Goodman GPH1424H41C, GPH1424H41D, GPH1430H41C, GPH1430H41D, GPH1436H41C User Manual

Service Instructions

*PH 14 PACKAGE HEAT PUMPS

*PC 14 PACKAGE COOLING

HORIZONTAL MODELS

WITH R-410A

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.

©2008 - 2014 Goodman Manufacturing Company, L.P.

RS6300014

September 2014

1

INDEX

IMPORTANT INFORMATION ......................................................................................................... 4 - 5

PRODUCT IDENTIFICATION - *PC/*PH14**H41** ...................................................................... 6 - 8

ACCESSORIES ................................................................................................................................... 9

PCCP101-103 ROOF CURB ........................................................................................................................................ 10

PCP101-103 DOWNFLOW PLENUM .......................................................................................................................... 10

PCEF101-103 ELBOW AND FLASHING KIT ................................................................................................................11

PCE101-103 ECONOMIZER .......................................................................................................................................... 11

PCMD101-103 DOWNFLOW MANUAL DAMPER ....................................................................................................... 12

GPHMD101-103 HORIZONTAL MOTORIZED DAMPER WITH DUCT FLANGE ........................................................... 12

SQRPC SQUARE TO ROUND CONVERTER ............................................................................................................... 13

SQRPCH SQUARE TO ROUND CONVERTER ............................................................................................................ 13

PCFR101-103 EXTERNAL FILTER KIT ....................................................................................................................... 14

PRODUCT DESIGN .......................................................................................................................... 15

ELECTRICAL WIRING ................................................................................................................................................. 16

LINE VOLTAGE WIRING .............................................................................................................................................. 17

SYSTEM OPERATION ...................................................................................................................... 18

*PC/*PH14**H41**

COOLING .................................................................................................................................................................... 18

COOLING CYCLE ........................................................................................................................................................ 18

HEATING CYCLE ......................................................................................................................................................... 18

DEFROST CYCLE ....................................................................................................................................................... 19

FAN OPERATION ........................................................................................................................................................ 19

SCHEDULED MAINTENANCE......................................................................................................... 22

ONCE A MONTH ......................................................................................................................................................... 22

ONCE A YEAR ............................................................................................................................................................. 22

TEST EQUIPMENT ...................................................................................................................................................... 22

SERVICING ....................................................................................................................................... 23

COOLING/HEAT PUMP- SERVICE ANALYSIS GUIDE ................................................................................................ 23

S-1 CHECKING VOLTAGE ........................................................................................................................................... 24

S-2 CHECKING WIRING .............................................................................................................................................. 24

S-3 CHECKING THERMOSTAT, WIRING, AND ANTICIPATOR .................................................................................... 24

S-3A Thermostat and Wiring ..................................................................................................................................... 24

S-3B Cooling Anticipator ........................................................................................................................................... 25

S-3C Heating Anticipator ........................................................................................................................................... 25

S-4 CHECKING TRANSFORMER AND CONTROL CIRCUIT ....................................................................................... 25

S-7 CHECKING CONTACTOR AND/OR RELAYS ........................................................................................................ 25

S-8 CHECKING CONTACTOR CONTACTS .................................................................................................................. 26

S-11 CHECKING LOSS OF CHARGE PROTECTOR ................................................................................................... 27

S-15 CHECKING CAPACITOR ..................................................................................................................................... 27

S-15A RESISTANCE CHECK ....................................................................................................................................... 28

S-15B CAPACITANCE CHECK ..................................................................................................................................... 28

S-16 CHECKING MOTORS .......................................................................................................................................... 29

S-16A CHECKING FAN AND BLOWER MOTOR WINDINGS (PSC MOTORS) ............................................................ 29

S-16D CHECKING EEM MOTORS ............................................................................................................................... 29

S-17 CHECKING COMPRESSOR WINDINGS ............................................................................................................. 30

S-17A RESISTANCE TEST .......................................................................................................................................... 30

S-17B GROUND TEST ................................................................................................................................................. 30

S-17D Operation Test ................................................................................................................................................. 31

2

INDEX

S-18 TESTING CRANKCASE HEATER ........................................................................................................................ 31

S-18A CHECKING CRANKCASE HEATER THERMOSTAT ........................................................................................... 31

S-21 CHECKING REVERSING VALVE AND SOLENOID .............................................................................................. 31

S-24 TESTING DEFROST CONTROL .......................................................................................................................... 32

S-25 TESTING DEFROST THERMOSTAT .................................................................................................................... 32

S-50 CHECKING HEATER LIMIT CONTROL(S) ........................................................................................................... 32

S-52 CHECKING HEATER ELEMENTS ........................................................................................................................ 32

S-100 REFRIGERATION REPAIR PRACTICE ............................................................................................................... 33

S-101 LEAK TESTING ................................................................................................................................................. 33

S-102 EVACUATION ..................................................................................................................................................... 33

S-103 CHARGING ........................................................................................................................................................ 34

S-104 CHECKING COMPRESSOR EFFICIENCY ......................................................................................................... 35

S-108 SUPERHEAT ...................................................................................................................................................... 35

S-109 CHECKING SUBCOOLING ................................................................................................................................36

S-111 FIXED ORIFICE RESTRICTION DEVICES ......................................................................................................... 36

S-112 CHECKING RESTRICTED LIQUID LINE ............................................................................................................ 37

S-113 REFRIGERANT OVERCHARGE ......................................................................................................................... 37

S-114 NON-CONDENSABLES ...................................................................................................................................... 37

S-115 COMPRESSOR BURNOUT ................................................................................................................................40

S-122 REVERSING VALVE REPLACEMENT ................................................................................................................ 40

S-200 CHECKING EXTERNAL STATIC PRESSURE .................................................................................................... 41

S-201 CHECKING TEMPERATURE RISE ..................................................................................................................... 41

WIRING DIAGRAMS .......................................................................................................................... 42

OT18-60A OUTDOOR THERMOSTAT ......................................................................................................................... 42

OT18-60A OUTDOOR THERMOSTAT ......................................................................................................................... 43

SINGLE PHASE HKR/P** HEAT KITS......................................................................................................................... 44

PCE* ECONOMIZER .................................................................................................................................................... 45

SPK* - SINGLE POINT WIRING KIT ......................................................................................................................... 46

3

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

THI S 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 CERTIF ED BY

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

G

OODMAN.

G

WARNING

O PREVENT THE RISK OF PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH,

T

DO NOT STORE COMBUSTIBLE MATERIALS OR USE GASOLINE OR OTHER

FLAMMABLE LIQUIDS OR VAPORS IN THE VICINITY OF THIS APPLIANCE.

WARNING

OODMA N WILL NO T BE R ESPONSIBLE FOR AN Y INJURY O R PROPERTY DAM AGE ARI SING FROM IMPROPER SERVICE OR SERVIC E PROCED URES.

G
IF YOU INSTALL OR PERFORM SERVICE ON THIS UNIT, YOU ASSUME RE SPONSIBILITY FOR A NY PERSONA L INJURY OR P ROPERTY DAM AGE WHICH

MAY RESULT.

ANY JURISDICTIONS REQUIRE A LICENSE TO INSTALL OR SERVICE HEATING AND AIR CONDITIONING EQUIPMENT.

M

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: [e-mail]

fax us at: [phone]

(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.

4

IMPORTANT INFORMATION

SAFE REFRIGERANT HANDLING

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

WARNING

EFRIGERANTS ARE HEAVIER THAN AIR. THEY CAN "PUSH OUT" THE

R

OXYGEN IN YOUR LUNGS OR IN ANY ENCLOSED SPACE.

POSSIBL E DIFF ICULTY IN BREAT HING O R DEATH:

EVER PURGE REFR IGERANT INTO AN ENCLOSED ROO M OR SPACE . BY

•

N

LAW, ALL REF RIGERANTS MUST BE RECLAIMED.

F AN INDOOR LEAK IS SUSPECTED, THOROUGHLY VENTILATE THE AREA

•

I

BEFORE BEGINNING WORK.

•

IQUID REFRIGERANT CAN BE VE RY COLD. TO AVOID POSSIBLE FROST-

L

BITE OR BLINDNESS, AVOID CONTACT WITH REFRIGERANT AND WEAR

GLOVES AND GOGGLES.

SKIN OR E YES, SEEK M EDICAL HELP IMMEDI ATELY.

•

ALWAYS FOLLOW EPA REG ULATIO NS. NEVER BURN REFRIGE RANT,

AS POISON OUS GAS WI LL BE PRODUC ED.

F LIQUID REFRIGERANT DOES CONTACT YOUR

I

O AVO ID

T

WARNING

TO AVOID POSSIBLE EXPLOSION:

• NEVER APPLY FLAME OR STEAM TO A REFRIGERANT CYLINDER. IF YOU

MUST HEAT A CYLINDE R FOR FASTER CHARGING, PARTI ALLY IMMERSE

IT IN WARM WATER.

• NEVER FILL A CYLINDER MORE THAN 80% FULL OF LIQUID REFRIGERANT.

• NEVER ADD ANYTHING OTHER T HAN 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 US ED.

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

AS A PLATFORM OR A ROLLER.

WARNING

O AVOI D POSSI BLE EX PLOSION, USE ONLY RETURNABLE (NOT DISPOSABL E)

T

SERVICE CYLINDERS WHEN REMOVING REFRIGERANT FROM A SYSTEM.

•

NSURE THE CYLIND ER IS FREE O F DAMAGE WHICH COULD LEAD TO A

E

LEAK OR EXPLOSION.

•

NSURE THE HYDROSTA TIC TEST DATE DOES NOT EXCEE D 5 YEARS .

E

•

NSURE THE PRESSURE RATING MEETS OR EXCEEDS 400 LBS.

E

HEN IN DOUBT, DO NOT USE CYLIND ER.

W

WARNING

WARNING

YSTEM CONTAMINANTS, IMPROPER SERVICE PROCEDURE AND/OR PHYSICAL

S

ABUSE AFFECTING HE RMETIC COMPRESSOR ELECTRICAL TERMI NALS 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.

T

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.

5

PRODUCT IDENTIFICATION

The model number is used for positive identification of component parts used in manufacturing. Please use this number when
requesting service or parts information.

PC1424 H 4 1 * *G / A

BRAND:

G: Goodman

Brand or
Distinctions

A: Amana

®

Brand

®

PRODUCT

TYPE:

Package

Cooling/Heating

PRODUCT

14: 14 SEER

PRODUCT

FAMILY:

C: Cooling
H: Heat Pump

SERIES:

Rating

CONFIGURATION:

H: Horizontal

NOMINAL

CAPACITY:

24: 24,000 BTUH
30: 30,000 BTUH
36: 36,000 BTUH
42: 42,000 BTUH
48: 48,000 BTUH
49: 48,000 BTUH
60: 60,000 BTUH

MINOR

REVISION:

MAJOR

REVIS ION:

REFRIGERANT:

4: R-410A

VOLTAGE:

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

Chassis Model A B

*PC1424 22 30

Small

Medium

Dimensions in inches

*PC1430 22 30

*PC1436 22 30

*PC1442 22 30

*PC1448 24 35

*PC1460 24 35

is a registered trademark of Maytag Corporation or its related entities and is used under license. All rights reserved.

6

Chassis Model A B

Small

Medium

Large

Dimensions in inches

*PH142441** 22.000 29.932

*PH143041** 22.000 29.932

*PH143641** 24.000 34.932

*PH144241** 24.000 34.932

*PH144841B* 24.000 34.932

*PH144841A* 24.000 38.682

*PH146041** 24.000 38.682

PRODUCT IDENTIFICATION

®

MODEL # PACKAGE COOLING DESCRIPTION

oodman® Brand or Distinctions Package Cooling -

GPC1424-48H41AA

GPC1424-48H41AB

GPC1424-48H41BA

GPC1460H41BA

GPC1424-48H41AC

GPC1460H41AB

GPC1424H41CA

GPC1430-60H41CA

A/GPC1424-60H41DA

G

14 Seer 208-230/1/60 Single-Phase Electric Cooling Unit with R-410A.

oodman® Brand or Distinctions Package Cooling -

G

14 Seer 208-230/1/60 Single-Phase Electric Cooling Unit with R-410A.
Models with 5 mm condenser coils.

oodman® Brand or Distinctions Package Cooling -

G

14 Seer 208-230/1/60 Single-Phase Electric Cooling Unit with R-410A.
Models with aluminum evaporator coils.

oodman® Brand or Distinctions Package Cooling -

G

14 Seer 208-230/1/60 Single-Phase Electric Cooling Unit with R-410A.
Models with 5 mm condenser coils and aluminum evaporator coils.

oodman

G

14 Seer 208-230/1/60 Single-Phase Electric Cooling Unit with R-410A.
Adds "T" to liquid line and re-locates the pressure switch on "H" series
cooling models.

oodman

G

14 Seer 208-230/1/60 Single-Phase Electric Cooling Unit with R-410A. Two
ton models with a Rechi compressor.

oodman

G

14 Seer 208-230/1/60 Single-Phase Electric Cooling Unit with R-410A.
Models with Broad Ocean Digi motor.

mana® Brand/Goodman

A

14 Seer 208-230/1/60 Single-Phase Electric Cooling Unit with R-410A.
Models that change static ratings to be max 0.88 on all E-Heat kits besides
20 kW.

Brand or Distinctions

®

Brand or Distinctions

®

Brand or Distinctions

ackage Cooling -

P

ackage Cooling -

P

ackage Cooling -

P

®

Brand or Distinctions

ackage Cooling -

P

7

PRODUCT IDENTIFICATION

-

MODEL # PACKAGE HEAT PUMP DESCRIPTION

®

Brand or Distinctions

GPH1424-60H41AB

GPH1424-60H41AA

GPH1424-60H41AC

GPH1424-60H41BA

GPH1424-60H41CA

oodman

G

14 Seer 208-230/1/60 Single-Phase Heat Pump with R-410A. Models are
changing to the PCBDM133 defrost control and with the addition of the
crankcase heaters where necessary.

oodman® Brand or Distinctions Package Heat Pum p -

G

14 Seer 208-230/1/60 Single-Phase Heat Pump with R-410A.

oodman® Brand or Distinctions Package Heat Pum p - 14 Seer 208-

G

230/1/60 Single-Phase Heat Pump with R-410A. Adds "T" to liquid line and re
locates the pressure switch on "H" series heat pumps.

oodman® Brand or Distinctions Package Heat Pum p - 14 Seer 208-

G

230/1/60 Single-Phase Heat Pump with R-410A. Models with Aluminum
Evaporator Coils.

oodman® Brand or Distinctions Package Heat Pum p - 14 Seer 208-

G

230/1/60 Single-Phase Heat Pump with R-410A. Models with Broad Ocean
Digi m otor.

ackage Heat Pum p -

P

A/GPH1424-42H41DA

A/GPH1448H41DA

GPH1460H41DA

mana® Brand/Goodman

A

14 Seer 208-230/1/60 Single-Phase Heat Pump with R-410A. Models that
change static ratings to be max 0.88 on all E-Heat kits besides 20 kW.

®

Brand or Distinctions

ackage Heat Pum p -

P

8

ACCESSORIES

Part Number Description

OT18-60A

OT/HER-60A Outdoor Thermostat with Emergency Heat Relay

HKR05A, 08, 10, CA Heater Kit for all *PC/*PH (H) Series

HKP05C, 10C Heater Kit for all *PC/*PH (H) Series

HKP15* Heater kit for *PC/*PH13/14 (30-60) (H) Series

HKP20* Heater Kit for *PC/*PH13/14 (42-60) (H) Series

PCCP101-103 Roof Curb

PCP101-103 Downflow Plenum Kit

PCP101-103R8 Downflow Plenum Kit w/ R-8 Insulation

GPCED101-103 Downflow Economizer for H Series Package Units (A/C) - To Be Used With PCP101-103

GPHED101-103 Downflow Economizer for H Series Package Units (Heat Pump) - To Be Used With PCP101-103

GPCEH101-103 Horizontal Economizer for H Series Package Units (A/C)

GPHEH101-103 Horizontal Economizer for H Series Package Units (Heat Pump)

PCMD101-103 Manual Damper - To Be Used With PCP101-103

PCMDM101-103 Motorized Damper - To Be Used With PCP101-103

GPHMD101-103 Manual Damper for Horizontal Applications

SPK* Single Point Wiring Kit

SQRPCH101 Square to Round Adapters 16"&14"

SQRPCH102-103 Square to Round Adapters 18"&14"

SQRPC101 Square to Round Adapter - For Use With PCCP101-103 Curb 16" Rounds

SQRPC102-103 Square to Round Adapter For Use With PCCP101-103 Curb 18" Rounds

PCFR101-103 External Horizontal Filter Rack

PCEF101-103 Elbow & Flashing w/ R-8 Liner

CDK36 Flush Mount Concentric Duct Kit

CDK36515 Flush Mount Concentric Duct Kit w/ Filter

CDK36530 Step Down Concentric Duct Kit

CDK36535 Step Down Concentric Duct Kit w/ Filter

CDK4872 Flush Mount Concentric Duct Kit

CDK4872515 Flush Mount Concentric Duct Kit w/ Filter

CDK4872530 Step Down Concentric Duct Kit

CDK4872535 Step Down Concentric Duct Kit w/ Filter

*PC/*PH14**H41*

ACCESSORIES *PC/*PH H SERIES

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

GOODMAN® BRAND THERMOSTATS

CH70TG Manual Changeover

CHSATG Manual Changeover

CHT18-60 Manual Changeover

CHT90-120 Manual Changeover Mechanical, Nonprogrammable 2 Heat - 2 Cool

CHTP18-60HD Manual Changeover Digital, Nonprogrammable 2 Heat - 1 Cool

CT18-60 Manual Changeover

Digital, Nonprogrammable 1 Heat - 1 Cool
Mechanical, Nonprogrammable 1 Heat - 1 Cool
Mechanical, Nonprogrammable 1 Heat - 1 Cool

Mechanical, Nonprogrammable Cool Only

AMANA® BRAND THERMOSTATS

1213401 White Manual Changeover
1213402 White Manual Changeover
1213403 White Manual Changeover 7 Day Programming Digital 2 Heat - 1 Cool
1213404 White Manual Changeover
1213406
1213407
1213408
1213410
1213411
1213412
1213431

Beige
White

White
White
White
White

White

Manual/Auto Ch angeover 5 + 2 Programming Digital 3 Heat - 2 Cool

Manual Changeover

Manual/Auto Changeover

Manual Changeover 5 + 2 Programming Digital 2 Heat - 1 Cool

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

5 + 2 Programming Digital 1 Heat - 1 Cool

Nonprogrammable Digital 1 Heat - 1 Cool

Nonprogrammable Digital 2 Heat - 1 Cool

5 + 2 Programming Digital 2 Heat - 2 Cool

7 Day Programming Digital 1 Heat - 1 Cool

Nonprogrammable Digital 2 Heat - 2 Cool

7 Day Programming Digital 3 Heat - 2 Cool

9

ACCESSORIES

33"

*PC/*PH14H41*

PCCP101-103 ROOF CURB

64"

59"

29 3/8"

29 3/4"

33"

26"

28 3/4"

31"

PCP101-103 DOWNFLOW PLENUM

(Use with PCCP Roof Curb)

14"

1" Flange

Roof
Curb

10

37"

13"

25 1/2"

33"

13"

ACCESSORIES

*PC/*PH14H41*

PCEF101-103 ELBOW AND FLASHING KIT

28"

35"

25"

33"

3"

4"

20 3/8"

17 3/4"

4"

25"

8"

PCE*101-103 ECONOMIZER*

(DOWNFLOW APPLICATIONS)

5"

27 3/4"

16 1/2"

17 3/4"

20" x 17 1/2"

Filter

3"

31 1/4"

Model Used With

PCEC101-103* *PC HORIZONTAL A/C

PCEH101-103* *PH HORIZONTAL HP

*Must be used with PCP101-103

11

ACCESSORIES

PCMDM101-103 DOWNFLOW MOTORIZED DAMPER*

2

1

PCMD101-103 DOWNFLOW MANUAL DAMPER*

*USED WITH PCP101-103 DOWNFLOW PLENUM

"

8

/

1

*PC/*PH14H41*

6"

10"

29 3/4"

MODEL DESCRIPTION

PCMDH101-103 Manual Damper

PCMDM101-103 Motorzied Damper

GPHMD101-103 HORIZONTAL MANUAL DAMPER WITH DUCT FLANGE

18"

8

1

/

4

"

18"

12

12"

6"

2"

17"

25 1/4"

17 1/4"

ACCESSORIES

"

A

*PC/*PH14H41*

SQRPC SQUARE TO ROUND CONVERTER

(DOWNFLOW APPLICATIONS)

1" FLANGES

1 1/2

SA

RA

OUTER FLANGE

29 1/2"

29 1/4"

SA 16" 18"
RA 16" 18"

SQRPCH SQUARE TO ROUND CONVERTER

(HORIZONTAL APPLICATIONS)

SQUARE TO ROUND
DUCT CONVERTER PANEL

BEAD

A

SQRPC101 SQRP102-103

C

2"

RETURN

2"

SUPPLY

B

STARTER FLANGE

SQRPCH-101 SQRPCH-102 SQRPCH-103 SQRPCH102-14 SQRPCH103-14

15" 17" 17" 15" 15"

B
C 17" 17" 19" 15" 15"
D

SUPPLY 14" 16" 16" 14" 14"

RETURN

15" 17" 17" 15" 15"

22 1/2" 24 1/2" 24 1/2" 24 1/2" 24 1/2"

16" 16" 18" 14" 14"

D

13

ACCESSORIES

*PC/*PH14H41*

PCFR101-103 EXTERNAL FILTER KIT

(HORIZONTAL APPLICATIONS)

14" x 25" x 2" FILTER

14

PRODUCT DESIGN

LOCATION & CLEARANCES

NOTE: To ensure proper condensate drainage, unit must be in­stalled in a level position.

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.

48” MIN.

10"

36"

36"

*PC/*PH14**H41*

WALL

UNIT

36"

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 and Platform

*PC/*PH14**H41*

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

NOTE: To ensure proper condensate drainage, unit must be in­stalled in a level position.

The connecting ductwork (Supply and Return) can be connected
for horizontal discharge airflow. In the down discharge applica­tions, a matching Platform/Roof Curb (PCCP101-103) and
Downflow Plenum (PCP101-103) 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. 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 restrictor orifices.
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.

15

PRODUCT DESIGN

The outdoor fan motor is a 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

Some H series package units use the Compliant Scroll com­pressor, instead of traditional reciprocating compressors. Still
other models use reciprocating compressors.

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.

• These scroll compressors use POE or polyolester oil which
is NOT compatiable 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.

INDOOR BLOWER MOTOR

All *PC/*PH 14 model package units use a EEM blower motor.
The EEM 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 EEM 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.

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.

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.

WARNING

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

WARNING

16

PRODUCT DESIGN

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.

17

SYSTEM OPERATION

SYSTEM OPERATION *PC/*PH14**H41*

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.

Heat Pump Models

Any time the room thermostat is switched to cool, the O
terminal is energized. This energizes the 24 volt coil on the
reversing valve and switches it to the cooling position.

When the contacts of the room thermostat close, this closes
the circuit from R to Y and R to G in the unit.

This energizes the compressor contactor and will energize
the indoor blower instantly on models equipped with EEM
blower motor.

When the thermostat is satisfied, it opens its contacts break­ing the low voltage circuit causing the compressor contactor
to open and indoor fan to stop after the programmed 60 sec­ond off delay on models equipped with EEM blower motors.

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.

HEATING CYCLE

Cooling Only Units

NOTE: The following only applies if the cooling only unit has
an approved electric heat kit installed for heating. If auxiliary
electric heaters should be used, they may be controlled by
outdoor thermostats (OT18-60A or OT/EHR18-60A).

*PC Models Equipped with EEM Blower Motors

With the thermostat set to the heat position and a call for
heat, R to W will be energized. This will energize the electric
heat sequencers and the EEM 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.

When the thermostat is satisfied, this breaks the circuit from
R to W. This will turn off the electric heaters, and the indoor
blower after the programmed 60 second off delay.

COOLING CYCLE

Cooling Only Models

When the contacts of the room thermostat close, making
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
24V signal from the thermostat.

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 fan off
delay.

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.

18

SYSTEM OPERATION

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 instantly on models equipped with EEM
blower motors.

When the thermostat is satisfied, breaking the circuit be­tween R to Y and R to G, the compressor and outdoor fan
motor will stop after the programmed 60 second off delay on
models equipped with EEM blower motors .

When auxiliary electric heaters are used, a two stage heat­ing single 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.

*PH Models Equipped with EEM Blower Motors

With the thermostat set to the emergency heat position, R to
W1 will be energized. This will energize the electric heat se­quencers and the EEM 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.

*PC/*PH14**H41*

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 setting the circuit board
jumper to 30, 60, or 90 respectively. Accumulation of time for
the timing period selected starts when the sensor closes
(approximately 32
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 twelve minute override interrupts the unit’s defrost
period.

FAN OPERATION

Continuous Fan Mode

Models Equipped With EEM Blower Motors

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

If a call for heat or cool occurs during a continuous fan call,
the EEM 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 EEM motor.

+ 2° F), and when the room thermostat

19

SYSTEM OPERATION

Typical Package Cooling

Indoor

Coil

Restrictor Orifice Assembly in Cooling Operation

Outdoor

Coil

Chatleff

Orifice

Assy

In the cooling mode the orifice is pushed into its seat forcing refrigerant to flow through the metered hole in the center of the
orifice.

20

SYSTEM OPERATION

Typical Heat Pump System in Cooling

Reversing Valve

(Energized)

Indoor

Coil

Accumulator

Typical Heat Pump System in Heating

Outdoor

Coil

Indoor

Coil

Reversing Valve

(De-Energized)

Outdoor

Coil

Accumulator

21

SCHEDULED MAINTENANCE

The owner should be made aware of the fact, that, as with any
mechanical equipment the Package Cooling and Heat Pump
units 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 the filters more often. If permanent type filters are
used, they should be washed with warm water, dried and
sprayed with an adhesive according to manufacturers
recommendations.

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 casing of the outdoor unit 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.

8. Check the combustion chamber (Heat Exchanger) for soot,
scale, etc. Inspect all burners for lint and proper position­ing.

9. Start the system, using the proper instrumentation check
gas inlet and manifold pressures, burner flame and microamp
signal. Adjust if necessary.

10. Start the system and run both a Cooling & Heating Perfor­mance Test. If the results of the test are not satisfactory,
see the "Service Problem Analysis" Chart of the possible
cause.

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 amperage and voltage.

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

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 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.

22

SERVICING

SERVICING

COOLING /HEAT PUMP- SERVICE ANALYSIS GUIDE

Co m plain t

POSSI BLE CAUSE

DOTS IN ANALYSIS

GUIDE INDICATE

"POSSI BLE CAUSE"

Po w e r Fa il ur e
Blow n Fu se
Unbalanced Pow er, 3PH
Loose Connection
Shorted or Broken Wires
Open Fan Overload
Fau lty Th er mos ta t
Fau lty Tr an s f or mer
Shorted or Open Capacitor
Internal Compres sor Ove rload Open
Shorted or Grounded Compressor
Compressor Stuck
Faulty Compress or Contactor
Faulty Fan Control
Open Control Circuit
Low Voltage
Faulty Evap. Fan Motor
Shorted or Grounded Fan Motor
Impr oper Cooling Antic ipator
Shortage of Refriger ant
Restricted Liquid Line
Open Element or Limit on Elec. Heater
Dirty Air Filter
Dirty Indoor Coil
Not enough air ac ross Indoor Coil
Too much air acr oss Indoor Coil
Overc harge of Refr igerant
Dirty Outdoor Coil
Noncondensibles
Recirculation of Condensing Air
Infiltration of Outdoor A ir
Impr operly Located Thermostat
Air Flow Unbalanced
System Undersized
Broken Internal Parts
Broken V alves
Ineff icient Compress or
Loose Hold-dow n Bolts
Faulty Rev ers ing V alv e
Faulty Defrost Control
Faulty Defr ost Thermostat
Flow rator Not Seating Properly

No Cooling

SYMPTO M

Sys tem will not s tar t

Compr essor will not start - fan r uns

Comp. an d Cond. Fan will not start

Evapo rator fan will not s tar t

Conden ser fan w ill not s tart

Compressor runs - goes off on overload

Compressor cycles on overload

•

•••

•••

•••

••••••

••

••• •

••

• ••••

•

••

•••

•••

•

•

•••

••

••

••

••

•• •• •

•• •

•• •

••

•• •

••

•

•

Cooling or Heating Cycle (Heat Pum p) Heating Cycle Only (Heat Pump)

•

Unsatisfactory

Cooling/Heating

System runs continuously - little cooling/htg

Too cool and then too warm

Not cool enough on warm days

Certain areas too cool, others too warm

Compr essor is noisy

Sys tem runs - blow s c old air in heat ing

♦

♦

♦

♦♦

••• •

••• •

••• •

•

♦

♦

•••

••

••

•• ••

•

♦

•

♦

•

♦♦♦ ♦♦♦

♦♦♦♦♦ ♦

♦♦♦♦♦♦♦

•••

♦

Unit will n ot ter minate defr ost

Pressures

Unit will not def ros t

Low s uction press ure

••

♦

System

Operating

Low head pressure

High s uction press ure

♦

•

••

••

Test Method

Reme dy

High head pressure

Test Vo ltage S-1
Inspect Fus e Size & Type S-1
Test Vo ltage S-1
Ins pect Connection - Tighten S-2, S-3
Test Circuits With Ohmmeter S-2, S-3
Test Continuity of Overload S-17A
Test continuity of Thermostat & Wiring S-3
Check control circuit w ith voltmeter S-4
Test Capacitor S-15
Test Continuity of Overload S-17A
Test Motor Windings S-1 7B
Us e Test Cor d S- 17 D
Test continuity of Coil & Contacts S-7, S-8
Test continuity of Coil And Contac ts S-7, S-9
Test Control Circuit w ith Voltmeter S-4
Test Vo ltage S-1
Repair or Replace S-16

♦

Test Motor Windings S-1 6A ,D
Check res istanc e of Anticipator S-3B
Test For Leaks, Add Refrigerant S-101,103
Remove Res triction, Replace Res tricted Part S- 112
Test Heater Element and Controls S-26,S- 27
Inspect Filter -Clean or Replace

♦

Ins pe ct Coil - Cle an

♦

Check Blow er Speed, Duct Static Press, Filter S-200

♦

Reduce Blow er Speed S-200
Recov er Part of Charge S- 113
Ins pe ct Coil - Cle an

•

Recov er Charge, Evac uate, Rechar ge S-114

•

Remove Obstruction to Air Flow
Check Window s, Doors , Vent Fans , Etc.
Relocate Thermostat
Readjust A ir Volume Damp ers
Refigure Cooling Load
Replace Compress or S-115
Test Compressor Efficiency S-104
Test Compressor Efficiency S-104
Tighten Bolts
Replace Valve or Solenoid S-21, 12 2
Test Control S-24
Test Defr ost Thermos tat S- 25
Check Flow rator & Seat or Replace Flow rator S- 111

See Servi ce Procedure Ref.

23

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

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.

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.

24

SERVICING

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

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

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.

WARNING

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

With power ON:

WARNING

LINE VOLTAGE NOW PRESENT.

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

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.

READS 4 AMPS
CURRENT DRAW
WOULD BE .4 AMPS

Checking Heat Anticipator Amp Draw

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.

1. Remove the leads from the holding coil.

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

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

S-8 CHECKING CONTACTOR CONTACTS

WARNING

DISCONNECT POWER SUPPLY BEFORE SERVICING.

25

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.

T2

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.

T1

CC

L1L2

26

SERVICING

S-11 CHECKING LOSS OF CHARGE
PROTECTOR

(Heat Pump Models)

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

The low pressure control is designed to cut-out (open) at ap­proximately 22
approximately 50 + 7 PSIG.

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

S-12 CHECKING HIGH PRESSURE CONTROL

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.

The high pressure control senses the pressure in the liquid
line. If abnormally high discharge 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.

2. Attach a gauge to the access fitting on the liquid line.

+ 7 PSIG. It will automatically cut-in (close) at

With power ON:

WARNING

LINE VOLTAGE NOW PRESENT.

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

4. 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. The control should reset at 420 PSIG ± 25 PSIG.

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.

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.

Your unit comes with a 180-second anti-short cycle to prevent
the compressor from starting and running backwards.

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.

27

SERVICING

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.

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

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

WARNING

1. Discharge capacitor and remove wire leads.

WARNING

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

Volt / Ohm
Meter

VOLT MET ER

15 AMP

FUSE

AMMETER

CAPACITOR

TESTING CAPACITANCE

28

tor

i

Capac

TESTING CAPACITOR RESISTANCE

SERVICING

S-16 CHECKING MOTORS

S-16A CHECKING FAN AND BLOWER MOTOR
WINDINGS (PSC MOTORS)

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.

Applies only to units with PSC Motors

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

WARNING

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

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

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

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

High Voltage
Connections

3/16"

C

123

LGN

4

5

Low Voltage Connections

1/4”

EEM MOTOR CONNECTIONS

S-17 CHECKING COMPRESSOR WINDINGS

S-16D CHECKING EEM (ENERGY EFFICIENT
MOTOR) MOTORS

Applies only to units with EEM Motors

The EEM 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 EEM fea­tures an integral control module.

Note: The GE TECMate will not currently operate the EEM
motor.

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

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

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

WARNING

HERMETIC COMPRESSOR ELECTRICAL TERMINAL
VENTING CAN BE DANGEROUS. WHEN INSULATING
MATERIAL WHICH SUPPORTS A HERMETIC COM­PRESSOR OR ELECTRICAL TERMINAL SUDDENLY
DISINTEGRATES DUE TO PHYSICAL ABUSE OR AS A
RESULT OF AN ELECTRICAL SHORT BETWEEN THE
TERMINAL AND THE COMPRESSOR HOUSING, THE
TERMINAL MAY BE EXPELLED, VENTING THE
VAPOR AND LIQUID CONTENTS OF THE COMPRES­SOR HOUSING AND SYSTEM.

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.

29

SERVICING

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.

C

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.

S

COMP

R

S-17B GROUND TEST

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.

WARNING

1. Remove the leads from the compressor terminals.

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

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

WARNING

SEE WARNINGS S-17 BEFORE REMOVING COMPRES­SOR TERMINAL COVER.

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

30

HI-POT

COMPRESSOR GROUND TEST

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.

SERVICING

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-17D OPERATION TEST

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

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

If the test shows:

a. Below normal high side pressure.

Above normal low side pressure.

b.

c.

Low temperature difference across coil.

d. Low amp draw at compressor.

and the charge is correct, test the reversing valve if equipped
(heat pump models only. See-S-21). If the reversing valves
test good, the compressor is faulty - replace the compressor.

S-18 TESTING CRANKCASE HEATER

(OPTIONAL ITEM)

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.

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

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

Note: Not all compressors use crankcase heaters.

The crankcase heater must be energized a minimum of twenty­four (24) 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.
On some models, the crankcase heater is controlled by a crank­case heater thermostat that is wired in series with the crank­case heater.

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-18A CHECKING CRANKCASE HEATER
THERMOSTAT

Note: Not all models with crankcase heaters will have a

crankcase heater thermostat.

1. Install a thermocouple type temperature test lead on the
discharge line adjacent to the crankcase heater thermo­stat.

2. Check the temperature at which the control closes its con­tacts by lowering the temperature of the control. The crank­case heater thermostat should close at 67°F ± 5°F.

3. Check the temperature at which the control opens its con­tacts by raising the temperature of the control. The crank­case heater thermostat should open at 85°F ± 5°F.

4. If not as above, replace control.

31

SERVICING

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

NOTE: PCBDM133 defrost controls have a three (3) minute
compressor off cycle delay.

NOTE: The PCBDM133 defrost controls are shipped from the

factory with the compressor delay option selected. This will
de-energize the compressor contactor for 30 seconds on defrost
initiation and defrost termination. If the jumper is set to Normal,
the compressor will continue to run during defrost initiation
and defrost termination. The control will also ignore the low
pressure switch connected to R-PS1 and PS2 for 5 minutes

upon defrost initiation and 5 minutes after defrost termination.
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" ("R-DFT" on PCBDM133) 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"
("O-RV" on PCBDM133). 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" (W on
PCBDM133) & "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. It should
close at approximately 32°F ± 2°F.

3. Check the temperature at which the control opens its con­tacts by raising the temperature of the control. It should
open at approximately 60°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.

32

SERVICING

WARNING

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.

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.

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.

S-101 LEAK TESTING

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:

WARNING

DISCONNECT ELECTRICAL POWER SUPPLY.

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.

(NITROGEN OR NITROGEN-TRACED)

WARNING

WARNING

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.

For a system that contains a refrigerant charge and is sus­pected of having a leak, stop the operation and hold the explor­ing tube of the detector as close to the tube as possible, check
all piping and fittings. If a leak is detected, do not attempt to
apply more brazing to the joint. Remove and capture the charge,
unbraze the joint, clean and rebraze.

For a system that has been newly repaired and does not con­tain a charge, connect a cylinder of refrigerant, through a gauge
manifold, to the liquid and suction line dill valves and/or liquid
line dill valve and compressor process tube.

33

SERVICING

NOTE: Refrigerant hoses must be equipped with dill valve de-

pressors or special adaptor used. Open the valve on the cylin­der and manifold and allow the pressure to build up within the
system. Check for and handle leaks, as described above.
After the test has been completed, remove and capture the
leak test refrigerant.

S-102 EVACUATION

WARNING

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.

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.

LOW SIDE

GAUGE

AND VALVE

HIGH SIDE

GAUGE

AND VALVE

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

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

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.

34

SERVICING

S-103 CHARGING

WARNINGWARNING

CAUTION

CAUTION

1. Using a quality set of charging scales, weigh the proper
amount of refrigerant for the system. 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.

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. 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

Charge the system with the exact amount of refrigerant.

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

After completing airflow measurements and adjustments, the
unit’s refrigerant charge must be checked. The unit comes
factory charged, but this charge is based on 400 CFM per ton
at minimum ESP per AHRI test conditions (generally between
.15 - .25 ESP). When air quantity or ESP is different than
above, charge must be adjusted to the proper amount.

All package units are charged to the superheat method at the
compressor suction line (these are fixed orifice devices).

For charging in the warmer months, 100F superheat at the com­pressor is required at conditions: 950F outdoor ambient (dry
bulb temperature), 800F dry bulb / 670F wet bulb indoor ambi­ent, approximately 50% humidity. This superheat varies when
conditions vary from the conditions described.

A superheat charge chart is available for other operating condi­tions. Use it to provide the correct superheat at the conditions
the unit is being charged at.

After superheat is adjusted it is recommended to check unit
sub-cooling at the condenser coil liquid line out. In most oper­ating conditions 12 + 40F of sub-cooling is adequate.

An inaccurately charged system will cause future problems.

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 start-up 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 access fitting caps.

6. Check system for leaks.

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

NOTE: Even though the compressor section of a Scroll com­pressor is more tolerant of liquid refrigerant, continued flood­back or flooded start conditions may wash oil from the bearing
surfaces causing premature bearing failure. S-104 CHECK-

ING 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.

35

SERVICING

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-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.

During the "OFF" cycle, the high side pressure bleeds to the
low side through the fixed orifice restriction device. Check
equalization time as follows:

1. Attach a gauge manifold to the suction and liquid line ac­cess fittings.

2. Start the system and allow the pressures to stabilize.

3. Stop the system and check the time it takes for the high
and low pressure gauge readings to equalize.

If it takes more than seven (7) minutes to equalize, the restrictor
device is inoperative. Replace, install a liquid line drier, evacu­ate and recharge.

S-108 SUPERHEAT

CHECKING SUPERHEAT

Refrigerant gas is considered superheated whenever 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.

CAUTION

To prevent personal injury, carefully connect and
disconnect manifold gauge hoses. Escaping liquid
refrigerant can cause burns. Do not vent refrigerant
to atmosphere. Recover during system repair
or final unit disposal.

1. Run system at least 10 minutes to allow pressure to sta­bilize.

3. Refer to the superheat table provided for proper system
superheat. Add charge to lower superheat or recover
charge to raise superheat.

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

Ambient Condenser

Inlet Temp (°F

Drybulb)

100

95
90
85
80
75 10 13 17 25 29
70 10 17 20 28 32
65 13 19 26 32 35
60 17 25 30 33 37

EXAMPLE:

a. Suction Pressure = 143

b. Corresponding Temp. °F. = 50

c. Thermometer on Suction Line = 59°F.

To obtain the degrees temperature of superheat, subtract 50.0
from 59.0°F.

The difference is 9° Superheat. The 9° Superheat would fall in
the ± range of allowable superheat.

Return Air Temp. (°F Drybulb)

65 70 75

-

-

-

-

-

-

10 13 17 20

-

10 15 21 26

-

80 85

10 10

-

10 10 10
12 15 18

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 pressure switch.

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

3. Record the gauge pressure and the temperature of the line.

4. 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.

2. Temporarily install thermometer on suction (large) line
near compressor with adequate contact and insulate for
best possible reading.

36

SERVICING

5. The difference between the thermometer reading and pres­sure to temperature conversion is the amount of subcooling.

Subcooling Formula = Sat. Liquid Temp. - Liquid Line
Temp.

EXAMPLE:

a. Liquid Line Pressure = 417
b. Corresponding Temp. °F. = 120°
c. Thermometer on Liquid line = 109°F.

To obtain the amount of subcooling, subtract 109°F from 120°F.

The difference is 11° subcooling. See the specification sheet
or technical information manual for the design subcooling range
for your unit.

See R410A Pressure vs. Temperature chart.

S-111 FIXED ORIFICE RESTRICTION
DEVICES

The fixed orifice restriction device (flowrator) used in conjunc­tion with the indoor coil is a predetermined bore (I.D.).

It is designed to control the rate of liquid refrigerant flow into an
evaporator coil.

The amount of refrigerant that flows through the fixed orifice
restriction device is regulated by the pressure difference be­tween the high and low sides of the system.

In the cooling cycle when the outdoor air temperature rises,
the high side condensing pressure rises. At the same time,
the cooling load on the indoor coil increases, causing the low
side pressure to rise, but at a slower rate.

Since the high side pressure rises faster when the tempera­ture increases, more refrigerant flows to the evaporator, increas­ing the cooling capacity of the system.

When the outdoor temperature falls, the reverse takes place.
The condensing pressure falls, and the cooling loads on the
indoor coil decreases, causing less refrigerant flow.

If a restriction should become evident, proceed as follows:

1. Recover refrigerant charge.

2. Remove the orifice assembly and clean or replace.

3. Replace liquid line drier, evacuate and recharge.

CHECKING EQUALIZATION TIME

During the "OFF" cycle, the high side pressure bleeds to the
low side through the fixed orifice restriction device. Check
equalization time as follows:

1. Attach a gauge manifold to the suction and liquid line dill
valves

2. Start the system and allow the pressures to stabilize.

3. Stop the system and check the time it takes for the high
and low pressure gauge readings to equalize.

If it takes more than seven (7) minutes to equalize, the restric­tion device is inoperative. Replace, install a liquid line 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 an exces­sively high head pressure.

An evaporator coil, using an expansion valve metering device,
will basically modulate and control a flooded evaporator and
prevent liquid return to the compressor.

An evaporator coil, using a fixed orifice restrictor device
(flowrator) metering device, could allow refrigerant to return to
the compressor under extreme overcharge conditions.

Also with a fixed orifice restrictor device (flowrator) metering
device, extreme cases of insufficient indoor air can cause icing
of the indoor coil and liquid return to the compressor, but the
head pressure would be lower.

There are other causes for high head pressure which may be
found in the "Service Problem Analysis Guide."

If other causes check out normal, an overcharge or a system
containing non-condensables would be indicated.

If this system is observed:

1. Start the system.

2. Remove and capture small quantities of refrigerant as from
the suction line access fitting until the head pressure is
reduced to normal.

3. Observe the system while running a cooling performance
test. If a shortage of refrigerant is indicated, then the sys­tem contains non-condensables.

S-114 NON-CONDENSABLES

If non-condensables are suspected, shut down the system and
allow the pressures to equalize. Wait at least 15 minutes.
Compare the pressure to the temperature of the coldest coil
since this is where most of the refrigerant will be. If the pres­sure indicates a higher temperature than that of the coil tem­perature, non-condensables are present.

Non-condensables are removed from the system by first re­moving the refrigerant charge, replacing and/or installing liquid
line drier, evacuating and recharging.

37

SERVICING

PSIG

100
102
104
106
108
110
112

°F
12
14
16
18
20
22
24
26
28 -17.9 130.0 44.7 232.0 78.9 334.0 103.7 436.0 123.5 538.0 140.1
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58 7.3 160.0 56.2 262.0 86.9 364.0 110.0 466.0 128.7 596.0 148.4
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88 25.4 190.0 66.4 292.0 94.3 394.0 115.8 496.0 133.6 656.0 156.6
90
92
94
96
98

-37.7

-34.7

-32.0

-29.4

-36.9

-24.5

-22.2

-20.0

-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

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

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

114.0

116.0

118.0

120.0

122.0

124.0

126.0

128.0

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

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

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

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

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

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

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

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

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

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

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

94.8

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

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

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

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

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

110.4

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

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

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

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

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

123.9

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

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

133.9

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

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

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

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

140.4

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

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

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

38

SERVICING

LIQUID PRESSURE

LIQUID PRESSURE

AT ACCESS FITTING (PSIG)

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

REQUIRED LIQUID LINE TEMPERATURE

REQUIRED SUBCOOLING TEMPERATURE (°F)

189 58 56 54 52 50 48
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

39

SERVICING

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

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.

NOTE: Goodman does NOT approve the flushing method
using R-11 refrigerant.

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.

Install a suction line filter drier. 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 the liquid line drier and expansion valve.

2. Purge all remaining components with dry nitrogen or car­bon dioxide until clean.

3 Install new components including liquid line drier.

4. Braze all joints, leak test, evacuate, and recharge system.

5. Start up the unit and record the pressure drop across the
drier.

6. 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.

7. 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.

8. If the pressure drop becomes greater, then it must be re­placed and steps 5 through 9 repeated until it does not
exceed 6 PSIG.

NOTICE: Regardless, the cause for burnout must be deter­mined and corrected before the new compressor is started.

S-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.

40

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.

Supply

Return

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.

T

SUPPLY

T

RETURN

RISE = SUPPLY -TRETURN

Checking Temperature Rise

T

41

WIRING DIAGRAMS

PACKAGE SYSTEM WIRING DIAGRAM - 1 STAGE ELECTRIC HEAT

SEE NOTE 1

#18 GAUGE 7 WIRE

REQUIRED FOR

HEAT PUMPS

ROOM THERMOSTAT

YO

CW1GRE

BR

PACKAGE UNIT

LOW VOLTAGE

JUNCTION BOX

W

R

Y

G

O

YELLOW

GREEN

ORANGE

WHITE

R

Y

G

O

R

TYPICAL HP

BL

BL

BLUE

BL

12

OUTDOOR T HERMOSTAT

CLOSE ON TEMPERATURE FALL

PACKAGE SYSTEM WIRING DIAGRAM - 2 STAGE ELECTRIC HEAT

ABOVE 10 KW

RED

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

SEE NOTE 1

#18 GAUGE 8 WIRE

FOR HEAT PUMPS

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

R

Y

G

O

BR

W

R

BL

R

Y

G

O

W

BR

BL

YELLOW

GREEN

ORANGE

WHITE

BROWN

BLUE

12

OUTDOOR THERMOSTAT

CLOSE ON TEMPERATURE 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

42

OT18-60A OUTDOOR THERMOSTAT

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

WIRING DIAGRAMS

PACKAGE SYSTEM WIRING DIAGRAM - HEAT PUMPS ONLY!

TWO-STAGE ELECTRIC HEAT ABOVE 10 kW

TYPICAL H/P

ROOM THERMOSTAT

W2 C RYO W1G E

#18 GAU GE 8 W IRE

PACKAGE HEAT PUMP

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

R

BL

12

Y

3

12

OUTDOOR THERMOSTAT #1

CLOSE ON TEMPERATURE FALL

BL

W

BR

BL

R

Y

G

O

R

Y

G

O

W

BR

BL

LOW VOLTAGE
JUNCTION BOX

RED

YELLOW

GREEN

ORANGE

WHITE

BROWN

BLUE

HIGH VOLTAGE!

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

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.

OT18-60A OUTDOOR THERMOSTAT

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

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

43

WIRING DIAGRAMS

*PC/*PH14H41*

BK

L1 L2

FL

BK

HTR1

M1

R

M2

BK

FL

FL

TL

HTR1

R

BK

BK

R

M1M2M3

R

M4

PU

BL

W

R

BK

BK

R

TL

BK

BL

W

PU

BK

R

PLM

1

2

3

4

5

6

7

8

TL

HTR2

R

9

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

L2L1

BK

R

PLM

1

2

3

4

5

6

7

8

9

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

5 KW

10 KW

FL

FL

FL

FL

FL

BL

Y

R

BK

BK

BK

R

PLM

BK

1

R

BL

BR

2

3

4

5

6

BK

Y

PU

BL

M1

M2

R2

W

7

8

9

TL

HTR1

FL

TL

HTR2

FL

HTR3

TL

R

Y

BK

M1

R

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

BK

BK

M2

M3

M4

R1

R

Y

R

HTR1

HTR2

HTR3

HTR4

BK

M1

M2

R

TL

TL

TL

TL

R

M3

M4

R1

Y

R

PU

BL

BK

M5

M6

BL

BK

Y

R

PLM

BK

1

2

BL

M7

M8

R2

W

3

R

BL

4

BR

5

6

7

8

9

44

L1

L2 L1 L2

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

L2L1 L1 L2

15 KW

20 KW

SINGLE PHASE HKR/P** HEAT KIT

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

WIRING DIAGRAMS

*PC/*PH14H41*

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.

PCE* ECONOMIZER FOR *PC/*PH****H41*

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

45

WIRING DIAGRAMS

GR

TO CONTROL BOX

B

A

SEE NOTES 1 & 2

BK

PU/BK-3

CCB

GR

B

B

A

TO ELECTRIC HEAT

A

BK

BK

BK-3

BK-3

BK

BK

BK

BK

GR

GR

COLOR CODE

BK --------------- BLACK

GR---------------- GREEN

BR --------------- BROW N

PU --------------- PURPLE

WH -------------- WHITE

WIRING CODE

FA CTORY WIRING

HIGH VOLTAGE

OPTIONAL HIGH VOLTAGE

FIELD WIRING

HIGH VOLTAGE

0140G02544-A

YL ---- ----------- Y ELLOW

46

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

A

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

BK

B

BK

208 / 240 / 1 / 60

SPB

GR

GR

NOTES:

1. FOR APC & GPC UNITS: A = L1 / B = L2

FOR APH & GPH UNITS: A = L2 / B = L1

2. 45, 40, 35, & 30 AMP BREAKERS WILL

SPK* - SINGLE POINT WIRING KIT

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

D

LEGEN

CCB - COMPRESSOR

CIRCUIT BREAKER

HAVE A PURPLE WIRE. 50 AND 60

AMP BREAKERS WILL HAVE BLACK

WIRE LABELED WITH A #3

SPB - SINGLE POINT BLOCK