Ge GSH130361CA User Manual

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Page 1

Service Instructions

Split System Air Conditioners,

Split System Heat Pumps

with R-22 Refrigerant

Blowers, Coils, & Accessories

This manual is to be used by qualified, professionally trained HVAC technicians only. Goodman does not assume any responsibility for property damage or personal injury due to improper service procedures or services performed by an unqualified person.

RS6100004r25

August 2011

Page 2

TABLE OF CONTENTS

IMPORTANT INFORMATION ......................... 2 - 3

MODEL IDENTIFICATION ............................ 4 - 13

AIR HANDLER/COIL IDENTIFICATION ..... 13 - 18

ACCESSORIES ......................................... 19 - 23

PRODUCT DESIGN ................................. 24 - 25

SYSTEM OPERATION .............................. 26 - 31

TROUBLESHOOTING CHART ......................... 32

SERVICING TABLE OF CONTENTS ................33

SERVICING .................................................34 - 65

ACCESSORIES WIRING DIAGRAMS ........66 - 74

IMPORTANT INFORMATION

Pride and workmanship go into every product to provide our customers with quality products. It is possible, however, that during its lifetime a product may require service. Products should be serviced only by a qualified service technician who is familiar with the safety procedures required in the repair and who is equipped with the proper tools, parts, testing instruments and the appropriate service manual. REVIEW ALL SERVICE INFORMATION IN THE APPROPRIATE

SERVICE MANUAL BEFORE BEGINNING REPAIRS.

IMPORTANT NOTICES FOR CONSUMERS AND SERVICERS

RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS

WARNING

This unit should not be connected to, or used in conjunction with, any devices that are not design certified for use with this unit or have not been tested and approved by Goodman. Serious property damage or personal injury, reduced unit performance and/or hazardous conditions may result from the use of devices that have not been approved or certified by Goodman.

WARNING

To prevent the risk of property damage, personal injury, or death, do not store combustible materials or use gasoline or other flammable liquids or vapors in the vicinity of this appliance.

WARNING

Goodman will not be responsible for any injury or property damage arising from improper service or service procedures. If you perform service on your own product, you assume responsibility for any personal injury or property damage which may result.

To locate an authorized servicer, please consult your telephone book or the dealer from whom you purchased this product. For further assistance, please contact:

CONSUMER INFORMATION LINE GOODMAN® BRAND PRODUCTS

TOLL FREE 1-877-254-4729 (U.S. only)

email us at: customerservice@goodmanmfg.com

fax us at: (713) 856-1821

(Not a technical assistance line for dealers.)

email us at: customerservice@goodmanmfg.com

CONSUMER INFORMATION LINE

AMANA® BRAND PRODUCTS

TOLL FREE 1-877-254-4729 (U.S. only)

fax us at: (713) 856-1821

(Not a technical assistance line for dealers.)

Outside the U.S., call 1-713-861-2500.(Not a technical assistance line for dealers.)

Your telephone company will bill you for the call.

Page 3

IMPORTANT INFORMATION

SAFE REFRIGERANT HANDLING

While these items will not cover every conceivable situation, they should serve as a useful guide.

WARNING

Refrigerants are heavier than air. They can "push out" the oxygen in your lungs or in any enclosed space.To avoid possible difficulty in breathing or death:

•

Never purge refrigerant into an enclosed room or

space. By law, all refrigerants must be reclaimed.

•

If an indoor leak is suspected, thoroughly ventilate

the area before beginning work.

• Liquid refrigerant can be very cold. To avoid possible frostbite or blindness, avoid contact with refrigerant and wear gloves and goggles. If liquid refrigerant does contact your skin or eyes, seek medical help immediately.

• Always follow EPA regulations. Never burn refrig erant, as poisonous gas will be produced.

To avoid possible explosion, use only returnable (not disposable) service cylinders when removing refrigerant from a system.

• Ensure the cylinder is free of damage which could lead to a leak or explosion.

• Ensure the hydrostatic test date does not exceed

WARNING

To avoid possible injury, explosion or death, practice safe handling of refrigerants.

5 years.

• Ensure the pressure rating meets or exceeds 400 lbs. When in doubt, do not use cylinder.

WARNING

System contaminants, improper service procedure and/or physical abuse affecting hermetic compressor electrical terminals may cause dangerous system venting.

The successful development of hermetically sealed refrigeration compressors has completely sealed the compressor's moving parts and electric motor inside a common housing, minimizing refrigerant leaks and the hazards sometimes associated with moving belts, pulleys or couplings.

Fundamental to the design of hermetic compressors is a method whereby electrical current is transmitted to the compressor motor through terminal conductors which pass through the compressor housing wall. These terminals are sealed in a dielectric material which insulates them from the housing and maintains the pressure tight integrity of the hermetic compressor. The terminals and their dielectric embedment are strongly constructed, but are vulnerable to careless compressor installation or maintenance procedures and equally vulnerable to internal electrical short circuits caused by excessive system contaminants.

In either of these instances, an electrical short between the terminal and the compressor housing may result in the loss of integrity between the terminal and its dielectric embedment. This loss may cause the terminals to be expelled, thereby venting the vaporous and liquid contents of the compressor housing and system.

A venting compressor terminal normally presents no danger to anyone, providing the terminal protective cover is properly in place.

If, however, the terminal protective cover is not properly in place, a venting terminal may discharge a combination of

(a) hot lubricating oil and refrigerant

(b) flammable mixture (if system is contaminated

with air)

in a stream of spray which may be dangerous to anyone in the vicinity. Death or serious bodily injury could occur.

Under no circumstances is a hermetic compressor to be electrically energized and/or operated without having the terminal protective cover properly in place.

See Service Section S-17 for proper servicing.

Page 4

PRODUCT IDENTIFICATION

Split System Air Conditioners R-22

Model # Description

GSC13018-241AA

oodman® Brand Split Condenser 13 Seer condensing units. Initial release. 26" chassis

GSC13036-481AA

GSC13036,48*AA

GSC1 30**1AB

GSC13036,48*AB

GSC13048*AC

GSC13018-30AC

GSC13018,24, 301AD

GSC1300421AC, 484AC

GSC 13018 , 24, 301 AE

GSC130481, 483AE/AF

GSC130363AE/AF

GSC130361DE/DD

GSC13048*AD

GSC130481AG

oodman® Brand Split Condenser 13 Seer condensing units. Initial release. 29" chassis

oodman® Brand Split Condenser 13 Seer condensing units.

Introduces new 13 SEER AC 3 PH R-22 Goodman Models

oodman® Brand Split Condenser 13 Seer condensing units. Move location of screw

hole.

oodman® Brand Split Condenser 13 Seer condensing units. Introduces new models

due to the replacement of 8-pole fan motors with 6-pole.

oodman® Brand Split Condenser 13 Seer condensing units. Move location of screw

hole.

oodman® Brand Split Condenser 13 Seer condensing units. Release Models

containing the broad ocean motor 0131M00060

oodman® Brand Split Condenser 13 Seer condensing units. Remove 1 hairpin from

coil.

oodman® Brand Split Condenser 13 Seer condensing units. Release Models contain

the broad ocean motor 0131M00061

oodman® Brand Split Condenser 13 Seer condensing units. Introduces new models

with Bristol compressors.

GSC130181BA

GSC130361BA

GSC130361BB

GSC130361DF

GSC130181CA

GSC13024 -3 01C A

GSC130241DA

GSC130361FA GSC130363BA GSC130301DA

GSC130601CA

GSC130603BA/4BA

oodman® Brand Split Condenser 13 Seer condensing units. Conversion of existing

m odels using 3/ 8" dia me ter tu be coils to 5 mm co ils.

oodman® Brand Split Condenser 13 Seer condensing units. Initial release. 35"

chassis.

oodman® Brand Split Condenser 13 Seer condensing units. Release Model with

Copeland Scroll Compressor.

oodman® Brand Split Condenser 13 Seer condensing units. Introduces new models

due to the replacement of 8-pole fan motors with 6-pole.

oodman® Brand Split Condenser 13 Seer condensing units. Introduces new models

with Bristol compressors.

oodman® Brand Split Condenser 13 Seer condensing units. Compressor changes

from a recip compressor to a Panasonic Rotary compressor

oodman® Brand Split Condenser 13 Seer condensing units. Introduces models with

re duced chas sis s ize fr om the cur ren t 29 x3 2.5 to 26x32

oodman® Brand Split Condenser 13 Seer condensing units. Release of Goodman 13

SEER Condensers, with 5 mm coils; compressor change:CR18K7-PFV-230; reduced refrigerant charge.

oodman® Brand Split Condenser 13 Seer condensing units. Converts from 3/8" to

5mm. 2.5 & 3 ton units have new coil slab height and new louver panels. 2.5 - small chassis; 3 ton medium chassis.

oodman® Brand Split Condenser 13 Seer condensing units with 5mm, 29" chassis.

Page 5

PRODUCT IDENTIFICATION

Split System Air Conditioners R-22

Model # Description

oodman® Brand Split Condenser 10 Seer condensing units with new ball

GSC100903AD

GSC100903BA GSC101203BA

GSC130181BB GSC130241DB GSC130301DB

GSC130361FB GSC130421BB GSC130481BB GSC130601CB

valve/brackets, suction tube/assembly and panel w/offset.

oodman® Brand Split Condenser 10 Seer condensing units. Initial release of light

commercial models with holding charge only in a double row coil.

CONTAIN REFRIGERANT

installation instructions.

oodman® Brand Split Condenser 13 Seer condensing units. Release models holding

charge only; and charged with R-22 per the installation instructions.

MODELS DO NOT CONTAIN REFRIGERANT

MODELS DO NOT

. Units must be evacuated and charged with R-22 per the

. Units must be evacuated

GSC130181DA GSC130241EA GSC130301EA GSC130361GA

GSC130363BB GSC130483BB GSC130603BB

GSC130181FA

GSC130241FA

GSC130301EB

oodman® Brand Split Condenser 13 Seer condensing units. Release models holding charge only; and charged with R-22 per the installation instructions. Replaces Copeland compressor with Bristol reciprocating compressor.

oodman® Brand Split Condenser 13 Seer condensing units. Release models holding

charge only; and charged with R-22 per the installation instructions.

oodman® Brand Split Condenser 13 Seer condensing units. Release models holding

charge only; and charged with R-22 per the installation instructions. Reduction of chassis to 23".

oodman® Brand Split Condenser 13 Seer condensing units. Release models holding charge only; and charged with R-22 per the installation instructions. Model listed has new 6 pole motor and corresponding fan blade.

MODELS DO NOT CONTAIN REFRIGERANT

. Units must be evacuated

Page 6

PRODUCT IDENTIFICATION

Split System Air Conditioners R-22

Model # Description

GSC140**1AA

GSC140**1AB

GSC140**1AC

GSC140**1AD

GSC14018-421BA

Model # Description

oodman® Brand Split Condenser 14 Seer condensing units. Introduces Goodman®

Brand 14 Seer AC R-22 models.

oodman® Brand Split Condenser 14 Seer condensing units. New revisions have screw

locations moved in the top panel, base pans, louvers, and control box covers.

oodman® Brand Split Condenser 14 Seer condensing units. Release models

containing the Broad Ocean motor 0131M00060 and 0131M00061

oodman® Brand Split Condenser 14 Seer condensing units. Revise condenser coils by

removing (1) hairpin. Reducing refrigerant quantities by 6 ounces.

oodman® Brand Split Condenser 14 Seer condensing units. Conversion of existing

models using 3/8" diameter tube coils to 5 mm coils.

Split System Air Conditioners R-22

mana® Brand Split Condenser 13 Seer condensing units. Initial release new models of

ASC130**1AA

ASC130**1AB

ASC130**1AC

ASC1301**1AD

ASC130601BD

Amana® Brand Deluxe 13 Seer AC R-22 conditioners.

mana® Brand Split Condenser 13 Seer condensing units. Move location of screw hole.

mana® Brand Split Condenser 13 Seer condensing units. Introduces horizontal style

louvers.

mana® Brand Split Condenser 13 Seer condensing unit s. Remove 1 hairpin from coil.

Special High Feature Split XCondenser 14 Seer condensing units.

hairpin from coil. Reduce refrigerant quantities by 6 ounces.

Split System Air Conditioners R-22

Model # Description

alue Split Condenser 13 Seer condensing units. Introduces Value 13 Seer AC R-22

VSC13018-601AA

VSC130181BA

VSC13030-361BA

models. 2 year part & 5 year compressor warranty in Bahama Beige.

alue Split Condenser 13 Seer condensing units. Converts models from 3/8" to 5mm with new coil slab height & new louver panels. 2 year part & 5 year compressor warranty in Bahama Beige.

. Remove 1

Page 7

PRODUCT IDENTIFICATION

Sp lit System Heat Pumps R-22

Model # Description

GSH10***AA

GSH10***AB

GSH100903AC GSH101203AC

GSH101203AD

GSH13***AA

GSH13**1AB

GSH13**1AC

GSH13036-48*AD

GSH13018-301BA

GSH130421AE

GSH13048*AG

oodman® B rand Split Heat Pump 10 S eer heat pump units. Initial release.

oodman® B rand Split Heat Pump 10 Seer heat pump units. Screw locations

moved in the top panel, base pans, louvers, and control box covers. .

oodman® B rand Split Heat Pump 10 S eer heat pump units. Initial release of light

commercial models without R-22 refrigerant.

REFRIGERANT

installation instructions.

oodman® B rand Split Heat Pump 10 S eer heat pump units without R-22

refrigerant with new ball valve/brackets, suction tube/assembly and panel w/offset.

oodman® B rand Split Heat Pump 13 S eer heat pump units. Initial release.

oodman® B rand Split Heat Pump 13 Seer heat pump units. Revision

introduces the following new models due to the replacement of 8-pole fan motors with 6-pole and screw locations moved in the top panel, base pans, louvers, and control box covers.

oodman® B rand Split Heat Pump 13 Seer heat pump units. Contain Broad Ocean motors Screw locations moved in the top panel, base pans, louvers, and control box covers. .

oodman® B rand Split Heat Pump 13 Seer heat pump units. Introduces models that contain the broad ocean motor

oodman® B rand Split Heat Pump 13 Seer heat pump units. Reduction in

chassis size from medium to small.

oodman® B rand Split Heat Pump 13 Seer heat pump units. Replaces V10 reversing valve with V6 r eversing valve.

oodman® B rand Split Heat Pump 13 Seer heat pump units. Introduces

model with Bristol Compressors.

. Units must be evacuated and charged with R-22 per the

MODELS DO NOT CONTAIN

GSH13036*BA/BB

GSH130181BB GSH130241BB GSH130301BB

GSH130361BC

GSH130421AF GSH130481AE

GSH130601AC

GSH130181CA GSH130241CA GSH130301CA GSH130361CA

GSH130(18,24,30,36)1CB

GSH130421AG

GSH130481AF

GSH130363AE GSH130483AE

GSH130603AC

oodman® B rand Split Heat Pump 13 Seer heat pump units. Improvements to

increase MOP values on 3 ton units.

oodman® B rand Split Pump 13 Seer condensing units. Release models holding

charge only; evacuated and charged with R-22 per the installation instructions.

oodman® B rand Split Pump 13 Seer condensing units. Release models holding charge only; evacuated and charged with R-22 per the installation instructions. Changing reciprocating compressor to scroll compressor.

oodman® B rand Split Pump 13 Seer condensing units. Release models holding

charge only; evacuated and charged with R-22 per the installation instructions. Models listed have new 6 pole motor and corresponding fan blades.

oodman® B rand Split Pump 13 Seer condensing units. Release models holding

charge only; evacuated and charged with R-22 per the installation instructions.

MODELS DO NOT CONTAIN REFRIGERANT

. Units must be

Page 8

PRODUCT IDENTIFICATION

Split System Heat Pumps R-22

Model # Description

GSH140**1AA

GSH140**1AB

GSH140**1AC

oodman® Brand Split Heat Pump 14 Seer heat pump units. Initial release.

oodman® Brand Split Heat Pump 14 Seer heat pump units. Screw locations

moved in the top panel, base pans, louvers, and control box covers.

oodman® Brand Split Heat Pump 14 Seer heat pump units. Releases

models with the Broad Ocean motor.

GSH140361AF,

GSH140421-48AD

GSH140601AE

oodman® Brand Split Heat Pump 14 Seer heat pump units. Releases

m odels that replac e TXV & com pensator with flowrator & accumu lator.

Split System Heat Pumps R-22

Model # Description

mana® Brand Split Heat Pump 13 Seer heat pump units. Initial release new

ASH130**1AA

ASH130**1AB

ASH130**1AC

models of Amana® Brand Deluxe 13 Seer R-22 heat pumps.

mana® Brand Split Heat Pump 13 Seer heat pump units. New revisions have

screw locations moved in the top panel, base pans, louvers, and control box covers.

mana® Brand Split Heat Pump 13 Seer heat pump units. New revisions have

horizontal style louvers.

Split System Heat Pumps R-22

Model # Description

VSH1318-601AA

alue Split Heat Pump 13 Seer heat pump units. Introduces Value 13 Seer HP R-

22 models. 2 year parts & 5 year compressor warranty in Bahama Beige.

Page 9

PRODUCT IDENTIFICATION

Single Piece Air Handlers

Model # Description

Single Piece R Multi-Position PSC Motor Unpainted Flowrater Introduction of new 13

ARUF****16A A

ARUF364216AB

ARUF486016AB

ARUF364216AC

ARUF****16B A

ARUF****1BA

SEER Air Handler Models . All Models will be suitable for use with R-22 and R-410A

Single Piece R Multi-Position PSC Motor Unpainted Flowrater.Revision replaces the

current spot welded blower housing with the s ame cinched or crimped design used on the 80% furnace line.

Single Piece R Multi-Position PSC Motor Unpainted Flowrater.Revision replaces the

current spot welded blower housing with the s ame cinched or crimped design used on the 80% furnace line.

Single Piece R Multi-Position PSC Motor Unpainted Flowrater.Revision replaces the

current spot welded blower housing with the s ame cinched or crimped design used on the 80% furnace line.

Single Piece R Multi-Position PSC Motor Unpainted Flowrater. Revision replaces all

ARUFcoils using wavy fin with louver enhanced fin.

Single Piece R Multi-Position PSC Motor Unpainted Flowrater Introducation of R-22

Only Air Handlers.

ARPF****16AA

ARPF364216AB

ARPF486016AB

ARPF****16BA

ARPF****1BA

ADPF****16AA

ADPF364216AB

ADPF486016AB

Single Piece R Multi-Position PSC Motor Painted Flowrater Introducation of new 13

SEER Air Handler Models . All Models will be suitable for use with R-22 and R-410A

Single Piece R Multi-Position PSC Motor Painted Flowrater. Revision replaces the

current spot welded blower housing with the s ame cinched or crimped design used on the 80% furnace line.

Single Piece R Multi-Position PSC Motor Painted Flowrater. Revision replaces the

current spot welded blower housing with the s ame cinched or crimped design used on the 80% furnace line.

Single Piece R Multi-Position PSC Motor Painted Flowrater. Revision replaces all

ARPFcoils using wavy fin with louver enhanced fin.

Single Piece R Multi-Position PSC Motor Painted Flowrater. Introducation of R-22

Only Air Handlers.

Single Piece Downflow PSC Motor Unpainted Flowrater. Introducation of new 13

SEER Air Handler Models . All Models will be suitable for use with R-22 and R-410A

Single Piece Downflow PSC Motor Unpainted Flowrater. Revision replaces the current

spot welded blower housing with the same c inched or crimped design used on the 80% furnace line.

Single Piece Downflow PSC Motor Unpainted Flowrater. Revision replaces the current

spot welded blower housing with the same c inched or crimped design used on the 80% furnace line.

ADPF304216AC

ADPF****1BA

Single Piece Downflow PSC Motor Unpainted Flowrater. Revision replaces the current

spot welded blower housing with the same c inched or crimped design used on the 80% furnace line.

Single Piece Downflow PSC Motor Unpainted Flowrater Revision replaces all

ARPFcoils using wavy fin with louver enhanced fin.

Page 10

PRODUCT IDENTIFICATION

Single Piece Air Han dlers

Model # Description

Single Piece E Multi-Position Variable-Speed Painted Flowrator. Introducation of

AEPF****16AA

AEPF****16BA

AEPF****16BB

AEPF****16CA

AEPF****1BA

new 13 SEER Air Handler Models. All Models will be suitable for use with R-22 and R-410A

Single Piece E Multi-Position Variable-Speed Painted Flowrator. Revision

introduces new models adding lower kw hit kits on the S&R plate

Single Piece E Multi-Position Variable-Speed Painted Flowrator. Revision replaces the current spot welded blower housing with the same cinched or crimped design used on the 80% furnace line.

Single Piece E Multi-Position Variable-Speed Painted Flowrator. Revision

replaces all ARPFcoils us ing wavy fin with louver enhanced fin.

Single Piece E Multi-Position Variable-Speed Painted Flowrator Introduction of R22 Only Air Handlers .

AEPF313716AA ASPF313716AA

ASPF****16AA

ASPF****16BA

AW UF****1AA

AWUF****16AA

AWUF3005-101AA

AW UF****1BA

AWUF370**16AA

AWUF****16BA

Single Piece E Multi-Position Variable-Speed Painted Flowrator

Single Piece S Multi-Position EEM m otor Painted Flowrator 3-Ton Air Handler units with 3-row coil.

Single Piece S Multi-Position EEM motor Painted Flowrator. Introduces new

ASPF Air Handlers

Single Piece S Multi-Position EEM motor Painted Flowrator. Revision introuces

modified ASPF control scheme, to ensure blower operation during and after call for heat on units with heat kits and replacing wavy fin with louver enhanced fin on coil

Single Piece Air Handler Wall Mount Unpainted Flowrator. Introduces 13 SEER

Dayton wall mount air handlers

Single Piece Air Handler Wall Mount Unpainted Flowrator. Introduces 13 SEER Dayton wall mount air handlers. All Models will be suitable for use with R-22 and R410A

Single Piece Air Handler Wall Mount Unpainted Flowrator. Introduces 13 SEER

Dayton wall mount air handlers using a Burr Oak Louvered Fin coil.

Single Piece Air Handler Wall Mount Unpainted Flowrator. Revision replaces current wavey fin design with new louvered fin design

Single Piece Air Handler Wall Mount Unpainted Flowrator. Introduction of

AWUF37 Air Handlers for use with R-22 and R410A.

Single Piece Air Handler Ceiling Mount N Uncased Flowrater. Revision has

louver fins & replaces copper tube hairpins with aluminum hairpins.

(AEPF)

(ASPF)

and

. Introduction of

ACNF****1AA

ACNF****16AA

ACNF****1AB

ACNF****1BA

AH**-1*

Single Piece Air Handler Ceiling Mount N Uncased Flowrater. Revision release

all models of 13 SEER Dayton uncased air handlers.

Single Piece Air Handler Ceiling Mount N Uncased Flowrater. Revision release

all models of 13 SEER Dayton uncased air handlers.All Models will be suitable for use with R-22 and R-410A

Single Piece Air Handler Ceiling Mount N Uncased Flowrater. Drain pan material change.

Single Piece Air Handler Ceiling Mount N Uncased Flowrater. Revision replaces

current wavey fin design with new louvered fin design

Single Piece Air Handler Hydronic Air Handler. Revision replaces the time delay

relay in the AH air handlers with the UTEC time delay control board.

Page 11

PRODUCT IDENTIFICATION

MBR/MBE Air Handlers

Model # Description

odular Blower R Multi-Position PSC Motor. Introduces module blower with PSC

MBR****AA-1AA

MBE****AA-1AA

MBE****AA-1BA

Model # Description

CAUF*****6AA

CAUF*****6BA

blow er motor.

odular Blower E Multi-Position Variable-Speed. Introduces module blower with

variable speed blower motor.

odular Blower E Multi-Position Variable-Speed.Revision introduces new models

adding lower kw hit kits on the S&R plate

Evaporator Coils

Indoor Coil A Upflow/Downflow Unca sed Flowrator. Introduces 13 SEER CAUF

Dayt on Up fl ow/Down fl ow coils.

Indoor Coil A Upflow/Downflow Unca sed Flowrator. Revision releases Burr Oak

Louvered Fin in place of the Wavy Fin currently in production.

CAUF****6*DA

CAUF*****6DB

CAPF*****6AA

CAPF*****6BA

CAPF/CAUF36***CA

CHPF*****6AA

CAPF*****6DA

CAPF*****6DB

CHPF*****6BA

Indoor Coil A Upflow/Downflow [Painted or Uncased] Flowrator. Revision

replaces existing copper coils and other associated parts with aluminum components.

Indoor Coil A Upflow/Downflow [Painted or Uncased] Flowrator. Drai n pan

material change.

Indoor Coil A Upflow/Downflow Painted Flowrator. Introduces 13 SEER CAPF

Dayt on Up fl ow/Down fl ow coils.

Indoor Coil A Upflow/Downflow Painted Flowrator. Revision releases Burr Oak

Louvered Fin in place of the Wavy Fin currently in production.

Indoor Coil A Upflow/Downflow [Painted or Uncased] Flowrator. Revision

redesigns for performance improvement from 2 row to 3 row.

Indoor Coil Horizontal A Coil Painted Flowrator. Release 13 SEER CHPF

horizontal A coil.

Indoor Coil A Upflow/Downflow [Painted or Uncased] Flowrator. Revision

replaces existing copper coils and other associated parts with aluminum components.

Indoor Coil A Upflow/Downflow [Painted or Uncased] Flowrator. Drai n pan

material change.

Indoor Coil Horizontal A Coil Painted Flowrator. Release 13 SEER CHPF horizontal A coil. Revision releases Burr Oak Louvered Fin in place of the Wavy Fin currently in production. The rows change by one, (i.e. 4 row to 3 row; 3 row to 2 row) where applicable.

Page 12

PRODUCT IDENTIFICATION

Evap orator Co ils

Mo d el # D escription

CHPF1824A6CA CHPF2430B6CA

CHPF3636B6CA CHPF3642C6CA CHPF3642D6CA

CHPF3743C6BA

CHPF3743D6BA CHPF4860D6DA

CHPF1824A6CB

CHPF2430B6CB

CHPF3636B6CB CHPF3642C6CB CHPF3642D6CB

CHPF3743C6BB

CHPF3743D6BB CHPF4860D6DB

CSCF*****6AA

CSCF*****6BA

Indoor Coil Horizontal A Coil Painted Flowrator. 13 SEER CH PF horizontal A

coil, revision has louver fins & replaces copper tube hairpins with aluminum hairpins.

Indoor Coil Horizontal A Coil Painted Flowrator. 13 SEER CH PF horizontal A

coil. Drain pan material change.

Indoor Coil S Horizontal Slab Coil C Upainted Flowrator. Release 13 SEER

CSCF slab horizontal coil.

Indoor Coil S Horizontal Slab Coil C Upainted Flowrator. Revision releases Burr

Oak Louvered Fin in place of the Wavy Fin currently in production. The rows change by one, (i.e. 4 row to 3 row; 3 row to 2 row) where applicable.

CSCF1824N6BB

CSCF3036N6BB CSCF3642N6CB CSCF4860N6CB

CTPF*****6AA CTPF1824*6AB CTPF3030*6AB CTPF3131*6AB

CTPF3636*6AC

CTPF3642*6AB CTPF4860*6AB

CTUF1824*6AA CTUF3030*6AA CTUF3131*6AA CTUF3636*6AA CTUF3642*6AA CTUF4860*6AA

CTUF1824*6AB CTUF3030*6AB CTUF3131*6AB CTUF3636*6AC CTUF3642*6AB CTUF4860*6AB

CKF24-2PA CKF36-2PA CKF36-5PA

CPKF36-2PA CPKF36-5PA CPKF48-5PA

Indoor Coil S Horizontal Slab Coil C Upainted Flowrator. Drain pan material

change.

Indoor Coil T Coated Painted Flowrator. Initial release of coated coils.

Indoor Coil T Coated Painted Flowrator. Drain pan m aterial change.

Indoor Coil T Coated Unpainted Flowrator. Initial release.

Indoor Coil T Coated Unpainted Flowrator. Drain pan material change.

Indoor Coil K Air Conditioner Flowrator.

Indoor Coil P Heat Pump K Air Conditioner Flowrator.

CKL36-1PA CKL49-1PA CKL60-1PA CKL60-3PA

Indoor Coil K

Page 13

PRODUCT IDENTIFICATION

GSC140361AA

BRAND:

G: Goodman

Amana

A: Amana

V: Value

Brand Distinctions

Brand

Brand /

PRODUCT CATEGORY:

S: Split System

UNIT T YPE:

C: Condenser R-22 H: Heat Pump R-22

SEER :

10: 10 SEER 13: 13 SEER 14: 14 SEER

NO MINAL CAPACITY:

018: 1.5 Tons 024: 2 Tons 030: 2.5 Tons 036: 3 Tons 042: 3.5 Tons 048: 4 Tons 060: 5 Tons

MINOR REVISI ON:

A: Initial Release

M AJOR REVISION:

A: Initial Re l ease

ELECTRICAL:

1: 208-230 V/1ph/60 Hz 3: 208-230 v/3ph/60 Hz 4: 460v/3ph/60Hz

C PKF 036 2 A

PRODUCT CATEGORY:

C: Split System

UNIT TYPE:

E: Commercial Air Conditioner K: Air Conditioner P: Heat Pum

REVISION:

A: Revision

ELECTRICAL:

1: 208-230V/1ph/60Hz 2: 220-240V/1ph/50 Hz 3: 208-230v/3ph/60Hz 4: 308/415V/3ph/50Hz

NOMINAL CAPACITY:

018: 1.5 Tons 048: 4 Tons 024: 2 Tons 060: 5 Tons 030: 2.5 Tons 070: 5 Tons 036: 3 Tons 090: 7.5 Tons 042: 3.5 Tons 120: 10 Tons

Page 14

PRODUCT IDENTIFICATION

C KL 036 2 A

PRODUCT CATEGORY:

C: Split System

UNIT TYPE:

E: Commercial Air Conditioner K: Air Conditioner P: Heat Pum

NOMINAL CAPACITY:

018: 1.5 Tons 048: 4 Tons 024: 2 Tons 060: 5 Tons 030: 2.5 Tons 070: 5 Tons

036: 3 Tons 090: 7.5 Tons 042: 3.5 Tons 120: 10 Tons

REVISION:

A: Revision

ELECTRICAL:

1: 208-230V/1ph/60Hz 2: 220-240V/1ph/50 Hz 3: 208-230v/3ph/60Hz 4: 308/415V/3ph/50Hz

C KF 036 2 A

PRODUCT CATEGORY:

C: Split System

UNIT TYPE:

E: Commercial Air Conditioner K: Air Conditioner P: Heat Pump

REVISION:

A: Revision

ELECTRICAL:

1: 208-230V/1ph/60Hz 2: 220-240V/1ph/50 Hz 3: 208-230v/3ph/60Hz 4: 308/415V/3ph/50Hz

NOMINAL CAPACITY:

018: 1.5 Tons 048: 4 Tons 024: 2 Tons 060: 5 Tons 030: 2.5 Tons 070: 5 Tons 036: 3 Tons 090: 7.5 Tons 042: 3.5 Tons 120: 10 Tons

Page 15

PRODUCT IDENTIFICATION

C E 120 5 A

PRODUCT CATEGORY:

C: Split System

UNIT T YPE:

E: Commercial Air Conditioner K: Air Cojditioner P: Heat Pum

NOMINAL CAPACITY:

018: 1.5 Tons 048: 4 Tons 024: 2 Tons 060: 5 Tons 030: 2.5 Tons 070: 5 Tons 036: 3 Tons 090: 7.5 Tons 042: 3.5 Tons 120: 10 Tons

REVISION:

A: Revision

ELECTRICAL:

1: 208-230V/1ph/60Hz 2: 220-240V/1ph/50 Hz 3: 208-230v/3ph/60Hz 4: 308/415V/3ph/50Hz

THIS NOMENCLATURE IS TO BE USED TRHOUGH JULY 2006

R U F 3642 1

Product Type

: Single Piece Air Handler

Application

C: Ceiling Mount PSC Motor D: Downflow PSC Motor E: Multi-Position Variable Speed Motor R: Multi-Position PSC Motor W: Wall Mount PSC Motor

Cabinet Finish

U: Unpainted P: Painted N: Uncased

Expansion Device

F: Flowrater

Nominal Capacity Range @ 13 SEER

Multi-Position & Downflow Applications

3642: 3 - 3 1/2 tons 1830: 1 1/2 - 3 1/2 tons 1729: 1 1/2 - 2 1/2 Tons 10 SEER (for export systems)

Ceiling Mount & Wall Mount Applications

1805: Nominal Cooling Capacity Electric Heat kw - 1 1/2 tons Cooling/5 kw Electric Heat 2405: Nominal Cooling Capacity Electric Heat kw - 2 Tons Cooling/5 kw Electric Heat 3608: Nominal Cooling Capacity Electric Heat kw - 3 Tons Cooling/8 kw Electric Heat

Minor Revision

: Initial Release

Major Revision

: Initial Release

Electrical

1: 208/230V, 1 Phase, 60 Hz

Page 16

PRODUCT IDENTIFICATION

)

THIS NOMENCLATURE IS TO BE USED AFTER JULY 2006

A W U F 3642 1 6 A A

EXPANSION

PRODUCT

TYPE:

A: Air Handler

CABINET FINISH:

U: Unpainted P: Painted N: Uncased

APPLICATION

C: Ceiling Mount PSC Motor D: Downflow PSC Motor E: Multi-Position Varible Speed Motor S: Energy-Efficient Motor R: Multi-Position PSC Motor T: Coated Coils W: Wall Mount PSC Motor

DEVICE:

F: Flowrater T: TXV (Expansion Device)

MINOR REVISION*

MAJOR REVISION*

REF RI GERAN T C HARGE :

No Digit: R-22 Only 6: R-410A or R-22

ELECTRICAL:

1: 208-2 30V/1ph/60 Hz

NOMINAL CAPACITY RANGE:

@ 13 SEER Dedicated Application 3636: 3 Tons

Multi-Position & Downflow Applications 3 137: 3 Tons 3642: 3 - 3 1/2 Tons 1 830: 1 1/ 2 - 3 1/2 Tons @10 SEER 1 729: 1 1/ 2 - 2 1/2 Tons (for export systems

All Airhandlers use DIRECT DRIVE MOTORS. Power supply is AC 208-230v, 60 hz, 1 phase.

Cei ling Mou nt & W all Mo unt Applic atio ns (Nominal Cooling Capacity/Electric Heat kW) 1 803: 1 1/ 2 Tons Coo ling / 3 kW Electri c He at 1 805: 1 1/ 2 Tons Coo ling / 5 kW Electri c He at 2 405: 2 Tons Coo ling / 5 kW Electri c He at 3 608: 3 Tons Coo ling / 8 kW Electri c He at 3105: 1.5 - 2.5 To ns Cooling / 5kW Ele ctric Heat 3210: 2 - 2.5 Tons Cooling / 10kW Electric Heat 3 705: 3 Tons Coo ling / 5 kW Electri c He at 3 708: 3 Tons Coo ling / 8 kW Electri c He at 3 710 : 3 Tons Coo ling / 10 kW Electric Heat

Page 17

PRODUCT IDENTIFICATION

CAPF1824A6A

PRODUCT

TYPE:

C: Indoor Coil

APPLICATION

A: Upflow/Downflow Coil H: Horizo ntal A Coil S: Horizontal Slab Coil T: Coated C oil

EXPANSION DEVICE:

F: Flowrate

CABINET FINI SH:

U: Unpainted P: Painted N: Unpainted Case

NOMINAL CAPACITY RANGE @ 13 SEER

1824: 1 1/2 to 2 Tons 3030: 2 1/2 Tons 3636: 3 Tons 3642: 3 to 3 1/2 Tons 3743: 3 to 3 1/2 Tons 4860: 4 & 5 Tons 4961: 4 & 5 Tons

REVISION

A: R evi s i on

REF RIGER AN T CHARGE:

6: R-410A or R-22 2: R-22 4: R-410a

NOMINAL WIDTH FOR GAS FURNACE

A: Fits 14" Furnace Cabinet B: F it s 17 1/ 2" Furnace Cabinet C: Fits 21" Furnace Cabinet D: Fits 24 1/2" Furnace Cabinet N: Does Not Apply (Horizontal Slab Coils)

MB R 8 00 A A 1

ELECTRICAL SUPPLY:

DESIGN SERIES:

MB: Modular Bl ower

MOTO R TYPE:

R: Constant Speed

E: Variable Speed

AIRFLOW DELIVERED

08: 800 CFM 12: 1200 CFM 16: 1600 CFM 20: 2000 CFM

FACTORY HEAT

00: No Heat

CIRCUIT BREAKER

A: No Circuit Breaker B: Ci rcuit Breaker

DESIGN SERIES

A: First Series

1: 208-230V/60hZ/1 ph

MODEL MFG. #

MBR0800 MBR0800 MBR1200 MBR1200 MBR1600 MBR1600 MBR2000 MBR2000 MBE1200 MBE1200 MBE1600 MBE1600 MBE2000 MBE2000

Page 18

ACCESSORIES

X X X

X X

X X X

Model

OT18 -60A

FSK01A*

AS C 01 TX 2N2 *

TX 3N2 *

TX 5N2 *

CSR-U-1

CSR-U-2

CSR-U-3

Model

OT18 -60A

FSK01A*

AS C 01

TX 2N2 *

TX 3N2 *

TX 5N2 *

CSR-U-1 CSR-U-2

CSR-U-3

Descripti on AS C130 18 ASC1 302 4 ASC13 030 ASC13036 ASC1304 2 ASC13048 ASC 13060

Outd oor Thermos ta t

Freeze Protection Kit

Anti Short Cycle Kit

TXV Kit

Hard Start Kit

Descri

Outd oor Thermos ta t

Freeze Protection Kit

Anti Short Cyc le K it

Hard Start Kit

Hard Start Kit Hard Start Kit

tion G/VSC13018G/VSC13024G/V SC13030 G/VS C1303

TXV Kit

--- --- --- --- - -- --- ---

--- --- --- --- --- ---

xxxx---------

--- --- --- ---

--- --- ---

--- --- --- --- - --

X X

--- --- --- ---

--- --- ---

xxxx

--- --- --- ---

--- --- ---

X X

--- --- --- ---

Model

OT18 -60A

FSK01A*

AS C 01

TX 2N2 * TX 3N2 *

TX 5N2 *

CSR-U-1

CSR-U-2

CSR-U-3

Model

FSK01A*

AS C 01

OT/EHR18-60

*Installed on indoor coil.

Description G/VSC13042 G/VSC13048 G/VSC13060

Outd oor Thermos ta t

Freeze Protection Kit

Anti Short Cyc le K it

TXV Kit TXV Kit

TXV Kit

Hard Start Kit

Descri

Freeze Protection Kit

Anti Short Cyc le K it

Emergency Heat relay kit

tion

--- --- ---

---

GSC100903 GSC100904 GSC101203 GSC101204

X X

xxxx xxxx

--- --- --- ---

Page 19

ACCESSORIES

X X X

X X

X X X

X X

Model

AF E 18 -6 0 A

OT18-60A

FSK01A* AS C 01

TX 2N2*

TX 3N2*

TX 5N2*

OT18-60A

OT/EHR18 -60

CSR-U-1

CSR-U-2 CSR-U-3

Model

AF E 18 -6 0 A

OT18-60A

FSK01A* AS C 01

TX 2N2*

TX 3N2*

TX 5N2*

OT18-60A

OT/EHR18 -60

CSR-U-1

CSR-U-2 CSR-U-3

Description G/VSH13018 G/VSH13024 G/VSH13030 G/VSH13036 G/VSH13042 G/VSH13048 G/VSH13060

All Fuel Kit

Ou tdoor Th ermo sta t

Freeze Protection Kit

Anti Short Cycle Kit X X X X X X X

TXV Kit

x --- --- --- --- --- --x X

--- --- ---

TXV Kit --- --- --- --- X X X

Outdoor Lockout Stat

Emergency Heat relay kit

Hard Start Kit

Hard Start Kit Hard Start Kit

Description ASH13018 ASH13024 ASH13030 ASH13036 ASH13042 ASH13048 ASH13060

All Fuel Kit

Ou tdoor Th ermo sta t

Freeze Protection Kit

Anti S hort Cycle K it

TXV Kit

X X X X X X X

--- --- ---

--- --- --- X

--- --- --- --- - --

X X X X X X X

X X

x --- --- --- --- --- ---

X X

TXV Kit x X X X - -- --- ---

TXV Kit

Outdoor Lockout Stat X X X X X X X

Emergency Heat relay kit

Hard Start Kit

Hard Start Kit Hard Start Kit

--- --- --- ---

X X X X X X X

--- --- ---

--- --- --- --- - --

--- --- ---

X X

Model Description GSH100903 GSH100904 GSH101203 GSH101204

FSK01A*

AS C 01 OT/EHR18 -60

*Installed on indoor coil.

Freeze Protection Kit

Anti Short Cycle Kit xxxx

Emergency Heat relay kit

xxxx

--- --- --- ---

Page 20

ACCESSORIES

Model

AFE18-60A OT18-60A

FSK01A*

ASC0 1

TX2N2*

TX3N2* TX5N2*

OT18-60A Outdoor Lockout Stat

OT/EHR18-60

CSR-U-1 Hard Start Kit

CSR-U-2

CSR-U-3 Hard Start Kit

Model

AFE18-60A OT18-60A

FSK01A* Freeze Protection Kit ASC0 1

TX2N2* TX3N2* TX5N2*

OT18-60A

OT/EHR18-60

CSR-U-1

CSR-U-2

CSR-U-3

Description

All Fuel Kit

Outdoor Thermostat

Freeze Protection Kit

Anti Short Cycle Kit

TXV Kit

Emergency Heat relay kit

Hard Start Kit

Description

All Fuel Kit

Outdoor Thermostat

Anti Short Cycle Kit

TXV Kit

Outdoor Lockout Stat

Emergency Heat relay kit

Hard Start Kit

CPKF24 CPKF36 CPKF42 CPKF48 CPKF60 CPKF61

xxxxxx xxxxxx xxxxxx xxxxxx

--- --- --- --- --- --x x --- --- --- ---

--- ---

xxxx

xxxxxx xxxxxx x x --- --- --- ---

---xxxxx

--- --- --- x x x

CKF24 CKF36 CKF48 CKF60 CKF70

--- --- --- --- ---

--- --- --- --- --xxxxx xxxxx

--- --- --- --- --x x --- --- ---

--- ---

---

--- --- --- --- ---

--- --- --- --- --x x --- --- ---

--- x x x ---

--- --- x x ---

Model

AFE18-60A OT18-60A

FSK01A* ASC0 1

TX2N2* TX3N2*

TX5N2*

OT18-60A

OT/EHR18-60

CSR-U-1

CSR-U-2

CSR-U-3

Model

AFE18-60A OT18-60A

FSK01A* ASC0 1

TX2N2*

TX3N2* TX5N2*

OT18-60A

OT/EHR18-60

CSR-U-1

CSR-U-2

CSR-U-3

Description

Outdoor Thermostat

Freeze Protection Kit

Anti Short Cycle Kit

TXV Kit

Outdoor Lockout Stat

Emergency Heat relay kit

Hard Start Kit

Description

Outdoor Thermostat

Freeze Protection Kit

Anti Short Cycle Kit

TXV Kit

Outdoor Lockout Stat

Emergency Heat relay kit

Hard Start Kit

All Fuel Kit

TXV Kit

All Fuel Kit

TXV Kit

CKL18 CKL24 CKL30 CKL36 CKL42 CKL49 CKL60

--- --- --- --- --- --- ---

--- --- --- --- --- --- --xxxxxxx xxxxxxx x --- --- --- --- --- --xxxx---------

--- --- --- --- x x x

--- --- --- --- --- --- ---

--- --- --- --- --- --- --xxxx---------

--- --- --- x x x x

--- --- --- --- --- x x

CE120

---

--x x

---

Page 21

ACCESSORIES

EXPANSION VALVE KITS

1/4 FLARE CONNECTION

BULB TO BE LOCATED AT 10 OR 2 O'CLOCK

For Applications requiring

a field installed access fitting

EVAPORATOR COIL

1/4' F LARE CONNECTION

SEAL SUPPLIED W/ KIT

REMOVE BEFORE INSTALLING EXPANSION VALVE

SUCTION LINE

BULB

EXPANSION VALVE

SUCTION LINE

EXPANSION VALVE

BULB

SEAL SUPPLIED W/ KIT

BULB TO BE LOCATED AT 10 OR 2 O'CLOCK

DISTRIBUTOR BODY

For Applications not requiring

a field installed access fitting

DISTRIBUTOR BODY

7/8" NUT

PISTON

SEAL

PISTON

SEAL

TAILPIECE

3/8"SWEAT

TAILPIECE

3/8"SWEAT

SEAL SUPPLIED W/ KIT

7/8" NUT

SEAL SUPPLIED W/ KIT

REMOVE BEFORE INSTALLING EXPANSION VALVE

OT/EHR18-60

OUTDOOR THERMOSTAT & EMERGENCY HEAT RELAY

OT18-60

Thermo sta t

DEAD DIAL

45º

Dial

COLD WARM

Set Point Indicator

Mark

(Shown @ Oº F)

(Turn Clockwise)

(Turn Counterclockwise)

315º

Set Point

djustmen t

Screw

Page 22

ACCESSORIES

Wire Nut

FSK01A

FREEZE THERMOSTAT

KIT

Wire Nut

Install Line

Thermostat

Here

ASC01A

ANTI-SHORT -CYCLE CONTROL KIT

SHORT CYCLE

Y1Y2R1

PROTECTOR

Install Line Thermostat

Here

Wire Nut

ELLOW 1

CONTACTOR

BLACK 1

T2 T1

BLACK 1

THERMOSTAT WIRE

UNIT

TERMINAL

BOARD

Page 23

ACCESSORIES

COIL MODEL TX2N2 TXV KIT TX3N2 TXV KIT TX5N2 TXV KIT FSK01A FREEZE PROTECTION KIT

CA*F030B4* --- X --- X

CA*F036B4* --- X --- X

CA*F042C4* --- --- X X

CA*F048C4* --- --- X X

CA*F057D4* --- --- X X

CA*F060D4* --- --- X X

CHPF030A4* --- X --- X

CHPF036B4* --- X --- X

CHPF042A4* --- --- X X

CHPF048D4* --- --- X X

CHPF060D4* --- --- X X

CH36FCB --- X --- X

CH48FCB --- --- X X

CH60FCB --- --- X X

CA*F18246* X X --- X

CA*F30306* --- X --- X

CA*F36426* --- X X X

CHPF18246* X --- X X

CHPF30306* --- --- X X

CHPF36426* --- --- X X

CSCF1824N6* X --- --- X

CSCF303N6* --- X --- X

CSCF3642N6* --- X X X

COIL ACCESSORIES

HKR SERIES ELECTRIC HEAT KITS

ELECTRIC HEAT KIT APPLICATIONS

MBR & MBE

BLOWER

MBR0800AA-1AA - X X X X X

MBR1200AA-1AA- X XXXXXXXXX

MBR1600AA-1AA- X XXXXXXXXX

MBR2000AA-1AA- X XXXXXXXXX

MBE1200AA-1AA - - - - X X X - - - -

MBE1600AA-1AA - - - - - X X - - - -

MBE2000AA-1AA - - - - - X X X - - -

MBE1200AA-1BA - X X X X X X - - - -

MBE1600AA-1BA - X X X X X X - - - -

MBE2000AA-1BA - X X X X X X X - - -

X = Allowable combination s ^ = Circuit 1: Single Phas e for Air Handl er Motor * = Revision lev el that my or may not b e designated

- = Restric ted combinati ons Circuit 2: 3-Phase for HKR3 Heater Kits C = Ci rcuit Breaker option

NO HEAT HKR-03* HKR05-(C)' HKR-06* HKR-08(C)* HKR-10(C)* HKR-15(C)* HKR-20(C)* HKR-21( C)* ^HKR3-15* ^HKR3-20A

ELECTRIC HEAT KIT

Page 24

PRODUCT DESIGN

This section gives a basic description of cooling unit operation, its various components and their basic operation. Ensure your system is properly sized for heat gain and loss according to methods of the Air Conditioning Contractors Association (ACCA) or equivalent.

CONDENSING UNIT

These units are designed for free air discharge. Condensed air is pulled through the condenser coil by a direct drive propeller fan and then discharged from the cabinet top. The unit requires no additional resistance (i.e. duct work) and should not be added.

The GSH13, GSH14, ASH13 and VSH13 Heat Pump condensing units are designed for 208-230 dual voltage single phase applications. The GSH13 3 ton model is available in 230V, 3 phase applications. The GSH13 4 and 5 ton models are available for 230V, 3-phase and 460V, 3-phase applications.

The units range in size from 1.5 to 5-ton and have a rating of 13 and 14 SEER. SEER efficiency is dependent upon the unit and its components. Refer to the "Technical Information" manual of the unit you are servicing for further details.

The GSC13, GSC14 and ASC13 and VSC13 Condensing Units are made in 1.5 through 5 ton sizes. They are designed for 208-240 volt single phase applications. The GSC13 3 ton model is available in 230V, 3 phase applications. The GSC13 4 and 5 ton models are available for 230V, 3-phase and 460V, 3-phase applications.

Suction and Liquid Line Connections

All units come equipped with suction and liquid valves designed for connection to refrigerant-type copper. Front seating valves are factory-installed to accept the field-run copper. The total refrigerant charge needed for a normal operation is also factory-installed. For additional refrigerant line set information, refer to the "Technical Information" manual of the unit you are servicing.

Compressors

GSC13, VSC13, GSH13 and VSH13 use a mix of reciprocating and scroll compressors, except for the VSC130181AA/BA which uses a rotary compressor. The ASC13 and ASH13 use the Copeland Scroll® Compressor. There are a number of design characteristics which differentiate the scroll compressor from the reciprocating compressor. One is the scroll. A scroll is an involute spiral which, when matched with a mating scroll form, generates a series of crescent-shaped gas pockets between the members (see following illustration). During compression, one scroll remains stationary while the other form orbits. This motion causes the resulting gas pocket to compress and push toward the center of the scrolls. When the center is reached, the gas is discharged out a port located at the compressor center.

GSC130361D* and GSC130481AG use Bristol® BENCHMARK™ compressors, the most advanced compressors in the industry today. The BENCHMARK™ reciprocating compressor can be recognized by a “J” in the fourth character of the compressor model number. Innovative mechanical design and gas management make the BENCHMARK™ compressor very efficient and remarkably quiet. The sound content (frequency) delivers exceptional acoustical characteristics and the virtually round housing design is compact and also helps to reduce the overall sound and vibration.

GSC130181BA and GSC130181CA use Panasonic® rotary compressors.

COILS AND BLOWER COILS

MBR/MBE blower cabinets are designed to be used as a twopiece blower and coil combination. MBR/MBE blower sections can be attached to cased evaporator coil. This two-piece arrangement allows for a variety of mix-matching possibilities providing greater flexibility. The MBE blower cabinet uses a variable speed motor that maintains a constant airflow with a higher duct static.

It is approved for applications with cooling coils of up to 0.8 inches W.C. external static pressure and includes a feature that allows airflow to be changed by +15%. The MBR blower cabinet uses a PSC motor. It is approved for applications with cooling coils of up to 0.5 inches W.C. external static pressure.

Page 25

PRODUCT DESIGN

The MBR/MBE blower cabinets with proper coil matches can be positioned for upflow, counterflow, horizontal right or horizontal left operation. All units are constructed with R-4.2 insulation. In areas of extreme humidity (greater than 80% consistently), insulate the exterior of the blower with insulation having a vapor barrier equivalent to ductwork insulation, providing local codes permit.

The CAPX/CHPX coils are equipped with a thermostatic expansion valve that has a built-in internal check valve for refrigerant metering. The CACF/CAPF/CHPF coils are equipped with a fixed restrictor orifice.

The coils are designed for upflow, counterflow or horizontal application, using two-speed direct drive motors on the CACF/CAPF/CHPX models and BPM (Brushless Permanent Magnet) or ECM motors on the MBE models.

The ARUF is a multi-position air handler (upflow/horizontal or downflow) and is equipped with a flowrator for cooling and heat pump applications. Because of its seamless copper tubing and aluminum fins, there are fewer leaks. The steel cabinet of the ARUF is fully insulated and rust resistant. Thermal expansion kits for air conditioning and heat pump applications are available.

ARPF*B 2 to 5 ton air handlers are dedicated for downflow operation and are approved for modular homes. Flowrater. transformer and blower time delay are on all standard ARPF units. Both the ARUF and ARPF have direct-drive multispeed motors.

AEPF is a multi-position, variable-speed air handler and can be used with R-410A or R-22 (models ending in 1/16). The unit's blower design includes a variable-speed DC motor and is compatible with heat pumps and variable-capacity cooling applications.

ASPF is a multi-position air handler that can be used with R410A or R-22 and it features a X-13 motor. This motor is a constant torque motor with very low power consumption and it is energized by a 24V signal. The X-13 features an integrated control module and is compatible with heat pumps and cooling applications.

Page 26

SYSTEM OPERATION

COOLING

The refrigerant used in the system is R-22. It is a clear, colorless, non-toxic, non-irritating, and non-explosive liquid. The chemical formula is CHCLF atmospheric pressure is -41.4°F.

A few of the important principles that make the refrigeration cycle possible are: heat always flows from a warmer to a cooler body, under lower pressure a refrigerant will absorb heat and vaporize at a low temperature, the vapors may be drawn off and condensed at a higher pressure and temperature to be used again.

The indoor evaporator coil functions to cool and dehumidify the air conditioned spaces through the evaporative process taking place within the coil tubes.

NOTE: The pressures and temperatures shown in the refrigerant cycle illustrations on the following pages are for demonstration purposes only. Actual temperatures and pressures are to be obtained from the "Expanded Performance Chart."

Liquid refrigerant at condensing pressure and temperatures, (270 psig and 122°F), leaves the outdoor condensing coil through the drier and is metered into the indoor coil through the metering device. As the cool, low pressure, saturated refrigerant enters the tubes of the indoor coil, a portion of the liquid immediately vaporizes. It continues to soak up heat and vaporizes as it proceeds through the coil, cooling the indoor coil down to about 48°F.

Heat is continually being transferred to the cool fins and tubes of the indoor evaporator coil by the warm system air. This warming process causes the refrigerant to boil. The heat removed from the air is carried off by the vapor.

As the vapor passes through the last tubes of the coil, it becomes superheated, that is, it absorbs more heat than is necessary to vaporize it. This is assurance that only dry gas will reach the compressor. Liquid reaching the compressor can weaken or break compressor valves.

The compressor increases the pressure of the gas, thus adding more heat, and discharges hot, high pressure superheated gas into the outdoor condenser coil.

In the condenser coil, the hot refrigerant gas, being warmer than the outdoor air, first loses its superheat by heat transferred from the gas through the tubes and fins of the coil. The refrigerant now becomes saturated, part liquid, part vapor and then continues to give up heat until it condenses to a liquid alone. Once the vapor is fully liquefied, it continues to give up heat which subcools the liquid, and it is ready to repeat the cycle.

. The boiling point, at

HEATING

The heating portion of the refrigeration cycle is similar to the cooling cycle. By energizing the reversing valve solenoid coil, the flow of the refrigerant is reversed. The indoor coil now becomes the condenser coil, and the outdoor coil becomes the evaporator coil.

The check valve at the indoor coil will open by the flow of refrigerant letting the now condensed liquid refrigerant bypass the indoor expansion device. The check valve at the outdoor coil will be forced closed by the refrigerant flow, thereby utilizing the outdoor expansion device.

The restrictor orifice used with the CA*F, CHPF coils and the AR*F air handler will be forced onto a seat when running in the cooling cycle, only allowing liquid refrigerant to pass through the orifice opening. In the heating cycle it will be forced off the seat allowing liquid to flow around the restrictor. A check valve is not required in this circuit.

COOLING CYCLE

When the contacts of the room thermostat close making terminals R to Y & G, the low voltage circuit of the transformer is completed. Current now flows through the magnetic holding coils of the compressor contactor (CC) and fan relay (RFC).

This draws in the normally open contact CC, starting the compressor and condenser fan motors. At the same time contacts RFC close starting the indoor fan motor.

When the thermostat is satisfied, it opens its contacts, breaking the low voltage circuit, causing the compressor contactor and indoor fan relay to open, shutting down the system.

If the room thermostat fan selector switch should be set on the "on" position, then the indoor blower would run continuous rather than cycling with the compressor.

Heat pumps energize the reversing valve thorough the "O" circuit in the room thermostat. Therefore the reversing valve remains energized as long as the thermostat subbase is in the cooling position. The only exception to this is during defrost.

Page 27

SYSTEM OPERATION

DEFROST CYCLE

The defrosting of the outdoor coil is jointly controlled by the defrost timing board, defrost (30/60) control, and compressor run time.

Solid State Defrost Control

During operation the power to the circuit board is controlled by a temperature sensor, which is clamped to a return bend (3/8" coils) or a feeder tube (5 mm coils) entering the outdoor coil. Defrost timing periods of 30, 60, or 90 minutes may be selected by connecting the circuit board jumper to 30, 60, or 90 respectively. Accumulation of time for the timing period selected starts when the sensor closes (approximately 31° F), and when the room thermostat calls for heat. At the end of the timing period, the unit’s defrost cycle will be initiated provided the sensor remains closed. When the sensor opens (approximately 75° F), the defrost cycle is terminated and the timing period is reset. If the defrost cycle is not terminated due to the sensor temperature, a ten minute override interrupts the unit’s defrost period. The new upgraded defrost control has a 12 minute override interrupt.

DF2

90 60 30

W2 DFT

DF1

HEATING CYCLE

The reversing valve on the heat pump models is energized in the cooling cycle through the "O" terminal on the room thermostat.

These models have a 24 volt reversing valve coil. When the thermostat selector switch is set in the cooling position, the "O" terminal on the thermostat is energized all the time.

Care must be taken when selecting a room thermostat. Refer to the installation instructions shipped with the product for approved thermostats.

Page 28

SYSTEM OPERATION

COOLING CYCLE

Reversing Valve

(Energized)

Indoor

Coil

HEATING CYCLE

Outdoor

Coil

Accumulator

Thermostatic

Expansion

Valve

Bi-Flow

Filter Dryer

Check Valve

Indoor

Coil

Reversing Valve

(De-Energized)

Outdoor

Coil

Accumulator

Thermostatic

Expansion

Valve

Bi-Flow

Filter Dryer

Check Valve

Page 29

SYSTEM OPERATION

EXPANSION VALVE/CHECK VALVE ASSEMBLY

IN COOLING OPERATION

Most expansion valves used in current Amana

use an internally checked expansion valve.

This type of expansion valve does not require an external check valve as shown above.

However, the principle of operation is the same.

RESTRICTOR ORIFICE ASSEMBLY

IN COOLING OPERATION

EXPANSION VALVE/CHECK VALVE ASSEMBLY

IN HEATING OPERATION

Brand Heat Pump products

RESTRICTOR ORIFICE ASSEMBLY

IN HEATING OPERATION

In the cooling mode, the orifice is pushed into its

seat, forcing refrigerant to flow through the metered

hole in the center of the orifice.

In the heating mode, the orifice moves back off its

seat, allowing refrigerant to flow unmetered around

the outside of the orifice.

Page 30

SYSTEM OPERATION

COOLING CYCLE - CONDENSING UNIT

Indoor

Coil

Outdoor

Coil

Thermostatic

Expansion

Valve

In the cooling mode, the orifice is pushed into its

seat, forcing refrigerant to flow through the metered

hole in the center of the orifice.

Page 31

SYSTEM OPERATION

AFE18-60A CONTROL BOARD

DESCRIPTION

The AFE18 control is designed for use in heat pump applications where the indoor coil is located above/downstream of a gas or fossil fuel furnace. It will operate with single and two stage heat pumps and single and two stage furnaces. The AFE18 control will turn the heat pump unit off when the furnace is turned on. An anti-short cycle feature is also incorporated which initiates a 3 minute timed off delay when the compressor goes off. On initial power up or loss and restoration of power, this 3 minute timed off delay will be initiated. The compressor won’t be allowed to restart until the 3 minute off delay has expired. Also included is a 5 second de-bounce feature on the “Y, E, W1 and O” thermostat inputs. These thermostat inputs must be present for 5 seconds before the AFE18 control will respond to it.

An optional outdoor thermostat, OT18-60A, can be used with the AFE18 to switch from heat pump operation to furnace operation below a specific ambient temperature setting, i.e. break even temperature during heating. When used in this manner, the “Y” heat demand is switched to the “W1” input to the furnace by the outdoor thermostat and the furnace is used to satisfy the first stage “Y” heat demand. On some

controls, if the outdoor thermostat fails closed in this position during the heating season, it will turn on the furnace during the cooling season on a “Y” cooling demand. In this situation, the furnace produces heat and increases the indoor temperature thereby never satisfying the cooling demand. The furnace will continue to operate and can only be stopped by switching the thermostat to the off position or removing power to the unit and then replacing the outdoor thermostat. When the AFE18 receives a “Y” and “O” input from the indoor thermostat, it recognizes this as a cooling demand in the cooling mode. If the outdoor thermostat is stuck in the closed position switching the “Y” demand to the “W1” furnace input during the cooling mode as described above, the AFE18 won’t allow the furnace to operate. The outdoor thermostat will have to be replaced to restore the unit to normal operation.

HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

Page 32

TROUBLESHOOTING CHART

COOLING/HP ANALYSIS CHART

Complaint

POSSIBLE CAUSE

DOTS IN ANAL YSI S

GUIDE INDICATE

"POSSIBLE CAUSE"

Power Failure Blown Fuse Unbalanced Power, 3PH Loose Connection Shorted or Broken Wires Open Fan Overload Faulty Thermostat Faulty Transformer Shorted or Open Capacitor Internal Compressor Overload Open Shorted or Grounded Compressor Compressor Stuck Faulty Compressor Contactor Faulty Fan Relay Open Control Circuit Low Voltage Faulty Evap. Fan Motor Shorted or Grounded Fan Motor Improper Cooling Anticipator Shortage of Refrigerant Restricted Liquid Line Open Element or Limit on Elec. Heater Dirty Air Filter Dirty Indoor Coil Not enough air across Indoor Coil Too much air across Indoor Coil Overcharge of Refrigerant Dirty Outdoor Coil Noncondensibles Recirculation of Condensing Air Infiltration of Outdoor Air Improperly Located Thermostat Air Flow Unbalanced System Undersized Broken Internal Parts Broken Valves Inefficient Compressor Wrong Type Expansion Valve Expansion Device Restricted Oversized Expansion Valve Undersized Expansion Valve Expansion Valve Bulb Loose Inoperative Expansion Valve Loose Hold-down Bolts Faulty Reversing Valve Faulty Defrost Control Faulty Defrost Thermostat Flowrator Not Seating Properly

No Cooling Unsatisfactory Cooling/Heating

SYMPTOM

System will not start

Compressor will not start - fan runs

Comp. and Cond. Fan will not start

Evaporator fan will not start

Condenser fan will not start

Compressor runs - goes off on overload

Compressor cycles on overload

System runs continuously - little cooling/htg

Too cool and then too warm

Not cool enough on warm days

•

•••

••••••

••

••• •

••

• ••••

•

••

•••

•

•••

••

•• •• •

♦♦

••• •

•• •

••

•• •

•••

••

•• ••

•

••• • ••

••• • •• •

••

••• • •

•• •

•

Cooling or Heating Cycle (Heat Pump) ♦

•••

System Operating Pressures

Certain areas too cool, others too warm

Compressor is noisy

System runs - blows cold air in heating

Unit will not terminate defrost

Unit will not defrost

Low suction pressure

Low head pressure

High suction pressure

High head pressure

Test Voltage S-1 Inspect Fuse Size & Type S-1 Test Voltage S-1 Inspect Connection - Tighten S-2, S-3 Test Circuits With Ohmmeter S-2, S-3 Test Continuity of Overload S-17A Test Continuity of Thermostat & W iring S-3 Check Control Circuit with Voltmeter S-4 Test Capacitor S-15

♦

•

♦

••

♦

••

•

♦♦♦ ♦♦♦ ♦♦♦♦♦ ♦ ♦♦♦♦♦♦♦

Heating Cycle Only (Heat Pump)

Test Continuity of Overload S-17A Test Motor Windings S-17B Use Test Cord S-17D Test Continuity of Coil & Contacts S-7, S-8 Test Continuity of Coil And Contacts S-7 Test Control Circuit with Voltmeter S-4 Test Voltage S-1 Repair or Replace S-16

♦

Test Motor Windings S-16 Check Resistance of Anticipator S-3B Test For Leaks, Add Refrigerant S-101,103 Remove Restriction, Replace Restricted Part S-112 Test Heater Element and Controls S-26,S-27 Inspect Filter-Clean or Replace

♦

Inspect Coil - Clean

♦

Check Blower Speed, Duct Static Press, Filter S-200

♦

Reduce Blower Speed S-200

•

Recover Part of Charge S-113

••

Inspect Coil - Clean

•

Recover Charge, Evacuate, Recharge S-114

•

Remove Obstruction to Air Flow Check Windows, Doors, Vent Fans, Etc. Relocate Thermostat Readjust Air Volume Dampers Refigure Cooling Load Replace Compressor S-115 Test Compressor Efficiency S-104 Test Compressor Efficiency S-104 Replace Valve S-110

♦

Remove Restriction or Replace Expansion Device S-110 Replace Valve Replace Valve Tighten Bulb Bracket S-105 Check Valve Operation S-110 Tighten Bolts Replace Valve or Solenoid S-21, 122 Test Control S-24 Test Defrost Thermostat S-25 Check Flowrator & Seat or Replace Flowrator S-111

Test Method

Remedy

See Service Procedure Ref.

Page 33

SERVICING

TABLE OF CONTENTS

S-1 Checking Voltage .......................................... 34

S-2 Checking Wiring ............................................ 34

S-3 Checking Thermostat, Wiring & Anticipator .. 34

S-3A Thermostat & Wiring ..................................... 34

S-3B Cooling Anticipator ........................................ 35

S-3C Heating Anticipator ........................................ 35

S-3D Checking Encoded Thermostats ................... 35

S-4 Checking Transformer & Control Circuit ....... 36

S-5 Checking Cycle Protector ............................. 36

S-6 Checking Time Delay Relay .......................... 36

S-7 Checking Contactor and/or Relays ................ 37

S-8 Checking Contactor Contacts ....................... 37

S-9 Checking Fan Relay Contact ........................ 37

S-10 Copeland Comfort™ Alert Diagnostics .......... 38

S-11 Checking Loss of Charge Protector ............... 40

S-15 Checking Capacitor ....................................... 40

S-15A Resistance Check ......................................... 40

S-15B Capacitance Check ....................................... 41

S-16A Checking Fan & Blower Motor

Windings (PSC Motors) ............................... 41

S-16B Checking Fan & Blower Motor (ECM Motors) 41

S-16C Checking ECM Motor Windings .................... 42

S-16D ECM CFM Adjustments ................................ 42

S-16E Checking GE X13™ Motors .......................... 46

S-17 Checking Compressor Windings ................... 46

S-17A Resistance Test ............................................ 46

S-17B Ground Test .................................................. 47

S-17D Operation Test .............................................. 47

S-18 Testing Crankcase Heater (optional item) ..... 48

S-21 Checking Reversing Valve Solenoid .............. 48

S-24 Testing Defrost Control .................................. 48

S-25 Testing Defrost Thermostat ........................... 48

S-40 MBR & AR*F Electronic Blower Time Delay .. 49

S-41 MBE & AEPF with Single Speed

Air Conditioning ............................................ 50

S-41A MBE & AEPF with Single Speed

Heat Pumps ................................................. 51

S-60 Electric Heater (optional item) ....................... 52

S-61A Checking Heater Limit Control(S) .................. 53

S-61B Checking Heater Fuse Line ........................... 54

S-62 Checking Heater Elements ........................... 54

S-100 Refrigeration Repair Practice ......................... 54

S-101 Leak Testing ................................................. 54

S-102 Evacuation .................................................... 55

S-103 Charging ........................................................ 55

S-104

S-105A Piston Kit Chart ............................................ 57

S-105B Thermostatic Expansion Valve ...................... 58

S-106 Overfeeding ................................................... 58

S-107 Underfeeding ................................................. 58

S-108 Superheat ..................................................... 58

S-109 Checking Subcooling .................................... 59

S-110 Checking Expansion Valve Operation ........... 60

S-111 Fixed Orifice Restriction Devices .................. 60

S-112 Checking Restricted Liquid Line .................... 61

S-113 Refrigerant Overcharge .................................. 61

S-114 Non-condensables ........................................ 61

S-115 Compressor Burnout ..................................... 61

S-120 Refrigerant Piping .......................................... 62

S-122 Replacing Reversing Valve ............................ 64

S-202 Duct Static Pressure

S-203 Air Handler External Static ........................... 64

S-204 Coil Static Pressure Drop ............................. 65

Checking Compressor Efficiency .................. 56

& Static Pressure Drop Across Coils ............ 64

HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

Page 34

SERVICING

S-1 CHECKING VOLTAGE

1. Remove outer case, control panel cover, etc., from unit being tested.

With power ON:

WARNING

Line Voltage now present.

S-2 CHECKING WIRING

2. Using a voltmeter, measure the voltage across terminals L1 and L2 of the contactor for the condensing unit or at the field connections for the air handler or heaters.

3. No reading - indicates open wiring, open fuse(s) no power or etc., from unit to fused disconnect service. Repair as needed.

4. With ample voltage at line voltage connectors, energize the unit.

5. Measure the voltage with the unit starting and operating, and determine the unit Locked Rotor Voltage. NOTE: If checking heaters, be sure all heating elements are energized.

Locked Rotor Voltage is the actual voltage available at the compressor during starting, locked rotor, or a stalled condition. Measured voltage should be above minimum listed in chart below.

To measure Locked Rotor Voltage attach a voltmeter to the run "R" and common "C" terminals of the compressor, or to the T1 and T2 terminals of the contactor. Start the unit and allow the compressor to run for several seconds, then shut down the unit. Immediately attempt to restart the unit while measuring the Locked Rotor Voltage.

6. Lock rotor voltage should read within the voltage tabulation as shown. If the voltage falls below the minimum voltage, check the line wire size. Long runs of undersized wire can cause low voltage. If wire size is adequate, notify the local power company in regard to either low or high voltage.

REMOTE CONDENSING UNITS

BLOWER COILS

VOLTAGE MIN. MAX.

208/230 198 253

115 104 127

1. Check wiring visually for signs of overheating, damaged insulation and loose connections.

2. Use an ohmmeter to check continuity of any suspected open wires.

3. If any wires must be replaced, replace with comparable gauge and insulation thickness.

S-3 CHECKING THERMOSTAT, WIRING, AND

ANTICIPATOR

THERMOSTAT WIRE SIZING CHART

LENGTH OF RUN

25 feet 18 50 feet 16

75 feet 14 100 feet 14 125 feet 12 150 feet 12

MIN. COPPER WIRE

GAUGE (AWG)

S-3A THERMOSTAT AND WIRING

WARNING

Line Voltage now present.

With power ON, thermostat calling for cooling

1. Use a voltmeter to check for 24 volts at thermostat wires C and Y in the condensing unit control panel.

2. No voltage indicates trouble in the thermostat, wiring or external transformer source.

3. Check the continuity of the thermostat and wiring. Repair or replace as necessary.

Indoor Blower Motor

With power ON:

NOTE: When operating electric heaters on voltages other than 240 volts, refer to the System Operation section on electric heaters to calculate temperature rise and air flow. Low voltage may cause insufficient heating.

WARNING

Line Voltage now present.

1. Set fan selector switch at thermostat to "ON" position.

2. With voltmeter, check for 24 volts at wires C and G.

3. No voltage indicates the trouble is in the thermostat or wiring.

Page 35

SERVICING

4. Check the continuity of the thermostat and wiring. Repair or replace as necessary.

Resistance Heaters

1. Set room thermostat to a higher setting than room temperature so both stages call for heat.

2. With voltmeter, check for 24 volts at each heater relay. Note: BBA/BBC heater relays are DC voltage.

3. No voltage indicates the trouble is in the thermostat or wiring.

4. Check the continuity of the thermostat and wiring. Repair or replace as necessary.

NOTE: Consideration must be given to how the heaters are wired (O.D.T. and etc.). Also safety devices must be checked for continuity.

S-3B COOLING ANTICIPATOR

The cooling anticipator is a small heater (resistor) in the thermostat. During the "off" cycle, it heats the bimetal

S-3D TROUBLESHOOTING ENCODED TWO STAGE COOLING THERMOSTATS OPTIONS

element helping the thermostat call for the next cooling cycle. This prevents the room temperature from rising too high before the system is restarted. A properly sized anticipator should maintain room temperature within 1 1/2 to 2 degree range.

The anticipator is supplied in the thermostat and is not to be replaced. If the anticipator should fail for any reason, the thermostat must be changed.

S-3C HEATING ANTICIPATOR

The heating anticipator is a wire wound adjustable heater which is energized during the "ON" cycle to help prevent overheating of the conditioned space.

The anticipator is a part of the thermostat and if it should fail for any reason, the thermostat must be replaced. See the following tables for recommended heater anticipator setting in accordance to the number of electric heaters installed.

Troubleshooting Encoded Two Stage Cooling Thermostats Options

T E S T

TEST FUNCTION SIGNAL OUT SIGNAL FAN

INDICATION

INPUT FROM

THERMOSTAT

POWER

THERMOSTAT

S1 +

* S1 - *

S1 + -

S2 +

S2 -

S2 + -

S3 +

* S3 - *

* S3 + - *

R + -

COM

NOTES:

1.) THE TEST SPA DE CAN BE CONNECTED T O ANY OTHER TEST SPADE ON EI THER BOARD.

2.) THE + LED WILL BE RED AND W ILL LIGHT TO INDICATE + HALF CYCLES. THE - LED WILL BE GREEN A ND WILL LIGHT TO INDICATE - HALF CYCLES. BOTH RED AND GREEN ILLUMINATE D WILL INDICATE FULL CYCLES DENOTED BY + - .

3.) SIGNAL OUT CONDITION FOR W1 , W2 H EATER WILL BE AFFECTED BY OT1 PJ 4 AND OT2 PJ2 JUMPERS AND OUTDOOR THERMOSTATS A TTACHED. THE TABLE ABOVE AS SUMES OT1 PJ4 IS REMOVED AND OT2 PJ2 IS MADE WITH NO OUTDOOR THERMOSTATS ATTACHED.

LOW SPEED COOL

* LO SPEED COOL *

HI SPEED COOL

LO SPEED HEAT

HI SPEED HEAT

N/A

24 VAC

GND

YCON +

* YCON - *

YCON + -

W1 HEATER

ED -

( FUTURE USE )

W1 HEATER

W2 HEATER

NONE

N/A

R TO T'STAT

COM TO T'STAT

* Y / Y2 HI *

Y / Y2

W / W1

EM / W2

N/A

C1 , C2

* ERROR CONDITION ( DIODE ON THERMOSTAT B ACKWARDS )

SEE NOTE 3

* ERROR CONDITION ( S3 CAN ONLY READ + )

The chart above provides troubleshooting for either version of the encoded thermostat option. This provides diagnostic information for the GMC CHET18-60 or a conventional two cool / two stage heat thermostat with IN4005 diodes added as called out in the above section.

A test lead or jumper wire can be added from the test terminal to any terminal on the B13682-74 or B13682-71 variable speed terminal board and provide information through the use of the LED lights on the B13682-71 VSTB control. Using this chart, a technician can determine if the proper input signal is being received by the encoded VSTB control and diagnose any problems that may be relayed to the output response of the B13682-74 VSTM control.

Page 36

SERVICING

S-4 CHECKING TRANSFORMER

AND CONTROL CIRCUIT

A step-down transformer (208/240 volt primary to 24 volt secondary) is provided with each indoor unit. This allows ample capacity for use with resistance heaters. The outdoor sections do not contain a transformer.

With power ON:

WARNING

Line Voltage now present.

1. Apply 24 VAC to terminals R1 and R2.

2. Should read 24 VAC at terminals Y1 and Y2.

3. Remove 24 VAC at terminals R1 and R2.

4. Should read 0 VAC at Y1 and Y2.

5. Reapply 24 VAC to R1 and R2 - within approximately three (3) to four (4) minutes should read 24 VAC at Y1 and Y2.

If not as above - replace relay.

WARNING

Disconnect ALL power before servicing.

1. Remove control panel cover, or etc., to gain access to transformer.

With power ON:

WARNING

Line Voltage now present.

2. Using a voltmeter, check voltage across secondary voltage side of transformer (R to C).

3. No voltage indicates faulty transformer, bad wiring, or bad splices.

4. Check transformer primary voltage at incoming line voltage connections and/or splices.

5 If line voltage available at primary voltage side of trans-

former and wiring and splices good, transformer is inoperative. Replace.

S-5 CHECKING CYCLE PROTECTOR

Some models feature a solid state, delay-on make after break time delay relay installed in the low voltage circuit. This control is used to prevent short cycling of the compressor under certain operating conditions.

The component is normally closed (R1 to Y1). A power interruption will break circuit (R1 to Y1) for approximately three minutes before resetting.

S-6 CHECKING TIME DELAY RELAY

Time delay relays are used in some of the blower cabinets to improve efficiency by delaying the blower off time. Time delays are also used in electric heaters to sequence in multiple electric heaters.

WARNING

Disconnect ALL power before servicing.

1. Tag and disconnect all wires from male spade connections of relay.

2. Using an ohmmeter, measure the resistance across terminals H1 and H2. Should read approximately 150 ohms.

3. Using an ohmmeter, check for continuity across terminals 3 and 1, and 4 and 5.

4. Apply 24 volts to terminals H1 and H2. Check for continuity across other terminals - should test continuous. If not as above - replace.

NOTE: The time delay for the contacts to make will be approximately 20 to 50 seconds and to open after the coil is de-energized is approximately 40 to 90 seconds.

OHMMETER

1. Remove wire from Y1 terminal.

2. Wait for approximately four (4) minutes if machine was running.

TESTING COIL CIRCUIT

Page 37

SERVICING

S-7 CHECKING CONTACTOR AND/OR RELAYS

WARNING

HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

The compressor contactor and other relay holding coils are wired into the low or line voltage circuits. When the control circuit is energized, the coil pulls in the normally open contacts or opens the normally closed contacts. When the coil is de-energized, springs return the contacts to their normal position.

NOTE: Most single phase contactors break only one side of the line (L1), leaving 115 volts to ground present at most internal components.

1. Remove the leads from the holding coil.

2. Using an ohmmeter, test across the coil terminals.

If the coil does not test continuous, replace the relay or contactor.

S-8 CHECKING CONTACTOR CONTACTS

VOLT/OHM

METER

Ohmmeter for testing holding coil Voltmeter for testing contacts

TESTING COMPRESSOR CONTACTOR

S-9 CHECKING FAN RELAY CONTACTS

L1L2

WARNING

DISCONNECT ELECTRICAL POWER SUPPLY.

Disconnect Electrical Power Supply:

1. Disconnect the wire leads from the terminal (T) side of the contactor.

2. With power ON, energize the contactor.

WARNING

Line Voltage now present.

3. Using a voltmeter, test across terminals.

A. L2 - T1 - No voltage indicates CC1 contacts open.

If a no voltage reading is obtained - replace the contactor.

1. Disconnect wires leads from terminals 2 and 4 of Fan Relay Cooling and 2 and 4, 5 and 6 of Fan Relay Heating.

2. Using an ohmmeter, test between 2 and 4 - should read open. Test between 5 and 6 - should read continuous.

3. With power ON, energize the relays.

WARNING

Line Voltage now present.

OHMMETER

TESTING FAN RELAY

4. Using an ohmmeter, test between 2 and 4 - should read continuous . Test between 5 and 6 - should read open.

5. If not as above, replace the relay.

Page 38

SERVICING

S-10 COPELAND COMFORT ALERT™

DIAGNOSTICS

Applies to ASC13 & ASH13

Comfort Alert™ is self-contained with no required external sensors and is designed to install directly into the electrical box of any residential condensing unit that has a Copeland Scroll™ compressor inside.

Once attached, Comfort Alert™ provides around-the-clock monitoring for common electrical problems, compressor defects and broad system faults. If a glitch is detected, an LED indicator flashes the proper alert codes to help you quickly pinpoint the problem. See Diagnostic Table on

following page.)

Page 39

SERVICING

DIAGNOSTICS TABLE

Status LED Status LED Description Status LED Troubleshooting Information

Green “POWER” Module has power

Red “TRIP”

Yellow “ALERT” Long Run Time

Flash Code 1

Yellow “ALERT” System Pressure Trip

Flash Code 2

Yellow “ALERT” Short Cycling

Flash Code 3

Yellow “ALERT” Locked Rotor

Flash Code 4

Yellow “ALERT” Open Circuit

Flash Code 5

Yellow “ALERT” Open Start Circuit

Flash Code 6

Yellow “ALERT” Open Run Circuit

Flash Code 7

Yellow “ALERT” Welded Contactor

Flash Code 8

Yellow “ALERT” Low Voltage

Flash Code 9

• Flash Code number corresponds to a number of LED flashes, followed by a pause and then repeated

• TRIP and ALERT LEDs flashing at same time means control circuit voltage is too low for operation.

• Reset ALERT Flash code by removing 24VAC power from module

• Last ALERT Flash code is displayed for 1 minute after module is powered on.

Thermostat demand signal 1. Compressor protector is open

Y1 is present, but the 2. Outdoor unit power disconnect is open

compressor is not 3. Compressor circuit breaker or fuse(s) is open

running 4. Broken wire or connector is not making contact

Compressor is 2. Evaporator blower is not running

running extremely 3. Evaporator coil is frozen

long run cycles 4. Faulty metering device

Discharge or suction 2. Condenser coil poor air circulation (dirty, blocked, damaged)

pressure out of limits or 3. Condenser fan is not running

compressor overloaded 4. Return air duct has substantial leakage

Compressor is running 2. Time delay relay or control board defective

only briefly 3. If high pressure switch present go to Flash Code 2 information

Current only in run circuit 2. Open circuit in compressor start wiring or connections

Current only in start circuit 2. Compressor run winding is damaged

Compressor always runs 2. Thermostat demand signal not connected to module

Control circuit < 17VAC 2. Low line voltage (contact utility if voltage at disconnect is low)

Supply voltage is present at module terminals

5. Low pressure switch open if present in system

6. Compressor contactor has failed open

1. Low refrigerant charge

5. Condenser coil is dirty

6. Liquid line restriction (filter drier blocked if present in system)

7. Thermostat is malfunctioning

1. High head pressure

5. If low pressure switch present in system,

check Flash Code 1 information

1. Thermostat demand signal is intermittent

4. If low pressure switch present go to Flash Code 1 information

1. Run capacitor has failed

2. Low line voltage (contact utility if voltage at disconnect is low)

3. Excessive liquid refrigerant in compressor

4. Compressor bearings are seized

1. Outdoor unit power disconnect is open

2. Compressor circuit breaker or fuse(s) is open

3. Compressor contactor has failed open

4. High pressure switch is open and requires manual reset

5. Open circuit in compressor supply wiring or connections

6. Unusually long compressor protector reset time

due to extreme ambient temperature

7. Compressor windings are damaged

1. Run capacitor has failed

3. Compressor start winding is damaged

1. Open circuit in compressor run wiring or connections

1. Compressor contactor has failed closed

1. Control circuit transformer is overloaded

Page 40

SERVICING

S-11 CHECKING LOSS OF CHARGE PROTECTOR

(Heat Pump Models)

The loss of charge protector senses the pressure in the liquid line and will open its contacts on a drop in pressure. The low pressure control will automatically reset itself with a rise in pressure.

The low pressure control is designed to cut-out (open) at approximately 7 PSIG. It will automatically cut-in (close) at approximately 25 PSIG.

Test for continuity using a VOM and if not as above, replace the control.

S-15 CHECKING CAPACITOR

CAPACITOR, RUN

A run capacitor is wired across the auxiliary and main windings of a single phase permanent split capacitor motor. The capacitors primary function is to reduce the line current while greatly improving the torque characteristics of a motor. This is accomplished by using the 90° phase relationship between the capacitor current and voltage in conjunction with the motor windings, so that the motor will give two phase operation when connected to a single phase circuit. The capacitor also reduces the line current to the motor by improving the power factor.

The line side of this capacitor is marked with "COM" and is wired to the line side of the circuit.

CAPACITOR, START

SCROLL COMPRESSOR MODELS

In most cases hard start components are not required on Scroll compressor equipped units due to a non-replaceable check valve located in the discharge line of the compressor. However, in installations that encounter low lock rotor voltage, a hard start kit can improve starting characteristics and reduce light dimming within the home. Only hard start kits approved by Amana "Kick Start" and/or "Super Boost" kits are not approved start assist devices.

The discharge check valve closes off high side pressure to the compressor after shut down allowing equalization through the scroll flanks. Equalization requires only about ½ second.

To prevent the compressor from short cycling, a Time Delay Relay (Cycle Protector) has been added to the low voltage circuit.

RELAY, START

A potential or voltage type relay is used to take the start capacitor out of the circuit once the motor comes up to speed. This type of relay is position sensitive. The normally closed contacts are wired in series with the start capacitor and the relay holding coil is wired parallel with the start winding. As the motor starts and comes up to speed, the increase in voltage across the start winding will energize the start relay holding coil and open the contacts to the start capacitor.

Two quick ways to test a capacitor are a resistance and a capacitance check.

brand or Copeland should be used.

START

CAPACITOR

VIOLET 20

YELLOW 12

RUN

CAPACITOR

RED 10

START RELAY

ORANGE 5

T2 T1

L1L2

CONTACTOR

HARD START KIT WIRING

S-15A RESISTANCE CHECK

1. Discharge capacitor and remove wire leads.

WARNING

Discharge capacitor through a 20 to 30 OHM resistor before handling.

OHMMETER

CAPACITOR

TESTING CAPACITOR RESISTANCE

2. Set an ohmmeter on its highest ohm scale and connect the leads to the capacitor -

A. Good Condition - indicator swings to zero and slowly returns to infinity. (Start capacitor with bleed resistor will not return to infinity. It will still read the resistance of the resistor).

Page 41

SERVICING

B. Shorted - indicator swings to zero and stops there replace.

C. Open - no reading - replace. (Start capacitor would read resistor resistance.)

S-15B CAPACITANCE CHECK

Using a hookup as shown below, take the amperage and voltage readings and use them in the formula:

VOLT ME T ER

15 AMP

FUSE

AMMETER

1. Remove the motor leads from its respective connection points and capacitor (if applicable).

2. Check the continuity between each of the motor leads.

3. Touch one probe of the ohmmeter to the motor frame (ground) and the other probe in turn to each lead.

If the windings do not test continuous or a reading is obtained from lead to ground, replace the motor.

S-16B CHECKING FAN AND BLOWER MOTOR

(ECM MOTORS)

An ECM is an Electronically Commutated Motor which offers many significant advantages over PSC motors. The ECM has near zero rotor loss, synchronous machine operation, variable speed, low noise, and programmable air flow. Because of the sophisticated electronics within the ECM motor, some technicians are intimated by the ECM motor; however, these fears are unfounded. GE offers two ECM motor testers, and with a VOM meter, one can easily perform basic troubleshooting on ECM motors. An ECM motor requires power (line voltage) and a signal (24 volts) to operate. The ECM motor stator contains permanent magnet. As a result, the shaft feels "rough" when turned by hand. This is a characteristic of the motor, not an indication of defective bearings.

CAPACITOR

TESTING CAPACITANCE

WARNING

Discharge capacitor through a 20 to 30 OHM resistor before handling.

Capacitance (MFD) = 2650 X Amperage

Voltage

S-16A CHECKING FAN AND BLOWER MOTOR

WINDINGS (PSC MOTORS)

The auto reset fan motor overload is designed to protect the motor against high temperature and high amperage conditions by breaking the common circuit within the motor, similar to the compressor internal overload. However, heat generated within the motor is faster to dissipate than the compressor, allow at least 45 minutes for the overload to reset, then retest.

WARNING

Line Voltage now present.

1. Disconnect the 5-pin connector from the motor.

2. Using a volt meter, check for line voltage at terminals #4 & #5 at the power connector. If no voltage is present:

3. Check the unit for incoming power See section S-1.

4. Check the control board, See section S-40.

5. If line voltage is present, reinsert the 5-pin connector and remove the 16-pin connector.

6. Check for signal (24 volts) at the transformer.

7. Check for signal (24 volts) from the thermostat to the "G" terminal at the 16-pin connector.

8. Using an ohmmeter, check for continuity from the #1 & #3 (common pins) to the transformer neutral or "C" thermostat terminal. If you do not have continuity, the motor may function erratically. Trace the common circuits, locate and repair the open neutral.

9. Set the thermostat to "Fan-On". Using a voltmeter, check for 24 volts between pin # 15 (G) and common.

10. Disconnect power to compressor. Set thermostat to call for cooling. Using a voltmeter, check for 24 volts at pin # 6 and/or #14.

11. Set the thermostat to a call for heating. Using a voltmeter, check for 24 volts at pin #2 and/or #11.

Page 42

SERVICING

Lines 1 and 2 will be connected for 12OVAC Power Connector

}

applications only

Gnd

AC Line Connection

4. Using an ohmmeter, check the motor windings for continuity to ground (pins to motor shell). If the ohmmeter indicates continuity to ground, the motor is defective and must be replaced.

5. Using an ohmmeter, check the windings for continuity (pin to pin). If no continuity is indicated, the thermal limit (over load) device may be open. Allow motor to cool and retest.

OUT - OUT +

DJUST +/-

Y1 Y/Y2

COOL

DELAY

COMMON2

W/W1

COMMON1 O (REV VALVE)

AC Line Connection

816

G (FAN)

EM Ht/W2

24 Vac (R)

HEAT

BK/PWM (SPEED)

16-PIN ECM HARNESS CONNECTOR

If you do not read voltage and continuity as described, the problem is in the control or interface board, but not the motor. If you register voltage as described , the ECM power head is defective and must be replaced.

S-16C CHECKING ECM MOTOR WINDINGS

1. Disconnect the 5-pin and the 16-pin connectors from the ECM power head.

2. Remove the 2 screws securing the ECM power head and separate it from the motor.

3. Disconnect the 3-pin motor connector from the power head and lay it aside.

3-pin motor connector

16-pin connector

5-pin connector

S-16D ECM CFM ADJUSTMENTS

MBE MOTOR

This section references the operation characteristics of the MBE model motor only. The ECM control board is factory set with the dipswitch #4 in the “ON” position and all other dipswitches are factory set in the “OFF” position. When MBE is used with 2-stage cooling units, dipswitch #4 should be in the "OFF" position.

For most applications, the settings are to be changed according to the electric heat size and the outdoor unit selection.

The MBE product uses a General Electric ECMTM motor. This motor provides many features not available on the traditional PSC motor. These features include:

• Improved Efficiency

• Constant CFM

• Soft Start and Stop

• Improved Humidity Control

MOTOR SPEED ADJUSTMENT

Each ECM™ blower motor has been preprogrammed for operation at 4 distinct airflow levels when operating in Cooling/Heat Pump mode or Electric Heat mode. These 4 distinct levels may also be adjusted slightly lower or higher if desired. The adjustment between levels and the trim adjustments are made by changing the dipswitch(s) either to an "OFF" or "ON" position.

Page 43

SERVICING

(

)

ity)

Check

for

undercharged

condition

Check

and

plug

leaks

return

ducts

cabinet

different

Troubleshooting Chart for ECM Variable Speed Air Circulator Blower Motors

have completel

- Turn power OFF prior to repair.

Wait 5 minutes after

disconnecting power before

opening motor.

- Turn power OFF prior to repair.

Wait 5 minutes after

disconnecting power before

opening motor.

- Handle electronic motor/control with care.

- Check 230 Vac power at motor.

- Check low voltage (24 Vac R to C) at motor.

- Check low voltage connections

(G, Y, W, R, C) at motor.

- Check for unseated pins in connectors

on motor harness.

- Test with a temporary jumper between R - G.

- Check for loose motor mount.

- Handle electronic motor/control with care.

- Make sure blower wheel is tight on shaft.

- Perform motor/control replacement check,

ECM motors only.

- Turn power OFF prior to repair.

- Check line voltage for variation or "sag".

- Check low voltage connections

(G, Y, W, R, C) at

motor, unseated pins in motor

harness connectors.

- Check-out system controls - Thermostat.

- Perform Moisture Check.*

- Turn power OFF prior to repair.

- Does removing panel or filter

reduce "puffing"?

- Check/replace filter.

- Check/correct duct restrictions.

- Adjust to correct blower speed setting.

capac

look alike, different modules ma

, en a

h the

oo muc

ow r

modes. Even thou

ow a or

e harnesses with "drip loop" under motor.

resu e

uce unexpec

rammed for specific operatin

pro

.- Arran

---- ---- ----

es an

are factor

warran

CHART CONTINUED ON NEXT PAGE

pro

s a

- Manual disconnect switch off or

- Incorrect or dirty filter(s).

- Incorrect supply or return ductwork.

- Variation in 230 Vac to motor.

- Unseated pins in wiring harness

connectors.

- Erratic CFM command from

"BK" terminal.

- Improper thermostat connection or setting.

- Loose motor mount.

- Blower wheel not tight on motor shaft.

door switch open.

- Blown fuse or circuit breaker.

- 24 Vac wires miswired.

- Unseated pins in wiring

harness connectors.

- Bad motor/control module.

- Moisture present in motor or control module.

- Bad motor/control module.

- Moisture present in motor/control module.

- Incorrect blower speed setting.

equipment manufacturer

e vo u

mo ro

con or

. -

or as recommended b

- "Hunts" or "puffs" at

- It is normal for motor to

oscillate with

- Motor rocks,

- This is normal start-up for

variable speed motor.

- No movement.

but won't start.

no load on shaft.

- Varies up and down

or intermittent.

high CFM (speed).

n p ra

ensa

Symptom Fault Description(s) Possible Causes Corrective Action Cautions and Notes

s con

*Moisture Check

- Motor

oscillates up &

down while

being tested

- Motor rocks

slightly

when starting.

- Motor won't

start.

off of blower.

- Motor starts,

but runs

erratically.

- Connectors are oriented "down"

e wron

n s

e: o

You must use the correct replacement control/motor module since the

mpor

functionality. The ECM variable speed motors are c

Note:

Page 44

SERVICING

(

)

ity)

Check

for

undercharged

condition

Check

and

plug

leaks

return

ducts

cabinet

different

- Turn power OFF prior to repair.

Wait 5 minutes after

disconnecting power before

opening motor.

- Handle electronic motor/control

with care.

- Turn power OFF prior to repair.

Wait 5 minutes after

disconnecting power before

opening motor.

- Handle electronic motor/control

with care.

- Turn power OFF prior to repair.

- Check low voltage (Thermostat)

wires and connections.

- Verify fan is not in delay mode -

wait until delay complete.

- Perform motor/control replacement

check, ECM motors only.

- Is fan in delay mode? - wait until delay time complete.

- Perform motor/control replacement check, ECM

motors only.

- Check for Triac switched t'stat

or solid state relay.

- Check/replace filter.

CHART CONTINUED FROM PREVIOUS PAGE

- 24 Vac wires miswired or loose.

- "R" missing/not connected at motor.

Troubleshooting Chart for ECM Variable Speed Air Circulator Blower Motors

- Fan in delay mode.

- Stays at low CFM despite

system call for cool

or heat CFM.

Symptom Fault Description(s) Possible Causes Corrective Action Cautions and Notes

- "R" missing/not connected at motor.

- Fan in delay mode.

- Stays at high CFM.

- Motor starts,

but runs

erratically.

- Current leakage from controls

into G, Y, or W.

- High static creating high blower speed.

- Incorrect supply or return ductwork.

- Blower won't shut off.

have completel

- Turn power OFF prior to repair.

- Check/correct duct restrictions.

- Adjust to correct blower speed setting.

- Check for loose blower housing,

- Turn power OFF prior to repair.

panels, etc.

- Check for air whistling thru seams in

ducts, cabinets or panels.

- Check for cabinet/duct deformation.

- Turn power OFF prior to repair.

- Does removing panel or filter

reduce "puffing"?

- Check/replace filter.

- Turn power OFF prior to repair.

Wait 5 minutes after

disconnecting power before

opening motor.

- Handle electronic motor/control

with care.

capac

look alike, different modules ma

, en a

h the

oo muc

ow r

modes. Even thou

ow a or

e harnesses with "drip loop" under motor.

- Check/correct duct restrictions.

- Adjust to correct blower speed setting.

- Replace motor and perform

Moisture Check.*

resu e

uce unexpec

rammed for specific operatin

pro

.- Arran

es an

are factor

warran uc

pro

s a

- Incorrect or dirty filter(s).

- Incorrect blower speed setting.

- Loose blower housing, panels, etc.

- High static creating high blower

speed.

- Air leaks in ductwork, cabinets,

or panels.

- High static creating high blower speed.

- Incorrect or dirty filter(s).

- Incorrect supply or return ductwork.

- Incorrect blower speed setting.

- Moisture in motor/control module.

equipment manufacturer

e vo u

mo ro

con or

. -

or as recommended b

- Air noise.

- Noisy blower or cabinet.

- "Hunts" or "puffs" at

high CFM (speed).

- Motor failure or

malfunction has

occurred and moisture

is present.

n p ra

ensa

s con

*Moisture Check

- Evidence of

- Excessive

noise.

Moisture.

- Connectors are oriented "down"

e wron

n s

e: o

You must use the correct replacement control/motor module since the

mpor

functionality. The ECM variable speed motors are c

Note:

Page 45

SERVICING

DIPSWITCH FUNCTIONS

The MBE air handler motor has an electronic control that contains an eight (8) position dip switch. The function of these dipswitches are shown in Table 1.

Dipswitch Number Function

1 2 3 4 5 6 7 8

Table 1

CFM DELIVERY

Tables 2, 2A and 3, 3A show the CFM output for dipswitch

combinations 1-2, 5-6 and 7-8.

Electric Heat Operation

Model Switch 1 Switch 2 CFM

OFF OFF 1,200

MBE120 0

OFF

OFF OFF 1,600

MBE160 0

OFF

MBE200 0

OFF ON 1,600

Table 2

Electric Heat

N/A

Indoor Thermostat

Cooling & Heat Pump CFM

CFM Trim Adjust

OFF

OFF OFF

1,000

800

600

1,400 1,200

1,000 2,000 1,800

1,200

Dips witch 1/2 & 7/8 AEPF 18 30

Heating

Element

(kw)

UP TO 10 O FF O FF O FF O FF 11 00 12 10

UP TO 10 ON OFF OFF OFF 890 935

5 OFF ON OFF OFF 700 770

AEPF3 036 / 3137 / 42 60

Heati ng

Element

(kw)

UP TO 20 O FF O FF O FF O FF 20 50 21 50

UP TO 20 ON OFF OFF OFF 1750 1835

UP TO 15 OFF ON OFF OFF 1600 1680

UP TO 10 O N O N O FF O FF 120 0 12 60

UP TO 10 ON ON OFF ON 1020 1070

Switch

Position

1278

Switch

Position

1278

Switch

Position

Switch

Position

Emergency

Backup

Emergency

Backup

Table 3

Dipswitch 5/6 & 7/8

AEPF 18 30

Switch

Position

5 6 7 8 Cooli ng Heat Pump

OFF OFF OFF OFF 1100 1100

ON OFF O FF OFF 800 800

OFF ON OFF OFF 600 600

AEPF3 036 / 3137 / 4260

Switch

Position

5 6 7 8 Cooli ng Heat Pump

OFF OFF OFF OFF 1800 1800

ON OFF O FF OFF 1580 1580

OFF ON OFF OFF 148 0 1480

ON ON OFF OFF 1200 1 200

ON ON OFF ON 1020 1020

Switch

Posit ion

Switch

Posit ion

Indoor Airflow

Table 3A

Heat Pump

With Backup

Heat Pump

With Backup

Cooling/Heat Pump Operation

Model Switch 5 Switch 6 CFM

OFF OFF 1,200

MBE1200

OFF

ON ON

OFF OFF 1,600

MBE1600

MBE2000

OFF

OFF ON 1,200

OFF

ON ON

OFF

Table 2A

1,000

800 600

1,400

1,200 1,000 1,600 1,400

1,000

THERMOSTAT “FAN ONLY” MODE

During Fan Only Operations, the CFM output is 30% of the cooling setting.

CFM TRIM ADJUST

Minor adjustments can be made through the dip switch combination of 7-8. Table 4 shows the switch position for this feature.

NOTE: The airflow will not make the decreasing adjustment in Electric Heat mode.

CFM Switch 7 Switch 8

+10% ON OFF

-15% OFF O N

Table 4

Page 46

SERVICING

HUMIDITY CONTROL

When using a Humidstat (normally closed), cut jumper PJ6 on the control board. The Humidstat will only affect cooling airflow by adjusting the Airflow to 85%.

TWO STAGE HEATING

When using staged electric heat, cut jumper PJ4 on the control board.

S-16E CHECKING GE X13TM MOTORS

The GE X13TM Motor is a one piece, fully encapsulated, 3 phase brushless DC (single phase AC input) motor with ball bearing construction. Unlike the ECM 2.3/2.5 motors, the GE X13TM features an integral control module.

S-17 CHECKING COMPRESSOR

WARNING

Hermetic compressor electrical terminal venting can be dangerous. When insulating material which supports a hermetic compressor or electrical terminal suddenly disintegrates due to physical abuse or as a result of an electrical short between the terminal and the compressor housing, the terminal may be expelled, venting the vapor and liquid contents of the compressor housing and system.

Note: The GE TECMate will not currently operate the GE

X13

motor.

1. Using a voltmeter, check for 230 volts to the motor connections L and N. If 230 volts is present, proceed to step 2. If 230 volts is not present, check the line voltage circuit to the motor.

2. Using a voltmeter, check for 24 volts from terminal C to either terminal 1, 2, 3, 4, or 5, depending on which tap is being used, at the motor. If voltage present, proceed to step 3. If no voltage, check 24 volt circuit to motor.

3. If voltage was present in steps 1 and 2, the motor has failed and will need to be replaced.

Note: When replacing motor, ensure the belly band is between the vents on the motor and the wiring has the proper drip loop to prevent condensate from entering the motor.

High Voltage Connections

3/16"

123

LGN

Low Voltage Connections

1/4”

If the compressor terminal PROTECTIVE COVER and gasket (if required) are not properly in place and secured, there is a remote possibility if a terminal vents, that the vaporous and liquid discharge can be ignited, spouting flames several feet, causing potentially severe or fatal injury to anyone in its path.

This discharge can be ignited external to the compressor if the terminal cover is not properly in place and if the discharge impinges on a sufficient heat source.

Ignition of the discharge can also occur at the venting terminal or inside the compressor, if there is sufficient contaminant air present in the system and an electrical arc occurs as the terminal vents.

Ignition cannot occur at the venting terminal without the presence of contaminant air, and cannot occur externally from the venting terminal without the presence of an external ignition source.

Therefore, proper evacuation of a hermetic system is essential at the time of manufacture and during servicing.

To reduce the possibility of external ignition, all open flame, electrical power, and other heat sources should be extinguished or turned off prior to servicing a system.

If the following test indicates shorted, grounded or open windings, see procedures S-19 for the next steps to be taken.

S-17A RESISTANCE TEST

Each compressor is equipped with an internal overload.

The line break internal overload senses both motor amperage and winding temperature. High motor temperature or amperage heats the disc causing it to open, breaking the common circuit within the compressor on single phase units.

Heat generated within the compressor shell, usually due to recycling of the motor, high amperage or insufficient gas to cool the motor, is slow to dissipate. Allow at least three to four hours for it to cool and reset, then retest.

Fuse, circuit breaker, ground fault protective device, etc. has not tripped -

GE X13TM MOTOR CONNECTIONS

Page 47

SERVICING

1. Remove the leads from the compressor terminals.

See warnings S-17 before removing compressor terminal cover.

2. Using an ohmmeter, test continuity between terminals SR, C-R, and C-S, on single phase units or terminals T2, T2 and T3, on 3 phase units.

HI-POT

COMPRESSOR GROUND TEST

3. If a ground is indicated, then carefully remove the compressor terminal protective cover and inspect for loose leads or insulation breaks in the lead wires.

4. If no visual problems indicated, carefully remove the leads at the compressor terminals.

WARNING

Damage can occur to the glass embedded terminals if the leads are not properly removed. This can result in terminal and hot oil discharging.

OHMMETER

TESTING COMPRESSOR WINDINGS

If either winding does not test continuous, replace the compressor.

NOTE: If an open compressor is indicated, allow ample time for the internal overload to reset before replacing compressor.

COMP

S-17B GROUND TEST

If fuse, circuit breaker, ground fault protective device, etc., has tripped, this is a strong indication that an electrical problem exists and must be found and corrected. The circuit protective device rating must be checked, and its maximum rating should coincide with that marked on the equipment nameplate.

With the terminal protective cover in place, it is acceptable to replace the fuse or reset the circuit breaker ONE TIME ONLY to see if it was just a nuisance opening. If it opens again, DO NOT continue to reset.

Disconnect all power to unit, making sure that all power legs are open.

1. DO NOT remove protective terminal cover. Disconnect the three leads going to the compressor terminals at the nearest point to the compressor.

2. Identify the leads and using a Megger, Hi-Potential Ground Tester, or other suitable instrument which puts out a voltage between 300 and 1500 volts, check for a ground separately between each of the three leads and ground (such as an unpainted tube on the compressor). Do not use a low voltage output instrument such as a voltohmmeter.

Carefully retest for ground, directly between compressor terminals and ground.

5. If ground is indicated, replace the compressor.

S-17D OPERATION TEST

If the voltage, capacitor, overload and motor winding test fail to show the cause for failure:

1. Remove unit wiring from disconnect switch and wire a test cord to the disconnect switch.

NOTE: The wire size of the test cord must equal the line wire size and the fuse must be of the proper size and type.

2. With the protective terminal cover in place, use the three leads to the compressor terminals that were disconnected at the nearest point to the compressor and connect the common, start and run clips to the respective leads.

3. Connect good capacitors of the right MFD and voltage rating into the circuit as shown.

4. With power ON, close the switch.

WARNING

Line Voltage now present.

Page 48

SERVICING

A. If the compressor starts and continues to run, the cause

for failure is somewhere else in the system.

B. If the compressor fails to start - replace.

COPELAND COMPRESSOR

03 A 12345 L

EAR

S-18 TESTING CRANKCASE HEATER

(OPTIONAL ITEM)

The crankcase heater must be energized a minimum of four (4) hours before the condensing unit is operated.

Crankcase heaters are used to prevent migration or accumulation of refrigerant in the compressor crankcase during the off cycles and prevents liquid slugging or oil pumping on start up.

A crankcase heater will not prevent compressor damage due to a floodback or over charge condition.

Disconnect ALL power before servicing.

1. Disconnect the heater lead in wires.

2. Using an ohmmeter, check heater continuity - should test continuous. If not, replace.

NOTE: The positive temperature coefficient crankcase heater is a 40 watt 265 voltage heater. The cool resistance of the heater will be approximately 1800 ohms. The resistance will become greater as the temperature of the compressor shell increases.

S-21 CHECKING REVERSING VALVE

AND SOLENOID

Occasionally the reversing valve may stick in the heating or cooling position or in the mid-position.

When stuck in the mid-position, part of the discharge gas from the compressor is directed back to the suction side, resulting in excessively high suction pressure. An increase in the suction line temperature through the reversing valve can also be measured. Check operation of the valve by starting the system and switching the operation from COOLING to HEATING cycle.

If the valve fails to change its position, test the voltage (24V) at the valve coil terminals, while the system is on the COOLING cycle.

If no voltage is registered at the coil terminals, check the operation of the thermostat an the continuity of the connecting wiring from the "O" terminal of the thermostat to the unit.

MONTH

WARNING

SERIAL

NUMBER

PLANT

If voltage is registered at the coil, tap the valve body lightly while switching the system from HEATING to COOLING, etc. If this fails to cause the valve to switch positions, remove the coil connector cap and test the continuity of the reversing valve solenoid coil. If the coil does not test continuous replace it.

If the coil test continuous and 24 volts is present at the coil terminals, the valve is inoperative - replace it.

S-24 TESTING DEFROST CONTROL

To check the defrost control for proper sequencing, proceed as follows: With power ON; unit not running.

1. Jumper defrost thermostat by placing a jumper wire across the terminals "DFT" and "R" at defrost control board.

2. Connect jumper across test pins on defrost control board.

3. Set thermostat to call for heating. System should go into defrost within 21 seconds.

4. Immediately remove jumper from test pins.

5. Using VOM check for voltage across terminals "C & O". Meter should read 24 volts.

6. Using VOM check for voltage across fan terminals DF1 and DF2 on the board. You should read line voltage (208230 VAC) indicating the relay is open in the defrost mode.

7. Using VOM check for voltage across "W2 & C" terminals on the board. You should read 24 volts.

8. If not as above, replace control board.

9. Set thermostat to off position and disconnect power before removing any jumpers or wires.

NOTE: Remove jumper across defrost thermostat before returning system to service.

S-25 TESTING DEFROST THERMOSTAT

1. Install a thermocouple type temperature test lead on the tube adjacent to the defrost control. Insulate the lead point of contact.

2. Check the temperature at which the control closes its contacts by lowering the temperature of the control. Part # 0130M00009P which is used on 2 and 2.5 ton units should close at 34°F ± 5°F. Part # 0130M00001P which is used on 3 thru 5 ton units should close at 31°F ± 3°F.

3. Check the temperature at which the control opens its contacts by raising the temperature of the control. Part # 0130M00009P which is used on 2 and 2.5 ton units should open at 60°F ± 5°F. Part # 0130M00001P which is used on 3 thru 5 ton units should open at 75°F ± 6°F.

4. If not as above, replace control.

Page 49

SERVICING

S-40 AR*F & MBR ELECTRONIC BLOWERS

TIME DELAY RELAY

The MBR contains an Electronic Blower Time Delay Relay board, B1370735. This board provides on/off time delays for the blower motor in cooling and heat pump heating demands when “G” is energized.

During a cooling or heat pump heating demand, 24Vac is supplied to terminal “G” of the EBTDR to turn on the blower motor. The EBTDR initiates a 7 second delay on and then energizes it’s onboard relay. The relay on the EBTDR board closes it’s normally open contacts and supplies power to the blower motor. When the “G” input is removed, the EBTDR initiates a 65 second delay off. When the 65 seconds delay expires the onboard relay is de-energized and it’s contacts open and remove power from the blower motor.

During an electric heat only demand, “W1” is energized but “G” is not. The blower motor is connected to the normally closed contacts of the relay on the EBTDR board. The other side of this set of contacts is connected to the heat sequencer on the heater assembly that provides power to the first heater element. When “W1” is energized, the sequencer will close it’s contacts within 10 to 20 seconds to supply power to the first heater element and to the blower motor through the normally closed contacts on the relay on the EBTDR. When the “W1” demand is removed, the sequencer opens it contacts within 30 to 70 seconds and removes power from the heater element and the blower motor.

The EBTDR also contains a speedup terminal to reduce the delays during troubleshooting of the unit. When this terminal is shorted to the common terminal, “C”, on the EBTDR board, the delay ON time is reduced to 3 seconds and the delay OFF time is reduced to 5 second.

Two additional terminals, M1 and M2, are on the EBTDR board. These terminals are used to connect the unused leads from the blower motor and have no affect on the board’s operation.

SEQUENCE OF OPERATION

This document covers the basic sequence of operation for a typical application with a mercury bulb thermostat. When a digital/electronic thermostat is used, the on/off staging of the auxiliary heat will vary. Refer to the installation instruc-

tions and wiring diagrams provided with the MBR and AR*F for specific wiring connections and system configuration.

AR*F & MBR

WITH SINGLE STAGE CONDENSERS

1.0 Cooling Operation

1.1 On a demand for cooling, the room thermostat energizes

“G” and “Y” and 24Vac is supplied to “Y” at the condensing unit and the “G” terminal on the EBTDR board.

1.2 The compressor and condenser fan are turned on and

after a 7 second on delay, the relay on the EBTDR board is energized and the blower motor starts.

1.3 When the cooling demand “Y” is satisfied, the room

thermostat removes the 24Vac from “G” and “Y”.

1.4 The compressor and condenser fan are turned off and after

a 65 second delay off, the relay on the EBTDR board is deenergized and the blower is turned off.

2.0 Heating Operation

2.1 On a demand for heat, the room thermostat energizes

“W1” and 24Vac is supplied to heat sequencer, HR1, on the heater assembly.

2.2 The contacts M1 and M2 will close within 10 to 20

seconds and turn on heater element #1. The normally closed contacts on the EBTDR are also connected to terminal M1. When M1 and M2 close, the blower motor will be energized thru the normally closed contacts on the EBTDR board. At the same time, if the heater assembly contains a second heater element, HR1 will contain a second set of contacts, M3 and M4, which will close to turn on heater element #2.

Note: If more than two heater elements are on the heater assembly, it will contain a second heat sequencer, HR2, which will control the 3rd and 4th heater elements if available. If the first stage heat demand, “W1” cannot be satisfied by the heat pump, the temperature indoors will continue to drop. The room thermostat will then energize “W2” and 24Vac will be supplied to HR2 on the heater assembly. When the “W2” demand is satisfied, the room thermostat will remove the 24Vac from HR2. The contacts on HR2 will open between 30 to 70 seconds and heater elements #3 and #4 will be turned off. On most digital/electronic thermostats, “W2” will

remain energized until the first stage demand “W1” is satisfied and then the “W1” and “W2” demands will be removed.

2.3 When the “W1” heat demand is satisfied, the room

thermostat will remove the 24Vac from HR1. Both set of contacts on the relay opens within 30 to 70 seconds and turn off the heater element(s) and the blower motor.

AR*F & MBR

WITH SINGLE STAGE HEAT PUMPS

3.0 Cooling Operation

On heat pump units, when the room thermostat set to the cooling mode, 24Vac is supplied to “O” which energizes the reversing valve. As long as the thermostat is set for cooling, the reversing valve will be in the energized position for cooling.

3.1 On a demand for cooling, the room thermostat energizes

“G” and “Y” and 24Vac is supplied to “Y” at the heat pump and the “G” terminal on the EBTDR board.

3.2 The heat pump turned on in the cooling mode and after a

7 second on delay, the relay on the EBTDR board is energized and the blower motor starts.

3.3 When the cooling demand is satisfied, the room thermo-

stat removes the 24Vac from “G” and “Y”.

3.4 The heat pump is turned off and after a 65 second delay

off, the relay on the EBTDR board is de-energized and the blower motor is turned off.

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4.0 Heating Operation

On heat pump units, when the room thermostat set to the heating mode, the reversing valve is not energized. As long as the thermostat is set for heating, the reversing valve will be in the de-energized position for heating except during a defrost cycle. Some installations may use one or more outdoor thermostats to restrict the amount of electric heat that is available above a preset ambient temperature. Use of optional controls such as these can change the operation of the electric heaters during the heating mode. This sequence of operation does not cover those applications.

4.1 On a demand for first stage heat with heat pump units, the

room thermostat energizes “G” and “Y” and 24Vac is supplied to “Y” at the heat pump unit and the “G” terminal on the EBTDR board. The heat pump is turned on in the heating mode and the blower motor starts after a 7 second on delay.

4.2 If the first stage heat demand cannot be satisfied by the

heat pump, the temperature indoors will continue to drop. The room thermostat will then energize terminal “W2’ for second stage heat and 24Vac will be supplied to heat sequencer HR1 on the heater assembly.

4.3 HR1 contacts M1 and M2 will close will close within 10

to 20 seconds and turn on heater element #1. At the same time, if the heater assembly contains a second heater element, HR1 will contain a second set of contacts, M3 and M4, which will close and turn on heater element #2. The blower motor is already on as a result of terminal “G” on the EBTDR board being energized for the first stage heat demand.

Note: If more than two heater elements are on the heater assembly, it will contain a second heat sequencer, HR2, which will control the 3rd and 4th heater elements if available. If the second stage heat demand, “W2” cannot be satisfied by the heat pump, the temperature indoors will continue to drop. The room thermostat will then energize “W3” and 24Vac will be supplied to HR2 on the heater assembly. When the “W3” demand is satisfied, the room thermostat will remove the 24Vac from HR2. The contacts on HR2 will open between 30 to 70 seconds and heater elements #3 and #4 will be turned off. On most digital/electronic thermostats, “W3” will

remain energized until the first stage heat demand “Y” is satisfied and then the “G”, “Y”, “W2” and “W3” demands will be removed.

4.4 As the temperature indoors increase, it will reach a point

where the second stage heat demand, “W2”, is satisfied. When this happens, the room thermostat will remove the 24Vac from the coil of HR1. The contacts on HR1 will open between 30 to 70 seconds and turn off both heater element(s). The heat pump remains on along with the blower motor because the “Y” demand for first stage heat will still be present.

4.5 When the first stage heat demand “Y” is satisfied, the

room thermostat will remove the 24Vac from “G” and “Y”. The heat pump is turned off and the blower motor turns off after a 65 second off delay.

5.0 Defrost Operation

On heat pump units, when the room thermostat is set to the heating mode, the reversing valve is not energized. As long as the thermostat is set for heating, the reversing valve will be in the de-energized position for heating except during a defrost cycle.

5.1 The heat pump will be on and operating in the heating mode as described the Heating Operation in section 4.

5.2 The defrost control in the heat pump unit checks to see if a defrost is needed every 30, 60 or 90 minutes of heat pump operation depending on the selectable setting by monitoring the state of the defrost thermostat attached to the outdoor coil.

5.3 If the temperature of the outdoor coil is low enough to cause the defrost thermostat to be closed when the defrost board checks it, the board will initiate a defrost cycle.

5.4 When a defrost cycle is initiated, the contacts of the HVDR relay on the defrost board open and turns off the outdoor fan. The contacts of the LVDR relay on the defrost board closes and supplies 24Vac to “O” and “W2”. The reversing valve is energized and the contacts on HR1 close and turns on the electric heater(s). The unit will continue to run in this mode until the defrost cycle is completed.

a. For models with defrost control PCBDM133, a 30

second compressor delay at defrost initiation/termination is optional. As shipped from the factory, the control is set for the delay (“DLY”), which will turn the compressor off for 30 seconds while the reversing valve shifts to/from the cooling mode position. To bypass the delay, which typically reduces sound levels during defrost mode, change the pin settings from “DLY” to “NORM”.

5.5 When the temperature of the outdoor coil rises high enough to causes the defrost thermostat to open, the defrost cycle will be terminated. If at the end of the programmed 10 minute override time the defrost thermostat is still closed, the defrost board will automatically terminate the defrost cycle.

5.6 When the defrost cycle is terminated, the contacts of the HVDR relay will close to start the outdoor fan and the contacts of the LVDR relay will open and turn off the reversing valve and electric heater(s). The unit will now be back in a normal heating mode with a heat pump demand for heating as described in the Heating Operation in section 4. See section 5.4a.

S-41 AEP* & MBE WITH SINGLE STAGE CON-

DENSERS

AEP* & MBE ELECTRONIC BLOWER TIME DELAY RELAY

SEQUENCE OF OPERATION

This document covers the basic sequence of operation for a typical application with a mercury bulb thermostat. When a digital/electronic thermostat is used, the on/off staging of the

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auxiliary heat will vary. Refer to the installation instructions and wiring diagrams provided with the MBE for specific wiring connections, dip switch settings and system configuration.

AEP* & MBE WITH SINGLE STAGE CONDENSERS

When used with a single stage condenser, dip switch #4 must be set to the on position on the VSTB inside the MBE. The “Y” output from the indoor thermostat must be connected to the yellow wire labeled “Y/Y2” inside the wire bundle marked “Thermostat” and the yellow wire labeled “Y/Y2” inside the wire bundle marked “Outdoor Unit” must be connected to “Y” at the condenser. The orange jumper wire from terminal “Y1” to terminal “O” on the VSTB inside the MBE must remain connected.

1.0 Cooling Operation

1.1 On a demand for cooling, the room thermostat energizes

“G” and “Y” and 24Vac is supplied to “G” and “Y/Y2” of the MBE unit. The VSTB inside the MBE will turn on the blower motor and the motor will ramp up to the speed programmed in the motor based on the settings for dip switch 5 and 6. The VSTB will supply 24Vac to “Y” at the condenser and the compressor and condenser are turned on.

1.2 When the cooling demand is satisfied, the room thermo-

stat removes the 24Vac from “G” and “Y”. The MBEand AEP* remove the 24Vac from “Y’ at the condenser and the compressor and condenser fan are turned off. The blower motor will ramp down to a complete stop based on the time and rate programmed in the motor.

2.0 Heating Operation

2.1 On a demand for heat, the room thermostat energizes

“W1” and 24Vac is supplied to terminal “E/W1” of the VSTB inside the MBEand AEP* units. The VSTB will turn on the blower motor and the motor will ramp up to the speed programmed in the motor based on the settings for dip switch 1 and 2. The VSTB will supply 24Vac to heat sequencer HR1 on the electric heater assembly.

2.2 HR1 contacts M1 and M2 will close within 10 to 20

seconds and turn on heater element #1. At the same time, if the heater assembly contains a second heater element, HR1 will contain a second set of contacts, M3 and M4, which will close and turn on heater element #2.

Note: If more than two heater elements are on the heater

assembly, it will contain a second heat sequencer, HR2, which will control the 3rd and 4th heater elements if available. For the 3rd and 4th heater elements to

operate on a second stage heat demand, the PJ4 jumper on the VSTB inside the MBE and AEP* must be cut. With the PJ4 jumper cut, the VSTB will run the

blower motor on low speed on a “W1” only demand. If the first stage heat demand, “W1” cannot be satisfied by the heat pump, the temperature indoors will continue to drop. The room thermostat will then energize “W2” and 24Vac will be supplied to HR2 on the heater assembly and the blower motor will change to high speed. When the “W2”

demand is satisfied, the room thermostat will remove the 24Vac from “W2” and the VSTB will remove the 24Vac from HR2. The contacts on HR2 will open between 30 to 70 seconds and heater elements #3 and #4 will be turned off and the blower motor will change to low speed. On

most digital/electronic thermostats, “W2” will remain energized until the first stage demand “W1” is satisfied and then the “W1” and “W2” demands will be removed.

2.3 When the “W1” heat demand is satisfied, the room

thermostat will remove the 24Vac from “E/W1” and the VSTB removes the 24Vac from HR1. The contacts on HR1 will open between 30 to 70 seconds and turn off the heater element(s) and the blower motor ramps down to a complete stop.

S-41A AEP* & MBE WITH SINGLE STAGE HEAT

PUMPS

When used with a single stage heat pump, dip switch #4 must be set to the ON position on the VSTB inside the MBE. The “Y” output from the indoor thermostat must be connected to the yellow wire labeled “Y/Y2” inside the wire bundle marked “Thermostat” and the yellow wire labeled “Y/Y2” inside the wire bundle marked “Outdoor Unit” must be connected to “Y” at the heat pump. The orange jumper wire from terminal

“Y1” to terminal “O” on the VSTB inside the MBE must be removed.

3.0 Cooling Operation

On heat pump units, when the room thermostat is set to the cooling mode, 24Vac is supplied to terminal “O” of the VSTB inside the MBE unit. The VSTB will supply 24Vac to “O” at the heat pump to energize the reversing valve. As long as the thermostat is set for cooling, the reversing valve will be in the energized position for cooling.

3.1 On a demand for cooling, the room thermostat energizes

“G” and “Y” and 24Vac is supplied to terminals “G” and “Y/ Y2” of the MBE unit. The VSTB will turn on the blower motor and the motor will ramp up to the speed programmed in the motor based on the settings of dip switch 5 and 6. The VSTB will supply 24Vac to “Y” at the heat pump.

3.2 The heat pump is turned on in the cooling mode.

3.3 When the cooling demand is satisfied, the room thermo-

stat removes the 24Vac from “G” and “Y/Y2” of the MBE and the VSTB removes the 24Vac from “Y” at the heat pump. The heat pump is turned off and the blower motor will ramp down to a complete stop based on the time and rate programmed in the motor.

4.0 Heating Operation

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outdoor thermostats to restrict the amount of electric heat that is available above a preset ambient temperature. Use of optional controls such as these can change the operation of the electric heaters during the heating mode. This sequence of operation does not cover those applications.

4.1 On a demand for first stage heat with heat pump units, the

room thermostat energizes “Y” and “G” and 24Vac is supplied to “G” and “Y/Y2” of the MBE. The VSTB will turn on the blower motor and the motor will ramp up to the speed programmed in the motor based on the settings of dip switch 1 and 2. The VSTB will supply 24Vac to “Y” at the heat pump and the heat pump is turned on in the heating mode.

4.2 If the first stage heat demand cannot be satisfied by the

heat pump, the temperature indoors will continue to drop. The room thermostat will then energize terminal “W2” for second stage heat and 24Vac will be supplied to “E/W1” of the MBE. The VSTB will supply 24Vac to heat sequencer, HR1, on the electric heater assembly.

4.3 HR1 contacts M1 and M2 will close within 10 to 20

Note: If more than two heater elements are on the heater assembly, it will contain a second heat sequencer, HR2, which will control the 3rd and 4th heater elements if available.

For the 3rd and 4th heater elements to operate on a third stage heat demand, the PJ4 jumper on the VSTB inside the MBE and AEP* must be cut. If the second stage heat

demand, “W2”, cannot be satisfied by the heat pump, the temperature indoors will continue to drop. The room thermostat will then energize “W3” and 24Vac will be supplied to “W/ W2” of the MBE. The VSTB will supply 24Vac to HR2 on the electric heater assembly. When the “W3” demand is satisfied, the room thermostat will remove the 24Vac from “W/W2” of the MBE and AEP*. The contacts on HR2 will open between 30 to 70 seconds and heater elements #3 and #4 will be turned off. On most digital/electronic thermostats,

“W3” will remain energized until the first stage demand “Y” is satisfied and then the “G”, “Y”, “W2” and “W3” demands will be removed.

4.4 As the temperature indoors increase, it will reach a point

where the second stage heat demand, “W2”, is satisfied. When this happens, the room thermostat will remove the 24Vac from “E/W1” of the MBE. The contacts on HR1 will open between 30 to 70 seconds and turn off both heater element(s). The heat pump remains on along with the blower motor because the “Y” demand for first stage heat will still be present.

4.5 When the first stage heat demand “Y” is satisfied, the

room thermostat will remove the 24Vac from “G” and “Y/ Y2” of the MBE and AEP*. The VSTB removes the 24Vac from “Y” at the heat pump and the heat pump is turned off. The blower motor will ramp down to a complete stop based on the time and rate programmed in the motor control.

5.0 Defrost Operation

5.1 The heat pump will be on and operating in the heating mode as described the Heating Operation in section 4.

5.3 If the temperature of the outdoor coil is low enough to cause the defrost thermostat to be closed when the defrost board checks it, the board will initiate a defrost cycle.

a. For models with defrost control PCBDM133, a 30

5.6 When the defrost cycle is terminated, the contacts of the HVDR relay on the defrost board will close to start the outdoor fan and the contacts of the LVDR relay will open and turn off the reversing valve and electric heater(s). The unit will now be back in a normal heating mode with a heat pump demand for heating as described in the Heating Operation in section 4. See section 5.4a.

S-60 ELECTRIC HEATER (OPTIONAL ITEM)

Optional electric heaters may be added, in the quantities shown in the specifications section, to provide electric resistance heating. Under no condition shall more heaters than the quantity shown be installed.

The low voltage circuit in the air handler is factory wired and terminates at the location provided for the electric heater(s).

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A minimum of field wiring is required to complete the installation.

Other components such as a Heating/Cooling Thermostat and Outdoor Thermostats are available to complete the installation.

The system CFM can be determined by measuring the static pressure external to the unit. The installation manual supplied with the blower coil, or the blower performance table in the service manual, shows the CFM for the static measured.

Alternately, the system CFM can be determined by operating the electric heaters and indoor blower WITHOUT having the compressor in operation. Measure the temperature rise as close to the blower inlet and outlet as possible.

If other than a 240V power supply is used, refer to the BTUH CAPACITY CORRECTION FACTOR chart below.

BTUH CAPACITY CORRECTION FACTOR

SUPPLY VOLTAGE 250 230 220 208

MULTIPLICATION FACTOR 1.08 .92 .84 .75

EXAMPLE: Five (5) heaters provide 24.0 KW at the rated 240V. Our actual measured voltage is 220V, and our measured temperature rise is 42°F. Find the actual CFM:

Answer: 24.0KW, 42°F Rise, 240 V = 1800 CFM from the TEMPERATURE RISE CHART, Table 5.

Heating output at 220 V = 24.0KW x 3.413 x .84 = 68.8 MBH.

Actual CFM = 1800 x .84 Corr. Factor = 1400 CFM.

NOTE: The temperature rise table is for sea level installations. The temperature rise at a particular KW and CFM will be greater at high altitudes, while the external static pressure at a particular CFM will be less.

TEMPERATURE RISE (F°) @ 240V

CFM

600 16 25 38 51 --- --- --- --700 14 22 33 43 --- --- --- ---

800 12 19 29 38 57 --- --- --900 11 17 26 34 51 --- --- ---

1000 10 15 23 30 46 --- --- --1100 9 14 21 27 41 55 --- --1200 8 13 19 25 38 50 --- ---

1300 7 12 18 23 35 46 --- --1400 7 1116 2232435465

1500 6 1015 2030405060 1600 6 9 14 19 28 38 47 57

1700 6 9 14 18 27 36 44 53 1800 5 8 13 17 25 34 42 50

1900 5 8 12 16 24 32 40 48 2000 5 8 12 15 23 30 38 45

2100 5 7 11 14 22 29 36 43 2200 4 7 11 14 21 27 34 41

2300 4 7 10 13 20 26 33 39

3 4.8 7.2 9.6 14.4 19.2 24 28.8

KW KW KW KW KW KW KW KW

Table 5

ELECTRIC HEATER CAPACITY BTUH

HTRKW3.0KW4.7KW6.0KW7.0KW9.5KW14.2KW19.5KW21.0

BTUH 10200 16200 20400 23800 32400 48600 66500 71600

Table 6

FORMULAS:

Heating Output = KW x 3413 x Corr. Factor

Actual CFM = CFM (from table) x Corr. Factor

BTUH = KW x 3413

BTUH = CFM x 1.08 x Temperature Rise (T)

CFM = KW x 3413

1.08 x T

T = BTUH CFM x 1.08

S-61A CHECKING HEATER LIMIT CONTROL(S)

Each individual heater element is protected with a limit control device connected in series with each element to prevent overheating of components in case of low airflow. This limit control will open its circuit at approximately 150°F.

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1. Remove the wiring from the control terminals.

2. Using an ohmmeter, test for continuity across the normally closed contacts. No reading indicates the control is open - replace if necessary.

IF FOUND OPEN - REPLACE - DO NOT WIRE AROUND.

S-61B CHECKING HEATER FUSE LINK

(OPTIONAL ELECTRIC HEATERS)

Each individual heater element is protected with a one time fuse link which is connected in series with the element. The fuse link will open at approximately 333°.

WARNING

Disconnect ALL power before servicing.

1. Remove heater element assembly so as to expose fuse link.

2. Using an ohmmeter, test across the fuse link for continuity - no reading indicates the link is open. Replace as necessary.

NOTE: The link is designed to open at approximately 333°F. DO NOT WIRE AROUND - determine reason for failure.

S-62 CHECKING HEATER ELEMENTS

WARNING

Disconnect ALL power before servicing.

1. Disassemble and remove the heating element.

2. Visually inspect the heater assembly for any breaks in the wire or broken insulators.

3. Using an ohmmeter, test the element for continuity - no reading indicates the element is open. Replace as necessary.

WARNING

Disconnect ALL power before servicing.

1. Never open a system that is under vacuum. Air and moisture will be drawn in.

2. Plug or cap all openings.

3. Remove all burrs and clean the brazing surfaces of the tubing with sand cloth or paper. Brazing materials do not flow well on oxidized or oily surfaces.

4. Clean the inside of all new tubing to remove oils and pipe chips.

5. When brazing, sweep the tubing with dry nitrogen to prevent the formation of oxides on the inside surfaces.

6. Complete any repair by replacing the liquid line drier in the system, evacuate and charge.

BRAZING MATERIALS

IMPORTANT NOTE: Torch heat required to braze tubes of

various sizes is proportional to the size of the tube. Tubes of smaller size require less heat to bring the tube to brazing temperature before adding brazing alloy. Applying too much heat to any tube can melt the tube. Service personnel must use the appropriate heat level for the size of the tube being brazed.

NOTE: The use of a heat shield when brazing is recommended to avoid burning the serial plate or the finish on the unit. Heat trap or wet rags should be used to protect heat sensitive components such as service valves and TXV valves.

Copper to Copper Joints - Sil-Fos used without flux (alloy of 15% silver, 80% copper, and 5% phosphorous). Recommended heat 1400°F.

Copper to Steel Joints - Silver Solder used without a flux (alloy of 30% silver, 38% copper, 32% zinc). Recommended heat - 1200°F.

S-101 LEAK TESTING

(NITROGEN OR NITROGEN-TRACED)

WARNING

To avoid the risk of fire or explosion, never use oxygen, high pressure air or flammable gases for leak testing of a refrigeration system.

S-100 REFRIGERATION REPAIR PRACTICE

DANGER

Always remove the refrigerant charge in a proper manner before applying heat to the system.

When repairing the refrigeration system:

WARNING

To avoid possible explosion, the line from the nitrogen cylinder must include a pressure regulator and a pressure relief valve. The pressure relief valve must be set to open at no more than 150 psig.

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Pressure test the system using dry nitrogen and soapy water to locate leaks. If you wish to use a leak detector, charge the system to 10 psi using the appropriate refrigerant then use nitrogen to finish charging the system to working pressure, then apply the detector to suspect areas. If leaks are found,

LOW SIDE

GAUGE

ND VALVE

repair them. After repair, repeat the pressure test. If no leaks exist, proceed to system evacuation.

800 PSI

RATED

S-102 EVACUATION

HOSES

WARNING

REFRIGERANT UNDER PRESSURE! Failure to follow proper procedures may cause property damage, personal injury or death.

UNIT SERVICE

This is the most important part of the entire service procedure.

VALVE PORTS

The life and efficiency of the equipment is dependent upon the thoroughness exercised by the serviceman when evacuating air (non-condensables) and moisture from the system.

Air in a system causes high condensing temperature and pressure, resulting in increased power input and reduced performance.

Moisture chemically reacts with the refrigerant oil to form corrosive acids. These acids attack motor windings and parts, causing breakdown.

The equipment required to thoroughly evacuate the system is a high vacuum pump, capable of producing a vacuum equivalent to 25 microns absolute and a thermocouple vacuum gauge to give a true reading of the vacuum in the system

NOTE: Never use the system compressor as a vacuum pump or run when under a high vacuum. Motor damage could occur.

3. If the vacuum pump is working properly, close the valve to the vacuum thermocouple gauge and open the high and low side valves to the high vacuum manifold set. With the valve on the charging cylinder closed, open the manifold valve to the cylinder.

4. Evacuate the system to at least 29 inches gauge before opening valve to thermocouple vacuum gauge.

5. Continue to evacuate to a maximum of 250 microns.

WARNING

Do not front seat the service valve(s) with the compressor open, with the suction line of the comprssor closed or severely restricted.

Close valve to vacuum pump and watch rate of rise. If vacuum does not rise above 1500 microns in three to five minutes, system can be considered properly evacuated.

6. If thermocouple vacuum gauge continues to rise and levels off at about 5000 microns, moisture and non-

1. Connect the vacuum pump, vacuum tight manifold set with high vacuum hoses, thermocouple vacuum gauge and charging cylinder as shown.

2. Start the vacuum pump and open the shut off valve to the

condensables are still present. If gauge continues to rise a leak is present. Repair and re-evacuate.

7. Close valve to thermocouple vacuum gauge and vacuum pump. Shut off pump and prepare to charge.

high vacuum gauge manifold only. After the compound gauge (low side) has dropped to approximately 29 inches

S-103 CHARGING

of vacuum, open the valve to the vacuum thermocouple gauge. See that the vacuum pump will blank-off to a maximum of 25 microns. A high vacuum pump can only produce a good vacuum if its oil is non-contaminated.

REFRIGERANT UNDER PRESSURE! * Do not overcharge system with refrigerant. * Do not operate unit in a vacuum or at negative pressure. Failure to follow proper procedures may cause property damage, personal injury or death.

{

WARNING

R-22

MANIFOLD

HIGH SIDE

GAUGE

AND VALVE

VACUUM PUMP

ADAPTER

VACUUM PUMP

EVACUATION

CHARGING

CYLINDER

AND SCALE

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CAUTION

Use refrigerant certified to AHRI standards. Used refrigerant may cause compressor damage and will void the warranty. Most portable machines cannot clean used refrigerant to meet AHRI standards.

CAUTION

Operating the compressor with the suction valve closed will void the warranty and cause serious compressor damage.

Charge the system with the exact amount of refrigerant.

Refer to the specification section or check the unit nameplates for the correct refrigerant charge.

An inaccurately charged system will cause future problems.

1. When using an ambient compensated calibrated charging cylinder, allow liquid refrigerant only to enter the high side.

2. After the system will take all it will take, close the valve on the high side of the charging manifold.

3. Start the system and charge the balance of the refrigerant through the low side. DO NOT charge in a liquid form.

4. With the system still running, close the valve on the charging cylinder. At this time, you may still have some liquid refrigerant in the charging cylinder hose and will definitely have liquid in the liquid hose. Reseat the liquid line core. Slowly open the high side manifold valve and transfer the liquid refrigerant from the liquid line hose and charging cylinder hose into the suction service valve port. CAREFUL: Watch so that liquid refrigerant does not enter the compressor.

5. With the system still running, reseat the suction valve core, remove hose and reinstall both valve core caps.

6. Check system for leaks.

NOTE: This charging procedure can only be done in the cooling mode of operation. (Early production "a" models only.) All models with compressor process tube access valve can be processed in heating cycle if this valve is used.

When charging a remote condensing unit with a non-matching evaporator coil, or a system where the charge quantity is unknown, alternate charging methods must be used. These systems must be charged according to subcooling or superheat.

SYSTEM SUPERHEAT

Ambient Condenser

Inlet Temp.

(°F Drybulb)

115

100

95 555

90 71218

85 5 101720

80 5 122126

75 5 10172529

70 5 14202832

65 13 19 26 32 35

Return Air Temperature

(°F Drybulb)

65 70 75 80 85

17 25 30 33 37

Table 7 Coils having flow control restrictors should be charged to match the System Superheat chart above. Coils with thermostatic expansion valves (TXV's) should be charged by subcooling. See "Checking Subcooling and Superheat" sections in this manual.

Due to their design, Scroll compressors are inherently more tolerant of liquid refrigerant.

NOTE: Even though the compressor section of a Scroll compressor is more tolerant of liquid refrigerant, continued floodback or flooded start conditions may wash oil from the bearing surfaces causing premature bearing failure.

If a restriction is located, replace the restricted part, replace drier, evacuate and recharge.

S-104 CHECKING COMPRESSOR EFFICIENCY

The reason for compressor inefficiency is broken or damaged suction and/or discharge valves, or scroll flanks on Scroll compressors, reducing the ability of the compressor to pump refrigerant vapor.

The condition of the valves or scroll flanks is checked in the following manner.

1. Attach gauges to the high and low side of the system.

2. Start the system and run a "Cooling Performance Test.

If the test shows:

a. Below normal high side pressure.

b. Above normal low side pressure.

c. Low temperature difference across coil.

d. Low amp draw at compressor.

and the charge is correct. The compressor is faulty - replace the compressor. NOTE: THIS TEST CANNOT BE DONE IN THE HEATING MODE

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SERVICING

Verification of proper rotation of Scroll Compressors is made as follows.

NOTE: The compressor may run backwards (noisy operation) for 1 or 2 seconds at shutdown. This is normal and does not harm the compressor.

1. Install gauges and verify that the suction pressure drops while the discharge pressure increases.

2. Listen for normal compressor sound levels. Reverse rotation results in elevated or unusual sound levels.

3. Reverse rotation will result in substantially reduced amp draw from tabulated values.

To correct improper rotation, switch any two power supply leads at the outdoor unit contactor.

The 3 phase Scroll Compressors are direction of rotation sensitive. They will rotate in either direction depending on the phasing of the power. There is no negative impact on durability caused by operating 3 phase compressors in reversed rotation. The compressors internal protector will trip, de-energizing the compressor. Continued operation of 3 phase scroll compressors with the rotation reversed will contribute to compressor failure. All 3 phase scroll compressors should be checked for correct phase rotation.

S-105A PISTON KIT CHART FOR ASC13,

GSC13, VSC13, GSC14, ASH13, GSH13, VSH14, GSH14 UNITS

Air Cond itione rs

GSC130181A* / B* / C* .055

VSC130181A* / B* .055 G/VSC130241A*

GSC130241C* G/VSH130241A* .061

AC30, AC NF24

AWB24/ AWUF24

# All ot her ARI Ma tches . 061 G /VS H13 030 1A* .0 68

G/V SC1 303 01A* / D* GS H13030 1B* . 07 0

VSC130301B* G/VSH130311A* .065

GSC130303A* G/VSH130361A* .073

AC36, AC NF30

AWB36, AWUF36

# All other ARI Matches

G/V SC1 303 61A* GS H13048 13A* / 4 A* . 08 4

GSC130363A* / B*

AWB36, AWUF36

# All other ARI Matches

GSC130361B* / F* .071 ASH130241A* .062

VSC130361B* .071

G/V SC1 304 21A* .0 78

GSC130421B* .084 ASH130421A* .082

G/VSC130481A .082

GSC 130483A*/ 4A* .082

GSC130481B*/3B*/ 4B* .088 GSH140361A* .076

G/V SC1 306 01A* .0 93 GSH1 4042 1A* .0 78

GSC130601C*/3B*/4B* .093 GSH140481A* .088

GSC 130603A*/ 4A* .093

ASC130181A* .055

ASC130241A* .061

ASC130301A* .065

ASC130361A* .071

ASC130421A* .078

ASC130481A* .082

ASC130601A* .093

GSC140181A* .053

GSC140241A* .061

GSC140301A* .067

GSC140361A* .074

GSC140421A* .078

GSC140481A* .084

GSC140601A* .096

GSC140181B* .055

GSC140241B* .062

GSC140301B* .067

GSC140361B* .073

GSC140421B* .080

Orifice

Size

.059

.065

.068

.065

.071

.074

Heat Pumps

G/ VSH 130181A * . 052

GS H130 181 B* . 05 5

G/ VSH 130191A * . 052

GS H130 241 B* . 06 1

G/ VSH 130251A * . 061

GS H130 361 3A* /1 B* .0 82

G/ VSH 130421A * . 082

G/ VSH 130481A * . 084

G/ VSH 130601A * . 093

GS H13060 13A* / 4 A* . 09 3

ASH130 181A* .052

ASH130 301A* .065

ASH130 361A* .073

ASH130 481A* .084

ASH130 601A* .093

Orifice

Size

Page 58

SERVICING

S-105B THERMOSTATIC EXPANSION VALVE

The expansion valve is designed to control the rate of liquid refrigerant flow into an evaporator coil in exact proportion to the rate of evaporation of the refrigerant in the coil. The amount of refrigerant entering the coil is regulated since the valve responds to temperature of the refrigerant gas leaving the coil (feeler bulb contact) and the pressure of the refrigerant in the coil. This regulation of the flow prevents the return of liquid refrigerant to the compressor.

The illustration below shows typical heat pump TXV/check valve operation in the heating and cooling modes.

COOLING HEATING

THERMOSTATIC EXPANSION VALVES (TXV VALVES)

Goodman® brand TXV valves contain an internal check valve thus eliminating the need for an external check valve and bypass loop. The three forces which govern the operation of the valve are: (1) the pressure created in the power assembly by the feeler bulb, (2) evaporator pressure, and (3) the equivalent pressure of the superheat spring in the valve. 0% bleed type expansion valves are used on indoor and outdoor coils. The 0% bleed valve will not allow the system pressures (High and Low side) to equalize during the shut down period. The TXV internal check valve will hold a pressure differential of 100 PSID.

The bulb must be securely fastened with two straps to a clean straight section of the suction line. Application of the bulb to a horizontal run of line is preferred. If a vertical installation cannot be avoided, the bulb must be mounted so that the capillary tubing comes out at the top.

THE VALVES PROVIDED BY GOODMAN® BRAND ARE DESIGNED TO MEET THE SPECIFICATION REQUIREMENTS FOR OPTIMUM PRODUCT OPERATION. DO NOT

USE SUBSTITUTES.

S-106 OVERFEEDING

Overfeeding by the expansion valve results in high suction pressure, cold suction line, and possible liquid slugging of the compressor.

If these symptoms are observed:

1. Check for an overcharged unit by referring to the cooling performance charts in the servicing section.

2. Check the operation of the power element in the valve as explained in S-110 Checking Expansion Valve Operation.

3. Check for restricted or plugged equalizer tube.

S-107 UNDERFEEDING

Underfeeding by the expansion valve results in low system capacity and low suction pressures.

If these symptoms are observed:

1. Check for a restricted liquid line or drier. A restriction will be indicated by a temperature drop across the drier.

2. Check the operation of the power element of the valve as described in S-110 Checking Expansion Valve Operation.

S-108 SUPERHEAT

The expansion valves are factory adjusted to maintain 12 to 18 degrees superheat of the suction gas. Before checking the superheat or replacing the valve, perform all the procedures outlined under Air Flow, Refrigerant Charge, Expansion Valve - Overfeeding, Underfeeding. These are the most common causes for evaporator malfunction.

CHECKING SUPERHEAT

Refrigerant gas is considered superheated when its temperature is higher than the saturation temperature corresponding to its pressure. The degree of superheat equals the degrees of temperature increase above the saturation temperature at existing pressure. See Temperature - Pressure Chart on following pages.

1. Run system at least 10 minutes to allow pressure to

stabilize.

2. Temporarily install thermometer on suction (large) line near

suction line service valve with adequate contact and insulate for best possible reading.

3. Refer to the superheat table provided for proper system

superheat. Add charge to lower superheat or recover charge to raise superheat.

Superheat Formula = Suct. Line Temp. - Sat. Suct. Temp.

EXAMPLE:

a. Suction Pressure = 98.7

b. Corresponding Temp. °F. = 50

c. Thermometer on Suction Line = 61°F.

To obtain the degrees temperature of superheat, subtract

50.0 from 61.0°F.

The difference is 11° Superheat. The 11° Superheat would fall in the ± range of allowable superheat.

NOTE: If superheat is measured for long line set or attic application, there may be a significant difference in the superheat from evaporator out to suction valve.

SUPERHEAT AND SUBCOOLING ADJUSTMENT ON TXV

APPLICATIONS

1. Run system at least 10 minutes to allow pressure to stabilize.

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SERVICING

2. Temporarily install thermometer on liquid (small) line near liquid line service valve with adequate contact and insulate for best possible reading.

3. Check subcooling and superheat. Systems with TXV application should have a subcooling and superheat of 7 ± 2ºF.

a. If subcooling and superheat are low, adjust TXV to 7 -

9ºF then check subcooling.

b. If subcooling is low and superheat is high, add charge

to raise subcooling to 7 ± 2ºF then check superheat.

c. If subcooling and superheat are high, adjust TXV valve

to 7 ± 9ºF then check subcooling.

d. If subcooling is high and superheat is low, adjust TXV

valve to 7 to 9ºF superheat and remove charge to lower the subcooling to 7 ± 2ºF.

The TXV should NOT be adjusted at light load conditions 55º to 60ºF, under such conditions only the subcooling can be evaluated. This is because suction pressure is dependent on the indoor coil match, indoor airflow, and wet bulb temperature. NOTE: Do NOT adjust charge based on suction pres- sure unless there is a gross undercharge.

4. Disconnect manifold set. Installation is complete.

Temp.

°F.

-40

-38

-36

-34

-32

-30

-28

-26

-24

-22

-20

-18

-16

-14

-12

-10

-8

-6

-4

-2 0 2 4 6 8

10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54

56 58

Gauge Pressure

(PSIG) Freon-22

0.61

1.42

2.27

3.15

4.07

5.02

6.01

7.03

8.09

9.18

10.31

11.48

12.61

13.94

15.24

16.59

17.99

19.44

20.94

22.49

24.09

25.73

27.44

29.21

31.04

32.93

34.88

36.89

38.96

41.09

43.28

45.53

47.85

50.24

52.70

55.23

57.83

60.51

63.27

66.11

69.02

71.99

75.04

78.18

81.40

84.70

88.10

91.5

95.1

98.8

Temp.

°F.

60 62 64 65 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96

96 100 102 104 106 108 110 112 114 116 118 120 122 124 126 128 130 132 134 136 136 140 142 144 146 158 150 152 154 156 158 160

Gauge Pressure (PSIG) Freon-22

102.5

106.3

110.2

114.2

118.3

122.5

126.8

131.2

135.7

140.5

145.0

149.5

154.7

159.8

164.9

170.1

175.4

180.9

186.5

192.1

197.9

203.8

209.9

216.0

222.3

228.7

235.2

241.9

248.7

255.6

262.6

269.7

276.9

284.1

291.4

298.8

306.3

314.0

321.9

329.9

338.0

346.3

355.0

364.3

374.1

384.3

392.3

401.3

411.3

421.8

433.3

S-109 CHECKING SUBCOOLING

Refrigerant liquid is considered subcooled when its temperature is lower than the saturation temperature corresponding to its pressure. The degree of subcooling equals the degrees of temperature decrease below the saturation temperature at the existing pressure.

1. Attach an accurate thermometer or preferably a thermocouple type temperature tester to the liquid line as it leaves the condensing unit.

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SERVICING

2. Install a high side pressure gauge on the high side (liquid) service valve at the front of the unit.

3. Record the gauge pressure and the temperature of the line.

4. Review the technical information manual or specification sheet for the model being serviced to obtain the design subcooling.

5. Obtain the Liquid Line Pressure gauge reading and convert the liquid line pressure gauge reading to temperature by finding the gauge reading in Temperature - Pressure Chart and reading to the left, find the temperature in the °F. Column.

6. The difference between the thermometer reading and pressure to temperature conversion is the amount of subcooling.

Add charge to raise subcooling. Recover charge to lower subcooling.

Subcooling Formula = Sat. Liquid Temp. - Liquid Line

Temp.

EXAMPLE:

a. Liquid Line Pressure = 274.5

b. Corresponding Temp. °F. = 120°

c. Thermometer on Liquid line = 109°F.

To obtain the amount of subcooling subtract 109°F from 120°F.

The difference is 11° subcooling. See the specification sheet or technical information manual for the design subcooling range for your unit.

S-111 FIXED ORIFICE RESTRICTOR DEVICES

The fixed orifice restrictor device (flowrator) used in conjunction with the indoor coil is a predetermined bore (I.D.). It is designed to control the rate of liquid refrigerant flow into an evaporator coil.

The amount of refrigerant that flows through the fixed orifice restrictor device is regulated by the pressure difference between the high and low sides of the system. In the cooling cycle when the outdoor air temperature rises, the high side condensing pressure rises. At the same time, the cooling load on the indoor coil increases, causing the low side pressure to rise, but at a slower rate.

Since the high side pressure rises faster when the temperature increases, more refrigerant flows to the evaporator, increasing the cooling capacity of the system.

When the outdoor temperature falls, the reverse takes place. The condensing pressure falls, and the cooling loads on the indoor coil decreases, causing less refrigerant flow.

If a restriction should become evident, proceed as follows:

1. Recover refrigerant charge.

2. Remove the orifice assembly clean or replace.

3. Replace liquid line drier, evacuate and recharge.

Capillary Tubes/Orifice Assembly

S-110 CHECKING EXPANSION VALVE

OPERATION

1. Remove the remote bulb of the expansion valve from the suction line.

2. Start the system and cool the bulb in a container of ice water, closing the valve. As you cool the bulb, the suction pressure should fall and the suction temperature will rise.

3. Next warm the bulb in your hand. As you warm the bulb, the suction pressure should rise and the suction temperature will fall.

4. If a temperature or pressure change is noticed, the expansion valve is operating. If no change is noticed, the valve is restricted, the power element is faulty, or the equalizer tube is plugged.

5. Capture the charge, replace the valve and drier, evacuate and recharge.

CHECKING EQUALIZATION TIME

During the “OFF” cycle, the high side pressure bleeds to the low side through the fixed orifice restriction device. Check equalization time as follows:

1. Attach a gauge manifold to the suction and liquid line dill valves.

2. Start the system and allow the pressures to stabilize.

3. Stop the system and check the time it takes for the high and low pressure gauge readings to equalize.

If it takes more than seven (7) minutes to equalize, the restrictor device is inoperative. Replace, install a liquid line drier, evacuate and recharge.

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S-112 CHECKING RESTRICTED LIQUID LINE

When the system is operating, the liquid line is warm to the touch. If the liquid line is restricted, a definite temperature drop will be noticed at the point of restriction. In severe cases, frost will form at the restriction and extend down the line in the direction of the flow.

Discharge and suction pressures will be low, giving the appearance of an undercharged unit. However, the unit will have normal to high subcooling.

Locate the restriction, replace the restricted part, replace drier, evacuate and recharge.

S-113 OVERCHARGE OF REFRIGERANT

An overcharge of refrigerant is normally indicated by an excessively high head pressure.

An evaporator coil, using an expansion valve metering device, will basically modulate and control a flooded evaporator and prevent liquid return to the compressor.

An evaporator coil, using a capillary tube metering device, could allow refrigerant to return to the compressor under extreme overcharge conditions. Also with a capillary tube metering device, extreme cases of insufficient indoor air can cause icing of the indoor coil and liquid return to the compressor, but the head pressure would be lower.

There are other causes for high head pressure which may be found in the "Service Problem Analysis Guide."

If other causes check out normal, an overcharge or a system containing non-condensables would be indicated.

If this system is observed:

1. Start the system.

2. Remove and capture small quantities of gas from the suction line dill valve until the head pressure is reduced to normal.

3. Observe the system while running a cooling performance test. If a shortage of refrigerant is indicated, then the system contains non-condensables.

S-114 NON-CONDENSABLES

If non-condensables are suspected, shut down the system and allow the pressures to equalize. Wait at least 15 minutes. Compare the pressure to the temperature of the coldest coil since this is where most of the refrigerant will be. If the pressure indicates a higher temperature than that of the coil temperature, non-condensables are present.

Non-condensables are removed from the system by first removing the refrigerant charge, replacing and/or installing liquid line drier, evacuating and recharging.

S-115 COMPRESSOR BURNOUT

When a compressor burns out, high temperature develops causing the refrigerant, oil and motor insulation to decompose forming acids and sludge.

If a compressor is suspected of being burned-out, attach a refrigerant hose to the liquid line dill valve and properly remove and dispose of the refrigerant.

NOTICE

Violation of EPA regulations may result in fines or other penalties.

Now determine if a burn out has actually occurred. Confirm by analyzing an oil sample using a Sporlan Acid Test Kit, AK3 or its equivalent.

Remove the compressor and obtain an oil sample from the suction stub. If the oil is not acidic, either a burnout has not occurred or the burnout is so mild that a complete clean-up is not necessary.

If acid level is unacceptable, the system must be cleaned by using the clean-up drier method.

CAUTION

Do not allow the sludge or oil to contact the skin. Severe burns may result.

NOTE: The Flushing Method using R-11 refrigerant is no

longer approved by Goodman Company, L.P.

Suction Line Drier Clean-Up Method

Use AMANA® brand part number RF000127 suction line filter drier kit. This drier should be installed as close to the compressor suction fitting as possible. The filter must be accessible and be rechecked for a pressure drop after the system has operated for a time. It may be necessary to use new tubing and form as required.

NOTE: At least twelve (12) inches of the suction line immediately out of the compressor stub must be discarded due to burned residue and contaminates.

1. Remove compressor discharge line strainer.

2. Remove the liquid line drier and expansion valve.

3 Purge all remaining components with dry nitrogen or

carbon dioxide until clean.

4. Install new components including liquid line drier.

5. Braze all joints, leak test, evacuate, and recharge system.

6. Start up the unit and record the pressure drop across the drier.

7. Continue to run the system for a minimum of twelve (12) hours and recheck the pressure drop across the drier. Pressure drop should not exceed 6 PSIG.

8. Continue to run the system for several days, repeatedly checking pressure drop across the suction line drier. If the pressure drop never exceeds the 6 PSIG, the drier has trapped the contaminants. Remove the suction line drier from the system.

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9. If the pressure drop becomes greater, then it must be replaced and steps 5 through 9 repeated until it does not exceed 6 PSIG.

NOTICE: Regardless, the cause for burnout must be determined and corrected before the new compressor is started.

S-120 REFRIGERANT PIPING

The piping of a refrigeration system is very important in relation to system capacity, proper oil return to compressor, pumping rate of compressor and cooling performance of the evaporator.

This long line set application guideline applies to all AHRI listed R22 air conditioner and heat pump split system matches of nominal capacity 18,000 to 60,000 Btuh. This guideline will cover installation requirements and additional accessories needed for split system installations where the line set exceeds 50 feet in actual length.

Additional Accessories:

1. Crankcase Heater- a long line set application can critically increase the charge level needed for a system. As a result, the system is very prone to refrigerant migration during its off-cycle and a crankcase heater will help minimize this risk. A crankcase heater is recommended for any long line application (50 watt minimum).

2. TXV Requirement: All line set applications over 50 ft will require a TXV.

3. Hard Start Assist- increased charge level in long line applications can require extra work from the compressor at start-up. A hard start assist device may be required to overcome this.

4. Liquid Line Solenoid - A long line set application can critically increase the charge level needed for a system. As a result, the system is very prone to refrigerant migration during its off-cycle and a liquid line solenoid will help minimize this. A liquid line solenoid is recommended for any long line application on straight cooling units.

Tube Sizing:

1. In long line applications, the “equivalent line length” is the sum of the straight length portions of the suction line plus losses (in equivalent length) from 45 and 90 degree bends.

Select the proper suction tube size based on equivalent length of the suction line (see Tables 9 & 10) and recalculated system capacity.

Equivalent length = Length horizontal + Length vertical +

Losses from bends (see Table 11)

2. For any residential split system installed with a long

line set, the liquid line size must never exceed 3/8".

Limiting the liquid line size to 3/8" is critical since an increased refrigerant charge level from having a larger liquid line could possibly shorten a compressor’s lifespan.

3. Single Stage Condensing Unit: The maximum length of tubing

must not exceed 150 feet.

• 50 feet is the maximum recommended vertical differ-

ence between the condenser and evaporator when the evaporator is above the condenser. Equivalent length is not to exceed 150 feet.

• The vertical difference between the condenser and evaporator when the evaporator is below the condenser can approach 150 feet, as long as the equivalent length does not exceed 150 feet.

• The distance between the condenser and evaporator in a completely horizontal installation in which the indoor and outdoor unit do not differ more than 10 feet in vertical distance from each other can approach 150 feet, as long as the equivalent length does not exceed 150 feet.

4. Two-Stage Condensing Unit: The maximum length of

tubing must not exceed 75 feet here indoor coil is located above the outdoor unit.

NOTE: When the outdoor unit is located above the indoor coil, the maximum vertical rise must not exceed 25 feet. If the maximum vertical rise exceeds 25 feet, premature compressor failure will occur due to inadequate oil return.

5. Vibration and Noise: In long line applications, refriger-

ant tubing is highly prone to transmit noise and vibration to the structure it is fastened to. Use adequate vibrationisolating hardware when mounting line set to adjacent structure.

Most refrigerant tubing kits are supplied with 3/8"-thick insulation on the vapor line. For long line installations over 50 feet, especially if the line set passes through a high ambient temperature, ½”-thick suction line insulation is recommended to reduce loss of capacity. The liquid line should be insulated if passing through an area of 120°F or greater. Do not attach the liquid line to any non-insulated portion of the suction line.

Table 9 lists multiplier values to recalculate system-cooling capacity as a function of a system’s equivalent line length (as calculated from the suction line) and the selected suction tube size. Table 10 lists the equivalent length gained from adding bends to the suction line. Properly size the suction

line to minimize capacity loss.

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REFRIGERANT LINE LENGTH (Ft)

Cond

Unit

Tons Suct Liq Suct Liq Suct Liq

1 1/2 5/8 1/4 3/4 3/8 3/4 3/8

2 5/81/43/43/83/43/8

2 1/2 3/4 3/8 3/4* 3/8 7/8 3/8

3 3/4 3/8 3/4** 3/8 7/8** 3/8

3 1/2 3/4 3/8 7/8** 3/8 1 1/8 3/8

4 7/8 3/8 1 1/8 3/8 1 1/8 3/8 5 7/8 3/8 1 1/8 3/8 1 1/8 3/8

0-24 25-49 50-74***

Line Diameter (In. OD)

Table 9

*7/8" required for full ratings

**1 1/8" required for full ratings

***Lines greater than 74 feet in length or vertical elevation changes more than 50 feet, refer to the long line set.

TABLE 10. CAPACITY MULTIPLIERS AS A FUNCTION OF

SUCTION LINE SIZE & EQUIVALENT LENGTH

Nominal

capacity

18,000 3/4 24,000 3/4 30,000 3/4

36,000

42,000

48,000

60,000

Btuh

Vapor line

diameter

(in.)

3/4 7/8 3/4 7/8

1-1/8

3/4 7/8

1-1/8

7/8

1-1/8

EQUIVALENT LINE LENGTH (FT)

.99 .97 .96 .95 .95

1 .99 .99 .98 .97 .98 .97 .96 .95 .94 .93 .90 .86 .83 .79 .98 .96 .94 .92 .90 .93 .90 .87 .83 .80 .97 .96 .94 .93 .92

1 1 .99 .99 .98 .90 .86 .82 .78 N/R .96 .94 .93 .91 .89

1 1 .99 .99 .98 .93 .91 .89 .86 .84 .99 .98 .98 .97 .97

100 125

150

2. For a system installation where the

evaporator is above the condenser, an inverted vapor line trap should be installed on the suction line just before the inlet to the evaporator (see Fig 6). The top of the inverted loop must be slightly above the top of the evaporator coil and can be created simply by brazing two 90° long radius elbows together, if a bending tool is unavailable. Properly support and secure the inverted loop to the nearest point on the indoor unit or adjacent structure.

Fig 6. Evaporator unit with inverted vapor loop

3. An oil trap is required at the evaporator only if the condenser is above the evaporator. Preformed oil traps are available at most HVAC supply houses, or oil traps may be created by brazing tubing elbows together (see diagram below). Remember to add the equivalent length from oil traps to the equivalent length calculation of the suction line. For example, if you construct an oil trap using two 45° elbows, one short and one long 90° elbow in a ¾” diameter suction line, the additional equivalent length would be 0.7+ 0.7+1.7+1.5, which equals 4.6 feet (refer to table 9).

Table 10

NOTE: For a condenser with a liquid valve tube connection less than 3/8" diameter, use 3/8" liquid line tubing for a line set greater than 25 feet.

TABLE 11. LOSSES FROM SUCTION LINE ELBOWS

(EQUIVALENT LENGTH, FT.)

Type of elbow fitting

3/4 7/8 1-1/8

90° short radius 1.7 2 2.3

90° lon

radius 1.5 1.7 1.6

45° 0.7 0.8 1

I.D. (in.)

Table 11

Installation Requirements

1. In a completely horizontal installation with a long line set where the evaporator is at the same altitude as (or slightly below) the condenser, the line set should be sloped towards the evaporator. This helps reduce refrigerant migration to the condenser during a system’s off-cycle.

Oil Trap Construction

Long Radius Street Ell

45 °

Ell

45°

Street

Ell

Short Radius

Street Ell

Fig 7. Oil Trap

4. Low voltage wiring. Verify low voltage wiring size is

adequate for the length used since it will be increased in a long line application.

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System Charging

R22 condensers are factory charged for 15 feet of line set. To calculate the amount of extra refrigerant (in ounces) needed for a line set over 15 feet, multiply the additional length of line set by 0.6 ounces. Note for the formula below, the linear feet of line set is the actual length of liquid line (or suction line, since both should be equal) used, not the equivalent length calculated for the suction line.

Extra refrigerant needed =

(Linear feet of line set – 15 ft) x X oz/ft.

Where X = 0.6 for 3/8" liquid tubing

Remember, for condensers with a liquid valve connection

less than 3/8" diameter, 3/8" liquid tubing is required for a

line set longer than 25 feet.

Follow the charging procedures in the outdoor unit I/O manual to ensure proper superheat and sub-cooling levels, especially on a system with a TXV installed in the indoor unit. Heat pumps should be checked in both heating and cooling mode for proper charge level. This guideline is meant to provide installation instructions based on most common long line set applications. Installation variables may affect system operation.

NO ADDITIONAL COMPRESSOR OIL IS NEEDED FOR

LONG LINE SET APPLICATIONS

ON RESIDENTIAL SPLIT SYSTEMS.

S-202 DUCT STATIC PRESSURES AND/OR

STATIC PRESSURE DROP ACROSS COILS

This minimum and maximum allowable duct static pressure for the indoor sections are found in the specifications section.

Tables are also provided for each coil, listing quantity of air (CFM) versus static pressure drop across the coil.

Too great an external static pressure will result in insufficient air that can cause icing of the coil. Too much air can cause poor humidity control and condensate to be pulled off the evaporator coil causing condensate leakage. Too much air can also cause motor overloading and in many cases this constitutes a poorly designed system.

S-203 AIR HANDLER EXTERNAL STATIC

To determine proper air movement, proceed as follows:

1. Using a draft gauge (inclined manometer), measure the static pressure of the return duct at the inlet of the unit, (Negative Pressure).

2. Measure the static pressure of the supply duct, (Positive Pressure).

3. Add the two readings together.

S-122 REVERSING VALVE REPLACEMENT

Remove the refrigerant charge from the system.

When brazing a reversing valve into the system, it is of extreme importance that the temperature of the valve does not exceed 250° F. at any time.

Wrap the reversing valve with a large rag saturated with water. "Re-wet" the rag and thoroughly cool the valve after each brazing operation of the four joints involved. The wet rag around the reversing valve will eliminate conducting of heat to the valve body when brazing the line connection.

The use of a wet rag sometimes can be a nuisance. There are commercial grades of heat absorbing paste that may be substituted.

After the valve has been installed leak test, evacuate and recharge.

TOTAL EXTERNAL STATIC

NOTE: Both readings may be taken simultaneously and read

directly on the manometer if so desired.

4. Consult proper table for quantity of air.

If external static pressure is being measured on a furnace to determine airflow, supply static must be taken between the "A" coil and the furnace.

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TOTAL EXTERNAL STATIC

S-204 COIL STATIC PRESSURE DROP

1. Using a draft gauge (inclined manometer), connect the positive probe underneath the coil and the negative probe above the coil.

2. A direct reading can be taken of the static pressure drop across the coil.

3. Consult proper table for quantity of air.

STATIC PRESSURE DROP

If the total external static pressure and/or static pressure drop exceeds the maximum or minimum allowable statics, check for closed dampers, dirty filters, undersized or poorly laid out duct work.

Page 66

ACCESSORIES WIRING DIAGRAMS

HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

ALL FUEL SYSTEM AFE18-60A CONTROL BOARD

POWER SUPPLY INPUT

FURNA CE DE MAND OUTPUT

BLOWER FAN DE MAND OUTPUT

POWER SUPPLY I NPUT (COMMON)

SECOND STAGE FURNACE DEMAND OUTPUT

COMPRESSOR OUTPUT

SECOND STAGE COMPRESSOR OUTPUT

REVERSING VALVE OUTPUT

POWER SUPPLY O UT TO THERMOSTAT

CALL FOR REVERSING VALVE

CALL FOR COMPRESSOR

CALL FOR EMERG ENCY HE AT

CALL FOR BLOWER FAN

CALL FOR FURNACE HEAT

POWER SUPPLY C OMMON OUT TO THERMOSTAT

CALL FOR 2ND STAGE FURNACE HEAT

CALL FOR 2ND STAGE COMPRESSOR

POWER SUPPLY O UT TO HP CONT ROL

HP CALL FOR FUR NACE (DURING DEFROST)

REVERSING VALVE OUTPUT

COMPRESSOR CONTACTOR OUTPUT

POWER SUPPLY C OMMON OUT TO HP CONTROL

ODT ( OUTDOOR THERM OSTAT)

2ND STAG E COM PRESSO R DEMAND OUTPUT

F U R N A C E

T H E R M O S T A T

H E A T

P U M P

OT-NO

OT-NC

OT-C

P1-8

P1-7

P1-4

P1-6

P1-5

P1-2

P1-3

P1-1

P2-2

P2-1

P2-7

P2-8

P2-5

P2-9

P2-3

P2-4

P2-6

P3-9

P3-8

P3-7

P3-2

P3-6

P3-3

P3-1

P3-4

P3-5

24VA C

POW ER SUP PLY

1.0K

6.8K

+5VDC

E/W 1

+VDC

+5VDC

+VDC

MICROP ROCESSOR

24VA C

+VDC

W1-FURN W2-HP

G-ST AT

G-FURN

Y2-HP

Y2-S TAT Y2-FU RN

Y-STAT Y-FU RN

Y-HP

BREAK FOR ODT

1 2

ALL FUEL SYSTEM CONTROL BOARD - AFE18-60A

This wiring diagram is for reference only. Not all wiring is as shown above.

Refer to the appropriate wiring diagram for the unit being serviced.

(For use with Heat Pumps in conjunction with 80% or 90% Single-Stage or Two-Stage Furnaces)

Page 67

ACCESSORIES WIRING DIAGRAMS

HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

10kw and Below, One Stage Electric Heat

From Air Handler

CGW2 R

BLUE

WHITE

BROWN

BLACK RED

GREE

WHITE

RED

EMERGENCY

HEAT

RELAY

THERMOSTAT

OT/EHR18-60

15kw and Above, Two Stage Electric Heat

BLUE

WHITE

BROWN

BLACK

RED

CRW2OY

RED

YEL

From Outdoor Unit

From Air Handler

CGW2 R

BROWN

RED

SEE NOTE

Indoor Thermostat

EMERGENCY

HEAT

RELAY

THERMOSTAT

OT/EHR18-60

CRW2OY

BLUE

Note:

When using a Thermostat with only one stage for electric heat (W2), tie white and

From Outdoor Unit

brown wires from air handler together.

Typical Wiring Schematics for OT/EHR18-60 (Outdoor Thermostat & Emergency Heat Relay).

This wiring diagram is for reference only. Not all wiring is as shown above.

Refer to the appropriate wiring diagram for the unit being serviced.

LOW

Indoor Thermostat

Page 68

ACCESSORIES WIRING DIAGRAMS

HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

15kw and Above with Two OT/EHR18-60's, Two Stage Electric Heat and Two Stage Thermostat

From Air Handler

OT/EHR18-60 #1

BLUE

WHITE

BROWN

BLACK RED

EEN

HITE

BLUE

CGW2 R

BROWN

EMERGEN CY

HEAT

RELAY

THERMOSTAT

OT/EHR18-60 #2

EMERGEN CY

HEAT

RELAY

THERMOSTAT

BLUE

WHITE

BROWN

BLACK

RED

CRW2OY

WHIT E

ORANGE

LOW

From Outdoor Unit

Indoor Thermostat

Typical Wiring Schematics for OT/EHR18-60 (Outdoor Thermostat & Emergency Heat Relay).

This wiring diagram is for reference only. Not all wiring is as shown above.

Refer to the appropriate wiring diagram for the unit being serviced.

Page 69

ACCESSORIES WIRING DIAGRAMS

HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

L2L1 L1 L2

208/240 VOLTS

SEE NOTE 1

HTR1

HTR2

HTR3

HTR4

PLM

PLF

EBTD R

COM

PLM

PLF

TLHTR2

HTR1 TL

M1M2M3

L2L1

EQUIPMEN T GROUND

USE COPPER OR ALUMINUM WIRE

GRD

4 5 678 9

4 5WH67489

SEE

NOTE

L2 L1 L2

HTR1

HTR2

HTR3

PLM

PLF

HTR1

L1 L2

ONE (1) ELEMENT ROWS TWO (2) ELEMENT ROWS THREE (3) ELEMENT ROWS FOUR (4) ELEMENT ROWS

NOTE: WHEN INSTALLING HEATER KIT, ENSURE SPEED TAP DOES NOT EXCEED MINIMUM BLOWER SPEED (MBS) SPECIFIED FOR THE AIRHANDLER/HEAT ER

KIT CO MBINATION O N THIS UNIT'S S&R PLATE. AFTER INSTALLING OPTIONAL HEAT KIT, MARK AN "X" IN THE PRO VIDED ABOVE.

MARK ACCORDING TO NUMBER OF HEATER ELEMENT ROWS INSTALLED. NO MARK INDICATES NO HEAT KIT INSTALLED.

TERMINAL BLOCK SHOW N

FOR 50HZ MO DELS ONLY

RD GR

SEE

NOTE

COPPER OR ALUMI NUM

POWER SUPPLY

(SEE RATING PLATE)

USE MI N. 75°C FIELD WIRE

IF REPLACEMENT OF THE ORIGINAL WIRES SUPPLIED WITH THIS ASSEMBLY IS NECESSARY, USE WIRE THAT CONFORMS TO THE NATIONAL EL ECT RIC CODE.

XFMR-R

XFMR-C

SPEEDUP

THREE SPE ED MOTOR WIRI NG

(SELECT MODELS ONLY)

SEE NOTE 5

EBTDR

SEE NOTE 3

COM

SEE

NOTE

R G

(M1) RD LOW

(M2)

MEDIUM

(COM) BK

(TR 1)

HIGH

3 SPEED

1 2

24V

SEE NOTE 1

240

COLOR CODE

BLACK

RED YELLOW

BLYLBLUE

COMPONENT CODE

EVAPORATOR MOTOR

RUN CAPACITO R

STRAI N RELIE F

RRELAY

ELECT RONIC BL OWER TIME

EBTD R

Notes:

1) Red wires to be on transformer terminal "3" for 240 volts and on terminal "2" for 208 volts.

2) See composite wiring diagrams in installation instructions for prop er low voltage wiring connections.

3) Confi rm speed ta p selected is appropriat e for appli cation. I f speed tap ne eds to be changed, connect appropriate motor wire (Red for low, Blue for medium, and Black for high speed) on "COM" connection of t he EBTDR. Inactive motor wires should be connected to "M1 or M2" on EBTDR.

4) Bro wn and whit e wires ar e used wi th Heat Kit s only.

EBTDR has a 7 second on delay when "G" is energized and a 65 second off delay when "G" is de-energized.

DELAY RELAY

EBTD R

24V

WH6BR

GREEN

PURP LE

BROWN

WHITEWH

EBTD R

PLF

WIRING CODE

FACT ORY W IRIN G HIGH VOLTAGE LOW VOLTAGE

FIELD WIRING HIGH VOLTAGE LOW VOLTAGE

TRANSF ORMER FEMALE PLUG CONNECTOR

PLF

MALE PLUG CONNECTOR

PLM

FL FUSE L INK

THERMA L L IMIT

HTR HEAT ELEMENT S

NOTE 2

0140 M00037

Typical Wiring Schematic ADPF, ARPF, ARUF with Electric Heat.

This wiring diagram is for reference only. Not all wiring is as shown above.

Refer to the appropriate wiring diagram for the unit being serviced.

Page 70

ACCESSORIES WIRING DIAGRAMS

HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

HTR2

FL HTR3

FL HTR4 TL

RS2

208/240

24V

EBTDR

XFMR-R XFMR-C

COM

SPEED UP

L1 L2

EQUIPMENT GROUND

USE COPPER OR ALUMINUM WIRE

BRSRPK

Typical Wiring Schematic MBR Blower with Electric Heat.

This wiring diagram is for reference only. Not all wiring is as shown above.

Refer to the appropriate wiring diagram for the unit being serviced.

Page 71

ACCESSORIES WIRING DIAGRAMS

HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

PJ4

HTR2

HTR3

HTR4

L2L1 L1 L2

TO LOW VOLTAGE TERMINAL BOARD

PL2

YCON

IN4005

DIODE

Y1YY2

SEE NOTE 1

FACTORY WIRING HIGH VOLT AGE LOW VOLTAGE FIELD W IRIN G HIGH VOLT AGE LOW VOLTAGE

THERM AL LIMIT

HEAT ELEMENT

HTR

RELAY

TLHTR1

SEE

NOTE 4

NOTE DIODE ON VSTB

*SEE N OTE 7

IRI NG CODE

1PL2

PL1

PL2

01 40A 000 00P

HTR1

L1 L2

ONE (1) ELEMENT ROWS TWO (2) E LEMENT ROWS THREE ( 3) ELEMENT ROWS F OUR (4) EL EMENT RO WS

AFTER IN STALLING OPTI ONAL HEAT KIT, MARK AN "X" IN THE PROVIDE D ABOVE.

* SE E NOTE 7

LOW VOLTAGE

FIELD CON NEC TION

BOX

PN. B1368270 REV. A

YCON

HUM

PJ6

DS1

COPPER

POWER SUPPLY

(SEE RATING PLATE)

CONTROLS SHOWN WITH UTILITIES IN "ON" POSITION AND THERMOSTAT IN "OFF" POSITION. IF REPLACEMENT OF THE ORIGINAL W IRES SUPPLIED WITH THIS ASSEMBLY IS NECESSARY, USE 105°C . WIRE. SIZE TO CONFO RM TO THE NATIONA L ELECTRIC CODE.

CONDE NSER

OT2

OT1

COM W 2OED

HEATPUMP

PJ2

PJ4

HEATER

24 VAC

J3J2

CONDENSER

THERMOSTAT

YCON

W2 R

W/W2

OTC OT1 COT2OE\W1

OUTDO OR

THERMOST

R Y1 G

Y/Y2

HUMIDISTAT

HUM

EQUIPMENT GROUND

HTR2

HTR1

M1M2M3

L2L1

MARK ACCORDIN G TO NUM BER OF HEATER ELEMENT ROW S INSTALLE D

NO MARK INDICATES NO HEAT KIT INSTALLED

L2 L1 L2

HTR1

HTR3

HTR2

Y1C

Y/Y2

PUW

RYG

USE COPPER WIRE

PL1

PL2

1R23

312

SEE NOTE 8

4567 89

456789

240

208

COM

24V

OTES:

1. F OR HEAT PUM P AP PLICATIO NS REMO VE ORANG E JUMPER W IRE BETWEE N O & Y1.

2. FOR TWO STAGE ELECTRIC HEAT APPLICATIONS CUT PJ4. (USE ONLY ON 15 & 20 KW MODELS).

3. FOR OUTDOOR THERMOSTAT OPERATION OF SECOND STAGE HEAT, CUT PJ2 & ADD OT18-60 TO OTC & OT2.

4. FOR SINGLE STAGE COOLING APPLICATIONS CONNECT THERMOSTAT TO Y/Y2 ONLY, TAPE OR REMOVE Y1 CO NN ECTION. CONNECT CONDENSIN G UNIT TO YCON & C.

5. W HEN HUM IDSTAT IS PRO VIDED CUT PJ6. T HERMOSTAT O PENS ON HU MIDITY RISE.

6. RED WI RES TO BE ON TRANSFORMER TE RMINAL 3 FOR 240 VOLTS AND ON TER MINAL 2 FOR 208 VOLTS.

7. SEE COMPOSITE WIRING D IAGRAMS IN INSTALLATION INSTRUCTIONS FOR PROPER LOW VOLTAGE

CONNECTIONS AND DETAILS ON COMPATIB LE THERMOSTATS AND THEIR CONNECTIONS.

8. DIS CARD O RIGINAL "PL1" PLUG CONNE CTOR WHEN INSTALLING OP TIONAL HEAT KIT.

SEE NOTE 5

PJ6

HUM

SEE NOTE 3

PL1

PL2

5 PL2

2OT1

PJ2,PJ4,PJ6

PJ2

W WHITE

R Y BL

EM PL

FL FUSE LINK

24 VOLT

SEE NOTE 2

COLOR CODE

BLACKBK RED YELLOW BLUE

EVAPORATOR MOTOR PLUG PROGRAM JUMPER

VARIABLE SPEED TRANSFORMERVSTB TR

PU PURPLE

0 PK

COMP

TERMINAL BOARD

GREENG

BROWNBR ORANGE PINK

208/240 VOLTS

W2W E

ONENT CODE

Typical Wiring Schematic AEPF with Electric Heat.

This wiring diagram is for reference only. Not all wiring is as shown above.

Refer to the appropriate wiring diagram for the unit being serviced.

Page 72

ACCESSORIES WIRING DIAGRAMS

HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

L2L1

24V

240

PN. B1368270 REV. A

TLHTR2

HTR1 TL

HKR Heat Kit

8 9

4 5

PL 1

Y/Y2

Y1C

THERMOSTAT

YCON

CONDENSER

456789

312

PL2

208

CONDENSER

YCON

OT1

OT2

HUM

W/W2

COMW2O

HEATPUMP

COM

OTC OT1 COT2OE\ W1

OUTDOOR

THERMOSTATS

PJ4

PJ2

PJ6

HEATER

HUMIDISTAT

24 VAC

RY1

HUM

Y/Y2

J3J2

DS1

VSTB

Blower Section

Typical Wiring Schematic MBE Blower with Electric Heat.

This wiring diagram is for reference only.

Not all wiring is as shown above.

Refer to the appropriate wiring diagram for the unit being serviced.

Page 73

ACCESSORIES WIRING DIAGRAMS

HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

HTR1

L1 L2

ONE (1) E LEMENT ROWS TWO (2) ELEMENT ROWS THREE (3) ELEMENT ROWS FOUR (4) ELEMENT ROWS

NOTE: WH EN INSTALLING HEATER KIT, ENSURE S PEED TAP DOES NOT EXCEED MINIMUM BLOWER SPEED (MBS) SPECIFIED FOR THE AIRHANDLER/HEAT ER

XFMR-R

COM

EBTDR

XFMR-C

COPPER OR ALUMINUM

POWER SUPPLY

(SEE RATING PLATE)

USE MIN. 75°C FIELD WIRE

IF REPLACEMENT OF THE ORIGINAL WIRES

SUPPLIED WITH THIS ASSEMBLY IS NECESSARY,

USE WIRE THAT CONFORMS TO THE

NATIONAL ELECTRIC CODE.

NO NC

TLHTR2

SEE NOTE 3

PLM

PLF

HTR1 TL

L2L1

KIT COMBINATION ON THIS UNIT'S S&R PLATE . AFTER I NSTALLING OPTIONAL HEAT KIT, MARK AN "X" IN THE PROVIDED ABOVE. MARK ACCORDING TO NUMBER OF HEATER ELEME NT ROWS INSTALLED. NO MARK INDICATES NO HEAT KIT I NSTALL ED.

TERMINAL BLOCK SHOWN

SEE NOTE 2

RCG W1W2 Y2Y1 O

FOR 50HZ MODELS ONLY

41 32 5DH

A B

M1M2M3

GRD

1 2 3

EQUIPMENT GROUND

USE COPPER OR ALUMINUM WIRE

4 5 678 9

4 5WH6789

24V

SEE NO TE 1

240

SEE NOTE 4

21 43 5

NC GL

HTR1

HTR2

HTR3

L2 L1 L2

208/240 VOLTS

PLM

PLF

C LGN

SEE NOTE 1

24V

PLF

W2R W1CG 4Y1 OY2 1DH 32 5

COLOR CODE

GREEN

BLACK

RED

YELLOW

BLYLBLUE

COM PONEN T CODE

EVAPORATOR MOTOR

TER MINA L BOARD

RELAY

CR CONTROL RELAY

EBTDR

ELECTRONI C BLOWER TIME DELAY RE LAY

Notes:

1) Red wires t o be on transformer terminal "3" for 240 volts and on terminal "2" for 208 volts.

2) See composite wiring diagra ms in installation instructions for proper l ow voltage wiring connections.

3) Confi rm speed tap select ed is appropria te for application. If speed tap needs to be changed, co nnect red wire fr om terminal 4 of CR relay to appropriate tap at TB

4) Brown and whit e wires are used with Heat Kits only.

PURPLE BROWN WHITEWH

FACT ORY WIR ING HIGH VOLTAGE LOW VOLTAGE

FIELD WIRING HIGH VOLTAGE LOW VOLTAGE

PLF

PLM

FL FUSE LINK

TL THERMAL LIMIT

HTR HEAT ELEMENTS

PLM

PLF

WIRIN G CODE

TRANSFORMER

FEMALE PLUG CONNECTOR MALE PLUG CONNECTOR

L2L1 L1 L2

7 4

HTR1

HTR2

HTR3

HTR4

XFMR-R

XFMR-C

COM

EBTDR

NO NC

1 2

3 4

0140A00034

Typical Wiring Schematic ASPF****16A* with Electric Heat.

This wiring diagram is for reference only. Not all wiring is as shown above.

Refer to the appropriate wiring diagram for the unit being serviced.

Page 74

ACCESSORIES WIRING DIAGRAMS

HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

Typical Wiring Schematic ASPF****16B* with Electric Heat.

This wiring diagram is for reference only. Not all wiring is as shown above.

Refer to the appropriate wiring diagram for the unit being serviced.