Goodman PH 16, PH 15 Service Instructions Manual

Download

Page 1

Service Instructions

*PH 16 PACKAGE HEAT PUMPS

*PC 15 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.

RS6334002r1

November 2015

Page 2

INDEX

IMPORT ANT INFORMA TION ......................................................................................................... 4 - 5

PRODUCT IDENTIFICATION - *PC15/*PH16**H41** ....................................................................... 6

PRODUCT DIMENSIONS ................................................................................................................... 7

ACCESSORIES................................................................................................................................... 8

PCCP101-103 ROOF CURB .......................................................................................................................................... 9

PCP101-103 DOWNFLOW PLENUM ............................................................................................................................ 9

PCEF101-103 ELBOW AND FLASHING KIT ............................................................................................................... 10

PCE101-103 ECONOMIZER ......................................................................................................................................... 10

PCMD101-103 DOWNFLOW MANUAL DAMPER ........................................................................................................11

GPHMD101-103 HORIZONT AL MOTORIZED DAMPER WITH DUCT FLANGE............................................................11

SQRPC SQUARE TO ROUND CONVERTER............................................................................................................... 12

SQRPCH SQUARE TO ROUND CONVERTER ............................................................................................................ 12

PCFR101-103 EXTERNAL FIL TER KIT ....................................................................................................................... 13

PRODUCT DESIGN .......................................................................................................................... 14

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

LINE VOLT AGE WIRING.............................................................................................................................................. 16

SYSTEM OPERATION ...................................................................................................................... 17

*PC15/*PH16**H41**

COOLING .................................................................................................................................................................... 17

COOLING CYCLE........................................................................................................................................................ 17

HEA TING CYCLE......................................................................................................................................................... 17

DEFROST CYCLE ....................................................................................................................................................... 18

FAN OPERA TION ........................................................................................................................................................ 18

SCHEDULED MAINTENANCE ......................................................................................................... 21

ONCE A MONTH ......................................................................................................................................................... 21

ONCE A YEAR............................................................................................................................................................. 21

TEST EQUIPMENT...................................................................................................................................................... 21

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

COOLING/HEA T PUMP- SERVICE ANAL YSIS GUIDE ................................................................................................ 23

S-1 CHECKING VOL TAGE ........................................................................................................................................... 24

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

S-3 CHECKING THERMOST A T , WIRING , AND ANTICIP A TOR.................................................................................... 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 CONT ACTOR AND/OR RELA YS........................................................................................................ 25

S-8 CHECKING CONT ACTOR CONT ACTS .................................................................................................................. 26

S-11 CHECKING LOSS OF CHARGE PROTECT OR ................................................................................................... 26

S-15 CHECKING CAP ACITOR ..................................................................................................................................... 26

S-15A RESIST ANCE CHECK ....................................................................................................................................... 27

S-15B CAP ACITANCE CHECK ..................................................................................................................................... 28

S-16 CHECKING MOTORS .......................................................................................................................................... 28

S-16A CHECKING F AN AND BLOWER MOTOR WINDINGS (PSC MOT ORS) ............................................................ 28

S-16D CHECKING EEM MOTORS ............................................................................................................................... 28

S-17 CHECKING COMPRESSOR WINDINGS ............................................................................................................. 29

S-17A RESIST ANCE TEST .......................................................................................................................................... 29

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

Page 3

INDEX

S-17D Operation T est ................................................................................................................................................. 30

S-18 TESTING CRANKCASE HEA TER ........................................................................................................................ 31

S-18A CHECKING CRANKCASE HEA TER THERMOST AT........................................................................................... 31

S-21 CHECKING REVERSING V ALVE AND SOLENOID .............................................................................................. 31

S-24 TESTING DEFROST CONTROL .......................................................................................................................... 31

S-25 TESTING DEFROST THERMOST AT.................................................................................................................... 31

S-50 CHECKING HEA TER LIMIT CONTROL(S) ........................................................................................................... 32

S-52 CHECKING HEA TER ELEMENTS ........................................................................................................................ 32

S-100 REFRIGERA TION REPAIR PRACTICE............................................................................................................... 32

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

S-102 EV ACUA TION..................................................................................................................................................... 33

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

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

S-108 SUPERHEA T ...................................................................................................................................................... 35

S-109 CHECKING SUBCOOLING ................................................................................................................................35

S-11 1 FIXED ORIFICE RESTRICTION DEVICES ......................................................................................................... 36

S-112 CHECKING RESTRICTED LIQUID LINE ............................................................................................................ 36

S-113 REFRIGERANT OVERCHARGE ......................................................................................................................... 36

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

S-115 COMPRESSOR BURNOUT ................................................................................................................................37

S-122 REVERSING VA LVE REPLACEMENT................................................................................................................ 37

S-125 THERMOST ATIC EXP ANSION V AL VE............................................................................................................... 40

S-200 CHECKING EXTERNAL ST A TIC PRESSURE .................................................................................................... 40

S-201 CHECKING TEMPERA TURE RISE ..................................................................................................................... 41

AIRFLOW........................................................................................................................................... 42

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

GPC15[24-48]H41** .................................................................................................................................................... 44

GPC1560H41** ........................................................................................................................................................... 45

APC15[24-48]H41**..................................................................................................................................................... 46

APC1560H41**............................................................................................................................................................ 47

GPH16[24-42]H41** .................................................................................................................................................... 48

GPH1648H41** ........................................................................................................................................................... 49

APH16[24-42]H41**..................................................................................................................................................... 50

APH1648H41**............................................................................................................................................................ 51

OT18-60A OUTDOOR THERMOST A T ........................................................................................................................ 52

OT18-60A OUTDOOR THERMOST A T ........................................................................................................................ 53

SINGLE PHASE HKR/P** HEA T KITS......................................................................................................................... 54

PCE* ECONOMIZER .................................................................................................................................................... 55

SPK* - SINGLE POINT WIRING KIT........................................................................................................................... 56

Page 4

IMPORTANT INFORMATION

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

SERVICE MANUAL BEFORE BEGINNING REPAIRS.

IMPORTANT NOTICES FOR CONSUMERS AND SERVICERS

RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS

WARNING

HIS UNIT SHOULD NOT BE CONNECTED TO. OR USED IN CONJUNCTION WITH, ANY DEVI CES THAT ARE NOT DESIGN CERTIFI ED FOR US E WITH THI S UNIT OR HAV E NOT BEEN TESTED AND APPROVED BY FROM THE USE OF DEVICES THAT HAVE NOT BEE N APPROVED OR CERTIFED BY

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

GOODM AN .

WARNING

O PREVENT THE RISK OF PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH, DO NOT STORE COMBUSTIBLE MATE RIALS OR USE GASOLINE OR OTHER FLAMMABLE LIQUIDS OR VAPORS IN THE VICINITY OF THIS APPLIANCE.

WARNING

GOODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES. IF YOU INSTALL OR PERFORM SERVICE ON THIS UNIT, YOU ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMAGE WHICH

MAY RESU LT.

MANY JURISDICTIONS REQUIRE A LICENSE TO INSTALL OR SERV ICE HEATING AND AIR CONDITIONING EQUIPMENT.

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

GOODMAN® BRAND PRODUCTS

TOLL FREE

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

email us at: customerservice@goodmanmfg.com

fax us at: (713) 856-1821

(Not a technical assistance line for dealers.)

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.

email us at: customerservice@goodmanmfg.com

AMANA® BRAND PRODUCTS

TOLL FREE

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

fax us at: (713) 856-1821

(Not a technical assistance line for dealers.)

Page 5

IMPORTANT INFORMATION

SAFE REFRIGERANT HANDLING

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

WARNING

REFRIGERANTS ARE H EAVIER T HAN AIR. THEY CAN "PUS H OUT" THE

OXYGEN IN YOUR LUNGS OR IN ANY ENCLOSED SPACE. POSSI BLE DIFFI CULTY IN BRE ATHIN G OR DEATH:

EVER PURGE REFRIGERANT INTO AN ENCLOSED ROOM OR SPACE. BY

•

LAW, ALL REFRIGERANTS MUST BE RECLAIMED.

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

• BEFORE BEGINNING WORK.

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

•

BITE OR BL INDNESS, AVOID CONTACT W ITH REFR IGERANT AND WEAR

GLOVES AND GOGGLES. SKIN OR EYES, SEEK MEDICAL HELP IMMEDIATELY.

LWAYS FOLLOW

• AS POIS ONOUS GA S WILL BE PRODUC ED.

F LIQUID REFRIGERANT DOES CONTACT YOUR

EPA

REGULATIONS. NEVER BURN REFRIGERANT,

O AVO ID

WARNING

TO AVOID POSSIBLE EXPLOSION:

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

•

MUST HEAT A CYLINDE R FOR FASTER CHARGING , PARTIALLY IMMERSE IT IN WARM WATER.

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

•

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

•

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

BE LISTED OR CERTIF IED FOR THE TYPE OF REF RIGERANT USED.

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

•

AS A PLATFORM OR A ROLLER.

WARNING

TO AVOID POSSIBLE EXPLOSION, USE ONLY RETURNABLE (NOT DISPOSABLE)

SERVICE CYLINDERS WHEN REMOVING REFRIGERANT FROM A SYSTEM.

•

ENSURE THE CYLINDER IS FREE OF DAMAGE WHICH COULD LEAD TO A

LEAK OR EX PLOS ION.

•

ENSURE THE HYDROST ATIC TEST DATE DOES NO T EXCEED 5 YEARS.

•

ENSURE THE PRESSURE RATING MEETS OR EXCEEDS 400 LBS.

WHEN IN DOUBT, DO NOT USE CYLINDER.

WARNING

SYSTEM CONTAMINANTS, IMPROPER SERVICE PROCEDURE AND/OR PHYSICAL

ABUSE AFFECTING HERMETIC COMPRESSOR ELE CTRICAL TERMINALS MAY CAUSE DANGEROUS SYSTEM VENTING.

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

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

O AVOID POSSIBLE INJURY, EXPLOSION OR DEATH, PRACTICE SAFE

HANDLING OF REFRIGERANTS.

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

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

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

(a ) hot lubricating oil and refrigerant (b ) flammable mixture (if system is contaminated

with air)

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

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

See Service Section S-17 for proper servicing.

Page 6

PRODUCT IDENTIFICATION

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

PC1524 H 41 * *G / A

BRAND:

G: Goodm an

Brand or Distinctions

A: Ama n a

PRODUCT

TYPE:

Package

Cooling/Heating

15: 15 SEER Rat ing 16: 16 SEER Rat ing

PRODUCT

FAMILY:

C: Co ol i n g H: He at Pump

PRODUCT

SERIES:

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

NOMINAL

CAPACITY:

MINOR

REVISION:

CONFIGURATION:

H: Horiz ont al

MAJOR

REVISION:

REFRIGERANT:

4: R-410A

VOLTAGE:

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

MODEL # PACKAG E COOLING/ HEATING D ESCR IPTION

*PC1524-60H41AA

*PH1624-48H41AA

*PC1524-60H41AB

*PH1624-48H41AB

mana® Br and/Goodman

15 Seer 20 8- 2 30/1/ 60 S in gle-Phase Elec tric Cooling Unit with R-410A.

Initial release of the 15 SE ER H model cooling units to meet Ready 15 requirements.

mana® Br and/Goodman

16 Seer 20 8- 2 30/1/60 Single-Phase Heat Pump with R- 410 A.

Initial release of the 15 SE ER H model cooling units to meet Ready 15 requirements.

mana® Br and/Goodman

15 Seer 20 8- 2 30/1/ 60 S in gle-Phase Elec tric Cooling Unit with R-410A.

R e lease of models wi th ac cess box remo ved.

mana® Br and/Goodman

16 Seer 20 8- 2 30/1/60 Single-Phase Heat Pump with R- 410 A.

R e lease of models wi th ac cess box remo ved.

Bran d or D istinct ions

Package Cooling -

Package Heat Pump -

Package Cooling -

Package Heat Pump -

Page 7

PRODUCT DIMENSIONS

(

)

BACK EW

DUCT OPENINGS

Chassis Model A B

*PC1524 22 30

Small

*PC1530 22 30 *PC1536 22 30 *PC1542 22 30

Medium

Dimensions in inches

*PC1548 24 35 *PC1560 24 35

Chassis Model A B

Medium

Dimensions in inches

Small

*PH162441** 22.000 29.932 *PH163041** 22.000 29.932 *PH163641** 24.000 34.932 *PH164241** 24.000 34.932 *PH164841** 24.000 34.932

Page 8

ACCESSORIES

Part Numb er D escr iption

OT18-60A OT/ HE R- 60A Outdoo r Thermost at wit h Emergenc y Heat Relay

HKR05A, 08, 10, CA Heater K it for all *PC/ *P H ( H) S er ies HKP05C, 10C Heater Kit for all *PC/*PH (H) Series HKP15* Heater k it f or *P C/*PH13/ 14 ( 30- 60) ( H) S er ie s HKP20* Heater K it for *PC/ *P H1 3/14 (42- 60) ( H) S er ies PCCP101- 103 Roof Curb PCP101-103 Downflow Plenum Kit PCP101-103R8 Downflow Plenum Kit w/ R-8 Insulation GP CE D101- 103 Downflow E c onomizer for H Ser ies Pac k age Units (A/ C) - To Be Use d W ith PCP101-103 GP HE D101- 103 Downflow E c onomizer for H Se r ies Pack age Units (Heat Pump) - To Be Used With PCP101- 103 GP CE H101- 103 Horizontal Economizer for H S er ies Pack age Un its (A /C) GP HE H101- 103 Horizontal Economizer for H S er ies Pack age Units (Heat P ump) PCMD101-103 Manual Damper - To Be Used With PCP101- 103 PCMDM101- 10 3 Motorized Damper - To B e Used With PCP101-103 GP HMD101-103 Manual Damper for Hor izontal Applications SPK* Single Point Wiring Kit SQ RP CH101 Square to Round Adapters 16"& 14 " SQ RP CH102- 103 Square to Round Adapters 18"&14" SQ RP C101 Square to Round Adapter - For Use Wit h P CCP 101- 103 Cur b 16" Rounds SQ RP C102- 103 Square to Round Adapter For Use Wit h PCCP101- 103 Cur b 18" Rounds PCF R101- 103 External Horizontal F ilter Rack PCEF101-103 Elbow & Flashing w/ R- 8 Li ner CDK36 Flush Mount Concent ric Duct K it CDK36515 Flush Mount Concent ric Duct K it w/ Filt er CDK36530 Ste p Down Conc entric Duc t Kit CDK36535 Ste p Down Conc entric Duc t Kit w/ Filter CDK4872 Flush Mount Concent ric Duct Kit CDK4872515 Flush Mount Concent r ic Duc t Kit w/ Filter CDK4872530 St ep Down Conc entric Duct K it CDK4872535 St ep Down Conc entric Duct K it w/ Filt er

*PC15/*PH16**H41*

ACCES SO RIES *PC/* PH H SERIES

Outdoor Thermostat ( Requ ir ed for heat pumps with 0° outdoor ambient and 50% or higher r e lative humidity.

GOODMAN® BRAND THERMOSTAT S

CH70TG Manual Changeover

CHSATG Man ua l Cha ng eover Mechanical, Nonprogram m a bl e 1 Heat - 1 Cool

CHT18-60 Manual Changeover

CHT90-120 Manual Changeover

CHTP18- 60HD Manual Changeover

CT18-60 Manual Changeover

1213401 White Manual Changeover 1213402 White Manual Changeover 1213403 White Manual Changeover 1213404 White Manual Changeover 1213406 1213407 1213408 1213410 1213411 1213412 1213431

Beige White

White White White White

White

Manual/Auto Changeover

Manual/Auto Changeover Manual/Auto Changeover

Digital, Nonprogrammab le 1 Heat - 1 Cool

Mechanical, Nonprogram m a bl e 1 Heat - 1 Cool Mechanical, Nonprogram m a bl e 2 Heat - 2 Cool

Digital, Nonprogrammab le 2 Heat - 1 Cool

Mechanical, Nonprogr am m a bl e Cool Only

AMANA® BRAND THERMOSTATS

5 + 2 Programming Digital 1 Heat - 1 Cool

Nonprogrammable Digital 1 Heat - 1 Cool

7 Day Programming Digital 2 Heat - 1 Cool

Nonprogrammable Digital 2 Heat - 1 Cool

5 + 2 Programming Digital 3 Heat - 2 Cool

Manual Changeover

Manual Changeover Manual Changeover

5 + 2 Programming Digital 2 Heat - 2 Cool

7 Day Programming Digital 1 Heat - 1 Cool

5 + 2 Programming Digital 2 Heat - 1 Cool

Nonprogrammable Digital 2 Heat - 2 Cool 7 Day Programming Digital 3 Heat - 2 Cool 7 Day Programming Digital 3 Heat - 2 Cool

Page 9

ACCESSORIES

33"

*PC15/*PH16H41*

PCCP101-103 ROOF CURB

64"

59"

29 3/8"

29 3/4"

33"

28 3/4"

31"

26"

PCP101-103 DOWNFLOW PLENUM

(Use with PCCP Roof Curb)

14"

1" Flange

Roof Curb

13"

37"

25 1/2"

33"

13"

Page 10

ACCESSORIES

*PC15/*PH14641*

PCEF101-103 ELBOW AND FLASHING KIT

28"

35"

25"

33"

20 3/8"

17 3/4"

25"

PCE*101-103 ECONOMIZER*

(DOWNFLOW APPLICATIONS)

27 3/4"

16 1/2"

17 3/4"

20" x 17 1/2"

Filter

31 1/4"

Model Used With

PCEC101-103* *PC HORIZONTAL A/C PCEH101-10 3* *P H HO RIZONTAL HP

*Must be used with PCP101-103

Page 11

ACCESSORIES

PCMDM101-103 DOWNFLOW MOTORIZED DAMPER*

PCMD101-103 DOWNFLOW MANUAL DAMPER*

*USED WITH PCP101-103 DOWNFLOW PLENUM

*PC15/*PH16H41*

10"

29 3/4"

MODEL DESCRIPTION

PCM DH 101 - 103 Ma nua l Dampe r

PCMDM101-103 Motorzie d Damper

GPHMD101-103 HORIZONTAL MANUAL DAMPER WITH DUCT FLANGE

18"

25 1/4"

12"

17"

17 1/4"

Page 12

ACCESSORIES

*PC15/*PH16H41*

SQRPC SQUARE TO ROUND CONVERTER

(DOWNFLOW APPLICATIONS)

1" FLANGES

1 1/2

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

SQR PC101 SQRP102-103

RETURN

STARTER FLANGE

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

15" 17" 17" 15" 15"

B 15" 17" 17" 15" 15" C 17" 17" 19" 15" 15" D 22 1/2" 24 1/2" 24 1/2" 24 1/2" 24 1/2"

SUPPLY 14" 16" 16" 14" 14"

RETURN 16" 16" 18" 14" 14"

SUPPLY

Page 13

ACCESSORIES

*PC15/*PH16H41*

PCFR101-103 EXTERNAL FILTER KIT

(HORIZONTAL APPLICATIONS)

14" x 25" x 2" FILTER

Page 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"

*PC15/*PH16**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 OPERA TIONS. TO F ACILITATE LIFTING AND MOVING IF A CRANE IS USED, PLACE THE UNIT IN AN ADEQUA TE 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

*PC15/*PH16**H41*

*PC15/*PH16 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.

The outdoor fan motor is a single phase capacitor type motors.

Page 15

PRODUCT DESIGN

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.

INDOOR BLOWER MOTOR

All *PC15/*PH16 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.

WARNING

TO AVOID PERSONAL IN JURY OR D EATH DUE TO ELECTRIC SHOCK, WI RI NG TO THE UNI T MUST BE PROPERLY POLARI ZED AND G ROUNDED.

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

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

Some design characteristics of the Compliant Scroll compressor are:

• Compliant Scroll compressors are more tolerant of liquid refrigerant.

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

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

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.

Page 16

PRODUCT DESIGN

WARNING

DO NOT EXCEED THE MAXIMUM OVERCURRENT DEVICE SIZE SHOWN ON THE UNI T 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.

EXPANSION VALVE (TXV) SYSTEM

SINGLE SPEED APPLICATION (APH1624-42)

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

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

3. Check subcooling and superheat. Systems with TXV application should have a subcooling and superheat within the range listed on the chart.

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

check subcooling.

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

to raise subcooling then check superheat.

c. If subcooling and superheat are high, adjust TXV valve

then check subcooling.

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

valve superheat and remove charge to lower the subcooling.

The TXV should NOT be adjusted at light load conditions 55º to 60ºF, under such conditions only the subcooling can be evaluated. This is because suction pressure is dependent on indoor air flow, and wet bulb temperature.

TWO SPEED APPLICATION (APH1648 / APC1560)

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

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

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

3. Check subcooling and superheat. Two stage systems running on low stage with TXV application should have a subcooling and superheat within the range listed on the chart.

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

4. Disconnect manifold set. Installation is complete.

Page 17

PRODUCT DESIGN

SATURATED

SUCTION PRESSURE

TEMPERATURE CHART

SATURATED

SUCTION

PRESSURE

PSIG R-410A PSIG R-410A

50 1 200 70

52 3 210 73

54 4 220 76

56 6 225 78

58 7 235 80

60 8 245 83

62 10 255 85

64 11 265 88

66 13 275 90

68 14 285 92

70 15 295 95

72 16 305 97

74 17 325 101

76 19 355 108

78 20 375 112

80 21 405 118

85 24 415 119

90 26 425 121

95 29 435 123

100 31 445 125

110 36 475 130

120 41 500 134

130 45 525 138

140 49 550 142

150 53 575 145

160 56 600 149 170 60 625 152

Suction Pressure

SUCTION

TEMPERATURE

ºF

PRESSURE

TABLE 6

SATURATED

LIQUID PRESSURE

TEMPERATURE CHART

SATURATED

LIQUID

TEMPERATURE

Liquid Pressure

GPC15

Design Superheat @ 95°F Outdoor Ambient

Tempe rature

ºF

Model #

Superheat

±2°F

Supercooling ±2°F

GPC1524H41 6° ---

GPC1530H41 8° ---

GPC1536H41 12° ---

GPC1542H41 7° ---

GPC1548H41 10° ---

GPC1560h41 12° 12°

GPH16

Design Superheat @ 95°F Outdoor Ambient

Tempe rature

Model #

Superheat

±2°F

Supercooling ±2°F

GPH1524H41 15° 7°

GPH1530H41 15° 7°

GPH1536H41 10° 13°

GPH1542H41 12° 13°

GPH1548H41 15° 15°

SUPERHEAT = SUCTION LINE TEMP - SAT. SUCTION

TEMP.

Page 18

SYSTEM OPERATION *PC15/*PH16**H41*

SYSTEM OPERATION

COOLING

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

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

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

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

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

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

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

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.

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.

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.

Page 19

SYSTEM OPERATION

*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 gized through the normally open contacts of the electric heat sequencers. The indoor blower will be energized through W from the thermostat.

DEFROST CYCLE

PACKAGE HEAT PUMPS

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

SOLID STATE DEFROST CONTROL

During operation the power to the circuit board is controlled by a temperature sensor, which is clamped to a feeder tube entering the outdoor coil. Defrost timing periods of 30, 60, or 90 minutes may be selected by 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

motor. The electric heat will be ener-

+ 2° F), and when the room thermostat

*PC15/*PH16**H41*

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.

ECM MOTOR

SPEED ADJUSTMENT

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

DIP SWITCH FUNCTIONS

The ECM motor has an electronic control that contains eight (8) 2-position dip switches. The function of these dip switches is shown in Table 6, Airflow charts pages 42 and 43.

For APC15 / APH16 [24-36] models, dip switch 4 must be set to ON. Dip switch 4 must be set to OFF for two-stage compressor models APC15 / APH16 [48-60]. Dip switch 4 ON energizes Y1 signal to the ECM motor anytime Y/Y2 is energized. The indoor motor will not operate properly if switch is not set correctly for the model.

THERMOSTAT “FAN ONLY” MODE

During Fan Only Operations, the CFM output is 50% of the high stage cooling setting.

HUMIDITY CONTROL

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

TWO-STAGE HEATING

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

THERMOSTAT WIRING

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

DIP SWITCH NUMBER FUNCTION

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

TABLE 6

Electric Heat

Coo l i ng & He a t Pump CFM

CFM Trim Ad just

Page 20

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.

Page 21

SYSTEM OPERATION

TYPICAL HEAT PUMP SYSTEM IN COOLING

Reversing Valve

(Energized)

Indoor

Coil

Accumulato r

TYPICAL HEAT PUMP SYSTEM IN HEATING

Outdoor

Coil

Indoor

Coil

Accumulato r

Reversing Valve

(De-Energized)

Outdoor

Coil

Page 22

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.

Page 23

SERVICING

COOLING /HEAT PUMP- SERVICE ANALYSIS GUIDE

Com p laint

POSSIBLE CAUSE

DOTS I N ANALYS I S

GUIDE I NDI CAT E

"PO S S IBL E CAUS E"

Pow er Failure Blow n Fuse Unbalanced Power, 3PH Loose Connection Shorted or Broken Wires Open Fan Overload Faulty Thermostat Faulty Transformer Shorted or Open Capacitor Internal Compressor Overload Open Shorted or Grounded Compressor Compressor Stuck Faulty Compress or Contactor Faulty Fan Control Open Control Circuit Low Voltage Faulty Evap. Fan Motor Shorted or Grounded Fan Motor Improper Cooling Anticipator Shortage of Refrigerant Restricted Liquid Line Open Element or Limit on Elec. Heater Dirty Air Filte r Dirty Indoor Coil Not enough air across Indoor Coil Too much air across Indoor Coil Overcharge of Refrigerant Dir ty O utdoor Coil Noncondensibles Recirculation of Condensing Air Infiltration of Outdoor Air Improper ly Located Thermostat Air Flow Unbalanced System Undersized Broken Internal Parts Broken Valves Inefficient Compressor Loose Hold-dow n Bolts Faulty Reversing Valve Faulty Defros t Control Faulty Defros t Thermostat Flow rator Not Seating Properly

No Coolin g

SYMPTOM

System wil l not start

Compressor will not start - fan runs

Comp. and Cond. Fan will not start

Evaporator fan will not start

Condenser fan will not start

Comp ressor runs - goes off on overload

Compressor cycles on overload

•

•••

••••••

••

••• •

••

•••••

•

••

•••

•

•••

••

•• •• •

•• •

••

•• •

••

•

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

•

Unsatisfactory

Cooling/He ating

System runs continuously - little cooling/htg

Too cool and then too warm

Not cool enough on warm days

Certain area s too cool, others too warm

Compressor is noisy

System runs - blows cold air in heating

♦

♦♦

••• •

•

♦

•••

••

♦

•• ••

•

♦

•

♦♦♦ ♦♦♦

♦♦♦♦♦ ♦

♦♦♦♦♦♦♦

•••

♦

Unit will not terminate defrost

Pressures

Unit will not defrost

Low suction pressure

••

♦

System

Operating

Low head pressure

High suction pressure

♦

•

••

Test Method

Remedy

High head pressure

Test Voltage S-1 Inspect Fuse Size & Type S-1 Test Voltage S-1 Inspect Connection - Tighten S-2, S-3 Test Circuits With Ohmmeter S- 2, S-3 Test Continuity of Overload S-17A Test continuity of Thermostat & 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-17B Use Test Cord S-17D Test continuity of Coil & Contacts S- 7, S-8 Test continuity of Coil And Contacts S-7, S-9 Test Control Circuit with Voltmeter S-4 Test Voltage S-1 Repair or Replace S-16

♦

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

♦

Inspect Coil - Clean

♦

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

♦

Reduce Blower Speed S-200 Recover Part of Charge S-113 Inspect Coil - Clean

•

Recover Charge, Evacuate, Recharge S-114

•

Remove Obstruction to Air Flow Check Windows, Doors, Vent Fans, Etc. Relocate Thermostat Readjust Air Volume Dampers Refigure Cooling Load Replace Compressor S-115 Test Compressor Efficiency S-104 Test Compressor Efficiency S-104 Tighten Bolts Replace Valve or Solenoid S-21, 122 Test Control S-24 Test Defrost Thermostat S-25 Check Flowrator & Seat or Replace Flowrator S-111

See S ervice Procedu re Ref.

Page 24

SERVICING

S-1 CHECKING VOLTAGE

WARNING

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

With power ON:

WARNING

LINE VOLTAGE NO W 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 V OLT AG E NOW PR ES ENT .

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 VOL TAG E NOW PRE S ENT.

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.

Page 25

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 VOL TAG E NOW PRE S ENT.

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 PO WER 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.

Page 26

SERVICING

S-8 CHECKING CONTACTOR CONTACTS

S-12 CHECKING HIGH PRESSURE CONTROL

WARNING

DISCONNECT POWER SUP PLY BEFORE SERVICING.

SINGLE PHASE

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

2. With power ON, energize the contactor.

WARNING

LINE VOLTAGE NO W PRESENT.

VOLT/OHM

METER

Ohmmeter for te sting holding co il Voltmeter for testing contacts

L1L2

HIGH VOLTAGE! Disconnect ALL power before servicing or insta llin g th is un it. M ult iple powe r 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.

With power ON:

WARNING

LINE V OLTAG E NO W PRES EN T.

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.

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.

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 + 7 PSIG. It will automatically cut-in (close) at approximately 50 + 7 PSIG.

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

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.

Page 27

SERVICING

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.

S-15A RESISTANCE CHECK

WARNING

1. Discharge capacitor and remove wire leads.

MODELS EQUIPPED WITH A HARD START DEVICE

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

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

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.

WARNING

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

Volt / Ohm Meter

Capacit

TESTING CAPACITOR RESISTANCE

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

A. Good Condition - indicator swings to zero and slowly returns to infinity. (Start capacitor 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).

Page 28

SERVICING

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. 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.

VOLTMETER

15 AMP

FUSE

AMMETER

CAPACITOR

TESTING CAPACITANCE

S-16 CHECKING MOTORS S-16A CHECKING FAN AND BLOWER MOTOR

WINDINGS (PSC MOTORS)

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.

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.

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.

Page 29

SERVICING

123

Low Voltage Connections

High Voltage Connections

3/16"

LGN

1/4”

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

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

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

S-17A RESISTANCE TEST

Each compressor is equipped with an internal overload. The line break internal overload senses both motor amperage

and winding temperature. High motor temperature or amperage heats the disc causing it to open, breaking the common circuit within the compressor on single phase units. The three phase internal overload will open all three legs.

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

WARNING

EEM MOTOR CONNECTIONS

S-17 CHECKING COMPRESSOR WINDINGS

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 EL ECTR ICAL SH ORT BE TWEEN THE TERMINAL AND THE COMPRESSOR HOUSING, THE TERMINAL MAY B E EXPEL LED, V ENTING 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.

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.

1. Remove the leads from the compressor terminals.

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.

OHMMETER

TESTING COMPRESSOR WINDINGS

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

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

COMP

Page 30

SERVICING

S-17B GROUND TEST

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

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

Disconnect all power to unit, making sure that 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.

all power legs

WARNING

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

S-17D OPERATION TEST

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

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.

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.

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.

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.

2. Start the system and run a “Cooling Performance Test. If the test shows:

a. Below normal high side pressure. b. Above normal low side pressure. c. Low temperature difference across coil. d. L ow 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.

Page 31

SERVICING

S-18 TESTING CRANKCASE HEATER

(OPTIONAL ITEM)

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.

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.

Page 32

SERVICING

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 ELECTRI CAL PO WER SUPPLY.

S-100 REFRIGERATION REPAIR PRACTICE

DANGER

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

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

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

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

When repairing the refrigeration system:

1. 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.

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.

WARNING

DISCONNECT ELECTRI CAL PO WER 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.

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 must be replaced.

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.

Aluminum to Aluminum and Copper to Aluminum Joints

- ZA-1 Brazing Rods use Flux System Cesium-Based Poly-

mer System (alloy of 78% Zinc and 22% Aluminum); Melting point 826°F - Flow point 905°F.

Page 33

SERVICING

S-101 LEAK TESTING

(NITROGEN OR NITROGEN-TRACED)

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.

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.

NOTE: Refrigerant hoses must be equipped with dill valve depressors 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.

WARNING

SCROLL COMPRESSORS DO NOT FRONT SEAT TH E SERVIC E VALV E(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 V ALVE

S-102 EVACUATION

WARNING

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

Page 34

SERVICING

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.

S-103 CHARGING

WARNINGWARNING

CAUTION

For charging in the warmer months, 10 pressor is required at conditions: 95 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.

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

F superheat at the com-

F outdoor ambient (dry

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).

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.

Page 35

SERVICING

NOTE: Even though the compressor section of a Scroll com-

pressor 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.

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.

CAUTION

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

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

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

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

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

Ambient Condenser

Inlet Temp (°F

Drybulb)

100 - - - 10 10

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 10 10

- - 12 15 18

- 10 13 17 20

- 10 15 21 26

80 85

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.

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.

Page 36

SERVICING

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.

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 liquid 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.

Page 37

SERVICING

S-114 NON-CONDENSABLES

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

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

S-115 COMPRESSOR BURNOUT

When a compressor burns out, high temperature develops causing the refrigerant, oil and motor insulation to decompose forming acids and sludge.

If a compressor is suspected of being burned-out, attach a refrigerant hose to the liquid line dill valve and properly remove and dispose of the refrigerant.

NOTICE

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

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.

including liquid line drier.

S-122 REVERSING VALVE REPLACEMENT

Remove the refrigerant charge from the system. When brazing a reversing valve into the system, it is of ex-

treme importance that the temperature of the valve does not exceed 250°F. at any time.

Wrap the reversing valve with a large rag saturated with water. "Re-wet" the rag and thoroughly cool the valve after each brazing operation of the four joints involved. The wet rag around the reversing valve will eliminate conduction of heat to the valve body when brazing the line connection.

The use of a wet rag sometimes can be a nuisance. There are commercial grades of heat absorbing paste that may be substituted.

After the valve has been installed, leak test, evacuate and recharge.

Page 38

SERVICING

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

°F

-37.7

-34.7

-32.0

-29.4

-36.9

-24.5

-22.2

-20.0

-17.9

-15.8

-13.8

-11.9

-10.1

-8.3

-6.5

-4.5

-3.2

-1.6

0.0

1.5

3.0

4.5

5.9

7.3

8.6

10.0

11.3

12.6

13.8

15.1

16.3

17.5

18.7

19.8

21.0

22.1

23.2

24.3

25.4

26.4

27.4

28.5

29.5

30.5

31.2

32.2

33.2

34.1

35.1

35.5

36.9

PSIG

100 102 104 106 108 110 112

PSIG

114.0

116.0

118.0

120.0

122.0

124.0

126.0

128.0

130.0

132.0

134.0

136.0

138.0

140.0

142.0

144.0

146.0

148.0

150.0

152.0

154.0

156.0

158.0

160.0

162.0

164.0

166.0

168.0

170.0

172.0

174.0

176.0

178.0

180.0

182.0

184.0

186.0

188.0

190.0

192.0

194.0

196.0

198.0

200.0

202.0

204.0

206.0

208.0

210.0

212.0

214.0

Pressure vs. Temperature Chart

R-410A

°F

37.8

38.7

39.5

40.5

41.3

42.2

43.0

43.8

44.7

45.5

46.3

47.1

47.9

48.7

49.5

50.3

51.1

51.8

52.5

53.3

54.0

54.8

55.5

56.2

57.0

57.7

58.4

59.0

59.8

60.5

61.1

61.8

62.5

63.1

63.8

64.5

65.1

65.8

66.4

67.0

67.7

68.3

68.9

69.5

70.1

70.7

71.4

72.0

72.6

73.2

73.8

PSIG

216.0

218.0

220.0

222.0

224.0

226.0

228.0

230.0

232.0

234.0

236.0

238.0

240.0

242.0

244.0

246.0

248.0

250.0

252.0

254.0

256.0

258.0

260.0

262.0

264.0

266.0

268.0

270.0

272.0

274.0

276.0

278.0

280.0

282.0

284.0

286.0

288.0

290.0

292.0

294.0

296.0

298.0

300.0

302.0

304.0

306.0

308.0

310.0

312.0

314.0

316.0

°F

74.3

74.9

75.5

76.1

76.7

77.2

77.8

78.4

78.9

79.5

80.0

80.6

81.1

81.6

82.2

82.7

83.3

83.8

84.3

84.8

85.4

85.9

86.4

86.9

87.4

87.9

88.4

88.9

89.4

89.9

90.4

90.9

91.4

91.9

92.4

92.8

93.3

93.8

94.3

94.8

95.2

95.7

96.2

96.6

97.1

97.5

98.0

98.4

98.9

99.3

99.7

PSIG

318.0

320.0

322.0

324.0

326.0

328.0

330.0

332.0

334.0

336.0

338.0

340.0

342.0

344.0

346.0

348.0

350.0

352.0

354.0

356.0

358.0

360.0

362.0

364.0

366.0

368.0

370.0

372.0

374.0

376.0

378.0

380.0

382.0

384.0

386.0

388.0

390.0

392.0

394.0

396.0

398.0

400.0

402.0

404.0

406.0

408.0

410.0

412.0

414.0

416.0

418.0

°F

100.2

100.7

101.1

101.6

102.0

102.4

102.9

103.3

103.7

104.2

104.6

105.1

105.4

105.8

106.3

106.6

107.1

107.5

107.9

108.3

108.8

109.2

109.6

110.0

110.4

110.8

111.2

111.6

112.0

112.4

112.6

113.1

113.5

113.9

114.3

114.7

115.0

115.5

115.8

116.2

116.6

117.0

117.3

117.7

118.1

118.5

118.8

119.2

119.6

119.9

120.3

PSIG

420.0

422.0

424.0

426.0

428.0

430.0

432.0

434.0

436.0

438.0

440.0

442.0

444.0

446.0

448.0

450.0

452.0

454.0

456.0

458.0

460.0

462.0

464.0

466.0

468.0

470.0

472.0

474.0

476.0

478.0

480.0

482.0

484.0

486.0

488.0

490.0

492.0

494.0

496.0

498.0

500.0

502.0

504.0

506.0

508.0

510.0

512.0

514.0

516.0

518.0

520.0

°F

120.7

121.0

121.4

121.7

122.1

122.5

122.8

123.2

123.5

123.9

124.2

124.6

124.9

125.3

125.6

126.0

126.3

126.6

127.0

127.3

127.7

128.0

128.3

128.7

129.0

129.3

129.7

130.0

130.3

130.7

131.0

131.3

131.6

132.0

132.3

132.6

132.9

133.3

133.6

133.9

134.0

134.5

134.8

135.2

135.5

135.8

136.1

136.4

136.7

137.0

137.3

PSIG

522.0

524.0

526.0

528.0

530.0

532.0

534.0

536.0

538.0

540.0

544.0

548.0

552.0

556.0

560.0

564.0

568.0

572.0

576.0

580.0

584.0

588.0

592.0

596.0

600.0

604.0

608.0

612.0

616.0

620.0

624.0

628.0

632.0

636.0

640.0

644.0

648.0

652.0

656.0

660.0

664.0

668.0

672.0

676.0

680.0

684.0

688.0

692.0

696.0

°F

137.6

137.9

138.3

138.6

138.9

139.2

139.5

139.8

140.1

140.4

141.0

141.6

142.1

142.7

143.3

143.9

144.5

145.0

145.6

146.2

146.7

147.3

147.9

148.4

149.0

149.5

150.1

150.6

151.2

151.7

152.3

152.8

153.4

153.9

154.5

155.0

155.5

156.1

156.6

157.1

157.7

158.2

158.7

159.2

159.8

160.3

160.8

161.3

161.8

*Based on ALLIED SIGNAL Data

Page 39

SERVICING

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

Page 40

SERVICING

S-125 THERMOSTATIC EXPANSION VALVE

The expansion valve is designed to control the rateof liquid refrigerant flow into an evaporator coil in exact proportion to the rate of evaporation of the refrigerant in the coil. The amount of refrigerant entering the coil is regulated since the valve responds to temperature of the refrigerant gas leaving the coil (feeler bulb contact) and the pressure of the refrigerant in the coil. This regulation of the flow prevents the return of liquid refrigerant to the compressor.

The illustration below shows typical heatpump TSV/check valve operation in the heating and cooling modes.

COOLING HEATING

TXV VALVES

Some TXV valves contain an internal check valve thus eliminating the need for an external check valve and bypass loop. The three forces which govern the operation of the valve are: (1) the pressure created in the power assembly by the feeler bulb, (2) evaporator pressure, and (3) the equivalent pressure ofthe superheat spring in the valve.

0% bleed type expansion valves are used on indoor and outdoor coils. The 0% bleed valve will not allow the system pressures (high and Low side) to equalize during the shut down period. The valve will shut of completely at approximately 100 PSIG.

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

The bulb must be securely fastened with two straps to a clean straight section of the suction line. Application of the bulb to a horizontal run of line is preferred. If a vertical installation cannot be avoided, the bult must be mounted so that the capillary tubing comes out at the top.

THE VALVES PROVIDED ARE DESIGNED TO MEET THE SPECIFICATION REQUIRMENTS FOR OPTIMUM PRODUCT OPERATION. DO NOT USE SUBSTITUTES.

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).

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.

Page 41

SERVICING

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

RISE = SUPPLY -TRETURN

Checking Temperature Rise

Page 42

AIRFLOW

ADJUSTING SPEED TAP FOR INDOOR BLOWER MOTOR

Evaporator Blower Specifications with ECM Motors

APH1624H41 / APC1524H41 APH1630H41 / APC1530H41

Cooling/HP

Speed

D Minus 721 D Minus 721 D Minus 969 D Minus 969 D Normal 909 D Normal 909 D Normal 985 D Normal 985 D Plus 953 D Plus 953 D Plus 1,073 D Plus 1,073

C Minus 800 C Minus 800 C Minus 930 C Minus 930 C Normal 905 C Normal 905 C Normal 1,032 C Normal 1,032 C Plus 986 C Plus 986 C Plus 1,135 C Plus 1,135 B Minus 743 B Minus 743 B Minus 834 B Minus 834 B Normal 847 B Normal 847 B Normal 984 B Normal 984 B Plus 939 B Plus 939 B Plus 1,101 B Plus 1,101 A Minus 714 A Minus 714 A Minus 833 A Minus 833 A Normal 815 A Normal 815 A Normal 937 A Normal 937 A Plus 903 A Plus 903 A Plus 1,036 A Plus 1,036

* @ 0.1 - 0.9 ESP * @ 0.1 - 0.9 ESP

Cooling/HP

Speed

D Minus 1,135 D Minus 1,135 D Minus 1,289 D Minus 1,289 D Norma l 1,270 D Normal 1,270 D Nor mal 1,392 D Normal 1,392 D Pl us 1,3 71 D P lus 1,371 D Pl us 1,440 D Plus 1,4 40

C Minus 1,042 C Minus 1,042 C Minus 1,219 C Minus 1,219 C Norma l 1,178 C Normal 1 ,178 C Normal 1,323 C Normal 1,323 C Pl us 1,307 C Plus 1,307 C Plus 1,4 19 C Plus 1,4 19 B Minus 932 B Minus 932 B Minus 1,182 B Minus 1,182 B Norma l 1,065 B Nor mal 1,065 B Normal 1,294 B Normal 1,2 94 B Pl us 1,181 B Plus 1,181 B Pl us 1,3 84 B Plus 1,3 84 A Minus 823 A Minus 823 A Minus 1,105 A Minus 1,105 A Normal 952 A Normal 952 A Normal 1,219 A Normal 1,219 A P lus 1,080 A P lus 1,080 A Pl us 1,304 A Plus 1,304

* @ 0.1 - 0.9 ESP * @ 0.1 - 0.9 ESP

Adjust

Tap

APH1636H41 / APC1536H41 APH1642H41 / APC1542H41

Adjust

Tap

CFM*

Elect ric

Heat

Elect ric

Heat

Adjust

Tap

Adjust

Tap

CFM*

Cooling/HP

Spee d

Cooling/HP

Spee d

Adjust

Tap

Adjust

Tap

CFM*

Electr ic

Heat

Electr ic

Heat

Adjust

Tap

Adjust

Tap

CFM*

APH1648H41 / APC15[48-60]H41

Cooling/HP

Speed

D Minus 1,506 D Minus 1,506 D Normal 1,699 D Normal 1,699 D Plus 1,872 D Plus 1,872

C Minus 1,420 C Minus 1,420 C Normal 1,596 C Normal 1,596 C Plus 1,764 C Plus 1,764 B Minus 1,323 B Minus 1,323 B Normal 1,491 B Normal 1,491 B Plus** 1 ,642 B Pl us ** 1,642 A Minus 1,217 A Minus 1,217 A Normal 1,385 A Normal 1,385 A Plus 1,537 A Plus 1,537

* @ 0.1 - 0.9 ESP

** Denotes factory settings for APC156041

Adjust

Tap

CFM*

Elect ric

Heat

Adjust

Tap

CFM*

Page 43

AIRFLOW

MOD EL

APC152 4

APH1 624

APC153 0

APH1 630

APC153 6

APH1 636

APC154 2

APH1 642

APC154 8

APH1 648

APC156 0

(F)

Factory Setting

SPEED

TAP

SWITCH1SWITCH2 ELECTRIC

HEAT (CFM)

A Off Off

B On Off 850 C Off On 907

D On On 955

A Off Off

B On Off 987 C Off On 1034

D On On 1,073

A Off Off

B On Off 1067 C Off On 1179

D On On 1273

A Off Off 1222 B On Off 1298

C Off On

D On On 1395

A Off Off

B On Off 1499 C Off On 1605

D On On 1708

A Off Off

B On Off 1600 C Off On 1700

D On On 1800

816

940

954

1327

1394

1500

MODEL

(F)

SPEED

TAP

APC1524

APH1624

SWITCH5SWITCH6COOLING/HP

CFM

A Off Off

B On Off 850

C Off On 907

816

(F)

D On On 955

(F)

APC1530

APH1630

A Off Off

B On Off 987

C Off On 1034

940

(F)

D On On 1,073

(F)

APC1536

APH1636

A Off Off

B On Off 1067

C Off On 1179

954

(F )

D On On 1273 A Off Off 1222

(F)

APC1542

APH1642

B On Off 1298

C Off On

1327

(F)

D On On 1395

(F)

APC1548

APH1648

(F)

APC1560

A Off Off

B On Off 1499

C Off On 1605

D On On 1708

A Off Off

B On Off 1600

C Off On 1700

1394

1500

(F)

D On On 1800

(F)

Fa ctory Setting

DIP Switch Settings

for Single & Two-Stage Thermostats

MODEL

SWITCH

N/A O N Si ngle Stage

APC15/H16**

N/A OFF Two-Stage

SWITCH

THERMOSTAT

Adjustments Through DIP Switch Combinations

7 - 8

CFM

SWITCH

Plus10% ON OFF

Normal OFF OFF

Minus10% OFF ON

SWITCH

Page 44

WIRING DIAGRAMS

GPC15[24-48]H41**

NOTE #2

IF USED

COMP

S.A.

SUPPLY VOLTAGE

NOTE #3

C L G N

2 3

SEE NOTE 2

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.

SA (IF USED) SEE NOTE 4

208-240/1/60

RCCF

NOTE #4

208-240

3 1

24V

208

24V

RCCF

NOTE #3

SEE NOTE 5

LVJB

YL RD GR

EQUIPMENT GROUND

FIELD GROUND

FIELD SPLICE

SWITCH (TEMP)

IGNITER

GND

Y R G

W2 C

CONTROL BOX

HPS

ACTORY WIRING LINE VOLTAGE LOW VOLTAGE

OPTIONAL HIGH

VOLTAGE

FIELD WIRING

HIGH VOLTAGE LOW VOLTAGE

WIRE CODE

BK BLACK BL BLUE BR BROWN GR GREEN OR ORANGE PU PURPLE RD RED WH WHITE YL YELLOW

2 0 8

2 4 0

T H E R M O S T A T

240

PLF

562

COMPONENT

LEGEND

BLOWER INTERLOCK RELAY

CONTACTOR

CRACKCASE HEATER

CONDENSER MOTOR

COMP

COMPRESSOR

EBTDR

ELECTRONIC BLOWER TIME DELAY RELAY

EVAPORATOR MOTOR

FAN CAPACITOR

GND

EQUIPMENT GROUND

LVJB

LOW VOLTAGE JUNCTION BOX

PLF

FEMALE PLUG / CONNECTOR

RCCF

RUN CAPACITOR FOR COMPRESSOR AND FAN

START ASSIST

TRANSFORMER

HPS

HIGH PRESSURE SWITCH

JUNCTION

TERMINAL

INTERNAL TO

INTEGRATED CONTROL

PLUG CONNECTION

SWITCH (PRESS.)

OVERCURRENT

PROT. DEVICE

COMP

PLF

R W2 W1 Y G C

THERMOSTAT

2 3

HPS

SEE NOTE #2

OTES:

1. REPLACEMENT WIRE MUST BE SAME SIZE AND TYPE INSULATION AS ORIGINAL (AT LEAST 105C) USE COPPER CONDUCTOR ONLY.

2. TO CHANGE EVAPORATOR MOTOR SPEED REPLACE LEAD ON EBTDR "COM" WITH LEAD ON EBTDR "M1" OR "M2"

3. FOR 208 VOLT TRANSFORMER OPERATION MOVE PURPLE WIRES FROM TERMINAL 3 TERMINAL 2 ON TRANSFORMER.

4. START ASSIST FACTOR EQUIPED WHEN REQUIRED

5. USE COPPER CONDUCTORS ONLY ++ USE N.E.C. CLASS 2 WIRE

SEE UNIT RATING PLATE FOR TYPE AND SIZE

OF OVER CURRENT PROTECTION

208-240/1/60 0140G00871-C

Page 45

WIRING DIAGRAMS

NOTE #2

NOTE #3

24V

208-230

240

208-230/1/60

SUPPLY VOLTAGE

COMP

S.A.

NOTE #4

RCCF

24V

208

COMP

PLF

562

LVJB

A T

NOTE #3

GND

208-230/1/60 0140G03702-A

C L G N

SEE NOTE 2

3 1

R W2 W1 Y G C

PLF

SEE NOTE #2

IF USED

THERMOSTAT

SEE UNIT RATING PLATE FOR TYPE AND SIZE

OF OVER CURRENT PROTECTION

2 3

SEE

NOTE 5

RD SA (IF USED) SEE NOTE 4

HPS

CONTROL BOX

HPS

COMPONENT

LEGEND

CM COMP

GND LVJB PLF RCCF

SA TR HPS CSR SOL

CONTACTOR

CONDENSER MOT OR COMPRESSOR

EVAPORATOR MOTOR

EQUIPMENT GROUND LOW VOLTAGE JUNCTION BOX FEMALE PLUG / CONNECTOR RUN CAPACI TOR FOR COMPRESSOR AND FAN START ASSIST TRANSFORMER HIGH PRESSURE SWITCH COMPRESSOR SOLENOID RELAY HI STAGE SOLENOID

ACTORY WIRING

LINE VOLTAGE

LOW VOLTAGE

OPTIONAL HIGH

VOLTAGE

FIELD WIRING

HIGH VOLTAGE

LOW VOLT AGE

WIRE CODE BK BLACK BL BLUE BR BROWN GR GREEN OR ORANGE PU PURPLE RD RED WH WHITE YL YELLOW

NOT

ES:

1. REPLACEMENT WIRE MUST BE SAME SIZE AND TYPE INSULATION AS ORIGINAL (AT LEAST 105C) USE COPPER CONDUCTOR ONLY.

2. TO CHANGE EVAPORATOR MOT OR SPEED MOVE YELLOW AND WHITE LEADS FROM EM "2" AND "3" TO "4" AND "5". IF BOTH LEADS ARE ENERIZED, THE HIGHER SPEED SETTING IS USED.

3. FOR 208 VOLT TRANSFORMER OPERATION MOVE PURPLE WIRE S FROM TERMINAL 3 TO TERMINAL 2 ON TRANSFORMER.

4. START ASSIST FACTOR EQUIPED WHEN REQUIRED

5. USE COPPER CONDUCTORS ONLY

USE N.E.C. CLASS 2 WIRE

EQUIPMENT GROUND

FIELD GROUND

FIELD SPLICE

SWITCH (TEMP)

IGNITER

SWITCH (PRESS.)

OVERCURRENT

PROT. DEVICE

JUNCTION

TERMINAL

INTERNAL TO

INTEGRATED CONTROL

PLUG CONNECTION

Y2YL

SOL

CSR

SOL

CSR

GPC1560H41**

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT . FAILURE TO

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

Page 46

WIRING DIAGRAMS

APC15[24-48]H41**

208

24V

SA (IF USED) SEE NOTE 3

RCCF

VSM

240

NOTE #2

PLF

562

SEE NOTE 4

GND

2 0 8

2 3 0 / 1 /

LVJB

W1 W2

G Y

CONTROL BOX

T H E R M O S T A T

OFF

DIP SWITCH

6 75 8

24 VAC

HEATER

THERMOSTAT

HUM

Y1/Y2

C RY1G

HUMIDIST A T

VSTB

W2ED

COM

YCON

CONDENSER

HEATPUMP

OUTDOOR

W/W2

CTO1TO2TO

E/W1

COMP

SUPPLY VOLTAGE

208-230/1/60

RCCF

NOTE #3

208-230

IF USED

S.A.

COMP

NOTE #2

3 1

VSM

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.

24V

PLF

COMPONENT LEGEND

BLOWER INTERLOCK RELAY

BR C

CONTACTOR

CRACKCASE HEATER

CONDENSER MOTOR

COMP

COMPRESSOR

EBTD

ELECTRONIC BLOWER TIME DELAY RELAY

EVAPORATOR MOTOR

FAN CAPACITOR

EQUIPMENT GROUND

GND

LOW VOLTA GE JUNCTION BOX

LVJB

FEMALE PLUG / CONNECTOR

PLF

RUN CAPACITOR FOR

RCCF

COMPRESSOR AND FAN

START ASSIST

TRANSFORMER

JUNCTION

TERMINAL

INTERNAL TO

INTEGRATED CONTROL

PLUG CONNECTION

SWITCH (PRESS.)

OVERCURRENT

PROT. DEVICE

NOTES:

1. REPLACEMENT WIRE MUST BE SAME SIZE AND TYPE INSULATION AS ORIGINAL (AT LEAST 105C) USE COPPER CONDUCTOR ONLY.

2. FOR 208 VOLT TRANSFORMER OPERATION MOVE PURPLE WIRES FROM TERMINAL 3 TO TERMINAL 2 ON TRANSFORMER.

3. START ASSIST FACTOR EQUIPED WHEN REQUIRED

4. USE C OPPER CONDUCTOR S ONLY

+ +

USE N.E.C. CLASS 2 WIRE

EQUIPMENT GROUND

FIELD GROUND

FIELD SPLICE

SWITCH (TEMP)

IGNITER

CTORY WIRING LINE VOLTAGE LOW V OLTAGE OPTIONAL HIGH VOLTAGE

FIELD WIRING HIGH VOLTAGE LOW V OLTAGE

WIRE CODE BK BLACK BL BLUE BR BROWN GR GREEN OR ORANGE PU PURPLE RD RED WH W HITE YL YELLOW

YCON

VSTB

THERMOSTAT

COM

SEE UNIT RATING PLATE FOR TYPE AND SIZE

OF OVER CURRENT PROTECTION

208-230/1/60 0140G03703-A

Page 47

WIRING DIAGRAMS

NOTE #2

VSM

24V

208-230

CONTROL BOX

240

208-230/1/60

SUPPLY VOLTAGE

COMP

S.A.

NOTE #3

RCCF

24V

208

COMP

PLF

562

NOTE #2

GND

208-230/1/60 0140G03704-A

3 1

PLF

IF USED

SEE

NOTE 4

RD SA (IF USED) SEE NOTE 3

COMPONENT LE GEND

CM COMP

GND LVJB PLF RCCF

SA TR HPS CSR SOL

CONTACTOR

CONDENSER MOTOR COMPRESSOR

EVAPORATOR MOTOR

EQUIPMENT GROUND LOW VOLT AGE JUNCTION BOX FEMALE PLUG / CONNECTOR RUN CAPACITOR FOR COMPRESSOR AND FAN START ASSIST TRANSFORMER HIGH PRESSURE SWITCH COMPRESSOR SOLENOID RELAY HI STAGE SOLENOID

FACTORY

WIRING

LINE VOLTAGE LOW VOLTAGE OPTIONAL HIGH VOLT AGE

FIELD WIRING HIGH V OLTAGE LOW VOLTAGE

WIRE CODE BK BLACK BL BLUE BR BROWN GR GREEN OR ORANGE PU PURPLE RD RED WH WHITE YL YELLOW

SEE UNIT RATING PLATE FOR TYPE AND SIZE

OF OVER CURRENT PROTEC TION

NOTES:

1. REPLACEMENT WIRE MUST BE SAME SI ZE AND TYPE INSULATION AS ORIGINAL (AT LEAST 105C) USE COPPER CONDUCTOR ONLY.

2. FOR 208 VOLT TRANSFORMER OPERATION MOVE PURPLE W IRES FROM TERMINAL 3 TO TERMINAL 2 ON TRANSFORMER.

3. START ASSIST FACTOR EQUIPED W HEN REQUIRED

4. USE COPPER CONDUCTORS ONLY

+ +

USE N.E.C. CLASS 2 WIRE

EQUIPMENT GROUND

FIELD GROUND

FIELD SPLICE

SWITCH (TEMP)

IGNITER

SWITCH (PRESS .)

OVERCURRENT

PROT. DEVICE

JUNCTION

TERMINAL

INTERNAL TO

INTEGRATED CONTROL

PLUG CONNECTION

A T

OT2

OT1OTC

W/W2

E/W1

YCON

COM

OUTDOOR

CONDENSER

HEATPUMP

VSTB

C RY1G

Y1/Y2

HUMIDIST A T

24VAC

431

875

DIP SWITCH

OFF

HUM

HEATER

THERMOSTAT

LVJB

VSM

W2Y2W1

COM

YCON

THERMOSTAT

Y\ Y2

VSTB

HPS

CSR

SOL

HPS

SOL

APC1560H41**

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT . FAILURE TO

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

Page 48

WIRING DIAGRAMS

GPH16[24-42]H41**

SEE NOTE 8

SEE NOTE 7

SEE NOTE 5

GND

LVJB

RD GR WH

Y R G W1

O W2 C

SEE NOTE 6

2 0 8

2 4 0 / 1 /

T H E R M O S T

A T

SEE NOTE 6

FACTORY WIRING LINE VOLTAGE LOW VOL TAGE OPTIONAL HIGH VOLTAGE

FIELD WIRING HIGH VOLTAGE LOW VOL TAGE

WIRE CODE BK BLACK BL BLUE BR BROWN GR GREEN OR ORANGE PU PURPLE RD RED WH WHITE YL YELLOW

EQUIPMENT GROUND

FIELD GROUND

FIELD SPLICE

SWITCH (TEMP)

0140G01640-C

208

240

24V

SA SEE NOTE 4

SEE NOTE 3

COMP

HPS

PLF

562

COMPONENT LEGEND

C CCR CH CHS CM COMP DC DFT EM GND HVDR LPS LVDR LVJB PLF RVC RCCF

SA TR HPS

CONTACTOR COMPRESSOR CONTACTOR RE LAY CRACKCASE HEATER CRACKCASE HEATER SW ITCH CONDENSER MOTOR COMPRESSOR DEFROST CONTROL DEFROST THERMOSTAT EVAPORATOR MOTOR EQUIPMENT GROUND HIGH VOLTAGE DEFROST RELAY LOW PRESSURE SWITCH LOW VOLTAGE DEFROST RELAY LOW VOLTAGE JUNCTION BOX FEMALE PLUG / CONNECTO R REVERSING VALVE COIL RUN CAPACITOR FOR COMPRESSOR AND FAN START ASSIST TRANSFORMER HIGH PRESSURE SWI TCH

JUNCTION

TERMINAL

INTERNAL TO

INTEGRATED CONTROL

PLUG CONNECTION

IGNITER

SWITCH (PRESS.)

OVERCURRENT PROT. DEVICE

NOTES:

1. REPLACEMENT WIRE MUST BE SAME SIZE AND TYPE INSULATION AS ORIGINAL (AT LEAST 105C) USE COPPER CONDUCTOR ONLY.

2. TO CHANGE EVAPORATOR MOTOR SPEED MOVE WHITE AND YELLOW LEADS FROM EM"2" AND "3" TO "4" AND "5". IF BOTH LEADS ARE ENERGIZED, THE HIGHER SPEED SETTING IS USED. 3 FOR 208 VOLT TRANSFORMER OPERATION MOVE PURPLE WIRES FROM TERMINAL 3 TO TERMINAL 2 ON TRANSFORMER.

4. START ASSIST FACTORY EQUIPPED WHEN REQUIRED

5. USE COPPER CONDUCTO RS ONLY

USE N.E.C. CLASS 2 WIRE

6. CRANKCASE HEATER AND CRANKCASE HEATER SWITCH FACTORY EQUIPPED WHEN REQUIRED.

7. DOUBLE POLE CO NTACTOR SHOWN. SINGLE POLE CONTACT OR COULD BE FACTORY EQUIPPED AS AN ALTERNATE CONFIGURATION.

8. COMMON SIDE OF CONTACTOR CAN NOT BE GROUNDED OR CONNECTED TO ANY OTHER COMMON (24V).

SEE UNIT RATING PLATE FOR TYPE AND SIZE

OF OVER CURRENT PROTECTION

RCCF

CONTROL BOX

DF2

RDYL

LPS

YL/PK

CCR

LVDR

DFT

DF2

S.A.

SEE NOTE 4

SEE NOTE 3

CNT

0-RV

C-RV

PS2

R-PS1

R-DFT

DFT

SUPPLY VOLTAGE

208-240/1/60

COMP

CHS

1 3

RCCF

SEE NOTE 6

208-240

RVC

DF1

HVDR

C D

HVDR

DF1

L G N

4 5

2 S

L N

4 5

SEE NOTE 2

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.

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

Page 49

WIRING DIAGRAMS

SEE NOTE 2

SEE NOTE 3

208-230

240

208-230/1/60

SUPPLY VOLTAGE

COMP

S.A.

DF1

SEE NOTE 4

RCCF

HVDR

DF2

RCCF

24V

208

COMP

PLF

LVJB

A T

SEE NOTE 3

GND

0140G03658-A

2 3

SEE NOTE 2

DFT

RVC

1 3

OTES:

1. REPLACEMENT W IRE MUST BE SAME SIZE AND TYPE INSULATION AS ORIGINAL (AT LEAST 105C) USE COPPER CONDUCTOR ONLY.

2. TO CHANGE EVAPORATOR MOTOR SPEED MOVE YELLOW AND W HITE LEADS FROM EM"2" AND "3" TO "4" AND "5". IF BOTH LEA DS ARE ENERGIZED, THE HIGHER SPEED SETTING IS USED. 3 FOR 208 VOLT TRANSFORMER OPERATION MOVE PURPLE WIRES FROM TERMINAL 3 TO TERMINAL 2 ON TRANSFORMER.

4. START ASSIST FACTORY EQUIPPED WHEN REQUIRED

5. USE COPPER CONDUCTORS ONLY

USE N.E.C. CLASS 2 WIRE

6. CRANKCASE HEATER AND CRANKCASE HEATER SWITCH FACTORY EQUIPPED WHEN REQUIRED.

7. DOUBLE POLE CONTACTOR SHOW N. SINGLE POLE CONTACTOR COULD BE FACTORY EQUIPPED AS AN ALTERNATE CONFIGURATION.

8. COMMON SIDE OF CONTACTOR CAN NOT BE GROUNDED OR CONNECTED TO ANY OTHER COMMON (24V).

SEE NOTE 5

SA SEE NOTE 4

4 5

HPS

CHS

LPS

YL/PK

4 5

SEE NOTE 6

CONTROL BOX

SEE NOTE 7

SEE NOTE 8

PS2

R-PS1

R-DFT

DFT

CNT

CCR

HVDR

LVDR

C-RV

0-RV

DF2

DF1

PONENT LEGEND

C CCR CH CHS CM COMP DC DFT EM GND HVDR LPS LVDR LVJB PLF RVC RCCF

SA TR HPS CSR SOL

CONTACTOR COMPRESSOR CONTACTOR RELAY CRACKCASE HEATER CRACKCASE HEATER SWITCH CONDENSER MOTOR COMPRESSOR DEFROST CONTROL DEFROST THERMOSTAT EVAPORATOR MOTOR EQUIPMENT GROUND HIGH VOLTAGE DEFROST RELAY LOW PRESSURE SWITCH LOW VOLTAGE DEFROST RELAY LOW VOLTAGE JUNCTION BOX FEMALE PLUG / CONNECTOR REVERSING VALVE COIL RUN CAPACITOR FOR COMPRESSOR AND FAN START ASSIST TRANSFORMER HIGH PRESSURE SWITCH COMPRESSOR SOLENOID RELAY HI STAGE SOLENOID

FACTORY

WIRING LINE VOLTAGE LOW VOLTAGE OPTIONAL HIGH VOLTAGE

FIELD W

IRING HIGH VOLTAGE LOW VOLTAGE

WIRE

CODE BK BLACK BL BLUE BR BROWN GR GREEN OR ORANGE PU PURPLE RD RED WH WHITE YL YELLOW

SEE UNIT RATING PLATE FOR TYPE AND SIZE

OF OVER CURRENT PROTECTION

EQUIPMENT GROUND

FIELD GROUND

FIELD SPLICE

SWITCH (TEMP)

IGNITER

SWITCH (PRESS.)

OVERCURRENT PROT. DEVICE

JUNCTION

TERMINAL

INTERNAL TO

INTEGRATED CONTROL

PLUG CONNECTION

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.

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

GPH1648H41**

Page 50

WIRING DIAGRAMS

APH16[24-42]H41**

16 PIN PLUG

SEE NOTE 9

SEE NOTE 8

SEE NOTE 4

GND

VSTB

OT1

OT2

COM

YCON

CONDENSER

HEATPUMP

OUTDOOR

W/W2

OTC

E/W1

OFF

DIP SWITCH

4213 8756

24 VAC

HEATER

THERMOSTAT

RY1G

Y1/Y2

SEE NOTES 5 & 6

LVJB

W1 W2

O C R

Y1/Y2

SEE NOTE 7

2 0 8

2 3 0

E R M O

240

SA SEE NOTE 3

BL/PK

SEE NOTE 2

PLF

562

HPS

HUM

HUMIDISTAT

COMP

RCCF

CONTROL BOX

1 C

208

24V

LPS

YL/PK

CCR

LVDR

HVDR

DFT

DF2

DF1

CNT

0-RV

C-RV

PS2

R-PS1

R-DFT

VSM

DFT

RVC

COMPO

NT LEGEND

SUPPLY VOLTAGE

208-230/1/60

SEE NOTE 7

CHS

COMP

S.A.

DF1

RCCF

HVDR

DF2

SEE NOTE 3

208-230

SEE NOTE 2

VSM

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.

4 5 6

HPS

PLF

YCON

THERMOSTAT

VSTB

COM

CONTACTOR

CCR

COMPRESSOR CONTACTOR RELAY

CRANKCASE HEATER

CHS

CRANKCASE HEATER SWITCH

CONDENSER MOTOR

COMP

COMPRESSOR

CSR

COMPRESSOR SOLENOID RELAY

DEFROST CONTROL

DFT

DEFROST THERMOSTAT

GND

EQUIPMENT GROUND

HPS

HIGH PRESSURE SWITCH

HVDR

HIGH VOLTAGE DEFROST RELAY

LPS

LOW PRESSURE SWITCH

LVDR

LOW VOLTAGE DEFROST RELAY

LVJB

LOW VOLTAGE JUNCTION BOX

PLF

FEMALE PLUG / CONNECTOR

RVC

REVERSING VALVE COIL

RCCF

RUN CAPACITOR FOR COMPRESSOR AND FAN

START ASSIST

SOL

HI STAGE SOLENOID

TRANSFORMER

VSM

VARIABLE SPEED MOTOR

VSTB

VARIABLE SPEED TERM BLOCK

FIELD GROUND

EQUIPMENT GROUND

JUNCTION

TERMINAL

INTERNAL TO

INTEGRATED CONTROL

PLUG CONNECTION

NOTE

1. REPLACEMENT WIRE MUST BE SAME SIZE AND TYPE INSULATION AS ORIGINAL (AT LEAST 105C) USE COPPER CONDUCTOR ONL Y.

2. FOR 208 VOLT TRANSFORMER OPERATION MOVE PURPLE AND RED WIRES FROM TERMINAL 3 TO TERMINAL 2 ON TRANSFORMER.

3. START ASSIST FACTOR EQUIPPED WHEN REQUIRED

4. USE COPPER CONDUCTORS ONLY

USE N.E.C. CLASS 2 WIRE

5. SET DIP SWITCH 4 ON VSTB TO OFF POSITION

6. REFER TO IO FOR FAN SPEED SETTINGS

7. CRANKCASE HEATER AND CRANKCASE HEATER SWITCH FACTORY EQUIPPED WHEN REQUIRED.

8. DOUBLE POLE CONTACTOR SHOWN. SINGLE POLE CONTACTOR COULD BE FACTORY EQUIPPED AS AN ALTERNATE CONFIGURATION.

9. COMMON SIDE OF CONTACTOR CAN NOT BE GROUNDED OR CONNECTED TO ANY OTHER COMMON (24V).

SEE UNIT RATING PLATE FOR TYPE AND SIZE

OF OVER CURRENT PROTECTION

FIELD SPLICE

SWITCH (TEMP)

IGNITER

SWITCH (PRESS.)

OVERCURRENT

PROT. DEVICE

LINE VOLTAGE LOW VOLTA GE OPTIONAL HIGH VOLTAGE

HIGH VOLTAGE LOW VOLTA GE

BK BLACK BL BLUE BR BROWN GR GREEN OR ORANGE PU PURPLE RD RED WH WHITE YL YELLOW

CTORYW

FIELD

IRE CO

IRING

WIRING

0140G03659-A

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

Page 51

WIRING DIAGRAMS

LPS

YL/PK

HVDR

DF1

DFT

SUPPLY VOLTAGE

208-230/1/60

SEE NOTE 7

COMP

S.A.

O-RV

CCR

LVDR

DF2

DFT

RCCF

208-230

1 3

24V

C-RV

YCON

THERMOSTAT

VSM

16 PIN PLUG

CHS

2 POLE ONLY SEE NOTE 8

VSM

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.

RVC

4 5 6

PLF

VSTB

CNT

0-RV

C-RV

PS2

R-DFT

R-PS1

RVC

DF1

SEE NOTE 3

SEE NOTE 2

R-DFT

R-PS1 PS2

LPS

HPS

KBKB

HVDR

S0L

APH1648H41**

CSR

1 C

208

24V

SEE NOTE 2

240

CONTROL BOX

RCCF

RDYL

RD PU

PLF

SA SEE NOTE 3

BL/PK

562

HPS

SOL

COMP

HUM

Y1/Y2

HUMIDISTAT

CHS

DF2

COMPONENT LEGEND

CONTACTOR

CCR

COMPRESSOR CONTACTOR RELAY

CRANKCASE HEATER

CHS

CRANKCASE HEATER SWITCH

CONDENSER MOTOR

COMP

COMPRESSOR

CSR

COMPRESSOR S OLENOID RELAY

DEFROST CONTROL

DFT

DEFROST THERMOSTAT

GND

EQUIPMENT GROUND

HPS

HIGH PRESSURE SWITCH

HVDR

HIGH VOLTAGE DEFROST RELAY

LPS

LOW PRESSURE SWITCH

LVDR

LOW VOLTAGE DEFROST RELAY

LVJB

LOW VOLTAGE JUNCTION BOX

PLF

FEMALE PLUG / CONNECTOR

RVC

REVERSING VALVE COIL

RCCF

RUN CAPACITOR FOR COMPRESSOR AND FAN

START ASSIST

SOL

HI STAGE SOLENOID

TRANSFORMER

VSM

VARIABLE SPEED MOTOR

VSTB

VARIABLE SPEED TERM BLOCK

FIELD GROUND

DFT

CNT

CSR

COM

EQUIPMENT GROUND

JUNCTION

TERMINAL

INTERNAL TO

INTEGRATED CONTROL

PLUG CONNECTION

NOTES:

1. REPLACEMENT WIRE MUST BE SAME SIZE AND TYPE INSULATION AS ORIGINAL (AT LEAST 105C) US E COPPER CONDUCTOR ONLY.

2. FOR 208 VOLT TRANSFORMER OPERATION MOVE PURPLE AND RED WIRES FROM TERMINAL 3 TO TERMINAL 2 ON TRANSFORMER.

3. START ASSIST FACTOR EQUIPPED WHEN REQUIRED

4. USE COPPER CONDUCTORS ONLY

USE N.E.C. CLASS 2 WIRE

5. SET DIP SWITCH 4 ON VSTB TO OFF POSITION

6. REFER TO IO FOR FAN SPEED SETTINGS

7. CRANKCASE HEATER AND CRANKCASE HEATER SWITCH FACTORY EQUIPPED WHEN REQUIRED.

8. DOUBLE POLE CONTACT OR SHOWN. SINGLE POLE CONTACTOR COULD BE FACTORY EQUIPPED AS AN ALTERNATE CONFIGURATION.

9. COMMON SIDE OF CONTACTOR CAN NOT B E GROUNDED OR CONNECTED TO ANY OTHER COMMON (24V).

SEE UNIT RATING PLATE FOR TYPE AND SIZE

OF OVER CURRENT PROTE CTION

FIELD SPLICE

SWITCH (TEMP)

IGNITER

SWITCH (PRESS.)

OVERCURRENT

PROT. DEVICE

SEE NOTE 4

OFF

VSTB

DIP SWITCH

875

24 VAC

HEATER

COM

HEATPUMP

THERMOSTAT

OUTDOOR

C RY1G

OT1

OTC

OT2

SEE NOTE 7

LINE VOLTAGE LOW VOLTAGE OPTIONAL HIGH VOLTAGE

HIGH VOLTAGE LOW VOLT AGE

BK BLACK BL BLUE BR BROWN GR GREEN OR ORANGE PU PURPLE RD RED WH WHITE YL YELLOW

SEE NOTE 9

SEE NOTE 8

GND

BR OR

YCON

CONDENSER

W/W2

E/W1

CTORY WIRING

FIELD WIRING

IRE CODE

SEE NOTES 5 & 6

LVJB

W1 W2

O C R Y1

SEE NOTE 7

0140G03657-A

2 0 8

2 3 0

T H E R M O S T A T

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

Page 52

WIRING DIAGRAMS

PACKAGE SYSTEM WIRING DIAG RA M - 1 STAGE ELECTRIC HEAT

SEE NOTE 1

#18 GAUGE 7 WIRE

REQUIRED FOR

HEAT PUMP S

ROOM THERMOSTAT

CW1GRE

PACKAGE UNIT LOW VOLTAGE JUNCTION BOX

R Y

YELLOW

GREEN

ORANGE

WHITE

G O

TYPICAL HP

BLUE

OUTDOOR THERMOSTAT

CLOSE ON TEMPERATURE FALL

PACKAGE SYSTEM WIRING DIA GRA M - 2 STAGE ELECTRIC HEAT

ABOVE 10 KW

RED

SEE NOTE 1

#18 GAUGE 8 WIRE

FOR HEAT PUMPS

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT . FAILURE TO

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

SEE NOTE 2

ROOM THERMOSTAT

W2 C RYO W1G E

PACKAGE UNIT LOW VOLTAG E JUNCTION BOX

RED

G O

R Y

YELLOW GREEN ORANGE

WHITE

BROWN

BLUE

OUTDOOR T HERMOSTAT

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

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.

Page 53

WIRING DIAGRAMS

PACKAGE SYSTEM WIRING DIAGRAM - HEAT PUMPS ONLY!

TWO-STAGE ELECTRIC HEAT ABOVE 10 kW

TYPICAL H/P

ROOM THERMOSTAT

#18 GAUGE 8 WIRE

OUTDOOR THERMOSTAT #2 (IF US ED, SEE NOTE 1)

OUTDOOR THERMOSTAT #1

CLOSE ON TEMPERATURE FALL

W2 C RYO W1G E

G O

PACKAGE HEAT PUMP

R Y

LOW VOLTAGE JUNCTION BOX

RED

YELLOW

GREEN

ORANGE

WHITE

BROWN

BLUE

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

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT . FAILURE TO

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

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

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-BL UE BR-BROWN O --ORANGE W -WHIT E G --GREEN

OT18-60A OUTDOOR THERMOSTAT

Page 54

WIRING DIAGRAMS

*PC15/*PH16H41*

L1 L2

HTR1

PLM

2 3 4 5 6 7 8

HTR1

HTR2

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

L2L1

PLM

1 2 3

4 5 6 7 8 9

5 KW

10 KW

FL FL FL

PLM

BL BR

2 3

5 6

7 8 9

HTR1

HTR2

HTR3

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT . FAILURE TO

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

HTR1

HTR2

HTR3

HTR4

M1 M2

TL TL TL

M5 M6

PLM

1 2

M8 R2

8 9

L2 L1 L2

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

15 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.

L2L1 L1 L2

20 KW

Page 55

WIRING DIAGRAMS

*PC15/*PH16H41*

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.

Page 56

WIRING DIAGRAMS

TO CONTROL BOX

SEE NOTES 1 & 2

PU/BK-3

CCB

TO ELECTRIC HEAT

BK-3

COLOR CODE

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

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

BR --------------- BROWN

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

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

WIRING CODE

FACTORY WIRING

HIGH VOLTAGE

OPTIONAL HIGH VOLTAGE

FIELD WIRING

HIGH VOLTAGE

0140G02544- A

YL --- - ----------- YELL O W

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.

208 / 240 / 1 / 60

SPB

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.

LEGEN

CCB - COM PRESSOR

CIRCUIT BREAK ER

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

HAVE A PURPLE WIRE. 50 AND 60

AMP BREAKERS WILL HAVE BLACK

WIRE LABELED WITH A #3

SPB - SINGLE POINT BLOCK

Goodman *PH 16, *PH 15 Service Instructions Manual

Goodman PH 16, PH 15 Service Instructions Manual