent) CN
30 Threadlocker, general purpose, removable, medium strength (CAGEC 12405, p/n BT
Loctite 242, or equivalent)
84 TM-55360-120
16 MAY 2011
9. APPENDIX
9.1 Appendix Contents

 Table 9-1 Refrigerant Temperature/Pressure Chart
 AC434-120-110, Electrical Schematic
 AC434-120-120, Refrigeration Diagram
TM-55360-120 85
16 MAY 2011
Table 9-1 Refrigerant Temperature/Pressure Chart
86 TM-55360-120
16 MAY 2011
AC434-120-110 Electrical Schematic
TM-55360-120 87
16 MAY 2011
AC434-120-120 Refrigeration Schematic
88 TM-55360-120
16 MAY 2011

Applied Companies TM 55360 120

Uploaded by

Copyright:

Available Formats

Applied Companies TM 55360 120

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Applied Companies TM 55360 120

Uploaded by

Copyright:

Available Formats

TM-55360-120

ENVIRONMENTAL CONTROL APPLIED COMPANIES

LIST OF FIGURES ................................................................................................................ iv

Figure 2-1 Major Components (Curbside)............................................................................ 11

Table 2-1 Environmental Control Unit and Accessories ........................................................ 9

1.2 Notice to User

This is an Environmental Control Unit (ECU); it incorporates several self-contained safety

1.3 Safety Summary

1.4 Warnings and Cautions

 Exposure of certain Chlorofluorocarbon (CFC) and Halogenated

4. Shut the unit down until the ice has melted.

5. Run vent fan only until coil is defrosted

Consult factory for no cost engineering assistance.

2.1 Equipment Description

2.2 Design Features

Capacity .................................................................................. 120,000 Btu/hr

2.2.2 Physical Characteristics

Height...................................................................................... 39.00 (990.6 mm)

2.3.1 Salt Spray Protection

2.3.2 Maintenance Features

2.3.2.1 Sight Glass

2.3.2.2 Service Valves

2.3.2.3 Diagnostic Lamps

2.3.3.1 Low/High Pressure Switches

2.3.3.2 Overheat Safety Switch

2.4 Major Components

Table 2-1 Environmental Control Unit and Accessories

NOMENCLATURE PART NUMBER

ENVIRONMENTAL CONTROL UNIT 55360

FLEXIBLE AIR DUCTS ASSEMBLY, 50 ft OR 25 ft (15.24 or 51983 or 51983-1

ECU MAIN POWER ASSEMBLY 52594

LOAD SHED CABLE ASSEMBLY 51865

2.4.1 Electrical Control Box and Control Panel

2.4.3 Condenser Compartment

2.4.5 Lifting Eyes

2.4.6 Flexible Air Ducts Assembly

2.4.7 Power Cable Assembly

Supply Air Ducts

Figure 2-2 Major Components (Roadside, Forward)

ECU Fresh Air

Access Cover Return Air

Figure 2-4 Major Components (Fresh Air Filter)

SOLENOID VALVE Cycle for temperature control.

COMPRESSOR UNLOADING VALVE For temperature control.

High Limit Trip Switch (HLS) set to break on electric

HIGH SIDE SERVICE VALVE To service unit.

LOW SIDE SERVICE VALVE To service unit.

TIME DELAY RELAY Prevents compressor from short-cycling.

TEMPERATURE CONTROL Thermostat.

THERMOSTATIC EXPANSION TXV set to maintain superheat of 10 – 15°F

DIAGNOSTIC LAMPS Assist in operator identification of potential problems.

3.2 Principles of Operation

The compressor is designed to increase refrigerant pressure (temperature) to a level high

3.3 Operational Description

 As the liquid refrigerant leaves the expansion valve, it passes through a

4.1 Environmental Control Unit Leveling

4.2 Ducting Installation

Figure 4-1 Duct Attachment, Open

4.3.1 12” D-Pak Installation