Goodman R-410A, APH1524M41AA, APH1536M41AA, APH1548M41AA, APH1560M41AA Service Instructions Manual

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Page 1

Service Instructions

*PH 15 SEER Multi-Position Package Heat Pumps with R-410A Refrigerant & Accessories

Model numbers listed on page 6

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.

RS6300008 Rev. 1

November 2007

Page 2

INDEX

IMPORTANT INFORMATION .......................................................................................................... 4

PRODUCT IDENTIFICATION - *PH15**M4* .................................................................................. 6

ACCESSORIES ............................................................................................................................... 7

GPGHFR101-103 ....................................................................................................................................................... 8

GPH13MFR FILTER RACK ....................................................................................................................................... 9

PGMDD101-103 DOWNFLOW MANUAL FRESH AIR DAMPERS .......................................................................... 10

PGMDMD102-103 DOWNFLOW MOTORIZED FRESH AIR DAMPERS .................................................................. 10

PGMDH102-103 HORIZONTAL MANUAL FRESH AIR DAMPERS .......................................................................... 10

PGMDH102-103 HORIZONTAL MOTORIZED FRESH AIR DAMPERS .................................................................... 10

SQRPG101-103 SQUARE TO ROUND CONVERTER, DOWNFLOW ...................................................................... 11

SQRPGH101-103 SQUARE TO ROUND CONVERTER, HORIZONTAL ................................................................... 11

GPH13MED103 DOWNFLOW ECONOMIZER ......................................................................................................... 12

PGEH102-103 HORIZONTAL ECONOMIZER ........................................................................................................... 12

PGC101-103 ROOF CURBS .................................................................................................................................... 13

PRODUCT DESIGN ...................................................................................................................... 13

LOCATION AND CLEARANCES ............................................................................................................................. 13

COMPRESSEOR ..................................................................................................................................................... 14

INDOOR BLOWER MOTOR .................................................................................................................................... 14

ELECTRICAL WIRING ............................................................................................................................................ 15

LINE VOLTAGE WIRING......................................................................................................................................... 15

SYSTEM OPERATION .................................................................................................................. 16

COOLING ................................................................................................................................................................ 16

COOLING CYCLE ................................................................................................................................................... 16

HEATING CYCLE .................................................................................................................................................... 16

DEFROST CYCLE ................................................................................................................................................... 17

FAN OPERATION .................................................................................................................................................... 17

AIRFLOW ADJUSTMENTS FOR INDOOR BLOWER MOTOR ............................................................................... 17

SCHEDULED MAINTENANCE..................................................................................................... 20

ONCE A MONTH ..................................................................................................................................................... 20

ONCE A YEAR ........................................................................................................................................................ 20

TEST EQUIPMENT ................................................................................................................................................. 20

SERVICING ................................................................................................................................... 22

COOLING /HEAT PUMP- SERVICE ANALYSIS GUIDE .......................................................................................... 21

S-1 CHECKING VOLTAGE ...................................................................................................................................... 22

S-2 CHECKING WIRING ......................................................................................................................................... 23

S-3 CHECKING THERMOSTAT, WIRING, AND ANTICIPATOR ............................................................................... 23

S-3A Thermostat and Wiring .......................................................................................................................... 23

S-3B Cooling Anticipator ................................................................................................................................ 23

S-3C Heating Anticipator ................................................................................................................................ 23

S-4 CHECKING TRANSFORMER AND CONTROL CIRCUIT .................................................................................. 24

S-7 CHECKING CONTACTOR AND/OR RELAYS ................................................................................................... 24

S-8 CHECKING CONTACTOR CONTACTS ............................................................................................................. 24

Page 3

INDEX

S-11 CHECKING LOSS OF CHARGE PROTECTOR .............................................................................................. 25

S-15 CHECKING CAPACITOR ................................................................................................................................25

S-15A Resistance Check ................................................................................................................................. 26

S-15B Capacitance Check ............................................................................................................................. 26

S-16 CHECKING MOTORS ..................................................................................................................................... 27

S-16B Checking Fan & Blower Motor (ECM Motors) .................................................................................... 27

S-16C Checking ECM Motor Windings .......................................................................................................... 30

S-16D Checking GEX13™ Motors .................................................................................................................. 30

S-17 CHECKING COMPRESSOR WINDINGS ........................................................................................................ 31

S-17A Resistance Test .................................................................................................................................... 31

S-17B Ground Test .......................................................................................................................................... 31

S-17C Unloader Test Procedure .................................................................................................................... 32

S-17D Operation Test ...................................................................................................................................... 32

S-18 TESTING CRANKCASE HEATER ................................................................................................................... 33

S-21 CHECKING REVERSING VALVE AND SOLENOID ......................................................................................... 33

S-24 TESTING DEFROST CONTROL ..................................................................................................................... 33

S-25 TESTING DEFROST THERMOSTAT ............................................................................................................... 33

S-50 CHECKING HEATER LIMIT CONTROL(S) ...................................................................................................... 33

S-52 CHECKING HEATER ELEMENTS ................................................................................................................... 33

S-100 REFRIGERATION REPAIR PRACTICE.......................................................................................................... 34

S-101 LEAK TESTING (NITROGEN OR NITROGEN-TRACED) ............................................................................... 34

S-102 EVACUATION................................................................................................................................................ 34

S-103 CHARGING ................................................................................................................................................... 35

S-104 CHECKING COMPRESSOR EFFICIENCY .................................................................................................... 36

S-105 THERMOSTATIC EXPANSION VALVE ......................................................................................................... 36

S-106 OVERFEEDING ............................................................................................................................................. 37

S-107 UNDERFEEDING ........................................................................................................................................... 37

S-108 SUPERHEAT ................................................................................................................................................. 37

S-109 CHECKING SUBCOOLING ........................................................................................................................... 38

S-110 CHECKING EXPANSION VALVE OPERATION ............................................................................................. 41

S-112 CHECKING RESTRICTED LIQUID LINE ....................................................................................................... 41

S-113 REFRIGERANT OVERCHARGE .................................................................................................................... 41

S-114 NON-CONDENSABLES ................................................................................................................................. 41

S-115 COMPRESSOR BURNOUT ........................................................................................................................... 41

S-122 REVERSING VALVE REPLACEMENT ........................................................................................................... 42

S-200 CHECKING EXTERNAL STATIC PRESSURE ............................................................................................... 43

S-201 CHECKING TEMPERATURE RISE ................................................................................................................ 43

WIRING DIAGRAMS ................................................................................................................ 44

OT18-60A OUTDOOR THERMOSTAT ..................................................................................................................... 44

OT18-60A OUTDOOR THERMOSTAT ..................................................................................................................... 45

HKR** HEAT KITS.................................................................................................................................................. 46

GPH13MED ECONOMIZER FOR GPH15**M4* ........................................................................................................ 47

Page 4

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

HIS UNIT SHOULD NOT BE CONNECTED TO. OR USED IN CONJUNCTION WITH, ANY DEVICES THAT ARE NOT DESIGN CERTIFI ED FOR USE WITH THIS UNIT OR HAVE NOT BEEN

TESTED AND APPROVED BY

FROM THE USE OF DEVICES THAT HAVE NOT BEEN APPROVED OR CERTIFED BY

GOODMAN. SERIOUS PROPERTY DAMAGE OR PERSONAL INJURY, REDUCED UNIT PERFORMANCE AND/OR HAZARDOUS CONDITIONS MAY RESULT

GOODMAN.

WARNING

O PREVENT THE RISK OF PROPE RTY DAMAGE, PERSONAL INJURY, OR DEATH,

DO NOT STORE COMBUSTIBLE MATE RIALS OR USE GASOLINE OR OTHER

FLAMMABLE LIQUIDS OR VAPORS IN THE VICINITY OF THIS APPLIANCE.

WARNING

OODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES.

F YOU INSTALL OR PERFORM SERVICE ON THIS UNIT, YOU ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMAGE WHICH

MAY RESU LT.

ANY JURISDICTIONS REQU IRE A LICENSE TO INSTALL OR SERVICE HEATING AN D AIR CONDITIONING EQUIPMENT.

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: hac.consumer.affairs@amanahvac.com

CONSUMER INFORMATION LINE

AMANA® BRAND PRODUCTS

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

fax us at: (931) 438- 4362

(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.

Outside the U.S., call 1-931-433-6101. (Not a technical assistance line for dealers.) Your telephone company will bill you for the call.

Page 5

IMPORTANT INFORMATION

SAFE REFRIGERANT HANDLING

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

WARNING

REFRIGERANTS ARE H EAVIER THAN AIR . THEY CAN "PUSH OUT" THE

OXYGEN IN YOUR LUNGS OR IN ANY ENCLOSED SPACE.

POSSIBLE DIF FICULT Y IN BREAT HING OR DEATH:

EVER PURGE REFRIGERANT INTO AN ENCLOSED ROOM OR SPACE. BY

•

LAW, ALL REFRIGERANTS MUST BE RECLAIMED.

IF AN INDOOR LEAK IS SUSPECTED, THOROUGHLY VENTIL ATE THE AREA

•

BEFORE BEGINNING WORK.

IQUID REFRIGERANT CAN BE VERY COLD. TO AVOID POSSIBLE FROST-

•

BITE OR BL INDNESS, AVOID CONTACT WITH REFRIGERANT AND WEAR

GLOVES AND GOGGLES.

SKIN OR EYES, SEEK MEDICAL HELP IMMEDIATELY.

LWAYS FOLLOW

•

AS POIS ONOUS GAS WILL BE PRODUCED.

F LIQUID REFRIGERANT DOES CONTACT YOUR

EPA

REGULATIONS. NEVER BURN REFRIGERANT,

O AVO ID

WARNING

TO AVOID POSSIBLE EXPLOSION:

EVER APPLY FLAME OR STEAM TO A REFRIGERAN T CYLINDER. IF YOU

•

MUST HEAT A CYLINDE R FOR FASTER CHARGING, PARTIALLY IMMERSE

IT IN WARM WATER.

NEVER FILL A CYLINDE R MORE THAN 80% FULL OF LIQUID REFRIGERANT.

•

NEVER ADD ANYTHING OTHER THAN R-22 TO AN R-22 CYLINDER OR

•

R-410A TO AN R-410A CYLINDER. THE SERVICE EQUIPMENT USED MUST

BE LISTED OR CERTIF IED FOR THE TYPE OF REFRIGERANT USED.

TORE CYLINDERS IN A CO OL, DRY PLACE. NEVER USE A CYLIND ER

•

AS A PLATFORM OR A ROLLER.

WARNING

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 EX PLOS ION .

•

ENSURE THE HYDROST ATIC TES T DATE DOES NOT EXCE ED 5 YEAR S.

•

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.

O AVOID POSSIBLE INJURY, EXPLOSION OR DEATH, PRACTICE SAFE

HANDLING OF REFRIGERANTS.

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 6

PRODUCT IDENTIFICATION

G P H 15 36 M 4 1 * *

Brand

G: Goodman® Brand or Distinctions A: Amana® Brand

Product Type

Package Cooling/Heating

Product Family

C: Cooling H: Heat Pump

Minor Revision

Major Revision

Voltage

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

Refrigerant

Product Series

15: 15 SEER Rating

Nominal Capacity

24: 24,000 BTUH 36: 36,000 BTUH 48: 48,000 BTUH 60: 60,000 BTUH

Configuration

M: Multi-Position

Single Phase Multiposition Package Heat Pumps

Model # Description

A/GPH15**M41AA

mana/Goodman Package Heat Pump 15 Seer R410A Multiposition heat

pump units. Initial release.

4: R-410A

GPH15**M41* APH15**M41*

Chassis Models Chassis Models

Medium 2 - 3 Ton Medium 2 - 3 Ton

Large 4 - 5 Ton Large 4 - 5 Ton

Page 7

ACCESSORIES

*PH15[24-60]M4*

ACCESSORIES

Part Number Description Fits Models

GPH13MED103 Economizer Downflow All

PGEH102 Economizer Horizontal Medium Chassis

PGEH103 Economizer Horizontal Large Chassis

PGMDD102 Downflow Manual 25% Fresh Air Damper Medium Chassis

PGMDD103 Downflow Manual 25% Fresh Air Damper Large Chassis

PGMDH102 Horizontal Manual 25% Fresh Air Damper Medium Chassis

PGMDH103 Horizontal Manual 25% Fresh Air Damper Large Chassis

PGMDMH102 Horizontal Motorized 25% Fresh Air Damper Medium Chassis

PGMDMH103 Horizontal Motorized 25% Fresh Air Damper Large Chassis

PGMDMD102 Downflow Motorized 25% Fresh Air Damper Medium Chassis

PGMDMD103 Downflow Motorized 25% Fresh Air Damper Large Chassis

SQRPG102 Downflow Square to Round Adapter Medium Chassis

SQRPG103 Downflow Square to Round Adapter Large Chassis

SQRPGH102 Horizontal Square to Round Adapter Medium Chassis

SQRPGH103 Horizontal Square to Round Adapter Large Chassis

PGC101/102/103 Roof Curb All

GPH13MFR Downflow Filter Rack All

GPGHFR101-103 External Horizontal Filter Rack All

OT18-60A

OT/EHR-60A Outdoor Thermostat with Emergency Heat Relay All

HKR05A, 08, 10, CA Heater Kit - Single Phase All GPH15**M41*

HKR15A, CA Heater Kit - Single Phase GPH15(36-60)M41*

HKR20A, CA Heater Kit - Single Phase GPH15(48-60)M41*

Outdoor Thermostat (Required for heat pumps with 0° outdoor ambient and 50% or higher relative humidity)

All

AMANA® BRAND THERMOSTATS

1213406 Beige Manual/Auto Changeover 5 + 2 Programming Digital 3 Heat - 2 Cool

1213407 White Manual Changeover 5 + 2 Programming Digital 2 Heat - 2 Cool

1213412 White Manual/Auto Changeover 7 Day Programming Digital 3 Heat - 2 Cool

1213431 White Manual/Auto Changeover 7 Day Programming Digital 3 Heat - 2 Cool

Page 8

ACCESSORIES

*PH15[24-60]M4*

EXTERNAL HORIZONTAL FILTER RACK

(GPGHFR101-103)

16"

24"

16" x 25" x 2" FILTER

17 1/4"

DOWNFLOW FILTER RACK

PANEL SIDE VIEW

26 1/2"

Filter Size: 16" x 25" x 2"

(Requires 1 filter)

Measurement in inches

(GPH13MFR)

DUCT SIDE VIEW

FILTER PLATFORM

RIGHT SIDE

DOWNFLOW R/A DUCT OPENING

Filter Size: 14" x 25" x 2" (Requires 2 filters) - Measurement in inches

LEFT SIDE

EVAPORATOR

COIL

Page 9

ACCESSORIES

MOTORIZED/MANUAL FRESH AIR DAMPERS -

*PH15[24-60]M4*

(DOWNFLOW APPLICATIONS)

7 5/8

5 3/4

Manual Fresh Air Dampers

MODEL A B

PGMDD101/102 16 16

PGMDD103 18 16

Motorized Fresh Air Dampers

MODEL A B

PGMDMD102 16 16

PGMDMD103 18 16

MOTORIZED/MANUAL FRESH AIR DAMPERS

(HORIZONTAL APPLICATIONS)

11 7/8

12 1/8

PGMDD103

12 1/8

PGMDD101/102

BOTTOM VIEW

5 3/4

11 7 /8

BOTTOM VIEW

5 3/4

11 7 /8

Manual Fresh Air Dampers

MODEL A B

PGMDH102 31 1/2 29 3/4

PGMDH103 39 29 3/4

Motorized Fresh Air Dampers

MODEL A B

PGMDMH102 31 1/2 29 3/4

PGMDMH103 39 29 3/4

Page 10

ACCESSORIES

*PH15[24-60]M4*

SQUARE TO ROUND CONVERTER

(DOWNFLOW APPLICATIONS)

12 1/4 14 3/4

MODEL ABCDRETURN SUPPLY

SQRPG101/102 22 3/4 12 1/4 22 1/4 14 3/4 16 16

SQRPG103 22 3/4 12 1/4 22 1/4 14 3/4 18 18

22 3/4 22 1/4

16 ø 16 ø

12 1/4 14 3/4

18 ø 18 ø

SQUARE TO ROUND CONVERTER

(HORIZONTAL APPLICATIONS)

MODEL ABC

SQRPGH101/102 16 16 1/2 16 1/2

SQRPGH103 18 18 1/2 18 1/2

Measurements are in inches.

Page 11

ACCESSORIES

*PH15[24-60]M4*

ECONOMIZER GPH13MED103

(DOWNFLOW APPLICATIONS )

Blockoff

External Hood Panel

Louver Assembly

ECONOMIZER PGEH102-103

(HORIZONTAL APPLICATIONS )

16 1/8

MODEL ABCDEFILTER

PGEH102 25 1/4 18 18 18 13 3/4 16 1/8 16 X 25 X1

PGEH103 35 1/4 18 1/8 18 18 1/4 16 1/8 16 X 25 X1

Measurements in inches

Page 12

ACCESSORIES

*PH15[24-60]M4*

ROOF CURBS

PGC101/102/103 46 1/4* 39 3/8* 14 1/2 12 1/2 x 23* 15 x 22 1/2*

MODEL A B C RETURN SUPPLY

*Inside Dimensions

1 5/8

14 1/2

1 3/8

Page 13

PRODUCT DESIGN

LOCATION & CLEARANCES

In installations where the unit is installed above ground level and not serviceable from the ground (Example: Roof Top installations) the installer must provide a service platform for the service person with rails or guards in accordance with local codes or ordinances.

*PH15[24-60]M41*

NOTE: Roof overhang should be no more than 36" and

provisions made to deflect the warm discharge air out from the overhang.

Minimum clearances are required to avoid air recirculation and keep the unit operating at peak efficiency.

WARNING

TO PREVENT POSSIBLE DAMAGE, THE UNIT SHOULD REMAIN IN AN UPRIGHT POSITION DURING ALL RIGGING AND MOVING OPERATIONS. TO FACILITATE LIFTING AND MOVING IF A CRANE IS USED, PLACE THE UNIT IN AN ADEQUATE CABLE SLIDE.

Refer to Roof curb Installation Instructions for proper curb installation. Curbing must be installed in compliance with the National Roofing Contractors Association Manual.

Lower unit carefully onto roof mounting curb. While rigging unit, center of gravity will cause condenser end to be lower than supply air end.

Roof Curb

*PH15[24-60]M4*

*PH Package Units are designed for outdoor installations only in either residential or light commercial applications.

The connecting ductwork (Supply and Return) can be connected for horizontal discharge airflow. In the down discharge applications, a matching Roof Curb (PGC101/102/103) is recommended for horizontal models only.

A return air filter must be installed behind the return air grille(s) or provision must be made for a filter in an accessible location within the return air duct. An internal filter rack (GPH13MFR102 & 103) and an external filter rack (GPGHFR101-103) are also available as accessories. The minimum filter area should not be less than those sizes listed in the Specification Section. Under no circumstances should the unit be operated without return air filters.

A 3/4" - 14 NPT drain connector is provided for removal of condensate water from the indoor coil. In order to provide proper condensate flow, do not reduce the drain line size.

Refrigerant flow control is achieved by use of TXV. These models use the FasTest Access Fitting System, with a saddle that is either soldered to the suction and liquid lines or is fastened with a locking nut to the access fitting box (core) and then screwed into the saddle. Do not remove the core from the

saddle until the refrigerant charge has been removed. Failure to do so could result in property damage or personal injury.

The single phase units use permanent split capacitors (PSC) design compressors. Starting components are therefore not required. A low MFD run capacitor assists the compressor to start and remains in the circuit during operation.

Page 14

PRODUCT DESIGN

The outdoor fan motors are single phase capacitor type motors.

Air for condensing (cooling) is drawn through the outdoor coil by a propeller fan, and is discharged vertically out the top of the unit. The outdoor coil is designed for .0 static. No additional restriction (ductwork) shall be applied.

Conditioned air is drawn through the filter(s), field installed, across the evaporator coil and back into the conditioned space by the indoor blower.

COMPRESSORS

The *PH15 4 and 5 ton M series package heat pump units use a two-stage scroll compressor. The two-step modulator has an internal unloading mechanism that opens a bypass port in the first compression pocket, effectively reducing the displacement of the scroll. The opening and closing of the bypass port is controlled by an internal electrically operated solenoid.

The ZPS two-step modulated scroll uses a single step of unloading to go from full capacity to approximately 67% capacity. A single speed, high efficiency motor continues to run while the scroll modulates between the two capacity steps.

As this motion occurs, the pockets between the two forms are slowly pushed to the center of the two scrolls while simultaneously being reduced in volume. When the pocket reaches the center of the scroll form, the gas, which is now at a high pressure, is discharged out of a port located at the center.

During compression, several pockets are being compressed simultaneously, resulting in a very smooth process. Both the suction process (outer portion of the scroll members) and the discharge process (inner portion) are continuous.

Some design characteristics of the Compliant Scroll compressor are:

• Compliant Scroll compressors are 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.

• These Scroll compressors use “POE” or polyolester oil which is NOT compatible with mineral oil based lubricants like 3GS. “POE” oil must be used if additional oil is required.

• Compliant scroll compressors perform "quiet" shutdowns that allow the compressor to restart immediately without the need for a time delay. This compressor will restart even if the system has not equalized.

NOTE: Operating pressures and amp draws may differ from standard reciprocating compressors. This information can be found in the unit's

Technical Information Manual.

A scroll is an involute spiral which, when matched with a mating scroll form as shown, generates a series of crescent shaped gas pockets between the two members.

During compression, one scroll remains stationary (fixed scroll) while the other form (orbiting scroll) is allowed to orbit (but not rotate) around the first form.

INDOOR BLOWER MOTOR

GPH15 M series model package units use a GE X13TM blower motor The GE X13TM motor is a 3 Phase brushless DC (single phase AC input), ball bearing construction motor with an integral control module with an internal FCC B EMI filter.

The GE X13TM motor is continuously powered with line voltage. The switched 24 volt control signal is controlled by the thermostat in the cooling and heat pump mode and the blower relay in the electric heat mode.

APH15 M series model package units use an ECM blower motor. These motors offer greater airflow flexibility as well as dehumidification. The airflow delivery for these models can be adjusted by changing the position of dip switches on a low voltage terminal board.

Page 15

PRODUCT DESIGN

ELECTRICAL WIRING

The units are designed for operation at the voltages and hertz as shown on the rating plate. All internal wiring is complete. Ensure the power supply to the compressor contactor is brought to the unit as shown on the supplied unit wiring diagram. The 24V wiring must be connected between the unit control panel and the room thermostat.

WARNING

TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK, WIRING TO THE UNIT MUST BE PROPERLY POLARIZED AND GROUNDED.

WARNING

TO AVOID THE RISK OF PROPERTY DAMAGE, PERSONAL INJURY OR FIRE, USE ONLY COPPER CONDUCTORS.

LINE VOLTAGE WIRING

Power supply to the unit must be N.E.C. Class 1, and must comply with all applicable codes. The unit must be electrically grounded in accordance with the local codes or, in their absence, with the latest edition of the National Electrical Code, ANSI/NFPA No. 70, or in Canada, Canadian Electrical Code, C22.1, Part 1. A fused disconnected must be provided and sized in accordance with the unit minimum circuit ampacity.

The best protection for the wiring is the smallest fuse or breaker which will hold the equipment on line during normal operation without nuisance trips. Such a device will provide maximum circuit protection.

WARNING

DO NOT EXCEED THE MAXIMUM OVERCURRENT DEVICE SIZE SHOWN ON THE UNIT DATA PLATE.

All line voltage connections must be made through weather proof fittings. All exterior power supply and ground wiring must be in approved weather proof conduit. Low voltage wiring from the unit control panel to the thermostat requires coded cable.

The unit transformer is connected for 230V operation. If the unit is to operate on 208V, reconnect the transformer primary lead as shown on the unit wiring diagram.

If it is necessary for the installer to supply additional line voltage wiring to the inside of the package unit, the wiring must comply with all local codes. This wiring must have a minimum temperature rating of 105°C. All line voltage splices must be made inside the unit or heat kit control box.

Page 16

SYSTEM OPERATION *PH15[24-60]M41*

SYSTEM OPERATION

COOLING

The refrigerant used in the system is R-410A. It is a clear, colorless, non-toxic and non-irritating liquid. R-410A is a 50:50 blend of R-32 and R-125. The boiling point at atmospheric pressure is -62.9°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.

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.

HEATING

The heating portion of the refrigeration cycle is similar to the cooling cycle. By de-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 in the TXV 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 in the TXV at the outdoor coil will be forced closed by the refrigerant flow, thereby utilizing the outdoor expansion device.

COOLING CYCLE

On heat pump models, when the thermostat is switched to cool, this completes a circuit from R to O energizing the reversing valve solenoid. 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 and fan motor for models with X13 motors and Variable Speed Terminal Board (VSTB) for models with ECM motors. . This draws in the normally open contact of the contactor, starting the compressor and condenser fan motors. At the same time, energizing the X13 motor for models so equipped and energizing the VSTB for ECM equipped models, starting the indoor fan motor.

When the thermostat is satisfied, it opens its contacts, breaking the low voltage circuit from R to Y & G, causing the compressor contactor to open, and de-energizing the indoor blower motor, shutting down the system.

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

APH and GPH models energize the reversing valve through the "O" circuit in the room thermostat. Therefore, the reversing valve remains energized as long as the thermostat subbase is in the cooling position.

HEATING CYCLE

*PH15**M41* Heat Pump Units

On a call for first stage heat, the contacts of the room thermostat close. This energizes terminals R to Y and R to G, the low voltage circuit to the contactor is completed starting the compressor and outdoor fan motor. This also energizes the indoor blower through the VSTB on delay on APH15 M series units, and instantly on the GPH15 M series units with the GE X13TM motor.

When the thermostat is satisfied, breaking the circuit between R to Y and R to G, the compressor and outdoor fan motor will stop. The indoor blower will stop after the 60 second off delay on the APH15 M series units, and after the programmed 60 second off delay on GPH15 M series units with the GE X13TM motor. .

When auxiliary electric heaters are used, a two stage heating two stage cooling thermostat would be installed.

Should the second stage heating contacts in the room thermostat close, which would be wired to W1 at the unit low voltage connections, this would energize the coil(s) of the electric heat relay(s). Contacts within the relay(s) will close, bringing on the electric resistance heaters.

If auxiliary electric heaters should be used, they may be controlled by outdoor thermostats (OT18-60A or OT/EHR18-60A).

Emergency Heat Mode (Heat Pumps)

NOTE: The following only applies if the unit has an approved electric heat kit installed for auxiliary heating.

Page 17

SYSTEM OPERATION

*PH15[24-60]M41*

APH15 M Series ECM equipped models only:

With the thermostat set to the emergency heat position and a call for 2nd stage heat, R to W1 will be energized. This will energize the electric heat sequencers and also energize W1 on the Variable Speed Terminal Board to start the indoor blower motor. When the normally open contacts of the heat sequencers close, this will energize the electric resistance heat.

GPH15 M Series X13 equipped models only:

With the thermostat set to the emergency heat position and a call for 2nd stage heat, R to W1 will be energized. This will energize the electric heat sequencers and the GE X13 motor. The electric heat will be energized through the normally open contacts of the electric heat sequencers. The indoor blower will be energized through W from the thermostat.

DEFROST CYCLE

Package Heat Pumps

The defrosting of the outdoor coil is jointly controlled by the defrost control board and the defrost thermostat.

Solid State Defrost Control

During operation the power to the circuit board is controlled by a temperature sensor, which is clamped to a feeder tube 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 34° 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 60° 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.

TEST

90 60 30

JUMPE R WIRE

CY W2 R R DFT

DF2

DF1

FAN OPERATION

Continuous Fan Mode

GPH15 M Series X13 equipped models only:

If the thermostat calls for continuous fan, the indoor blower will be energized from the G terminal of the thermostat to the X13 blower motor.

If a call for heat or cool occurs during a continuous fan call,

the GE X13

motor will always recognize the call for the

highest speed and ignore the lower speed call.

If the thermostat is not calling for heat or cool, and the fan switch on the thermostat is returned to the automatic position, the fan will stop after the programmed 60 second off delay on units with the GE X13

motor.

AIRFLOW ADJUSTMENTS FOR INDOOR BLOWER MOTOR

APH15 M Series ECM equipped models only:

Dip switch 4 must be set to ON for APH1524- 36. Dip switch 4 must be set to OFF for 2-stage compressor models APH1548-60. Dip switch 4 ON energizes Y1 signal to the ECM motor anytime Y/Y2 is energized. The indoor motor will not operate properly if switch is not set correctly for the model.

ECM Motor

The ECM control board is factory set with the dip switch #4 in the “ON” position for single stage units and to the "OFF" position for the 2 stage units. All other dip switches are factory set in the “OFF” position. For most applications, the

settings are to be changed according to the electric heat size.

The ECM 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 dip switch(s) either to an "OFF" or "ON" position.

APH15 M Series ECM equipped models only:

If the thermostat calls for continuous fan, the indoor blower will be energized through the VSTB at 30% of selected second stage cooling speed on APH15 units.

If the thermostat is not calling for heat or cool, and the fan switch on the thermostat is returned to the automatic position, the fan will stop after a 60 second delay on APH15 units.

Dip Switch Functions

The ECM motor has an electronic control that contains eight (8) 2-position dip switches. The function of these dip switches is shown in Table 1.

Page 18

SYSTEM OPERATION

Dip Switch Number Function

1 2 3N/A 4 Indoor Thermostat 5 6 7 8

Table 1

Electric Heat

Cooling & Heat Pump CFM

CFM Trim Adjust

CFM Delivery

Tables 2 and 4 show the CFM output for dip switch combinations 1-2 (Electric Heat), and 5-6 (Cooling/Heating).

Tables 3 shows the dip switch settings for 1 and 2-stage thermostats.

Model Switch 1 Switch 2 Electric Heat CFM

(F)

1050

APH1524

OFF OFF

ON OFF 950

OFF ON 825

ON ON 700

(F)

1250

APH1536

OFF OFF

ON OFF 1100

OFF ON 1000

ON ON 800

(F)

1800

APH1548

OFF OFF

ON OFF 1700

OFF ON 1400

ON ON 1225

(F)

2000

APH1560

OFF OFF

ON OFF 1800

OFF ON 1600

ON ON 1400

(F)

Factory

Table 2

Model Switch 3 Switch 4 Thermostat

APH15**

N/A ON 1-Stage N/

OFF 2-Stage

Table 3

Model Switch 5 Switch 6 Cooling/HP CFM

(F)

1050

APH1524

OFF OFF

ON OFF 950

OFF ON 825

ON ON 700

(F)

1250

APH1536

OFF OFF

ON OFF 1100

OFF ON 1000

ON ON 800

(F)

1800

APH1548

OFF OFF

ON OFF 1700

OFF ON 1400

ON ON 1225

(F)

2000

APH1560

OFF OFF

ON OFF 1800

OFF ON 1600

ON ON 1400

(F)

Factory

Table 4

Thermostat “Fan Only” Mode

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

CFM Trim Adjust

Minor adjustments can be made through the dip switch combination of 7-8. Table 5 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

Normal OFF OFF

-15% OFF ON

Table 5

Humidity Control

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

Two Stage Heating

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

Thermostat Wiring

Use thermostat wiring diagrams provided with the thermostat when making these connections.

See Specification Sheet for APH model series for CFM vs ESP tables.

Page 19

SYSTEM OPERATION

Typical Heat Pump System in Cooling

Reversing Valve

(Energized)

Indoor

Coil

Accumulator

Typical Heat Pump System in Heating

Outdoor

Coil

Indoor

Coil

Accumulator

Reversing Valve

(De-Energized)

Outdoor

Coil

Page 20

SCHEDULED MAINTENANCE

Package heat pumps require regularly scheduled maintenance to preserve high performance standards, prolong the service life of the equipment, and lessen the chances of costly failure.

In many instances the owner may be able to perform some of the maintenance; however, the advantage of a service contract, which places all maintenance in the hands of a trained serviceman, should be pointed out to the owner.

WARNING

ONCE A MONTH

1. Inspect the return filters of the evaporator unit and clean

or change if necessary. NOTE: Depending on operation conditions, it may be necessary to clean or replace the filters more often. If permanent type filters are used, they should be washed with warm water and dried.

2. When operating on the cooling cycle, inspect the condensate line piping from the evaporator coil. Make sure the piping is clear for proper condensate flow.

ONCE A YEAR

Qualified Service Personnel Only

1. Clean the indoor and outdoor coils.

2. Clean the cabinet inside and out .

3. Motors are permanently lubricated and do not require oiling. TO AVOID PREMATURE MOTOR FAILURE, DO NOT OIL.

4. Manually rotate the outdoor fan and indoor blower to be sure they run freely.

5. Inspect the control panel wiring, compressor connections, and all other component wiring to be sure all connections are tight. Inspect wire insulation to be certain that it is good.

6. Check the contacts of the compressor contactor. If they are burned or pitted, replace the contactor.

7. Using a halide or electronic leak detector, check all piping and etc. for refrigerant leaks.

TEST EQUIPMENT

Proper test equipment for accurate diagnosis is as essential as regular hand tools.

The following is a must for every service technician and service shop:

1. Thermocouple type temperature meter - measure dry bulb temperature.

2. Sling psychrometer- measure relative humidity and wet bulb temperature.

3. Amprobe - measure current.

4. Volt-Ohm Meter - testing continuity, capacitors, motor windings and voltage.

5. Accurate Leak Detector - testing for refrigerant leaks.

6. High Vacuum Pump - evacuation.

7. Electric Vacuum Gauge, Manifold Gauges and high vacuum hoses - to measure and obtain proper vacuum.

8. Accurate Charging Cylinder or Electronic Scale - measure proper refrigerant charge.

9. Inclined Manometer - measure static pressure and pressure drop across coils.

Other recording type instruments can be essential in solving abnormal problems, however, in many instances they may be rented from local sources.

Proper equipment promotes faster, more efficient service, and accurate repairs with less call backs.

Page 21

SERVICING

COOLING /HEAT PUMP- SERVICE ANALYSIS GUIDE

Complaint

No Cooling

Unsatisfact ory Cooling/ Heating

System Opera ting

Pressures

POSSIBLE CAUSE

DOTS IN ANALYSIS GUIDE

INDICATE SYMPTOM

"POSSIBLE CAUSE"

Pow er Failure

Blow n Fuse

Unbalanced Pow er, 3PH

Loose Connection

Shorted or Br oken Wires

Open Fan Overloa d

Faulty Thermos tat

Faulty Transfor mer

Shorted or O pen Capacitor

Internal Compres sor Overload Open

Shorted or G rounded Compressor

Compressor Stuck

Faulty Compres sor Contactor

Compressor High Stage Not W orking

Open Control Cir cuit

Low Voltage

Faulty Evap. Fan Motor

Shorted or G rounded Fan Motor

Improper Cooling Anticipator

Shortage of Refrigerant

Restrict ed Liquid Line

Open Element or Limit on Elec. Heater

Dirty Air Filter

Dirty Indoor Co il

Not enough air acros s Indoor Coil

Too much air acr oss Indoor Coil

Overcharg e of Refrigerant

Dirty Outdoor Coil

Noncondensibles

Recirculation of Condensing Air

Infiltration of Outdoor Air

Improperl y Loc ated Thermostat

Air Flow Unbalanced

System Unders ized

Broken Internal Par ts

Broken Valves

Inefficient Compressor

Loose Hold-dow n B olts

Faulty Reversing Valve

Faulty Defrost Control

Faulty Defrost Thermostat

Flow rator Not Seating Properly

System will not start

Compressor will not start -fan runs

•

• •

•

• • • • • •

• • •

• •

•

♦

•

Condenser fan will not start

Evaporator fan will not start

Comp. and Cond. Fan will not start

Compressor runs - goes off on overload

Compressor cycles on overload

Too cool and then too warm

System runs continuously - little cooling/htg

• •

•

• •

•

• • •

• •

•

♦

• •

•

• •

•

• •

•

♦

Compressor is noisy

Not cool enough on warm days

System runs -blows cold air in heating

Certain areas too cool, others too warm

♦

Unit will not defrost

Unit will not terminate defrost

Low suction pressure

•

• •

Low head pressure

High suction pressure

♦

High head pressure

•

♦ ♦

• • •

• •

•

• • •

•

• •

•

♦

•

♦♦♦ ♦♦♦

•

♦♦♦ ♦ ♦ ♦

•

♦

•

♦

•

♦

•

♦

•

♦

♦ ♦

•

• •

•

♦

•

• •

♦♦♦ ♦ ♦♦♦

•

• •

Test Method Remedy

Test Voltage

Inspect Fuse Size & Type

Test Voltage

Inspect Connect ion - Tighten

Test Circuits With Ohmmeter

Test Continuity of Ove rload

Test continuity of Thermostat & Wiring

Check control ci rcuit w ith voltmeter

Test Capacitor

Test Continuity of Ove rload

Test Motor Windings

Use Test Cord

Tes t cont inuity of Coi l & Contact s

Test Voltage to Unloader Plug, Test Pl ug S-17C

Test Control Circuit w ith Voltmeter

Test Voltage

Repair or Rep lace

Test Motor Windings

Check resi stance of Anticipator

Test For Leak s, Add Refrigerant

Remove Restriction, Replace Restricted Part S-112

Test Heater Element and Controls

Inspect Filt er-Clean or Replace

Inspect Coil - Clean

Check Blow er Speed, Duc t Static Pre ss, Filter S-200

Reduce Blow er Speed

Recover Part of Charge

Inspect Coil - Clean

Recover C harg e, Evacuate, Recharg e

Remove Obstruction to Air Flow

Check Window s, Doors, Vent Fans, Etc.

Relocate Therm ostat

Readjust Air Volume Dampers

Refigure Cooling Lo ad

Replace Com pressor

Test Compressor Efficiency

Tighten Bolts

Replace Valve or Solenoid

Test Contro l

Test Defr ost Thermos tat

Check Flow rator & Seat or Replace Flow rat or S-111

S-1

S-2, S-3

S-17A

S-3

S-4

S-15

S-17A

S-17B

S-17D

S-7, S-8

S-4, S-11, S- 12

S-1

S-16

S-16A,D

S-3B

S-101,103

S-26,S-27

S-200

S-113

S-114

S-115

S-104

S-21, 122

S-24

S-25

See Service Procedure Ref.

•

Cooling or Heating Cycle (Heat Pump)

♦

Heating Cycle Only (Heat Pump)

Page 22

SERVICING

S-1 CHECKING VOLTAGE

WARNING

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

With power ON:

WARNING

LINE VOLTAGE NOW PRESENT.

2. Using a voltmeter, measure the voltage across terminals L1 and L2 of the contactor for single phase units, and L3, for 3 phase units.

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.

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. 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 regards to either low or high voltage.

Unit Supply Voltage

Voltage Min. Max.

460 437 506

208/230 198 253

Three phase units require a balanced 3 phase power supply to operate. If the percentage of voltage imbalance exceeds 3% the unit must not be operated until the voltage condition is corrected.

Max. Voltage Deviation % Voltage = Imbalance Average Voltage

To find the percentage of imbalance, measure the incoming power supply.

L1 - L2 = 240V

L1 - L3 = 232V Avg. V = 710 = 236.7

L2 - L3 = 238V 3

Total 710V

To find Max. deviation: 240 - 236.7 = +3.3

Max deviation was 4.7V

% Voltage Imbalance = 4.7 = 1.99%

If the percentage of imbalance had exceeded 3%, it must be determined if the imbalance is in the incoming power supply or the equipment. To do this rotate the legs of the incoming power and retest voltage as shown below.

By the voltage readings we see that the imbalance rotated or traveled with the switching of the incoming legs. Therefore the power lies within the incoming power supply.

If the imbalance had not changed then the problem would lie within the equipment. Check for current leakage, shorted motors, etc.

From Average Voltage X 100

232 - 236.7 = -4.7

238 - 236.7 = +1.3

236.7

L1 - L2 = 240V L1 - L3 = 227V L2 - L3 = 238V

L3L2

Rotate all 3 incoming legs as shown.

L1 - L2 = 227V L1 - L3 = 238V L2 - L3 = 240V

Page 23

SERVICING

S-2 CHECKING WIRING

WARNING

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

S-3A THERMOSTAT AND WIRING

WARNING

LINE VOLTAGE NOW PRESENT.

With power ON and thermostat calling for cooling.

1. Use a voltmeter to verify 24 volts present at thermostat wires C and R.

2. If no voltage present, check transformer and transformer wiring. If 24 volts present, proceed to step 3.

3. Use a voltmeter to check for 24 volts at thermostat wires C and Y.

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

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

5. No voltage, indicates the trouble is in the thermostat or wiring.

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

S-3B COOLING ANTICIPATOR

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

To determine the proper setting, use an amp meter to measure the amperage on the "W" wire going to the thermostat.

Use an amprobe as shown below. Wrap 10 turns of thermostat wire around the stationary jaw of the amprobe and divide the reading by 10.

10 TURNS OF THERMOSTAT WIRE (From "W" on thermostat)

STATIONARY JAW OF AMPROBE

Indoor Blower Motor

With power ON:

WARNING

LINE VOLTAGE NOW PRESENT.

1. Use a voltmeter to verify 24 volts present at thermostat wires C and R.

2. If no voltage present, check transformer and transformer wiring. If 24 volts present, proceed to step 3.

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

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

READS 4 AMPS CURRENT DRAW WOULD BE .4 AMPS

Checking Heat Anticipator Amp Draw

Page 24

SERVICING

S-4 CHECKING TRANSFORMER AND CONTROL CIRCUIT

A step-down transformer (208/240 volt primary to 24 volt secondary) is provided with each package unit. This allows ample capacity for use with resistance heaters.

WARNING

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 is present at the primary voltage side of the

transformer and 24 volts is not present on the secondary side, then the transformer is inoperative. Replace.

S-7 CHECKING CONTACTOR AND/OR RELAYS

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 deenergized, springs return the contacts to their normal position.

WARNING

DISCONNECT POWER SUPPLY BEFORE SERVICING.

S-8 CHECKING CONTACTOR CONTACTS

WARNING

DISCONNECT POWER SUPPLY BEFORE SERVICING.

SINGLE PHASE

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.

VOLT/OHM

METER

Ohmmeter for testing holding coil Voltmeter for testing contacts

TESTING COMPRESSOR CONTACTOR

(Single Phase)

3. Using a voltmeter, test across terminals.

A. L1 to L2 - No voltage. Check breaker or fuses on main

power supply. If voltage present, proceed to step B.

B. T1 to T2 - Meter should read the same as L1 to L2 in

step A. If voltage readings are not the same as step A, replace contactor.

THREE PHASE

Using a voltmeter, test across terminals:

A. L1-L2, L1-L3, and L2-L3 - If voltage is present, pro-

ceed to B. If voltage is not present, check breaker or fuses on main power supply..

B. T1-T2, T1-T3, and T2-T3 - If voltage readings are not

the same as in "A", replace contactor.

L1L2

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.

Page 25

SERVICING

T3L3T2

VOLT/OHM

METER

Ohmmeter for testing holding coil Voltmeter for testing contacts

TESTING COMPRESSOR CONTACTOR

(Three-phase)

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 50 PSIG. It will automatically cut-in (close) at approximately 95 PSIG.

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

S-12 CHECKING HIGH PRESSURE CONTROL

WARNING

4. Start the system and place a piece of cardboard in front of the condenser coil, raising the condensing pressure.

5. Check pressure at which the high pressure control cutsout.

If it cuts-out at 610 PSIG ± 10 PSIG, it is operating normally (See causes for high head pressure in Service Problem Analysis Guide). If it cuts out below this pressure range, 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.

CAPACITOR, START

SCROLL COMPRESSOR MODELS

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 hard start kits are available and may improve low voltage starting characteristics. Only hard start kits approved by Goodman should be used. "Kick Start" and/or "Super Boost" kits are not approved start assist devices.

This check valve closes off high side pressure to the compressor after shut down allowing equalization through the scroll flanks. Equalization requires only about one or two seconds during which time the compressor may turn backwards.

or Copeland

The high pressure control capillary senses the pressure in the compressor discharge line. If abnormally high condensing pressures develop, the contacts of the control open, breaking the control circuit before the compressor motor overloads. This control is automatically reset.

1. Using an ohmmeter, check across terminals of high pressure control, with wire removed. If not continuous, the contacts are open.

3. Attach a gauge to the dill valve port on the base valve.

With power ON:

WARNING

LINE VOLTAGE NOW PRESENT.

MODELS EQUIPPED WITH A HARD START DEVICE

A start capacitor is wired in parallel with the run capacitor to increase the starting torque. The start capacitor is of the electrolytic type, rather than metallized polypropylene as used in the run capacitor.

A switching device must be wired in series with the capacitor to remove it from the electrical circuit after the compressor starts to run. Not removing the start capacitor will overheat the capacitor and burn out the compressor windings.

Page 26

SERVICING

These capacitors have a 15,000 ohm, 2 watt resistor wired across its terminals. The object of the resistor is to discharge the capacitor under certain operating conditions, rather than having it discharge across the closing of the contacts within the switching device such as the Start Relay, and to reduce the chance of shock to the servicer. See the Servicing Section for specific information concerning capacitors.

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.

S-15A RESISTANCE CHECK

WARNING

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 will bleed resistor will not return to infinity. It will still read the resistance of the resistor).

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

WARNING

DISCHARGE CAPACITOR THROUGH A 20 TO 30 OHM RESISTOR BEFORE HANDLING.

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

Capacitance (MFD) = 2650 X Amperage

Voltage

1. Discharge capacitor and remove wire leads.

WARNING

DISCHARGE CAPACITOR THROUGH A 20 TO 30 OHM RESISTOR BEFORE HANDLING.

Volt / Ohm Meter

Capacito

Volt / Ohm Meter

15 AMP FUSE

AMMETER

TESTING CAPACITANCE

TESTING CAPACITOR RESISTANCE

Page 27

SERVICING

S-16 CHECKING MOTORS

S-16B CHECKING FAN AND BLOWER MOTOR

(ECM MOTORS)

APH15 M Series Only

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.

OUT - OUT +

DJUST +/-

Y1 Y/Y2

COOL

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

}

applications only

Gnd

AC Line Connection

816

G (FAN)

EM Ht/W2

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

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

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

7. Using an ohmmeter, check for continuity from the #1 & #3

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.

DELAY

COMMON2

W/W1

COMMON1 O (REV VALVE)

16-PIN ECM HARNESS CONNECTOR

(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.

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

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

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

24 Vac (R)

HEAT

BK/PWM (SPEED)

Page 28

SERVICING

(

)

ity)

Check

for

undercharged

condition

Check

and

plug

leaks

return

ducts

cabinet

different

have completel

- 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.

Troubleshooting Chart for ECM Variable Speed Air Circulator Blower Motors

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

- Manual disconnect switch off or

door switch open.

- Blown fuse or circuit breaker.

- 24 Vac wires miswired.

- Unseated pins in wiring

harness connectors.

- This is normal start-up for

variable speed motor.

- No movement.

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

- Motor rocks

slightly

when starting.

- Motor won't

- Turn power OFF prior to repair.

- Test with a temporary jumper between R - G.

- Bad motor/control module.

- Moisture present in motor or control module.

start.

Wait 5 minutes after

disconnecting power before

opening motor.

- Handle electronic motor/control with care.

- Check for loose motor mount.

- Make sure blower wheel is tight on shaft.

- Perform motor/control replacement check,

ECM motors only.

- Check line voltage for variation or "sag".

- Turn power OFF prior to repair.

- 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.*

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

- 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.

- Motor rocks,

- Blower wheel not tight on motor shaft.

- Bad motor/control module.

- It is normal for motor to

oscillate with

but won't start.

- Motor

no load on shaft.

oscillates up &

down while

being tested

off of blower.

- Varies up and down

- Moisture present in motor/control module.

or intermittent.

- Motor starts,

but runs

erratically.

- Turn power OFF prior to repair.

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.

- Does removing panel or filter

reduce "puffing"?

- Check/replace filter.

- Check/correct duct restrictions.

- Adjust to correct blower speed setting.

.- Arran

- Incorrect or dirty filter(s).

- Incorrect supply or return ductwork.

- Incorrect blower speed setting.

- "Hunts" or "puffs" at

high CFM (speed).

equipment manufacturer

or as recommended b

n p ra

ensa

s con

*Moisture Check

- Connectors are oriented "down"

resu e

uce unexpec

rammed for specific operatin

pro

es an

are factor

warran uc

pro

s a

e vo u

mo ro

con or

. -

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:

CHART CONTINUED ON NEXT PAGE

Page 29

SERVICING

(

)

ity)

Check

for

undercharged

condition

Check

and

plug

leaks

return

ducts

cabinet

different

have completel

- 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.

- Turn power OFF prior to repair.

- Check/replace filter.

- 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.

- Check/correct duct restrictions.

- 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.

- Adjust to correct blower speed setting.

- Replace motor and perform

Moisture Check.*

resu e

CHART CONTINUED FROM PREVIOUS PAGE

- 24 Vac wires miswired or loose.

- "R" missing/not connected at motor.

- Fan in delay mode.

- "R" missing/not connected at motor.

Troubleshooting Chart for ECM Variable Speed Air Circulator Blower Motors

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

- Stays at low CFM despite

system call for cool

or heat CFM.

- Stays at high CFM.

- Motor starts,

but runs

erratically.

uce unexpec

rammed for specific operatin

pro

.- Arran

- Fan in delay mode.

- Current leakage from controls

into G, Y, or W.

- High static creating high blower speed.

- Incorrect supply or return ductwork.

- 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.

- Blower won't shut off.

- Air noise.

- Noisy blower or cabinet.

- Excessive

- "Hunts" or "puffs" at

high CFM (speed).

noise.

- Moisture in motor/control module.

- Motor failure or

malfunction has

occurred and moisture

is present.

- Evidence of

Moisture.

equipment manufacturer

or as recommended b

n p ra

ensa

s con

*Moisture Check

- Connectors are oriented "down"

es an

are factor

warran uc

pro

s a

e vo u

mo ro

con or

. -

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 30

SERVICING

S-16C CHECKING ECM MOTOR WINDINGS

APH15 M Series Only

WARNING

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

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.

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.

3-pin motor connector

16-pin connector

5-pin connector

Connections

3/16"

123

LGN

Low Voltage Connections

1/4”

GE X13TM MOTOR CONNECTIONS

S-17 CHECKING COMPRESSOR WINDINGS

S-16D CHECKING GE X13TM MOTORS

GPH15 M Series Only

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 X13 features an integral control module.

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.

WARNING

HERMETIC COMPRESSOR ELECTRICAL TERMINAL VENTING CAN BE DANGEROUS. WHEN INSULATING MATERIAL WHICH SUPPORTS A HERMETIC COM-

PRESSOR 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.

Page 31

SERVICING

If the compressor terminal PROTECTIVE COVER and gasket (if required) is 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 procedure 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. The three phase internal overload will open all three legs.

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.

2. Using an ohmmeter, test continuity between terminals SR, C-R, and C-S, on single phase units or terminals T1, T2 and T3, on 3 phase units.

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.

WARNING

1. Remove the leads from the compressor terminals.

WARNING

SEE WARNINGS S-17 BEFORE REMOVING COMPRESSOR TERMINAL COVER.

DAMAGE CAN OCCUR TO THE GLASS EMBEDDED TERMINALS IF THE LEADS ARE NOT PROPERLY REMOVED. THIS CAN RESULT IN TERMINAL AND HOT OIL DISCHARGING.

HI-POT

COMPRESSOR GROUND TEST

Page 32

SERVICING

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 volt-ohmmeter.

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.

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

5. If ground is indicated, replace the compressor.

S-17C UNLOADER TEST PROCEDURE

A nominal 24-volt direct current coil activates the internal unloader solenoid. The input control circuit voltage must be 18 to 28 volt ac. The coil power requirement is 20 VA. The external electrical connection is made with a molded plug assembly. This plug contains a full wave rectifier to supply direct current to the unloader coil.

4. Next check the molded plug.

A. Voltage check: Apply control voltage to the plug wires

(18 to 28 volt ac). The measured dc voltage at the female connectors in the plug should be around 15 to 27 vdc.

B. Resistance check: Measure the resistance from the

end of one molded plug lead to either of the two female connectors in the plug. One of the connectors should read close to zero ohms while the other should read infinity. Repeat with other wire. The same female connector as before should read zero while the other connector again reads infinity. Reverse polarity on the ohmmeter leads and repeat. The female connector that read infinity previously should now read close to zero ohms.

C. Replace plug if either of these test methods doesn’t

show the desired results.

S-17D OPERATION TEST

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

UNLOADER SOLENOID

Unloader Test Procedure

If it is suspected that the unloader is not working, the following methods may be used to verify operation.

1. Operate the system and measure compressor current. Cycle the unloader ON and OFF at 10 second intervals. The compressor amperage should go up or down at least 25 percent.

2. If step one does not give the expected results shut unit off. Apply 18 to 28 volt ac to the unloader molded plug leads and listen for a click as the solenoid pulls in. Remove power and listen for another click as the unloader returns to its original position.

3. If clicks can’t be heard, shut off power and remove the control circuit molded plug from the compressor and measure the unloader coil resistance. The resistance should be 32 to 60 ohms, depending on compressor temperature.

(Molded Pl ug)

WARNING

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.

4. With power ON, close the switch.

WARNING

LINE VOLTAGE NOW PRESENT.

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.

Page 33

SERVICING

S-18 TESTING CRANKCASE HEATER

Note: Not all compressors use crankcase heaters.

The crankcase heater must be energized a minimum of four (4) hours before the compressor 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. Scroll Compressors are not equipped with a crankcase heaters.

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

WARNING

DISCONNECT POWER SUPPLY BEFORE SERVICING.

1. Disconnect the heater lead wires.

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

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 and the continuity of the connecting wiring from the "O" terminal of the thermostat to the unit.

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. The defrost control should close at 34°F ± 5°F.

3. Check the temperature at which the control opens its contacts by raising the temperature of the control. The defrost control should open at 60°F ± 5°F.

4. If not as above, replace control.

S-50 CHECKING HEATER LIMIT CONTROL(S)

(OPTIONAL ELECTRIC HEATERS)

Each individual heater element is protected with an automatic rest limit control 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. to 160°F and close at approximately 110°F.

WARNING

DISCONNECT ELECTRICAL POWER SUPPLY.

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. Make sure the limits are cool before testing.

IF FOUND OPEN - REPLACE - DO NOT WIRE AROUND.

S-52 CHECKING HEATER ELEMENTS

Optional electric heaters may be added, in the quantities shown in the spec sheet for each model unit, to provide electric resistance heating. Under no condition shall more heaters than the quantity shown be installed.

Page 34

SERVICING

WARNING

At any time the system has been open for repair, the factory installed liquid line filter drier

BRAZING MATERIALS

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.

must be replaced.

1. Disassemble and remove the heating element(s).

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.

S-100 REFRIGERATION REPAIR PRACTICE

DANGER

ALWAYS REMOVE THE REFRIGERANT CHARGE IN A PROPER MANNER BEFORE APPLYING HEAT TO THE SYSTEM.

These models use the FasTest Access Fitting System, with a saddle that is either soldered to the suction and liquid lines or is fastened with a locking nut to the access fitting box (core) and then screwed into the saddle. Do not remove the core

from the saddle until the refrigerant charge has been removed. Failure to do so could result in property damage or personal injury.

When installing a new core or reinstalling the core after removal, it is very important to note that before inserting the core into the saddle, the core and saddle must be free of debris and the “O” Ring must have a thin coating of refrigerant oil applied to it. The oil is to prevent the “O” Ring from being deformed when the core is tightened completely. The core should be torqued to 8 ft. lb.

When repairing the refrigeration system:

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.

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.

WARNING

TO AVOID POSSIBLE EXPLOSION, THE LINE FROM THE NITROGEN CYLINDER MUST INCLUDE A PRESSURE REGULATOR AND A PRESSURE RELIEF

ALVE. THE PRESSURE RELIEF VALVE MUST BE SET

TO OPEN AT NO MORE THAN 150 psig.

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

S-102 EVACUATION

WARNING

REFRIGERANT UNDER PRESSURE! FAILURE TO FOLLOW PROPER PROCEDURES MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

This is the most important part of the entire service procedure. The life and efficiency of the equipment is dependent upon the thoroughness exercised by the serviceman when evacuating air (non-condensable) and moisture from the system.

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

Page 35

SERVICING

Moisture chemically reacts with the refrigerant and oil to form corrosive hydrofluoric and hydrochloric acids. These 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.

WARNING

SCROLL COMPRESSORS DO NOT FRONT SEAT THE SERVICE VALVE(S) WITH THE COMPRESSOR OPERATING IN AN ATTEMPT TO SAVE REFRIGERANT. WITH THE SUCTION LINE OF THE COMPRESSOR CLOSED OR SEVERLY RESTRICTED, THE SCROLL COMPRESSOR WILL DRAW A DEEP VACUUM VERY QUICKLY. THIS VACUUM CAN CAUSE INTERNAL ARCING OF THE FUSITE RESULTING IN A DAMAGED OR FAILED COMPRESSOR.

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

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 minimum of 250 microns. 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-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.

S-103 CHARGING

WARNING

LOW SIDE

GAUGE

AND VALVE

800 PSI

RATED

HOSES

UNIT SERVICE

VALVE PORTS

HIGH SIDE

GAUGE

AND VALVE

VACUUM PUMP

ADAPTER

VACUUM PUMP

CHARGING CYLINDER

AND SCALE

2. Start the vacuum pump and open the shut off valve to the high vacuum gauge manifold only. After the compound gauge (low side) has dropped to approximately 29 inches 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.

CAUTION

USE REFRIGERANT CERTIFIED TO ARI STANDARDS. USED REFRIGERANT MAY CAUSE COMPRESSOR DAMAGE AND WILL VOID THE WARRANTY. MOST PORTABLE MACHINES CANNOT CLEAN USED REFRIGERANT TO MEET ARI 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. Using a calibrated set of refrigerant scales, 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.

Page 36

SERVICING

NOTE: R410A should be drawn out of the storage container or drum in liquid form due to its fractionation properties, but should be "Flashed" to its gas state before entering the system. There are commercially available restriction devices that fit into the system charging hose set to accomplish this. DO NOT charge liquid R410A into the compressor.

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.

Final Charge Adjustment

The outdoor temperature must be 60°F or higher. Set the room thermostat to COOL, fan switch to AUTO, and set the temperature control well below room temperature.

After system has stabilized per startup instructions, compare the operating pressures and outdoor unit amp draw to the numbers listed in the technical manual. If pressures and amp draw are too low, add charge. If pressures and amp draw are too high, remove charge. Check subcooling and superheat as detailed in the following section.

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

6. Check system for leaks.

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

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-

⇒ Below normal high side pressure.

Above normal low side pressure.

⇒

Low temperature difference across coil.

⇒ Low amp draw at compressor.

-and the charge is correct. The compressor is faulty - replace the compressor.

S-105 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 heatpump TXV/check valve operation in the heating and cooling modes.

COOLING HEATING

TXV VALVES

Some 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 valve will shut off completely at approximately 100 PSIG.

30% bleed valves used on some other models will continue to allow some equalization even though the valve has shut-off completely because of the bleed holes within the valve. This type of valve should not be used as a replacement for a 0% bleed valve, due to the resulting drop in performance.

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 ARE DESIGNED TO MEET THE SPECIFICATION REQUIREMENTS FOR OPTIMUM PRODUCT OPERATION. DO NOT USE SUBSTITUTES.

Page 37

SERVICING

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 15 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.

CAUTION

Superheat Formula = Suct. Line Temp. - Sat. Suct. Temp.

EXAMPLE:

a. Suction Pressure = 143

b. Corresponding Temp. °F. = 50

c. Thermometer on Suction Line = 66°F.

To obtain the degrees temperature of superheat, subtract 50.0 from 66.0°F.

The difference is 16° Superheat. The 16° Superheat would fall in the ± range of allowable superheat.

See R410A Pressure vs. Temperature chart on page 40.

SUPERHEAT AND SUBCOOLING ADJUSTMENT ON TXV APPLICATIONS

Single Speed Application (*PH1524**-*PH1536**)

1. Purge gauge lines. Connect service gauge manifold to access fittings. Run system at least 10 minutes to allow pressure to stabilize.

2. Temporarily install thermometer on liquid (small) line near liquid line access fitting with adequate contact and insulate for best possible reading.

3. Check subcooling and superheat. Systems with TXV application should have a subcooling of 10 heat of 15 to 18ºF.

a. If subcooling and superheat are low, adjust TXV to

15 - 18ºF then check subcooling.

b. If subcooling is low and superheat is high, add charge

to raise subcooling to10 ± 2ºF then check superheat.

c. If subcooling and superheat are high, adjust TXV

valve to 15 - 18ºF then check subcooling.

d. If subcooling is high and superheat is low, adjust

TXV valve to 15 to 18ºF superheat and remove charge to lower the subcooling to 10 ± 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 indoor airflow, and wet bulb temperature.

NOTE: Do NOT adjust charge based on suction pressure unless there is a gross undercharge.

+ 2°F and super-

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.

4. Disconnect manifold set. Installation is complete.

Page 38

SERVICING

SUBCOOLING = SAT. LIQUID TEMP. - LIQUID LINE TEMP.

SATURATED LIQUID PRESSURE

TEMPERATURE CHART

Liquid

Pressure

PSIG R-410A

200 70 210 73 220 76 225 78 235 80 245 83 255 85 265 88 275 90 285 92 295 95 305 97 325 101 355 108 375 112 405 118

Two Speed Application (*PH1548**-*PH1560**)

Run the unit on low stage cooling for 10 minutes until refrigerant pressures stabilize. Follow the guidelines and methods below to check unit operation and ensure that the refrigerant charge is within limits. Charge the unit on low stage.

1. Purge gauge lines. Connect service gauge manifold to

access fittings. Run system at least 10 minutes to allow pressure to stabilize.

2. Temporarily install thermometer on liquid (small) line near

liquid line access fitting with adequate contact and insulate for best possible reading.

3. Check subcooling and superheat. Two stage systems run-

ning on low stage with TXV application should have a subcooling of 5 to 7 ºF and superheat of 15 to 18ºF.

a. If subcooling and superheat are low, adjust TXV to

15 to 18ºF superheat, then check subcooling.

NOTE: To adjust superheat, turn the valve stem clockwise to increase and counter clockwise to decrease.

b. If subcooling is low and superheat is high, add charge

to raise subcooling to 5 to 7 ºF then check superheat.

c. If subcooling and superheat are high, adjust TXV

valve to 15 to 18ºF superheat, then check subcooling.

Saturated Liquid

Tem

erature °F

d. If subcooling is high and superheat is low, adjust

TXV valve to 15 to 18ºF superheat and remove charge to lower the subcooling to 5 to 7 ºF.

NOTE: Do NOT adjust the charge based on suction pressure unless there is a gross undercharge.

4. Disconnect manifold set, installation is complete.

SUBCOOLING = SAT. LIQUID TEMP. - LIQUID LINE TEMP.

Heat Pump - Heating Cycle

The proper method of charging a heat pump in the heat mode is by weighing the charge according to the total charge listed on the rating plate.

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 close to the high pressure access fitting process tube.

2. Install a high side pressure gauge on the high side (liquid) access fitting.

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. Compare the hi-pressure reading to the "Required Liquid Line Temperature" chart . Find the hi-pressure value on the left column. Follow that line right to the column under the design subcooling value. Where the two intersect is the required liquid line temperature.

Alternately you can 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 = SAT. LIQUID TEMP. - LIQUID LINE TEMP.

EXAMPLE:

a. Liquid Line Pressure = 417 b. Corresponding Temp. °F. = 120° c. Thermometer on Liquid line = 113°F.

To obtain the amount of subcooling subtract 113°F from 120°F.

The difference is 7° subcooling, which would fall in the + range of allowable subcooling.

Page 39

SERVICING

12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98

°F

-37.7

-34.7

-32.0

-29.4

-36.9

-24.5

-22.2

-20.0

-17.9

-15.8

-13.8

-11.9

-10.1

-8.3

-6.5

-4.5

-3.2

-1.6

0.0

1.5

3.0

4.5

5.9

7.3

8.6

10.0

11.3

12.6

13.8

15.1

16.3

17.5

18.7

19.8

21.0

22.1

23.2

24.3

25.4

26.4

27.4

28.5

29.5

30.5

31.2

32.2

33.2

34.1

35.1

35.5

36.9

PSIG

100 102 104 106 108 110 112

PSIG

114.0

116.0

118.0

120.0

122.0

124.0

126.0

128.0

130.0

132.0

134.0

136.0

138.0

140.0

142.0

144.0

146.0

148.0

150.0

152.0

154.0

156.0

158.0

160.0

162.0

164.0

166.0

168.0

170.0

172.0

174.0

176.0

178.0

180.0

182.0

184.0

186.0

188.0

190.0

192.0

194.0

196.0

198.0

200.0

202.0

204.0

206.0

208.0

210.0

212.0

214.0

Pressure vs. Temperature Chart

R-410A

°F

37.8

38.7

39.5

40.5

41.3

42.2

43.0

43.8

44.7

45.5

46.3

47.1

47.9

48.7

49.5

50.3

51.1

51.8

52.5

53.3

54.0

54.8

55.5

56.2

57.0

57.7

58.4

59.0

59.8

60.5

61.1

61.8

62.5

63.1

63.8

64.5

65.1

65.8

66.4

67.0

67.7

68.3

68.9

69.5

70.1

70.7

71.4

72.0

72.6

73.2

73.8

PSIG

216.0

218.0

220.0

222.0

224.0

226.0

228.0

230.0

232.0

234.0

236.0

238.0

240.0

242.0

244.0

246.0

248.0

250.0

252.0

254.0

256.0

258.0

260.0

262.0

264.0

266.0

268.0

270.0

272.0

274.0

276.0

278.0

280.0

282.0

284.0

286.0

288.0

290.0

292.0

294.0

296.0

298.0

300.0

302.0

304.0

306.0

308.0

310.0

312.0

314.0

316.0

°F

74.3

74.9

75.5

76.1

76.7

77.2

77.8

78.4

78.9

79.5

80.0

80.6

81.1

81.6

82.2

82.7

83.3

83.8

84.3

84.8

85.4

85.9

86.4

86.9

87.4

87.9

88.4

88.9

89.4

89.9

90.4

90.9

91.4

91.9

92.4

92.8

93.3

93.8

94.3

94.8

95.2

95.7

96.2

96.6

97.1

97.5

98.0

98.4

98.9

99.3

99.7

PSIG

318.0

320.0

322.0

324.0

326.0

328.0

330.0

332.0

334.0

336.0

338.0

340.0

342.0

344.0

346.0

348.0

350.0

352.0

354.0

356.0

358.0

360.0

362.0

364.0

366.0

368.0

370.0

372.0

374.0

376.0

378.0

380.0

382.0

384.0

386.0

388.0

390.0

392.0

394.0

396.0

398.0

400.0

402.0

404.0

406.0

408.0

410.0

412.0

414.0

416.0

418.0

°F

100.2

100.7

101.1

101.6

102.0

102.4

102.9

103.3

103.7

104.2

104.6

105.1

105.4

105.8

106.3

106.6

107.1

107.5

107.9

108.3

108.8

109.2

109.6

110.0

110.4

110.8

111.2

111.6

112.0

112.4

112.6

113.1

113.5

113.9

114.3

114.7

115.0

115.5

115.8

116.2

116.6

117.0

117.3

117.7

118.1

118.5

118.8

119.2

119.6

119.9

120.3

PSIG

420.0

422.0

424.0

426.0

428.0

430.0

432.0

434.0

436.0

438.0

440.0

442.0

444.0

446.0

448.0

450.0

452.0

454.0

456.0

458.0

460.0

462.0

464.0

466.0

468.0

470.0

472.0

474.0

476.0

478.0

480.0

482.0

484.0

486.0

488.0

490.0

492.0

494.0

496.0

498.0

500.0

502.0

504.0

506.0

508.0

510.0

512.0

514.0

516.0

518.0

520.0

°F

120.7

121.0

121.4

121.7

122.1

122.5

122.8

123.2

123.5

123.9

124.2

124.6

124.9

125.3

125.6

126.0

126.3

126.6

127.0

127.3

127.7

128.0

128.3

128.7

129.0

129.3

129.7

130.0

130.3

130.7

131.0

131.3

131.6

132.0

132.3

132.6

132.9

133.3

133.6

133.9

134.0

134.5

134.8

135.2

135.5

135.8

136.1

136.4

136.7

137.0

137.3

PSIG

522.0

524.0

526.0

528.0

530.0

532.0

534.0

536.0

538.0

540.0

544.0

548.0

552.0

556.0

560.0

564.0

568.0

572.0

576.0

580.0

584.0

588.0

592.0

596.0

600.0

604.0

608.0

612.0

616.0

620.0

624.0

628.0

632.0

636.0

640.0

644.0

648.0

652.0

656.0

660.0

664.0

668.0

672.0

676.0

680.0

684.0

688.0

692.0

696.0

°F

137.6

137.9

138.3

138.6

138.9

139.2

139.5

139.8

140.1

140.4

141.0

141.6

142.1

142.7

143.3

143.9

144.5

145.0

145.6

146.2

146.7

147.3

147.9

148.4

149.0

149.5

150.1

150.6

151.2

151.7

152.3

152.8

153.4

153.9

154.5

155.0

155.5

156.1

156.6

157.1

157.7

158.2

158.7

159.2

159.8

160.3

160.8

161.3

161.8

*Based on ALLIED SIGNAL Data

Page 40

SERVICING

LIQUID PRESSURE

AT SERVICE VALVE (PSIG) 8 10 12 14 16 18

REQUIRED LIQUID LINE TEMPERATURE

REQUIRED SUBCOOLING TEMPERATURE (°F)

189 585654525048 195 605856545250 202 626058565452 208 646260585654 215 666462605856 222 686664626058 229 706866646260 236 727068666462 243 747270686664 251 767472706866 259 787674727068 266 807876747270 274 828078767472 283 848280787674 291 868482807876 299 888684828078 308 908886848280 317 929088868482 326 949290888684 335 969492908886 345 989694929088 354 100 98 96 94 92 90 364 102 100 98 96 94 92 374 104 102 100 98 96 94 384 106 104 102 100 98 96 395 108 106 104 102 100 98 406 110 108 106 104 102 100 416 112 110 108 106 104 102 427 114 112 110 108 106 104 439 116 114 112 110 108 106 450 118 116 114 112 110 108 462 120 118 116 114 112 110 474 122 120 118 116 114 112 486 124 122 120 118 116 114 499 126 124 122 120 118 116 511 128 126 124 122 120 118

Page 41

SERVICING

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.

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.

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

S-113 REFRIGERANT OVERCHARGE

An overcharge of refrigerant is normally indicated by excessively high head pressure and/or liquid return to the compressor.

If high head pressure is not indicated, an overcharge or a system containing non-condensables could be the problem.

If overcharging is indicated:

1. Start the system.

2. Remove 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. See S-114 NonCondensables.

S-114 NON-CONDENSABLES

Check for non-condensables.

1. Shut down the system and allow the pressures to equalize for a minimum of 15 minutes.

2. Take a pressure reading.

3. Compare this 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.

To remove the non-condensables.

1. Remove the refrigerant charge.

2. Replace and/or install liquid line drier

3. Evacuate and recharge.

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

IOLATION OF EPA REGULATIONS MAY RESULT

IN FINES OR OTHER PENALITIES.

Now determine if a burn out has actually occurred. Confirm by analyzing an oil sample using a Sporlan Acid Test Kit, AK-3 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.

Page 42

SERVICING

NOTE: The Flushing Method using R-11 refrigerant is no longer

approved by Goodman® Manufacturing Company, L.P.

Suction Line Drier Clean-Up Method

The POE oils used with R410A refrigerant is an excellent solvent. In the case of a burnout, the POE oils will remove any burnout residue left in the system. If not captured by the refrigerant filter, they will collect in the compressor or other system components, causing a failure of the replacement compressor and/or spread contaminants throughout the system, damaging additional components.

Use AMANA 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 car-

bon 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.

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.

brand part number RF000127 suction line filter

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 conduction 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.

Page 43

SERVICING

S-200 CHECKING EXTERNAL STATIC

PRESSURE

The minimum and maximum allowable duct static pressure is found in the Technical Information Manual.

Too great of an external static pressure will result in insufficient air that can cause icing of the coil, whereas too much air can cause poor humidity control, and condensate to be pulled off the evaporator coil causing condensate leakage. Too much air can cause motor overloading and in many cases this constitutes a poorly designed system. 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).

S-201 CHECKING TEMPERATURE RISE

Temperature rise is related to the BTUH output of the unit and the amount of air (CFM) circulated over the indoor coil.

All units are designed for a given range of temperature increase. This is the temperature of the air leaving the unit minus the temperature of the air entering the unit.

The more air (CFM) being delivered through a given unit the less the rise will be; so the less air (CFM) being delivered, the greater the rise. The temperature rise should be adjusted in accordance to a given unit specifications and its external static pressure.

1. Take entering and leaving air temperatures.

2. Select the proper speed tap from the unit's blower performance data in the Technical Manual for the specific unit.

3. Take motor amperage draw to determine that the motor is not overloaded during adjustments.

Total External Static

2. Measure the static pressure of the supply duct, (Positive Pressure).

3. Add the two readings together.

NOTE: Both readings may be taken simultaneously and read directly on the manometer as shown in the illustration above, if so desired.

4. Consult proper table for quantity of air.

If the external static pressure exceeds the minimum or maximum allowable statics, check for closed dampers, dirty filters, undersized or poorly laid out ductwork.

RISE = SUPPLY -

Checking Temperature Rise

T T

Page 44

WIRING DIAGRAMS

PACKAGE SYSTEM WIRING DIAGRAM - 1 STAGE ELECTRIC HEAT

SEE NOTE 1

#18 GAUGE 7 WIRE

REQUIRED F OR

HEAT PUM PS

ROOM THERMOSTAT

CW1GRE

PACKAGE UNIT LOW VOLTAGE JUNCTION BOX

YELLOW

GREEN

ORANGE

WHITE

TYPICAL HP

BLUE

OUTDOOR T HERMOSTAT

CLOSE ON TEMPERAT URE FALL

PACKAGE SYSTEM WIRING DIAGRAM - 2 STAGE ELECTRIC HEAT

ABOVE 10 KW

RED

SEE NOTE 1

#18 GAUGE 8 WIRE

FOR HEAT PUMPS

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.

SEE NOTE 2

ROOM THERMOSTAT

W2 C RYO W1G E

PACKAGE UNIT LOW VOLTAGE

JUNCTION BOX

RED

YELLOW

GREEN

ORANGE

WHITE

BROWN

BLUE

OUTDOOR THERMOSTAT

CLOSE ON TEMPERAT URE FALL

TYPICAL HP

NOTES:

1) "O" and "E" used on heat pumps only.

2) Connect wire from terminal #1 on outdoor thermostat to the white wire on package units if single stage indoor thermostat is used.

Color Codes

R - Red Y - Yellow BL - Blue BR - Brown O - Orange W - White G - Green

OT18-60A OUTDOOR THERMOSTAT

Page 45

WIRING DIAGRAMS

PACKAGE SYSTEM WIRING DIAGRAM - HEAT PUMPS ONLY!

TWO-STAGE ELECTRIC HEAT ABOVE 10 kW

TYPICAL H/P

ROOM THERMOSTAT

#18 G AUGE 8 W IRE

OUTDOOR THERMOSTAT #2 (IF USED, SEE NOTE 1)

OUTDOOR THERMOSTAT #1

CLOSE ON TEMPERATURE FALL

W2 C RYO W1G E

PACKAGE HEAT PUMP

LOW VOLTAGE JUNCTION BOX

RED

YELLOW

GREEN

ORANGE

WHITE

BROWN

BLUE

For outdoor temperatures below 0° F with 50% or higher relative humidity, set outdoor thermostat at 0° F

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.

NOTE 1: OT18 #2 CAN BE CONNECTED BETWEEN W2 OF THERMOSTAT AND BROWN WIRE IF DESIRED.

COLOR CODES R --RED Y --YELLOW BL-BLUE BR-BROWN O --ORANGE W -WHITE G --GREEN

OT18-60A OUTDOOR THERMOSTAT

Page 46

WIRING DIAGRAMS

*PH15**M4*

L1 L2

HTR1

PLM

HTR2

ONE (1) ELEMENT ROWS TWO (2) ELEMENT ROWS

L2L1

PLM

5 KW

10 KW

PLM

HTR1

HTR2

HTR3

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

HTR2

HTR3

HTR4

PLM

L2 L1 L2

THREE (3) ELEMENT ROWS FOUR (4) ELEMENT ROWS

15 KW

SINGLE PHASE HKR** HEAT KIT

L2L1 L1 L2

20 KW

Page 47

WIRING DIAGRAMS

*PH15**M4*

ROOFTOP UNITS

GOODMAN MANUFACTURING CO.

*PH SERIES WIRING DIAGRAM

MODEL GPH13MED ECONOMIZER

WHITE

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.

YELLOW

ORANGE

GPC & GPH SERIES WIRING DIAGRAM

GPH13MED ECONOMIZER FOR *PH15**M4*

NOTE: RECOMMEND MULTI-STAGE T'STAT

Goodman R-410A, APH1524M41AA, APH1536M41AA, APH1548M41AA, APH1560M41AA Service Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual