Goodman Mfg RT6100004R13 User Manual

Service Instructions

Split System Air Conditioners,

Split System Heat Pumps

with R-22 Refrigerant

Blowers, Coils, & Accessories

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

RT6100004r13

May 2009

TABLE OF CONTENTS

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

MODEL IDENTIFICATION............................4 - 15

AIR HANDLER/COIL IDENTIFICATION ............15

ACCESSORIES......................................... 16 - 20

PRODUCT DESIGN ................................. 21 - 22

SYSTEM OPERATION ..............................23 - 27

TROUBLESHOOTING CHART .........................28

SERVICING TABLE OF CONTENTS ................29

SERVICING .................................................30 - 60

ACCESSORIES WIRING DIAGRAMS ........61 - 69

IMPORTANT INFORMATION

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

SERVICE MANUAL BEFORE BEGINNING REPAIRS.

IMPORTANT NOTICES FOR CONSUMERS AND SERVICERS

RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS

WARNING

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

WARNING

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

WARNING

Good ma n will not be respo nsible for any injury or prop erty dam age arising from imprope r service or service procedures. If you perform service o n your own product, you assum e responsibility for any personal inju ry or property dam age wh ich may result.

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

CONSUMER INFORMA TION LINE GOODMAN® BRAND PRODUCTS

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

email us at: customerservice@goodmanmfg.com

fax us at: (713) 856-1821

(Not a technical assistance line for dealers.)

email us at: hac.consumer.affairs@amanahvac.com

CONSUMER INFORMATION LINE

AMANA® BRAND PRODUCTS

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

fax us at: (931) 438- 4362

(Not a technical assistance line for dealers.)

Outside the U.S., call 1-713-861-2500. (Not a technical assistance line for dealers.) Your telephone company will bill you for the call.

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

IMPORTANT INFORMATION

SAFE REFRIGERANT HANDLING

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

WARNING

Refrige rants are heavier than ai r. T hey can "push out" the oxygen in your lungs or in any enclosed space.To avoid possible difficulty in breathing or death:

•

Never purge refrigerant into an enclosed room or

space. By law, all refrigerants must be reclaimed.

•

If an in door leak is suspec ted, t horo ughl y vent ilat e

th e ar ea b ef ore b egi nn i ng w or k.

• Liqui d ref ri ge ra nt can be ver y co l d. To av oi d pos si ble frostbit e or blind ness , avoi d co ntac t wi th re fri geran t and wear gloves and goggles. If li quid refrigerant does cont act your skin or eyes , s eek me dica l hel p immediate ly.

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

To avoid possible explosion, us e only returnable (not disposable) service cylinders when removing refrigerant from a s yst em.

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

• Ensure the hydrostatic test date does no t exceed

WARNING

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

5 years.

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

WARNING

System contamina nts, improper se rvice procedure and/or physical abuse affecting hermetic com pressor electrical terminals may cause dangerous s ystem venting.

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

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

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

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

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

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

with air)

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

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

See Service Section S-17 for proper servicing.

PRODUCT IDENTIFICATION

Split System Air Conditioners R-22

Model # Description

GSC13018-241AA

GSC13036-481AA

GSC1 303 6,48*AA

GSC130**1AB

GSC1 303 6,48*AB

GSC1 3048* AC

GSC13018- 30AC

GSC1301 8,24, 301AD

GS C1300421AC, 484AC

GS C1 3018 , 24, 301 A E

GSC130 48 1, 48 3 AE/A F

GSC130363AE/AF

GSC130361DE/DD

o odman® Br and Split Co ndenser 13 Seer condensi ng units . Init ial release . 26 " chassis

o odman® Br and Split Co ndenser 13 Seer condensi ng units . Init ial release . 29 " chassis

o odman® Br and Split Co ndenser 13 S eer co ndensing units.

Introduce s new 13 SEER AC 3 P H R- 22 Goodm an M odels

o odman® Br and Split Co ndenser 13 S eer co ndensing units. Move locat ion of screw

hole.

o odman® Br and Split Co ndenser 13 S eer co ndensing units. Int r oduces new models

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

o odman® Br and Split Co ndenser 13 S eer co ndensing units. Move locat ion of screw

hole.

o odman® Br and Split Co ndenser 13 S eer co ndensing units. Release M odels

contai ning the br oad oc ean motor 0131M00 06 0

o odman® Br and Split Co ndenser 13 S eer co ndensing units. Remo v e 1 hairpin from

coil.

o odman® Br and Split Co ndenser 13 S eer co ndensing units. Release Models contain

GSC1 3048* AD

GSC130481AG

GSC130181BA

GSC130361BA

GSC130361BB

GSC130361DF

GSC13024-301CA

GSC130241DA

GSC13036 1FA GSC130363BA GSC130301DA

the broad ocean motor 0131M 00061

o odman® Br and Split Co ndenser 13 S eer co ndensing units. Int r oduces new models

with Bristol compressors.

o odman® Br and Split Co ndenser 13 Seer condensi ng units . Co nver s ion of existin g

mod e ls us i ng 3/ 8" dia m e t er tube c oi ls t o 5 mm c o il s.

o odman® Br and Split Co ndenser 13 Seer condensi ng units . Init ial release . 35 "

chassis.

o odman® Br and Split Co ndenser 13 S eer co ndensing units. Release M odel wi th

Cop eland Scr oll Compressor .

o odman® Br and Split Co ndenser 13 S eer co ndensing units. Int r oduces new models

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

o odman® Br and Split Co ndenser 13 S eer co ndensing units. Int r oduces new models

with Bristol compressors.

o odman® Br and Split Co ndenser 13 S eer co ndensing units. Int r oduces mo dels wit h

reduced chas sis size from the cur rent 29x3 2.5 to 26x32

o odman® Br and Split Co ndenser 13 S eer co ndensing units. Release of Goodman 13

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

o odman® Br and Split Co ndenser 13 Seer condensi ng units . Co nver t s from 3/ 8" to

5mm. 2.5 & 3 to n units hav e new coil sl ab height and ne w lo uv er panels . 2.5 - sma ll chas s is; 3 ton medium chassis.

PRODUCT IDENTIFICATION

Split System Air Conditioners R-22

M ode l # Des c ri ptio n

o odm an® Br and Split Condenser 14 Seer condensing units. Intr oduces Goodman®

GSC14 0**1AA

GSC14 0**1AB

GSC140**1AC

GSC140**1AD

GSC14018-421BA

Brand 1 4 Seer AC R-2 2 models.

o odm an® Br and Split Condenser 14 Seer condensing units. New rev isions hav e screw

locations m ov ed in the top pa nel, bas e pans, l ouv ers , an d c ont r ol b ox c ov er s .

o odm an® Br and Split Condenser 14 Seer condensing units. Relea se models

cont aining th e B ro ad Ocea n m otor 013 1 M00060 and 0131M000 61

o odm an® Br and Split Condenser 14 Seer condensing units. Revise c ondenser coils by

remov ing (1) hairpin. Reducing r efrigerant quanti ties by 6 ounces.

o odm an® Br and Split Condenser 14 Seer condensing units. Conver s ion of existing

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

Split System Air Conditioners R-22

M ode l # Des c ri ptio n

ASC130**1AA

ASC130**1AB

ASC130**1AC

ASC1301**1AD

ASC130601BD

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

Amana® Brand Deluxe 13 S eer AC R-22 c onditioners.

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

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

louvers.

mana® Br and Split Co ndenser 13 Se er condensing unit s . Re mo v e 1 hairpin fro m coil.

Sp ec ial Hi gh Fe atu re S p lit X Co nd en ser 14 See r conde ns in g uni t s.

hai rpin fr om coil. Reduce refrigerant quantities by 6 ounces.

Split System Air Conditioners R-22

M ode l # Des c ri ptio n

VSC13018-601AA

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

models. 2 year part & 5 y ear com pressor warra nty in B ahama Bei ge.

. Remove 1

PRODUCT IDENTIFICATION

Split System Heat Pumps R-22

M ode l # De sc r iption

GSH10***AA

GSH10***AB

GSH13***AA

GSH13**1AB

GSH13**1AC

GSH13036-48*AD

GSH13018-301BA

GSH130421AE

o odm an® Brand Sp lit Hea t Pum p 10 Se er heat pump units. Initial releas e.

o odm an® Brand Spl it Heat P um p 10 S eer heat pump unit s. S c rew location s

mov ed in th e to p panel, ba se pans, lo uv er s , and co ntrol box cov er s . .

o odm an® Brand Sp lit Hea t Pum p 13 Se er heat pump units. Initial releas e.

o odm an® Brand Spl it Heat P um p 13 S eer heat pump unit s. Revis ion

intr oduces the f ollowing new models due to the rep lacement of 8-pole fa n mo to r s wi th 6-pole and screw locations mov ed in t he t op panel, bas e pans, l ouv ers , an d control box covers.

o odm an® Brand Spl it Heat P um p 13 S eer heat pump unit s. Cont ain Broad

Oce an m otors S c re w locat ions moved in the top pane l, base pans, louvers, and control box covers. .

o odm an® Brand Spl it Heat P um p 13 S eer heat pump unit s. I ntroduces m odels

that contain the broad ocean motor

o odm an® Brand Spl it Heat P um p 13 S eer heat pump unit s. Reducti on in

chass is size from medium to smal l.

o odm an® Brand Spl it Heat P um p 13 S eer heat pump unit s. Repl a ces V 10

rever s ing valve with V 6 r ev er sing v alve.

GSH13048*AG

GSH13036*BA/BB

GSH140**1AA

GSH140**1AB

GSH1 40* *1AC

GSH140361AF,

GSH140421-48AD

GSH140601AE

o odm an® Brand Spl it Heat P um p 13 S eer heat pump unit s. I ntroduces

model with Bristol Compressors.

o odm an® Brand Spl it Heat P um p 13 S eer heat pump unit s. I m pr ov ements to

increase MOP values on 3 ton units.

o odm an® Brand Spl it Heat P um p 14 S eer heat pump unit s. I nitial re lease.

o odm an® Brand Spl it Heat P um p 14 S eer heat pump unit s. S c rew location s

mov ed in th e to p panel, ba se pans, lo uv er s , and co ntrol box cov er s .

o odm an® Brand Spl it Heat P um p 14 S eer heat pump unit s. Releases

models wit h the Broad Ocean mot or .

o odm an® Brand Spl it Heat P um p 14 S eer heat pump unit s. Releases

models tha t replace TXV & co mp ens ato r with flowrator & ac cu mulator.

PRODUCT IDENTIFICATION

Split System Heat Pump s R-22

Model # D e scr ip t ion

ASH130**1AA

ASH130**1AB

ASH130**1AC

Model # D e scr ip t ion

VSH13 18-601AA

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

mode ls of Amana® Br and D e lux e 13 S eer R-22 heat pum ps .

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

scr ew locations moved in the top panel, b ase pans, louvers, an d cont rol box covers.

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

horizon tal style louv ers.

Split System Heat Pump s R-22

alue Split He at Pump 13 Seer h eat pum p units . Introd uc es Value 13 Se er HP R-

22 mode ls. 2 year parts & 5 ye ar compressor wa rranty i n Bahama Beige.

PRODUCT IDENTIFICATION

Single Piec e Air Ha ndl e r s

Model # Description

Singl e P i ec e R Multi-Position PSC Motor Unpainte d Flowrater Introduc t i on of new 13

ARUF****16AA

ARUF364216AB

ARUF486016AB

ARUF364216AC

ARUF****16BA

ARUF****1BA

SE E R A i r Handler Model s. All M odel s will be suitable for us e with R-22 and R-410A

Singl e P i ec e R Multi-Position PSC Motor Unpainte d Flowrater. Revision replac es the

current s pot wel ded blower hous i ng wit h the same cinched or cri m ped des i gn used on the 80% furnace l i ne.

Singl e P i ec e R Multi-Position PSC Motor Unpainte d Flowrater. Revision replac es the

current s pot wel ded blower hous i ng wit h the same cinched or cri m ped des i gn used on the 80% furnace l i ne.

Singl e P i ec e R Multi-Position PSC Motor Unpainte d Flowrater. Revision replac es the

current s pot wel ded blower hous i ng wit h the same cinched or cri m ped des i gn used on the 80% furnace l i ne.

Singl e P i ec e R Multi-Position PSC Motor Unpainte d Flowrater. Revi s i on replaces all

ARUFc oi l s using wavy fin wit h l ouver enhanced fin.

Singl e P i ec e R Multi-Position PSC Motor Unpainte d Flowrater Introduc at i on of R-22

Only A i r Handlers .

ARPF****16AA

ARPF364216AB

ARPF486016AB

ARPF****16BA

ARPF****1BA

ADPF****16AA

ADPF364216AB

ADPF486016AB

Singl e P i ec e R Multi-Position PSC Motor Painted Flowrater Introduc at i on of new 13

SE E R A i r Handler Model s. All M odel s will be suitable for us e with R-22 and R-410A

Singl e P i ec e R Multi-Position PSC Motor Painted Flowrater. Revision replac es the

current s pot wel ded blower hous i ng wit h the same cinched or cri m ped des i gn used on the 80% furnace l i ne.

Singl e P i ec e R Multi-Position PSC Motor Painted Flowrater. Revision replac es the

current s pot wel ded blower hous i ng wit h the same cinched or cri m ped des i gn used on the 80% furnace l i ne.

Singl e P i ec e R Multi-Position PSC Motor Painted Flowrater. Revision replac es all

ARPF coils using wavy fin with louver enhanced fin.

Singl e P i ec e R Multi-Position PSC Motor Painted Flowrater. Introduc ation of R-22

Only A i r Handlers .

Singl e P i ec e Downflow PSC Mot or Unpainted Flowrater. Introduc at i on of new 13

SE E R A i r Handler Model s. All M odel s will be suitable for us e with R-22 and R-410A

Singl e P i ec e Downflow PSC Mot or Unpainted Flowrater. Revi s i on replaces the current

spot wel ded blower hous i ng wit h the same c i nched or crimped des i gn us ed on t he 80% furnace line.

Singl e P i ec e Downflow PSC Mot or Unpainted Flowrater. Revi s i on replaces the current

spot wel ded blower hous i ng wit h the same c i nched or crimped des i gn us ed on t he 80% furnace line.

Singl e P i ec e Downflow PSC Mot or Unpainted Flowrater. Revi s i on replaces the current

ADPF304216AC

ADPF****1BA

spot wel ded blower hous i ng wit h the same c i nched or crimped des i gn us ed on t he 80% furnace line.

Singl e P i ec e Downflow PSC Mot or Unpainted Flowrater Revision replaces all

ARPF coils using wavy fin with louver enhanced fin.

PRODUCT IDENTIFICATION

S ing le Pie ce Air Ha n dl ers

Mode l # Description

Single Piece E Mult i-P os ition Vari able-Speed Painted Flowrator. Introducation of

AEPF****16AA

AEPF****16BA

AEPF****16BB

AEPF****16CA

AEPF****1BA

new 13 SE E R Air Handler M odels. A ll M odels w il l be s uitable for us e wit h R- 22 and R-410A

Single Piece E Mult i-P os ition Vari able-Speed Painted Flowrator. Revision

introduces new models add ing low er kw hit ki ts on the S &R plate

Single Piece E Mult i-P os ition Vari able-Speed Painted Flowrator. Revision

replaces t he c ur r ent spo t welded blower housing w ith t he same c inch ed o r crimped design use d on the 80% fu r n ac e l i ne.

Single Piece E Mult i-P os ition Vari able-Speed Painted Flowrator. Revision

replaces all ARP Fcoils us i ng wavy fin w ith louver enhanc ed fin.

Single Piece E Mult i-P os ition Vari able-Speed Painted Flowr at or Intr o ducti o n of R

22 O nly Air Han dlers.

AEPF313716AA ASPF313716AA

ASPF****16AA

ASPF****16BA

AWUF****1AA

AWUF****16AA

AWUF3005-101AA

AWUF****1BA

AWUF370**16AA

(ASPF)

(AEPF)

. Introduction of

Single Piece E Mult i-P os ition Vari able-Speed Painted Flowrator Sin gle Piece S Mult i -Position EEM mo tor Painted Flowrator 3-Ton Air Handle r units wi th 3-row co i l.

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

ASPF Air H andlers

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

modi fied ASPF control scheme, to ensur e blower operation duri ng and after call for hea t on units wi th heat k it s and r eplacing wav y fi n with louver enhance d fin on coi l

Single Piece Ai r Handler Wal l Mount Unpainted Flo wrator. Introduc es 13 SEER

Dayto n wall mount air ha ndlers

Single Piece Ai r Handler Wal l Mount Unpainted Flo wrator. Introduc es 13 SEER

Dayton wall mount air handlers. All Models will be suitable for use with R-22 and R410A

Single Piece Ai r Handler Wal l Mount Unpainted Flo wrator. Introduc es 13 SEER

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

Single Piece Ai r Handler Wal l Mount Unpainted Flowrat o r . Revision replace s

cur r ent wavey fin design wit h new louv ered fin design

Single Piece Ai r Handler Wal l Mount Unpainted Flowrator. Introduction of

AWUF37 Air Handl er s for use wit h R- 22 and R410A .

and

AWUF****16BA

ACNF****1AA

ACNF****16 AA

ACNF****1BA

AH**-1*

Single Piece Ai r Handler Ceiling Mount N Un ca s ed Flow rater. Rev ision has

louv er fins & replaces copper tu be hairpi ns with aluminum hairpins.

Single Piece Ai r Handler Ceiling Mount N Un ca s ed Flow rater. Rev ision re lease

all models of 13 SEE R Dayt on u n c ase d ai r handler s.

Single Piece Ai r Handler Ceiling Mount N Un ca s ed Flow rater. Rev ision re lease

all models of 13 SEER Dayton u n c as ed air handlers.All M odels w ill be s uitable for use with R-22 and R-410A

Single Piece Ai r Handler Ceiling Mount N Un ca s ed Flow rater. Rev ision repla c es

cur r ent wavey fin design wit h new louv ered fin design

Single Piece Ai r Handler Hydronic Air Hand ler. Revision replaces the time dela y r e lay in the AH a i r ha ndl ers w i th the UTE C t ime del ay co ntr ol bo ard.

PRODUCT IDENTIFICATION

MBR/MBE Air Handlers

Mo del # Description

odular Blower R Multi- P os iti on P S C M otor. Introduc es module blo wer wit h P S C

MBR****AA-1AA

MBE****AA-1AA

MBE****AA-1BA

Mo del # Description

CAUF*****6AA

CAUF*****6BA

b l ower m o t o r .

odular Blower E Multi- Pos ition Variable-Speed . I ntrodu c es module blower wit h

variable speed blo wer m ot or .

odular Blower E Multi- Pos ition Variabl e- S peed .Revision in troduces new m odels

adding lower kw hit kits on the S&R plate

Evaporator Coils

Indoor Coil A Upfl ow/Downflow Uncased Flowrator. In troduces 13 SEER CAUF

Dayton Upflow/Downflow coils.

Indoor Coil A Upfl ow/Downflow Uncased Flo wrator. Revision releases Burr Oak

Lou v er ed F in in pl ac e of th e Wavy Fin current ly in pr oducti on.

CAPF*****6AA

CAPF*****6BA

CAPF/CAUF36***CA

CHPF*****6AA

CHPF*****6BA

CHPF1824A6CA CHPF2430B6CA CHPF3636B6CA CHPF3642C6CA CHPF3642D6CA CHPF3743C6BA CHPF3743D6BA CHPF4860D6D

CSCF*****6AA

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

Dayton Upflow/Downflow coils.

Indoor Coil A Upfl ow/Downflow Painted Flow rator. Rev ision releases Burr Oa k

Lou v er ed F in in pl ac e of th e Wavy Fin current ly in produ c tion.

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

redesigns for pe rfor m ance impr ovement from 2 row to 3 row.

Indoor Coil Horizontal A Coil Painte d Flowrator. Release 13 SEER CHPF

horizon tal A coil.

Indoor Coil Horizontal A Coil Painte d Flowrator. Release 13 SEER CHPF horizon tal A coil. Rev is ion rele as es Bur r O ak Louvered Fin in place of the Wavy Fin c ur rently in product ion. T he rows chang e by one, (i . e. 4 r ow to 3 row; 3 row t o 2 row) where appl ic able.

Indoor Coil Horizontal A Coil Painte d Fl owr ato r . 13 S EER CHPF hor izontal A

coil, revision has louver fins & replaces copper tu be hairpins with a luminum hairpins.

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

CSCF slab hor izontal coil.

CSCF*****6BA

Indoor Coil S Horizontal Slab Coil C Upainted Flow rator. Revi sion r eleases Bur r

Oak Louvered Fin in place of the Wavy Fin currently in production. The rows change by one, ( i. e. 4 row to 3 r ow; 3 r ow t o 2 r ow) where app lic able .

PRODUCT IDENTIFICATION

GSC140361AA

BR A ND:

G: Goodm a n Amana A: Amana

V: Val ue

Brand Dist inctio ns

Brand

Brand /

PRODU CT CATE GORY:

S: Split System

UNIT TYPE:

C: Condense r R-22 H: Heat Pum p R-22

SEER:

10 : 10 SE E R 13 : 13 SE E R 14 : 14 SE E R

NOMINAL CA PACITY :

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

MINOR REVIS ION:

A: Initial Releas e

MAJOR REVISION:

A: I n itial Re lea s e

ELEC TRICAL:

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

CPKF036 2 A

PROD UCT CATE GOR Y :

C : Split System

UNIT TYPE:

E: Commercial Air Con ditioner K: Air Cojd itioner P: Heat Pum

REVISION:

A: Re vision

ELECT RICAL:

1: 208- 230V/1ph/60Hz 2: 220- 240V/1ph/50 Hz 3: 208-23 0v /3ph/60 Hz 4: 308/415V /3 ph/ 50Hz

NOMINAL CAPACITY:

018: 1 .5 Ton s 048: 4 Tons 024: 2 Tons 060: 5 Tons 030: 2 .5 Ton s 070: 5 Tons 036: 3 Tons 090: 7.5 T ons 042: 3 .5 Ton s 120: 1 0 Tons

PRODUCT IDENTIFICATION

C KF 036 2 A

P R O D UCT CATEGORY :

C : Split Sy s tem

UNIT TYPE:

E: Co m mercial Air Conditioner K: Air Cojditioner P: Heat Pum

NOMINAL CAPACITY:

018: 1.5 T ons 048: 4 Tons 024: 2 Tons 060: 5 Tons 030: 2.5 T ons 070: 5 Tons 036: 3 Tons 090: 7.5 T ons 042: 3.5 T ons 120: 1 0 Tons

REVISION:

A: Re vision

ELECTRICAL:

1: 20 8- 230V/1ph/60Hz 2: 22 0- 240V/1ph/50 Hz 3: 20 8- 230v/3ph/60Hz 4: 30 8/415V/3 ph/50Hz

CKL0362A

PRODUC T CATE GO R Y :

C : Split Sys tem

UNIT TYPE:

E: Commercial Air Conditione r K: Air Cojditioner P: Heat Pum

REVISION:

A: Revi sion

ELECTRICAL:

1: 20 8-23 0V /1ph/60 Hz 2: 22 0-24 0V /1ph/5 0 Hz 3: 20 8-23 0v /3ph/60 Hz 4: 308/415V/3ph/50Hz

NOMINAL CAP ACITY:

018: 1.5 Tons 04 8: 4 Tons 024: 2 Tons 060: 5 Tons 030: 2.5 Tons 07 0: 5 Tons 036: 3 Tons 090: 7.5 Tons 042: 3.5 Tons 120: 10 Tons

PRODUCT IDENTIFICATION

C E 120 5 A

PRODUCT CATEGOR Y:

C : Split Syst em

UNIT TYPE:

E: Comm ercial Air Conditioner K: Air Cojdit ioner P: Heat Pum

N OMINA L CAPACI TY:

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

REVISION :

A: Revision

ELECTRICAL:

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

THIS NOMENCLATURE IS TO BE USED TRHOUGH JULY 2006

R U F 3642 1

Product Type

: Single Piece Air Handler

Application

C: Ceiling Mo un t P S C Mo to r D: Downflow PSC Motor E: Multi-Position Variable Speed Motor R: Multi-Position PSC Motor W: Wall Mount PSC Motor

Cabinet Finish

U: Unpainted P: Painted N: Uncased

Expansion Device

F: Flowrater

Nominal Capacity Range @ 13 SEER

Multi-Position & Downflow Applications

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

Ceiling Mount & Wall Mount Applications

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

Minor Revisi on

: Initial Release

Major Revision

: Initial Release

Electrical

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

PRODUCT IDENTIFICATION

THIS NOMENCLATURE IS TO BE USED AFTER JULY 2006

A W U F 3642 1 6 A A

EXP ANSION

PRODUCT

TYPE:

A: Air Han dler

CABINE T FINISH:

U: U npainted P: Pa ited N: Uncased

APPLICATION

C: Ceiling Mount PSC M otor D: Downflow PSC Motor E: Mul ti-Position Varible-Speed Motor S: Energy-Efficient Mo tor R: Multi-Position PSC Motor T: Coated Coils W: Wall M o unt PS C Motor

DEVICE:

F: Flowrater T: TXV (Expansion Device)

MINOR R EVISION*

MAJOR REVISION*

R EFRIG ERANT C H ARG E:

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

ELECTRICA L:

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

NOMINA L CAPA CITY RANGE:

@ 13 SEER Dedicat ed Application 36 36: 3 T o ns

Multi-Posit ion & Dow nfl ow A ppli cations 31 37: 3 T o ns 3642: 3 - 3 1/2 Tons 1830: 1 1/2 - 3 1/2 Tons @10 S E E R 1729: 1 1/2 - 2 1/2 Tons (for expo r t sys tems)

Ceiling Mount & Wall Mount Applications (Nominal Cooling Capacity/Ele c tric Heat kW) 1805: 1 1/2 Tons Cooling / 5 kW Electric Heat 2 4 05: 2 Tons Co o lin g / 5 k W Ele ctr i c He at 3 6 08: 3 Tons Co o lin g / 8 k W Ele ctr i c He at 3 7 05: 3 Tons Co o lin g / 5 k W Ele ctr i c He at 3 7 08: 3 Tons Co o lin g / 8 k W Ele ctr i c He at

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

PRODUCT IDENTIFICATION

C A P F 1824 A 6 A

PRODUCT

TYPE:

C: Indoor Coil

A PPLICATION

A: U pfl ow /Downflo w Coil H: Horizontal A Coil S: Horizontal Slab Coil

EXPANSION DEVICE:

F: Flowrate

CAB INE T FINIS H:

U: Unpai n t ed P: Pai nted N: Unp ainted Case

REVISION

A: Revision

REFRIGERANT CHARGE:

6: R-410A or R-22 2: R- 22 4: R- 41 0a

NOMINAL WIDT H FOR GAS F URNAC E

A : Fits 14" Furnace Cabinet B: Fits 17 1/2" Furnace Cabinet C: Fits 21" Fu r nac e C abi ne t D: Fits 24 1/2" Furnace Cabinet N: Does Not Apply ( Hor izontal Slab Coils)

NOMINAL CAPACITY RANGE @ 13 SEER

18 24 : 1 1/2 to 2 T on s 30 30 : 2 1/2 To ns 36 36 : 3 Ton s 3642: 3 to 3 1/2 T ons 48 60 : 4 & 5 Ton s

MB R 8 00 A A 1

DESIGN SERIES:

MB: Modular Blower

MOTOR TYPE:

R: Consta nt Speed

E: Variable Speed

FACTORY HE AT

0 0: No Heat

AIRFLOW DE LI V E RE D

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

ELECTRI CA L SUPPLY:

1 : 208-23 0V /60hZ/1 ph

DESIGN SERI ES

A: First Series

CIRCUIT BREAKER

A : No Cir c uit B r eak er B: C irc uit B rea k er

MODEL MFG. #

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

ACCESSORIES

X X X

X X

X X X

X X

X X X

X X

X X X

X X

Mo del AFE18-60A OT18-60A FSK01A*

ASC01 TX2N2* TX3N2* TX5N2* OT18-60A OT/EHR18-60 CSR-U-1 CSR-U-2 CSR-U-3

Descript ion G/VSH 13018 G /VSH13024 G/VSH 13030 G /VSH 13 036 G/VSH13042 G/VSH 13048 G /VSH13060

All Fuel Kit

Outdoor Thermostat

Freeze Pr ote ct ion Ki t

Anti Short Cycle Kit

TXV Kit

TXV Kit Outdoor Lockout Stat Emer ge ncy H eat relay kit Hard Start Kit Hard Start Kit Hard Start Kit

X X

X X X X

X X

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

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

X X X

--- --- ---

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

X X X X

--- --- ---

X X X

--- --- ---

X X X X

X X X

X X

Mo del AFE18-60A OT18-60A

FSK01A* ASC01 TX2N2* TX3N2* TX5N2* OT18-60A OT/EHR18-60 CSR-U-1 CSR-U-2 CSR-U-3

Model

OT18-60A FSK01A* ASC01 TX2N2* TX3N2* TX5N2* CSR-U-1 CSR-U-2 CSR-U-3

Descr iption A SH13018 ASH1 3024 ASH13030 ASH13036 AS H13042 A SH 13048 ASH13060

All Fuel Kit

Outdoor Thermosta

Freeze Pr ote ct ion Ki t

Anti Short Cycle Kit

TXV Kit

TXV Kit Outdoor Lockout Stat Emer ge ncy H eat relay kit Hard Start Kit Hard Start Kit Hard Start Kit

Description ASC 13018 ASC13024 ASC13030 ASC13036 ASC13042 AS C 13 048 ASC13060

Outdoor Thermosta

Freeze Pr ote ct ion Ki t

Anti Short Cycle Kit

TXV Kit TXV Kit

TXV Kit Hard Start Kit Hard Start Kit Hard Start Kit

X X

X X X X

X X

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

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

X X

--- --- ---

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

X X X X

--- --- ---

X X X

--- --- ---

X X

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

X X X

X X

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

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

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

--- --- ---

X X

--- --- ---

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

X X X X

X X X

X X

Model OT18-60A FSK01A* ASC01

TX2N2* TX3N2* TX5N2* CSR-U-1 CSR-U-2 CSR-U-3

Model Description GSC100903 GSC100904 GSC101203 GSC101204 FSK01A* ASC01 OT/EHR18-60

Model Description GSH100903 GSH100904 GSH101203 GSH101204 FSK01A* ASC01 OT/EHR18-60

Descript ion G/VSC 13018 G /VSC13024 G/VSC 13030 G /VSC 13 036 G/VSC13042 G/VSC 13048 G /VSC13060

Outdoor Thermostat

Freeze Pr ote ct ion Ki t

nti Short Cycle Ki

TXV Kit TXV Kit

TXV Kit Hard Start Kit Hard Start Kit Hard Start Kit

Freeze Pr ote ct ion Ki t

Anti Short Cycle Kit

Emer ge ncy H eat relay kit

Freeze Pr ote ct ion Ki t

Anti Short Cycle Kit

Emer ge ncy H eat relay kit

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

X X

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

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

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

--- --- ---

X X

--- --- ---

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

X X

xxxx xxxx

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

*Installed on indoor coil.

xxxx xxxx

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

X X

ACCESSORIES

Model

AFE18-60A OT18-60A FSK01A* ASC01 TX2N2* TX3N2* TX5N2* OT18-60A Outdoor Lockout Stat OT/EHR18-60 CSR-U-1 Hard Start Kit CSR-U-2 CSR-U-3 Hard Start Kit

Description All Fuel Kit

Outdoor Thermostat

Freeze Protection Kit

Anti Short Cycle Kit

TXV Kit

Emergency Heat relay kit

Hard Start Kit

CPKF24 CPKF36 CPKF42 CPKF48 CPKF60 CPKF61

xxxxxx xxxxxx xxxxxx xxxxxx

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

--- ---

xxxx

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

---xxxxx

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

Model

AFE18-60A OT18-60A FSK01A* Freeze Protection Kit ASC01 TX2N2* TX3N2* TX5N2* OT18-60A OT/EHR18-60 CSR-U-1 CSR-U-2 CSR-U-3

Model

AFE18-60A OT18-60A FSK01A* ASC01 TX2N2* TX3N2* TX5N2* OT18-60A OT/EHR18-60 CSR-U-1 CSR-U-2 CSR-U-3

Description

All Fuel Kit

Outdoor Thermostat

Anti Short Cycle Kit

TXV Kit

TXV Kit Outdoor Lockout Stat Emergency Heat relay kit Hard Start Kit Hard Start Kit Hard Start Kit

Description

All Fuel Kit

Outdoor Thermostat

Freeze Protection Kit

Anti Short Cycle Kit

TXV Kit

Outdoor Lockout Stat Emergency Heat relay kit

Hard Start Kit Hard Start Kit Hard Start Kit

CKF24 CKF36 CKF48 CKF60 CKF70

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

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

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

--- ---

---

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

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

--- x x x ---

--- --- x x ---

CKL18 CKL24 CKL30 CKL36 CKL42 CKL49 CKL60

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

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

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

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

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

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

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

Model

AFE18-60A OT18-60A FSK01A* ASC01 TX2N2* TX3N2* TX5N2* OT18-60A OT/EHR18-60 CSR-U-1 CSR-U-2 CSR-U-3

Description

Outdoor Thermostat

Freeze Protection Kit

Anti Short Cycle Kit

TXV Kit

Outdoor Lockout Stat Emergency Heat relay kit Hard Start Kit Hard Start Kit Hard Start Kit

All Fuel Kit

TXV Kit TXV Kit

CE120

---

--x x

---

ACCESSORIES

EXP ANSION VALVE KITS

1/4 FLARE CONNECTION

BULB TO BE LOCATED AT 10 OR 2 O'CLOCK

For Applications requiring

a field installed access fitting

EVAPORATOR COIL

1/4' FLARE CONNECTION

SEAL SUPP L IE D W/ KIT

REMOVE BEFORE INSTALLI NG EXP ANS IO N VALVE

SUCTION LINE

BULB

EXPANSION VALVE

SUCTION LINE

EXPAN SION VALVE

BULB

SEAL SUPPLIED W/ KIT

BULB TO BE LOCATED AT 10 OR 2 O'CLOCK

DISTRIBUTOR BODY

For Applications not requiring

a field installed access fitting

DISTRIBUTOR BODY

7/8" NUT

PISTON

SEAL

PISTON

SEAL

TAILPIECE

3/8"SWEAT

TAILPIECE

3/8"SWEAT

SEAL SUPPLIED W/ KIT

7/8" NUT

SEAL SUPPLIED W/ KIT

REMOVE BEFORE INSTALLING EXPANSION VALVE

OT/EHR18-60

OUTDOOR THERMOSTAT & EMERGENCY HEAT RELAY

OT18-60

Thermostat

DEAD DIAL

45º

Dial

COLD WARM

Set Point

Indicato r

Mark

(Shown @ Oº F)

(Turn Clockwise)

(Turn Counterclockwise)

315º

Set Point

djustmen t

Screw

ACCESSORIES

Wire Nut

FSK01A

FREEZE THERMOSTAT

KIT

Wire Nut

Install L ine

Thermostat

Here

ASC01A

ANTI-SHORT -CYCLE CONTROL KIT

Y1Y2R1

Install Line

Thermostat

Wire Nut

SHOR T CYCLE PROTECTOR

Here

Wire Nut

ELLOW 1

CONTACTOR

BLACK 1

T2 T1

BLACK 1

THERMOSTAT WIRE

UNIT

TERMINAL

BOARD

ACCESSORIES

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

CA*F030B4* --- X --- X CA*F036B4* --- X --- X CA*F042C4* --- --- X X CA*F048C4* --- --- X X CA*F057D4* --- --- X X

CA*F060D4* --- --- X X CHPF030A4* --- X --- X CHPF036B4* --- X --- X CHPF042A4* --- --- X X CHPF048D4* --- --- X X CHPF060D4* --- --- X X

CH36FCB --- X --- X CH48FCB --- --- X X

CH60FCB --- --- X X CA*F18246* X X --- X CA*F30306* --- X --- X CA*F36426* --- X X X

CHPF18246* X --- X X CHPF30306* --- --- X X CHPF36426* --- --- X X

CSCF1824N6* X --- --- X

CSCF303N6* --- X --- X

CSCF3642N6* --- X X X

COIL ACCESSORIES

HKR SERIES ELECTRIC HEA T KITS

ELECTRIC HEAT KIT APPLICATIONS

MBR & MBE

BLOWER

MBR0800AA-1AA - X X X X X MBR1200AA-1AA- XXXXXXXXXX MBR1600AA-1AA- XXXXXXXXXX MBR2000AA-1AA- XXXXXXXXXX MBE1200AA-1AA - - - - X X X - - - MBE1600AA-1AA - - - - - X X - - - MBE2000AA-1AA - - - - - X X X - - MBE1200AA-1BA - X X X X X X - - - MBE1600AA-1BA - X X X X X X - - - MBE2000AA-1BA - X X X X X X X - - -

X = Allowable combinations ^ = Circuit 1: Single Phase for Air Handler Motor * = Revision level that my or may not be designated

- = Restricted combinations Circuit 2: 3-Phase for HKR3 Heater Kits C = Circuit Breaker option

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

ELE CTRIC HEAT KIT

PRODUCT DESIGN

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

CONDENSING UNIT

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

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

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

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

Suction and Liquid Line Connections

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

Compressors

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

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

GSC130181BA use Panasonic® rotary compressors.

COILS AND BLOWER COILS

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

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

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

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

PRODUCT DESIGN

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

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

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

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

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

SYSTEM OPERA TION

COOLING

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

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

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

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

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

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

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

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

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

. The boiling point, at

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

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

COOLING CYCLE

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

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

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

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

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

DEFROST CYCLE

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

HEATING CYCLE

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

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

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

HEATING

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

SYSTEM OPERA TION

COOLING CYCLE

Reversing Valve

(Energized)

Indoor

Coil

HEATING CYCLE

Outdoor

Coil

Accumulator

Thermostatic

Expansion

Valve

Bi-Flow

Filter Dryer

Check Valve

Indoor

Coil

Reversing Valve

(De-Energized)

Outdoor

Coil

Accumulator

Thermostatic

Expansion

Valve

Bi-Flow

Filter Dryer

Check Valve

SYSTEM OPERA TION

EXPANSION VALVE/CHECK VALVE ASSEMBLY

IN COOLING OPERATION

Most expansion valves used in current Amana

use an internally checked expansion valve.

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

However, the principle of operation is the same.

RESTRICTOR ORIFICE ASSEMBLY

IN COOLING OPERATION

EXPANSION VALVE/CHECK VALVE ASSEMBLY

IN HEATING OPERATION

Brand Heat Pump products

RESTRICTOR ORIFICE ASSEMBLY

IN HEATING OPERATION

In the cooling mode, the orifice is pushed into its

seat, forcing refrigerant to flow through the metered

hole in the center of the orifice.

In the heating mode, the orifice moves back off its

seat, allowing refrigerant to flow unmetered around

the outside of the orifice.

SYSTEM OPERA TION

COOLING CYCLE - CONDENSING UNIT

Indoor

Coil

Outdoor

Coil

Thermostatic

Expansion

Valve

In the cooling mode, the orifice is pushed into its

seat, forcing refrigerant to flow through the metered

hole in the center of the orifice.

SYSTEM OPERA TION

AFE18-60A CONTROL BOARD

DESCRIPTION

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

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

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

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

TROUBLESHOOTING CHART

COOLING/HP ANALYSIS CHART

Complaint

POSSIBLE CAUSE

DOTS IN ANALYSIS

GUIDE INDICATE

"POSSIBLE CAUSE"

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

No Cooling Unsatisfactory Cooling/Heating

SYMPTOM

System will not start

Compressor will not start - fan runs

Comp. and Cond. Fan will not start

Evaporator fan will not start

Condenser fan will not start

Compressor runs - goes off on overload

Compressor cycles on overload

System runs continuously - little cooling/htg

Too cool and then too warm

Not cool enough on warm days

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Cooling or Heating Cycle (Heat Pump) ♦

•••

System

Operating

Pressures

Certain areas too cool, others too warm

Compressor is noisy

System runs - blows cold air in heating

Unit will not terminate defrost

Unit will not defrost

Low suction pressure

Low head pressure

High suction pressure

High head pressure

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

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♦♦♦ ♦♦♦ ♦♦♦♦♦ ♦ ♦♦♦♦♦♦♦

Heating Cycle Only (Heat Pump)

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

♦

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

♦

Inspect Coil - Clean

♦

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

♦

Reduce Blower Speed S-200

•

Recover Part of Charge S-113

••

Inspect Coil - Clean

•

Recover Charge, Evacuate, Recharge S-114

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

♦

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

Test Method

Remedy

See Service Procedure Ref.

SERVICING

TABLE OF CONTENTS

S-1 Checking Voltage.......................................... 30

S-2 Checking Wiring............................................30

S-3 Checking Thermostat, Wiring & Anticipator .. 30

S-3A Thermostat & Wiring ..................................... 30

S-3B Cooling Anticipator ........................................ 31

S-3C Heating Anticipator........................................ 31

S-3D Checking Encoded Thermostats ................... 31

S-4 Checking Transformer & Control Circuit ....... 32

S-5 Checking Cycle Protector ............................. 32

S-6 Checking Time Delay Relay.......................... 32

S-7 Checking Contactor and/or Relays................ 33

S-8 Checking Contactor Contacts .......................33

S-9 Checking Fan Relay Contact ........................ 33

S-10 Copeland Comfort™ Alert Diagnostics .......... 3 4

S-11 Checking Loss of Charge Protector............... 36

S-15 Checking Capacitor....................................... 36

S-15A Resistance Check......................................... 37

S-15B Capacitance Check....................................... 3 7

S-16A Checking Fan & Blower Motor

Windings (PSC Motors) ............................... 37

S-16B Checking Fan & Blower Motor (ECM Motors) 3 8

S-16C Checking ECM Motor Windings .................... 41

S-16D ECM CFM Adjustments................................ 41

S-16E Checking GE X13™ Motors .......................... 42

S-17 Checking Compressor Windings ................... 43

S-17A Resistance Test............................................ 43

S-17B Ground Test .................................................. 43

S-17D Operation Test .............................................. 44

S-18 Testing Crankcase Heater (optional item) .....4 4

S-21 Checking Reversing Valve Solenoid .............. 44

S-24 Testing Defrost Control.................................. 44

S-25 Testing Defrost Thermostat ........................... 4 5

S-40 MBR & AR*F Electronic Blower Time Delay..45 S-41 MBE & AEPF with Single Speed

Air Conditioning............................................ 47

S-41A MBE & AEPF with Single Speed

Heat Pumps................................................. 47

S-60 Electric Heater (optional item)....................... 4 9

S-61A Checking Heater Limit Control(S).................. 50

S-61B Checking Heater Fuse Line........................... 50

S-62 Checking Heater Elements ........................... 5 0

S-100 Refrigeration Repair Practice......................... 50

S-101 Leak Testing .................................................5 1

S-102 Evacuation ....................................................51

S-103 Charging........................................................ 52

S-104 Checking Compressor Efficiency .................. 53

S-105A Piston Kit Chart ............................................ 53

S-105B Thermostatic Expansion Valve...................... 53

S-106 Overfeeding ...................................................54

S-107 Underfeeding ................................................. 54

S-108 Superheat ..................................................... 54

S-109 Checking Subcooling .................................... 55

S-110 Checking Expansion Valve Operation ........... 55

S-111 Fixed Orifice Restriction Devices .................. 56

S-112 Checking Restricted Liquid Line.................... 56

S-113 Refrigerant Overcharge .................................. 56

S-114 Non-condensables ........................................ 56

S-115 Compressor Burnout .....................................56

S-120 Refrigerant Piping.......................................... 57

S-122 Replacing Reversing Valve ............................ 59

S-202 Duct Static Pressure

& Static Pressure Drop Across Coils ............ 59

S-203 Air Handler External Static ........................... 5 9

S-204 Coil Static Pressure Drop ............................. 60

HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. F AILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEA T H.

SERVICING

S-1 CHECKING VOLTAGE

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

With power ON:

WARNING

Line Voltage now present.

S-2 CHECKING WIRING

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

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

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

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

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

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

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

REMOTE CONDENSING UNITS

BLOWER COILS

VOLTAGE MIN. MAX.

208/230 198 253

115 104 127

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

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

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

S-3 CHECKING THERMOSTAT, WIRING, AND

ANTICIPATOR

THERMO ST AT WIRE SIZ ING CHA RT

LENGTH OF RUN

25 fe et 18 50 fe et 16

75 fe et 14 100 fe et 14 125 fe et 12 150 fe et 12

M IN. COPPER WI RE

GAUGE (AWG)

S-3A THERMOSTAT AND WIRING

WARNING

Line Voltage now present.

With power ON, thermostat calling for cooling

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

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

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

Indoor Blower Motor

With power ON:

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

WARNING

Line Voltage now present.

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

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

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

SERVICING

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

Resistance Heaters

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

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

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

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

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

S-3B COOLING ANTICIPATOR

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

S-3D TROUBLESHOOTING ENCODED TWO STAGE COOLING THERMOSTATS OPTIONS

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

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

S-3C HEATING ANTICIPATOR

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

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

Troubleshooting Encoded Two Stage Cooling Thermostats Options

T E S T

TEST FUNCTION SIGNAL OUT SIGNAL FAN

INDICATION

INPUT FROM

THERMOSTAT

POWER

THERMOSTAT

S1 +

* S1 - *

S1 + -

S2 +

S2 -

S2 + -

S3 +

* S3 - *

* S3 + - *

R + -

COM

NOTES:

1.) THE TEST SPADE CAN BE CONNECTED TO ANY OTHER TEST SPADE ON EITHER BOARD.

2.) THE + LED WILL BE RED AND WILL LIGHT TO INDICATE + HALF CYCLES. THE - LED WILL BE GREEN AND WILL LIGHT TO INDICATE - HALF CYCLES. BOTH RED AND GREEN ILLUMINATED WILL INDICATE FULL CYCLES DENOTED BY + - .

3.) SIGNAL OUT CONDITION FOR W1 , W2 HEATER WILL BE AFFECTED BY OT1 PJ4 AND OT2 PJ2 JUMPERS AND OUTDOOR THERMOSTATS ATTACHED. THE TABLE ABOVE ASSUMES OT1 PJ4 IS REMOVED AND OT2 PJ2 IS MADE WITH NO OUTDOOR THERMOSTATS ATTACHED.

LOW SPEED COOL

* LO SPEED COOL *

HI SPEED COOL

LO SPEED HEAT

HI SPEED HEAT

G N/A N/A

24 VAC

GND

YCON +

* YCON - *

YCON + -

W1 HEATER

ED -

( FUTURE USE )

W1 HEATER W2 HEATER

NONE

N/A N/A

R TO T'STAT

COM TO T'STAT

* Y / Y2 HI *

Y / Y2

W / W1

EM / W2

G N/A N/A

C1 , C2

* ERROR CONDITION ( DIODE ON THERMOSTAT BA CKWARDS )

SEE NOTE 3

* ERROR CONDITION ( S3 CAN ONLY READ + ) * ERROR CONDITION ( S3 CAN ONLY READ + )

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

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

SERVICING

S-4 CHECKING TRANSFORMER

AND CONTROL CIRCUIT

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

With power ON:

WARNING

Line Voltage now present.

1. Apply 24 VAC to terminals R1 and R2.

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

3. Remove 24 VAC at terminals R1 and R2.

4. Should read 0 VAC at Y1 and Y2.

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

If not as above - replace relay.

WARNING

Disconnect ALL power before servicing.

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

With power ON:

WARNING

Line Voltage now present.

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

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

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

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

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

S-5 CHECKING CYCLE PROTECTOR

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

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

S-6 CHECKING TIME DELAY RELAY

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

WARNING

Disconnect ALL power before servicing.

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

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

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

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

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

OHMMETER

1. Remove wire from Y1 terminal.

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

TESTING COIL CIRCUIT

SERVICING

S-7 CHECKING CONTACTOR AND/OR RELAYS

WARNING

HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property dama ge, p ersonal injur y or death.

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

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

1. Remove the leads from the holding coil.

2. Using an ohmmeter, test across the coil terminals. If the coil does not test continuous, replace the relay or

contactor.

S-8 CHECKING CONTACTOR CONTACTS

VOLT/OHM

METER

Ohmmeter for testing holding coil Voltmete r f o r te st in g con ta cts

TESTING COMPRESSOR CONTACTOR

S-9 CHECKING FAN RELAY CONTACTS

L1L2

WARNING

DISCONNECT ELECTRICAL POWER SUPPLY.

Disconnect Electrical Power Supply:

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

2. With power ON, energize the contactor.

WARNING

Line Voltage now present.

3. Using a voltmeter, test across terminals. A. L2 - T1 - No voltage indicates CC1 contacts open.

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

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

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

3. With power ON, energize the relays.

WARNING

Line Voltage now present.

OHMMETER

TESTING FAN RELAY

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

5. If not as above, replace the relay.

SERVICING

S-10 COPELAND COMFORT ALERT™ DIAGNOSTICS

Applies to ASC13 & ASH13

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

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

following page.)

SERVICING

DIAGNOSTICS TABLE

Status LED Status LED Description Status LED Troubleshooting Information Green “POWER” Module has power Red “TRIP”

Yellow “ALERT” Long Run Time

Flash Code 1

Yellow “ALERT” System Pressure Trip

Flash Code 2

Yellow “ALERT” Short Cycling

Flash Code 3

Yellow “ALERT” Locked Rotor

Flash Code 4

Yellow “ALERT” Open Circuit

Flash Code 5

Yellow “ALERT” Open Start Circuit

Flash Code 6

Yellow “ALERT” Open Run Circuit

Flash Code 7

Yellow “ALERT” Welded Contactor

Flash Code 8

Yellow “ALERT” Low Voltage

Flash Code 9

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

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

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

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

Thermostat demand signal 1. Compressor protector is open Y1 is present, but the 2. O u tdoor unit power disconn ect is open compressor is not 3. Compressor circuit breaker or fuse(s) is open running 4. Broken wire or connector is not making contact

Compressor is 2. Evaporator blower is not running running ext remely 3. Evaporator coil is frozen long run cycles 4. Faulty metering device

Discharge or suction 2. Condenser co il poor air circulation (dirty, blocked, damaged) pressure out of limits or 3. Co ndenser fan is not running compressor overloaded 4. Return air duct has substantial leakage

Compressor is running 2. Time delay relay or control board defective only briefly 3. If high pressure switch present go to Flash Code 2 information

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

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

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

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

Supply voltage is present at module terminals

5. Low pressure switch open if present in system

6. Compressor contactor has failed open

1. Low refrigerant charge

5. Condenser coil is dirty

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

7. Thermostat is malfunc tioning

1. High head pressure

5. If low pressure switch present in system, check Flash Code 1 information

1. Thermostat demand sign al is intermittent

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

1. Run capaci tor has failed

2. Low line voltage ( c ontact utility if voltage at disc onnect is low)

3. Excessive liquid refrigerant in compressor

4. Compre ssor bearings are seized

1. Outdoor unit power disconnect is open

2. Compre ssor circuit breaker or fuse(s) is open

3. Compressor contactor has failed open

4. High press ure switch is open and requires manual reset

5. Open circ uit in compressor supply wiring or connections

6. Unusually long compressor protector reset time due to extreme ambient temperature

7. Compressor windings are damaged

1. Run capaci tor has failed

3. Compressor start win ding is damaged

1. Open circuit in compressor run wiring or connections

1. Compressor contactor has failed closed

1. Control circuit transformer is overloaded

SERVICING

S-11 CHECKING LOSS OF CHARGE PROTECTOR

(Heat Pump Models)

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

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

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

S-15 CHECKING CAPACITOR

CAPACITOR, RUN

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

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

CAPACITOR, START SCROLL COMPRESSOR MODELS

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

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

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

RELAY, START

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

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

brand or Copeland should be used.

START

CAPACITO R

VIOLET 20

YELLOW 12

RUN

CAPACITOR

RED 10

START RELAY

ORANGE 5

T2 T1

L1L2

CONTACTOR

HARD START KIT WIRING

S-15A RESISTANCE CHECK

1. Discharge capacitor and remove wire leads.

WARNING

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

OHMMETER

CAPACITOR

TESTING CAPACITOR RESISTANCE

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

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

SERVICING

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

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

S-15B CAPACITANCE CHECK

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

VOLTMETER

15 AMP

FUSE

AMMETER

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

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

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

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

S-16B CHECKING FAN AND BLOWER MOTOR

(ECM MOTORS)

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

CAPACITOR

TESTING CAPACITANCE

WARNING

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

Capacitance (MFD) = 2650 X Amperage

Voltage

S-16A CHECKING FAN AND BLOWER MOTOR

WINDINGS (PSC MOTORS)

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

WARNING

Line Voltage now present.

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

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

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

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

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

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

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

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

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

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

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

SERVICING

1 2 3 4

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

}

applications only

Gnd AC Line Connection

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

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

OUT - OUT +

DJUST +/-

Y1 Y/Y2

COOL

DELAY

COMMON2

W/W1

COMMON1 O (REV VALVE)

AC Line Connection

816

G (FAN)

EM Ht/W2

24 Vac (R)

HEAT

BK/PWM (SPEED)

16-PIN ECM HARNESS CONNECTOR

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

S-16C CHECKING ECM MOTOR WINDINGS

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

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

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

3-pin m otor connector

16-pin connector

5-pin connector

S-16D ECM CFM ADJUSTMENTS

MBE MOTOR

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

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

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

• Improved Efficiency

• Constant CFM

• Soft Start and Stop

• Improved Humidity Control

MOTOR SPEED ADJUSTMENT

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

SERVICING

(

)

ity)

Check

for

undercharged

condition

Check

and

plug

leaks

return

ducts

cabinet

different

Troubleshooting Chart for ECM Variable Speed Air Circulator Blower Motors

have completel

- Turn power OFF prior to repa ir .

Wait 5 minutes after

disconnecting power before

opening motor.

- Turn power OFF prior to repa ir .

Wait 5 minutes after

disconnecting power before

opening motor.

- Handle electronic motor/control with care.

- Check 230 Vac power at motor.

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

- Check low voltage co nnections

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

- Check for unseated pins in connectors

on motor harness .

- Test with a temporary jumper between R - G.

- Check for loos e motor mount.

- Handle electronic motor/control with care.

- Make sure blower wheel is tight on shaft.

- Perform mot or/control replacement chec k,

ECM motors only.

- Turn power OFF prior to repa ir .

- Check line voltage for variation or "sag".

- Check low voltage co nnections

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

motor, unseated pins in motor

harness connect ors.

- Check-out system controls - Thermostat.

- Perform Moisture Check.*

- Turn power OFF prior to repa ir .

- Does removing panel or filter

reduce "puffing"?

- Check/replace filter.

- Check/correct duct restrictions.

- Adjust to correct blower speed setting.

capac

look alike, different modules ma

, en a

h the

oo muc ow

modes. Even thou

ow a or

e harnesses with "dr i p loop" under motor.

resu e

uce unexpec

rammed for specific operatin

pro

.- Arran

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

es an

are factor

warran

CHART CONTINUED ON NEXT PAGE

uc pro

s a

- Manual disconnect switch off or

- Incorrect or dirty filter(s).

- Incorrect s upply or return ductwork.

- Variation in 230 Vac to motor.

- Unseated pins in wiring harness

connectors.

- Erratic CFM command from

"BK" terminal.

- Improper thermostat connection or set ting.

- Loose motor mount.

- Blower wheel not tight on motor shaft.

door switch open.

- Blown fuse or ci rcuit breaker.

- 24 Vac wires miswired.

- Unseated pins in wiring

harness connectors.

- Bad motor/control module.

- Moisture present in motor or control module.

- Bad motor/control module.

- Moisture present in motor/control module.

- Incorrect blower speed setting.

equipment manufacturer

e vo u

mo ro

con or

. -

or as recommended b

- "Hunts" or "puf fs" at

- It is normal for motor to

oscillate with

- Motor rocks,

- This is normal start-up for

variable speed mo tor.

- No movement.

but won't start.

no load on shaft.

- Varies up and down

or intermittent.

high CFM (speed).

u n p

ra e

ensa

Symptom Fault Description(s) Possible Causes Corrective Action Cautions and No tes

s con

*Moisture Check

- Motor

oscillates up &

down while

being tested

- Motor rocks

slightly

when starting.

- Motor won't

start.

off of blower.

- Motor starts,

but runs

erratically.

- Connectors a re oriented "down"

e wron n

e: o

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

mpor

functionality. The ECM variable speed motors are c

Note:

SERVICING

(

)

ity)

Check

for

undercharged

condition

Check

and

plug

leaks

return

ducts

cabinet

different

- Turn power OFF prior to repair.

Wait 5 minutes after

disconnecting power bef ore

opening motor.

- Handle electronic motor/control

with care.

- Turn power OFF prior to repair.

Wait 5 minutes after

disconnecting power bef ore

opening motor.

- Handle electronic motor/control

with care.

- Turn power OFF prior to repair.

- Check low voltage (Thermostat)

wires and connections .

- Verify fan is not in delay mode -

wait until delay com plete.

- Perform mot or /control replacement

check, ECM motors only.

- Is fan in delay m ode? - wait until delay time complete.

- Perform mot or /control replacement check , ECM

motors only.

- Check for Triac switched t'stat

or solid state rel ay .

- Check/replace filter.

CHART CONTINUED FROM PREVIOUS PAGE

- 24 Vac wires mis wir ed or loose.

- "R" missing/not connected at motor.

Troubleshooting Chart for ECM Variable Speed Air Circulator Blower Motors

- Fan in delay mode.

- Stays at low CFM despit e

system call for cool

or heat CFM.

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

- "R" missing/not connected at motor.

- Fan in delay mode.

- Stays at high CF M.

- Motor starts,

but runs

erratically.

- Current leakage from controls

into G, Y, or W.

- High static creating high blower speed.

- Incorrect s upply or return ductwork.

- Blower won't shut off.

have completel

- Turn power OFF prior to repair.

- Check/correct duct restrictions.

- Adjust to corr ec t blower speed setting.

- Check for loose b lower ho us ing,

- Turn power OFF prior to repair.

panels, etc.

- Check for air whist ling thru seams in

ducts, cabi nets or panels.

- Check for cabine t/duct deformation.

- Turn power OFF prior to repair.

- Does removing panel or filter

reduce "puffing"?

- Check/replace filter.

- Turn power OFF prior to repair.

Wait 5 minutes after

disconnecting power bef ore

opening motor.

- Handle electronic motor/control

with care.

capac

look alike, different modules ma

, en a

h the

oo muc ow

modes. Even thou

ow a or

e harnesses with "drip loop" under motor.

- Check/correct duct restrictions.

- Adjust to corr ec t blower speed setting.

- Replace motor and per form

Moisture Check.*

resu e

uce unexpec

rammed for specific operatin

pro

.- Arran

es an

are factor

warran uc

pro s a

- Incorrect or dirty filter(s).

- Incorrect blower speed setting.

- Loose blower housing, panels, etc.

- High static c reating high blower

speed.

- Air leaks in ductwork, cabinets,

or panels.

- High static creating high blower speed.

- Incorrect or dirty filter(s).

- Incorrect s upply or return ductwork.

- Incorrect blower speed setting.

- Moisture in mo tor/control module.

equipment manufacturer

e vo u

mo ro

con or

. -

or as recommended b

- Air noise.

- Noisy blower or cabinet.

- "Hunts" or "puffs" at

high CFM (speed).

- Motor failure or

malfunction has

occurred and moisture

is present.

u n p

ra e

ensa

s con

*Moisture Check

- Evidence of

- Excessive

noise.

Moisture.

- Connectors are oriented "down"

e wron n

e: o

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

mpor

functionality. The ECM variable speed motors are c

Note:

SERVICING

DIPSWITCH FUNCTIONS

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

Dipswitch Number Function

1 2 3 4 5 6 7 8

Table 1

CFM DELIVERY

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

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

Electric Heat Operation

Model Switch 1 Swi tch 2 CFM

OFF OFF 1,200

MBE1200

OFF

OFF OFF 1,600

MBE1600

OFF

MBE2000

OFF ON 1,600

T able 2

Elec tric H ea t

N/A

Indoor Thermostat

Cooling & Heat Pump CFM

CFM Trim Adjust

OFF

ON ON

OFF

ON OFF OFF

1,000

800 600

1,400 1,200 1,000 2,000 1,800

1,200

Dipswitch 1/2 & 7/8 AEPF 1830

Heating

Element

(kw)

UP TO 10 OFF OFF OFF OFF 1100 1210 UP TO 10 ON OFF OFF OFF 890 935

5 OFF ON OFF OFF 700 770

AEPF3036 / 31 37 / 4260

Heating

Element

(kw)

UP TO 20 OFF OFF OFF OFF 2050 2150 UP TO 20 ON OFF OFF OFF 1 7 5 0 1 8 35 UP TO 1 5 OFF ON OFF OFF 160 0 1680 UP TO 10 ON ON OFF OFF 1200 1260 UP TO 10 ON ON OF F ON 1020 1 070

Switch

Position

1278

Switch

Position

1278

Switch

Position

Switch

Position

Emergency

Backup

Emergency

Backup

T able 3

Dipswitch 5/6 & 7/8 AEPF 1830

Switch

Position

5 6 7 8 Cooling Heat Pum p

OFF OFF OFF OFF 1100 1100

ON OFF OFF OFF 800 800

OFF ON OFF OFF 600 600

AEPF3036 / 3137 / 4260

Switch

Position

5 6 7 8 Cooling Heat Pum p

OFF OFF OFF OFF 1800 1800

ON OFF OFF OFF 1580 1580

OFF ON OFF OFF 1480 1480

ON ON OFF OFF 1200 1200 ON ON OFF ON 1020 1020

Swi tch

Position

Swi tch

Position

Indoor Airflow

Table 3A

Hea t Pump

Wit h Backup

Hea t Pump

Wit h Backup

Cooling/Heat Pump Operation

Model Switch 5 Switch 6 CFM

OFF OFF 1,200

MBE1200

OFF

ON ON

OFF OFF 1,600

MBE1600

MBE2000

OFF

OFF ON 1,200

OFF

ON OFF OFF

Table 2A

1,000

800 600

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

1,000

THERMOSTA T “FAN ONL Y” MODE

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

CFM TRIM ADJUST

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

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

CFM Switch 7 Switch 8

+10% ON OFF

-1 5 % O F F O N

Table 4

SERVICING

HUMIDITY CONTROL

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

TWO STAGE HEA TING

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

S-16E CHECKING GE X13TM MOTORS

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

S-17 CHECKING COMPRESSOR

WARNING

Hermetic compressor electrical terminal venting can be dangerous. When insulatin g material which supports a hermetic compressor or electrical terminal suddenly disintegr ates due to physical abuse o r as a result of an electrical short between the term inal and the compressor housing, the terminal m ay be expelled, venting th e vapor and liquid conten ts of the compressor housing and system.

Note: The GE TECMate will not currently operate the GE

X13

motor.

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

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

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

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

High Voltage Connections

3/16"

123

LGN

Low Voltage Connections

1/4”

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

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

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

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

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

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

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

S-17A RESISTANCE TEST

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

and winding temperature. High motor temperature or amperage heats the disc causing it to open, breaking the common circuit within the compressor on single phase units.

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

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

GE X13TM MOTOR CONNECTIONS

SERVICING

1. Remove the leads from the compressor terminals.

See warnings S-17 before removing compressor terminal cover.

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

HI-POT

COMPRESSOR GROUND TEST

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

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

WARNING

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

OHMMETER

TESTING COMPRESSOR WINDINGS

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

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

COMP

S-17B GROUND TEST

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

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

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

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

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

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

5. If ground is indicated, replace the compressor.

S-17D OPERATION TEST

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

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

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

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

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

4. With power ON, close the switch.

WARNING

Line Voltage now present.

SERVICING

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

for failure is somewhere else in the system.

B.If the compressor fails to start - replace.

COPELAND COMPRESSOR

03 A 12345 L

EAR

S-18 TESTING CRANKCASE HEATER

(OPTIONAL ITEM)

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

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

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

Disconnect ALL power before servicing.

1. Disconnect the heater lead in wires.

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

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

S-21 CHECKING REVERSING VALVE

AND SOLENOID

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

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

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

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

MONTH

WARNING

SERIAL

NUMBER

PLANT

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

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

S-24 TESTING DEFROST CONTROL

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

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

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

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

4. Immediately remove jumper from test pins.

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

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

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

8. If not as above, replace control board.

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

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

S-25 TESTING DEFROST THERMOSTAT

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

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

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

4. If not as above, replace control.

SERVICING

S-40 AR*F & MBR ELECTRONIC BLOWERS

TIME DELAY RELAY

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

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

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

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

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

SEQUENCE OF OPERATION

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

AR*F & MBR

WITH SINGLE STAGE CONDENSERS

1.0 Cooling Operation

1.1 On a demand for cooling, the room thermostat energizes

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

1.2 The compressor and condenser fan are turned on and after a 7 second on delay, the relay on the EBTDR board is energized and the blower motor starts.

1.3 When the cooling demand “Y” is satisfied, the room thermostat removes the 24Vac from “G” and “Y”.

1.4 The compressor and condenser fan are turned off and after a 65 second delay off, the relay on the EBTDR board is deenergized and the blower is turned off.

2.0 Heating Operation

2.1 On a demand for heat, the room thermostat energizes

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

2.2 The contacts M1 and M2 will close within 10 to 20 seconds and turn on heater element #1. The normally closed contacts on the EBTDR are also connected to terminal M1. When M1 and M2 close, the blower motor will be energized thru the normally closed contacts on the EBTDR board. At the same time, if the heater assembly contains a second heater element, HR1 will contain a second set of contacts, M3 and M4, which will close to turn on heater element #2.

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

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

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

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

AR*F & MBR

WITH SINGLE STAGE HEAT PUMPS

3.0 Cooling Operation

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

3.1 On a demand for cooling, the room thermostat energizes “G” and “Y” and 24Vac is supplied to “Y” at the heat pump and the “G” terminal on the EBTDR board.

3.2 The heat pump turned on in the cooling mode and after a 7 second on delay, the relay on the EBTDR board is energized and the blower motor starts.

3.3 When the cooling demand is satisfied, the room thermostat removes the 24Vac from “G” and “Y”.

3.4 The heat pump is turned off and after a 65 second delay off, the relay on the EBTDR board is de-energized and the blower motor is turned off.

SERVICING

4.0 Heating Operation

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

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

4.2 If the first stage heat demand cannot be satisfied by the heat pump, the temperature indoors will continue to drop. The room thermostat will then energize terminal “W2’ for second stage heat and 24Vac will be supplied to heat sequencer HR1 on the heater assembly.

4.3 HR1 contacts M1 and M2 will close will close within 10 to 20 seconds and turn on heater element #1. At the same time, if the heater assembly contains a second heater element, HR1 will contain a second set of contacts, M3 and M4, which will close and turn on heater element #2. The blower motor is already on as a result of terminal “G” on the EBTDR board being energized for the first stage heat demand.

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

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

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

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

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

5.0 Defrost Operation

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

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

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

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

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

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

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

DENSERS

AEP* & MBE ELECTRONIC BLOWER TIME DELAY RELA Y

SEQUENCE OF OPERATION

This document covers the basic sequence of operation for a typical application with a mercury bulb thermostat. When a digital/electronic thermostat is used, the on/off staging of the auxiliary heat will vary. Refer to the installation instructions and wiring diagrams provided with the MBE for specific wiring connections, dip switch settings and system configuration.

SERVICING

AEP* & MBE WITH SINGLE STAGE CONDENSERS

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

1.0 Cooling Operation

1.1 On a demand for cooling, the room thermostat energizes

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

1.2 When the cooling demand is satisfied, the room thermostat removes the 24Vac from “G” and “Y”. The MBEand AEP* remove the 24Vac from “Y’ at the condenser and the compressor and condenser fan are turned off. The blower motor will ramp down to a complete stop based on the time and rate programmed in the motor.

2.0 Heating Operation

2.1 On a demand for heat, the room thermostat energizes

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

2.2 HR1 contacts M1 and M2 will close within 10 to 20 seconds and turn on heater element #1. At the same time, if the heater assembly contains a second heater element, HR1 will contain a second set of contacts, M3 and M4, which will close and turn on heater element #2.

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

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

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

blower motor on low speed on a “W1” only demand. If the first stage heat demand, “W1” cannot be satisfied by the heat pump, the temperature indoors will continue to drop.

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

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

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

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

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

PUMPS

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

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

3.0 Cooling Operation

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

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

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

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

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

SERVICING

rate programmed in the motor.

4.0 Heating Operation

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

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

4.2 If the first stage heat demand cannot be satisfied by the heat pump, the temperature indoors will continue to drop. The room thermostat will then energize terminal “W2” for second stage heat and 24Vac will be supplied to “E/W1” of the MBE. The VSTB will supply 24Vac to heat sequencer, HR1, on the electric heater assembly.

4.3 HR1 contacts M1 and M2 will close within 10 to 20 seconds and turn on heater element #1. At the same time, if the heater assembly contains a second heater element, HR1 will contain a second set of contacts, M3 and M4, which will close to turn on heater element #2.

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

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

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

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

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

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

will still be present.

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

5.0 Defrost Operation

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

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

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

S-60 ELECTRIC HEATER (OPTIONAL ITEM)

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

The low voltage circuit in the air handler is factory wired and terminates at the location provided for the electric heater(s). A minimum of field wiring is required to complete the instal-

SERVICING

lation. Other components such as a Heating/Cooling Thermostat

and Outdoor Thermostats are available to complete the installation.

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

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

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

BTUH CAPACITY CORRECTION FACTOR

SUPPLY VOLTAGE 250 230 220 208

MULTIPLICATION FACTOR 1.08 .92 .84 .75

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

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

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

Actual CFM = 1800 x .84 Corr. Factor = 1400 CFM. NOTE: The temperature rise table is for sea level installa-

tions. The temperature rise at a particular KW and CFM will be greater at high altitudes, while the external static pressure at a particular CFM will be less.

TEMPERATURE RISE (F°) @ 240V

CFM

600 25 38 51 - - - 700 22 33 43 - - - 800 19 29 38 57 - - -

900 17 26 34 51 - - 1000 15 23 30 46 - - 1100 14 21 27 41 55 - 1200 13 19 25 38 50 - 1300 12 18 23 35 46 - 1400 11 16 22 32 43 54 65 1500 10 15 20 30 40 50 60 1600 9 14 19 28 38 47 57 1700 9 14 18 27 36 44 53 1800 8 13 17 25 34 42 50 1900 8 12 16 24 32 40 48 2000 8 12 15 23 30 38 45 2100 7 11 14 22 29 36 43 2200 7 11 14 21 27 34 41 2300 7 10 13 20 26 33 39

4.8

7.2KW9.6KW14.4KW19.2KW24.0KW28.8 KW

Table 5

ELECTRIC HEATER CAPACITY BTUH

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

BTUH 10200 16200 20400 23800 32400 48600 66500 71600

Table 6

FORMULAS:

Heating Output = KW x 3413 x Corr. Factor Actual CFM = CFM (from table) x Corr. Factor BTUH = KW x 3413 BTUH = CFM x 1.08 x Temperature Rise (T) CFM = KW x 3413

1.08 x T

T = BTUH CFM x 1.08

S-61A CHECKING HEATER LIMIT CONTROL(S)

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

SERVICING

1. Remove the wiring from the control terminals.

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

IF FOUND OPEN - REPLACE - DO NOT WIRE AROUND.

S-61B CHECKING HEATER FUSE LINK

(OPTIONAL ELECTRIC HEATERS)

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

WARNING

Disconnect ALL power before servicing.

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

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

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

S-62 CHECKING HEATER ELEMENTS

WARNING

Disconnect ALL power before servicing.

1. Disassemble and remove the heating element.

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

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

WARNING

Disconnect ALL power before servicing.

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

2. Plug or cap all openings.

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

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

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

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

BRAZING MATERIALS IMPORTANT NOTE: Torch heat required to braze tubes of

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

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

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

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

S-101 LEAK TESTING

(NITROGEN OR NITROGEN-TRACED)

WARNING

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

S-100 REFRIGERATION REPAIR PRACTICE

DANGER

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

When repairing the refrigeration system:

SERVICING

WARNING

R-22

MANIFOLD

To avoid possible explosion, the line from the nitrogen cylinder m ust include a pressure regulator and a pressure relief valve. The pressure relief valve

LOW SIDE

GAUGE

ND VALVE

HIGH SIDE

GAUGE

AND VALVE

must be set to open at no more than 150 psig.

800 PSI

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,

RATED HOSES

CHARGING

CYLINDER

AND SCALE

then apply the detector to suspect areas. If leaks are found, repair them. After repair, repeat the pressure test. If no leaks exist, proceed to system evacuation.

S-102 EVACUATION

{

TO UNIT SERVICE VALVE PORTS

VACUUM PUMP

ADAPTER

WARNING

REFRIGERA NT U NDER PR ESSUR E! Failure to follow proper procedures may cause property damage, pe rsonal injury or death.

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

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

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

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

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

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

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

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

WARNING

pump. Shut off pump and prepare to charge.

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

S-103 CHARGING

EVACUATION

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

2. Start the vacuum pump and open the shut off valve to the high vacuum gauge manifold only. After the compound gauge (low side) has dropped to approximately 29 inches of vacuum, open the valve to the vacuum thermocouple gauge. See that the vacuum pump will blank-off to a maximum of 25 microns. A high vacuum pump can only produce a good vacuum if its oil is non-contaminated.

WARNING

REFRIGERANT UNDE R PRESSURE! * Do not overcharge sy stem w ith refrigerant. * Do not operate unit in a vacuum or at negative pressure. Failure to follow proper procedures may cause property damage, personal injury or death.

SERVICING

CAUTION

Use refrige rant certified to AHRI standards. Used refrigerant may cause compressor damage and will void the warr an t y. Most portabl e machines cannot clean use d re f ri gerant to meet AHRI standards .

CAUTION

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

Charge the system with the exact amount of refrigerant. Refer to the specification section or check the unit name-

plates for the correct refrigerant charge.

An inaccurately charged system will cause future problems.

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

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

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

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

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

6. Check system for leaks.

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

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

SYSTEM SUPERHEAT

Ambient Condenser

Inlet Temp.

(°F Drybulb)

115 100

95 555 90 71218 85 5 101720 80 5 122126 75 5 10172529 70 5 14202832 65 13 19 26 32 35 60

Return Air Temperature

(°F Drybulb)

65 70 75 80 85

17 25 30 33 37

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

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

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

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

S-104 CHECKING COMPRESSOR EFFICIENCY

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

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

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

2. Start the system and run a "Cooling Performance Test. If the test shows: a. Below normal high side pressure. b. Above normal low side pressure. c. Low temperature difference across coil. d. Low amp draw at compressor. and the charge is correct. The compressor is faulty - replace

the compressor. NOTE: THIS TEST CANNOT BE DONE IN THE HEATING MODE

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

SERVICING

NOTE: The compressor may run backwards (noisy opera-

tion) for 1 or 2 seconds at shutdown. This is normal and does not harm the compressor.

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

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

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

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

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

S-105A PISTON KIT CHART FOR ASC13,

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

Air Conditioners

G/VSC130181A* .055 GSC130181B* .055

G/VSC130241A* GSC130241C* G/VSH130241A* .061

AC30, AC NF24 AWB24/AWUF24

# All other ARI Matches .061 G/VSH130301A* .068 G/VSC130301A* / D* GSH130301B* .070 GSC130303A* G/VSH130311A* .065

AC36, AC NF30

AWB 36, AWUF36

# All ot her ARI Matches G/VSC130361A* G/VSH130481A* .084 GSC130363A* / B*

AWB 36, AWUF36

# All ot her ARI Matches GSC130361B* / F* G/VSC130421A* .078 ASH130241A* .062 G/VSC130481A .082 GS C1 304 83A */ 4A * .0 82 G/VSC130601A* .093 ASH130421A* .082 GS C1 306 03A */ 4A * .0 93 ASC130181A* .055 ASC130241A* .061 GSH140361A* .076 ASC130301A* .065 GSH140421A* .078 ASC130361A* .071 GSH140481A* .088 ASC130421A* .078 ASC130481A* .082 ASC130601A* .093 GSC140181A* .053 GSC140241A* .061 GSC140301A* .067 GSC140361A* .074 GSC140421A* .078 GSC140481A* .084 GSC140601A* .096 GSC140181B* .055 GSC140241B* .062 GSC140301B* .067 GSC140361B* .073 GSC140421B* .080

Orifice

Size

.059

.059 .059

.065 .068 .065

.071 .071 .074

.071

Heat Pumps

G/VSH130181A* .052 GSH130181B* .055 G/VSH130191A* .052

GSH130241B* .061 G/VSH130251A* .061

G/VSH130361A* .073 GSH1303613A*/1B* .082 G/VSH130421A* .082

GSH1304813A*/ 4A* .084 G/VSH130601A* .093 GSH1306013A*/ 4A* .093 ASH130181A* .052

ASH130301A* .065 ASH130361A* .073

ASH130481A* .084 ASH130601A* .093

Orifice

Size

S-105B THERMOSTATIC EXPANSION VALVE

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

The illustration below shows typical heat pump TXV/check valve operation in the heating and cooling modes.

SERVICING

COOLING HEATING

THERMOSTATIC EXPANSION VALVES

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

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

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

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

THE VALVES PROVIDED BY GOODMAN ARE DESIGNED TO MEET THE SPECIFICATION REQUIREMENTS FOR OPTIMUM PRODUCT OPERATION. DO NOT USE SUB-

STITUTES.

S-106 OVERFEEDING

Overfeeding by the expansion valve results in high suction pressure, cold suction line, and possible liquid slugging of the compressor.

If these symptoms are observed:

1. Check for an overcharged unit by referring to the cooling performance charts in the servicing section.

2. Check the operation of the power element in the valve as explained in S-110 Checking Expansion Valve Operation.

3. Check for restricted or plugged equalizer tube.

S-107 UNDERFEEDING

Underfeeding by the expansion valve results in low system capacity and low suction pressures.

If these symptoms are observed:

1. Check for a restricted liquid line or drier. A restriction will be indicated by a temperature drop across the drier.

2. Check the operation of the power element of the valve as described in S-110 Checking Expansion Valve Operation.

S-108 SUPERHEAT

The expansion valves are factory adjusted to maintain 12 to 18 degrees superheat of the suction gas. Before checking the superheat or replacing the valve, perform all the procedures outlined under Air Flow, Refrigerant Charge, Expansion Valve - Overfeeding, Underfeeding. These are the most common causes for evaporator malfunction.

CHECKING SUPERHEAT

Refrigerant gas is considered superheated when its temperature is higher than the saturation temperature corresponding to its pressure. The degree of superheat equals the degrees of temperature increase above the saturation temperature at existing pressure. See Temperature - Pressure Chart Table

1. Attach an accurate thermometer or preferably a thermocouple type temperature tester to the suction line at a point at least 6" from the compressor.

2. Install a low side pressure gauge on the suction line service valve at the outdoor unit.

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

4. Convert the suction 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 superheat.

EXAMPLE:

a. Suction Pressure = 84 b. Corresponding Temp. °F. = 50 c. Thermometer on Suction Line = 63°F.

To obtain the degrees temperature of superheat subtract 50.0 from 63.0°F.

The difference is 13° Superheat. The 13° Superheat would fall in the ± range of allowable superheat.

SUPERHEAT ADJUSTMENT

The expansion valves used on Amana® brand coils are factory set and are not field adjustable. If the superheat setting becomes disturbed, replace the valve.

On systems using capillary tubes or flow control restrictors, superheat is adjusted in accordance with the "DESIRED SUPERHEAT vs. OUTDOOR TEMP" chart as explained in section S-103 CHARGING.

SERVICING

Temp.

°F.

-40

-38

-36

-34

-32

-30

-28

-26

-24

-22

-20

-18

-16

-14

-12

-10

-8

-6

-4

-2 0 2 4 6 8

10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54

56 58

Gauge Pressure (PSIG) Freon-22

0.61

1.42

2.27

3.15

4.07

5.02

6.01

7.03

8.09

9.18

10.31

11.48

12.61

13.94

15.24

16.59

17.99

19.44

20.94

22.49

24.09

25.73

27.44

29.21

31.04

32.93

34.88

36.89

38.96

41.09

43.28

45.53

47.85

50.24

52.70

55.23

57.83

60.51

63.27

66.11

69.02

71.99

75.04

78.18

81.40

84.70

88.10

91.5

95.1

98.8

Temp.

°F.

60 62 64 65 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96

96 100 102 104 106 108 110 112 114 116 118 120 122 124 126 128 130 132 134 136 136 140 142 144 146 158 150 152 154 156 158 160

Gauge Pressure (PSIG) Freon-22

102.5

106.3

110.2

114.2

118.3

122.5

126.8

131.2

135.7

140.5

145.0

149.5

154.7

159.8

164.9

170.1

175.4

180.9

186.5

192.1

197.9

203.8

209.9

216.0

222.3

228.7

235.2

241.9

248.7

255.6

262.6

269.7

276.9

284.1

291.4

298.8

306.3

314.0

321.9

329.9

338.0

346.3

355.0

364.3

374.1

384.3

392.3

401.3

411.3

421.8

433.3

S-109 CHECKING SUBCOOLING

Refrigerant liquid is considered subcooled when its temperature is lower than the saturation temperature corresponding to its pressure. The degree of subcooling equals the degrees of temperature decrease below the saturation temperature at the existing pressure.

1. Attach an accurate thermometer or preferably a thermocouple type temperature tester to the liquid line as it leaves the condensing unit.

2. Install a high side pressure gauge on the high side (liquid) service valve at the front of the unit.

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

4. 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.

EXAMPLE:

a. Liquid Line Pressure = 260 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. The normal subcooling

range is 9° - 13° subcooling for heat pumps units, 14 to 18 for straight cool units.

S-110 CHECKING EXPANSION VALVE

OPERATION

1. Remove the remote bulb of the expansion valve from the

suction line.

2. Start the system and cool the bulb in a container of ice

water, closing the valve. As you cool the bulb, the suction pressure should fall and the suction temperature will rise.

3. Next warm the bulb in your hand. As you warm the bulb,

the suction pressure should rise and the suction temperature will fall.

4. If a temperature or pressure change is noticed, the

expansion valve is operating. If no change is noticed, the valve is restricted, the power element is faulty, or the equalizer tube is plugged.

5. Capture the charge, replace the valve and drier, evacuate

and recharge.

SERVICING

S-111 CAPILLARY TUBES/RESTRICTOR ORIFICES

The capillary tubes/restrictor orifices used in conjunction with the indoor and outdoor coil, are a predetermined length and bore (I.D.).

They are designed to control the rate of liquid refrigerant flow into an evaporator coil.

The amount of refrigerant that flows through the capillary tube/ restrictor orifice 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 decrease, causing less refrigerant flow.

A strainer is placed on the entering side of the tubes to prevent any foreign material from becoming lodged inside the capillary tubes.

If a restriction should become evident, proceed as follows:

1. Capture the refrigerant charge.

2. Remove the capillary tubes/restrictor orifice or tube strainer assembly. and replace.

3. Replace liquid line drier, evacuate and recharge.

Discharge and suction pressures will be low, giving the appearance of an undercharged unit. However, the unit will have normal to high subcooling.

Locate the restriction, replace the restricted part, replace drier, evacuate and recharge.

S-113 OVERCHARGE OF REFRIGERANT

An overcharge of refrigerant is normally indicated by an excessively high head pressure.

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

An evaporator coil, using a capillary tube metering device, could allow refrigerant to return to the compressor under extreme overcharge conditions. Also with a capillary tube metering device, extreme cases of insufficient indoor air can cause icing of the indoor coil and liquid return to the compressor, but the head pressure would be lower.

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

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

If this system is observed:

1. Start the system.

2. Remove and capture small quantities of gas from the suction line dill valve until the head pressure is reduced to normal.

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

Capillary Tubes/Orifice Assembly

CHECKING EQUALIZATION TIME

During the "OFF" cycle, the high side pressure bleeds to the low side through the capillary tubes/restrictor orifices. 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 the capillary tubes/ restrictor orifices are 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.

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.

SERVICING

NOTICE

Violation of EPA regulations may result in fines or other penalties.

Now determine if a burn out has actually occurred. Confirm by analyzing an oil sample using a Sporlan Acid Test Kit, AK3 or its equivalent.

Remove the compressor and obtain an oil sample from the suction stub. If the oil is not acidic, either a burnout has not occurred or the burnout is so mild that a complete clean-up is not necessary.

If acid level is unacceptable, the system must be cleaned by using the clean-up drier method.

CAUTION

Do no t allow th e slud ge o r oil to co ntac t the skin . Severe bu rns may result.

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

longer approved by Goodman Company, L.P.

Suction Line Drier Clean-Up Method

Use AMANA® brand part number RF000127 suction line filter drier kit. This drier should be installed as close to the compressor suction fitting as possible. The filter must be accessible and be rechecked for a pressure drop after the system has operated for a time. It may be necessary to use new tubing and form as required.

NOTE: At least twelve (12) inches of the suction line immediately out of the compressor stub must be discarded due to burned residue and contaminates.

1. Remove compressor discharge line strainer.

2. Remove the liquid line drier and expansion valve. 3 Purge all remaining components with dry nitrogen or

carbon dioxide until clean.

4. Install new components including liquid line drier.

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

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

7. Continue to run the system for a minimum of twelve (12) hours and recheck the pressure drop across the drier. Pressure drop should not exceed 6 PSIG.

8. Continue to run the system for several days, repeatedly checking pressure drop across the suction line drier. If the pressure drop never exceeds the 6 PSIG, the drier has trapped the contaminants. Remove the suction line drier from the system.

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

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

S-120 REFRIGERANT PIPING

The piping of a refrigeration system is very important in relation to system capacity, proper oil return to compressor, pumping rate of compressor and cooling performance of the evaporator.

This long line set application guideline applies to all AHRI listed R22 air conditioner and heat pump split system matches of nominal capacity 18,000 to 60,000 Btuh. This guideline will cover installation requirements and additional accessories needed for split system installations where the line set exceeds 50 feet in actual length.

Additional Accessories:

1. Crankcase Heater- a long line set application can critically increase the charge level needed for a system. As a result, the system is very prone to refrigerant migration during its off-cycle and a crankcase heater will help minimize this risk. A crankcase heater is recommended for any long line application (50 watt minimum).

2. TXV Requirement: All line set applications over 50 ft will require a TXV.

3. Hard Start Assist- increased charge level in long line applications can require extra work from the compressor at start-up. A hard start assist device may be required to overcome this.

4. Liquid Line Solenoid - A long line set application can critically increase the charge level needed for a system. As a result, the system is very prone to refrigerant migration during its off-cycle and a liquid line solenoid will help minimize this. A liquid line solenoid is recommended for any long line application on straight cooling units.

Tube Sizing:

1. In long line applications, the “equivalent line length” is the sum of the straight length portions of the suction line plus losses (in equivalent length) from 45 and 90 degree bends. Select the proper suction tube size based on

equivalent length of the suction line (see Tables 9 &

10) and recalculated system capacity.

Equivalent length = Length horizontal + Length vertical +

Losses from bends (see Table 11)

2. For any residential split system installed with a long

line set, the liquid line size must never exceed 3/8".

Limiting the liquid line size to 3/8" is critical since an increased refrigerant charge level from having a larger liquid line could possibly shorten a compressor’s lifespan.

3. Single Stage Condensing Unit: The maximum length of tubing must not exceed 150 feet.

• 50 feet is the maximum recommended vertical differ-

ence between the condenser and evaporator when the evaporator is above the condenser. Equivalent length is not to exceed 150 feet.

• The vertical difference between the condenser and

evaporator when the evaporator is below the condenser can approach 150 feet, as long as the equivalent length does not exceed 150 feet.

SERVICING

• The distance between the condenser and evaporator in a completely horizontal installation in which the indoor and outdoor unit do not differ more than 10 feet in vertical distance from each other can approach 150 feet, as long as the equivalent length does not exceed 150 feet.

4. Two-Stage Condensing Unit: The maximum length of tubing must not exceed 75 feet here indoor coil is located above the outdoor unit.

NOTE: When the outdoor unit is located above the indoor coil, the maximum vertical rise must not exceed 25 feet. If the maximum vertical rise exceeds 25 feet, premature compressor failure will occur due to inadequate oil return.

5. Vibration and Noise: In long line applications, refrigerant tubing is highly prone to transmit noise and vibration to the structure it is fastened to. Use adequate vibration-isolating hardware when mounting line set to adjacent structure.

Most refrigerant tubing kits are supplied with 3/8"-thick insulation on the vapor line. For long line installations over 50 feet, especially if the line set passes through a high ambient temperature, ½”-thick suction line insulation is recommended to reduce loss of capacity. The liquid line should be insulated if passing through an area of 120°F or greater. Do not attach the liquid line to any non-insulated portion of the suction line.

Table 9 lists multiplier values to recalculate system-cooling capacity as a function of a system’s equivalent line length (as calculated from the suction line) and the selected suction tube size. Table 10 lists the equivalent length gained from adding bends to the suction line. Properly size the suction

line to minimize capacity loss.

REFRIGERANT LINE LENGTH (Ft)

Cond

Unit

Tons Suct Liq Suct Liq Suct Liq

1 1/2 5/8 1/4 3/4 3/8 3/4 3/8

2 5/81/43/43/83/43/8

2 1/2 3/4 3/8 3/4* 3/8 7/8 3/8

3 3/4 3/8 3/4** 3/8 7/8** 3/8

3 1/2 3/4 3/8 7/8** 3/8 1 1/8 3/8

4 7/8 3/8 1 1/8 3/8 1 1/8 3/8 5 7/8 3/8 1 1/8 3/8 1 1/8 3/8

0-24 25-49 50-74***

Line Diameter (In. OD)

Nominal

capacity

18,000 3/4 24,000 3/4 30,000 3/4

36,000

42,000

48,000

60,000

Btuh

Vapor line

diameter

(in.)

3/4 7/8 3/4 7/8

1-1/8

3/4 7/8

1-1/8

7/8

1-1/8

EQUIVALENT LINE LENGTH (FT)

.99 .97 .96 .95 .95

1 .99 .99 .98 .97 .98 .97 .96 .95 .94 .93 .90 .86 .83 .79 .98 .96 .94 .92 .90 .93 .90 .87 .83 .80 .97 .96 .94 .93 .92

1 1 .99 .99 .98 .90 .86 .82 .78 N/R .96 .94 .93 .91 .89

1 1 .99 .99 .98 .93 .91 .89 .86 .84 .99 .98 .98 .97 .97

100

125

150

Table 10

NOTE: For a condenser with a liquid valve tube connection less than 3/8" diameter, use 3/8" liquid line tubing for a line set greater than 25 feet.

TABLE 11. LOSSES FROM SUCTION LINE ELBOWS

(EQUIVALENT LENGTH, FT .)

Type of elbow fitting

90° short radius 1.7 2 2.3

90° long radius 1.5 1.7 1.6

45° 0.7 0.8 1

3/4 7/8 1-1/8

I.D. (in.)

Table 11

Installation Requirements

1. In a completely horizontal installation with a long line set where the evaporator is at the same altitude as (or slightly below) the condenser, the line set should be sloped towards the evaporator. This helps reduce refrigerant migration to the condenser during a system’s off-cycle.

2. For a system installation where the evaporator is above the condenser, an inverted vapor line trap should be installed on the suction line just before the inlet to the evaporator (see Fig 6). The top of the inverted loop must be slightly above the top of the evaporator coil and can be created simply by brazing two 90° long radius elbows together, if a bending tool is unavailable. Properly support and secure the inverted loop to the nearest point on the indoor unit or adjacent structure.

Table 9

*7/8" required for full ratings **1 1/8" required for full ratings ***Lines greater than 74 feet in length or vertical elevation changes more than 50 feet, refer to the long

line set.

T ABLE 10. CAPACITY MUL TIPLIERS AS A FUNCTION OF

SUCTION LINE SIZE & EQUIV ALENT LENGTH

Fig 6. Evaporator unit with inverted vapor loop

SERVICING

3. An oil trap is required at the evaporator only if the condenser is above the evaporator. Preformed oil

traps are available at most HVAC supply houses, or oil traps may be created by brazing tubing elbows together (see diagram below). Remember to add the equivalent length from oil traps to the equivalent length calculation of the suction line. For example, if you construct an oil trap using two 45° elbows, one short and one long 90° elbow in a ¾” diameter suction line, the additional equivalent length would be 0.7+ 0.7+1.7+1.5, which equals 4.6 feet (refer to table 9).

Oil Trap Co n str u c tion

Long Radius Street Ell

45 °

Ell

45°

Street

Ell

Short Radius

Street Ell

Follow the charging procedures in the outdoor unit I/O manual to ensure proper superheat and sub-cooling levels, especially on a system with a TXV installed in the indoor unit. Heat pumps should be checked in both heating and cooling mode for proper charge level. This guideline is meant to provide installation instructions based on most common long line set applications. Installation variables may affect system operation.

NO ADDITIONAL COMPRESSOR OIL IS NEEDED FOR

LONG LINE SET APPLICATIONS

ON RESIDENTIAL SPLIT SYSTEMS.

S-122 REVERSING VALVE REPLACEMENT

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

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

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

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

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

Fig 7. Oil Trap

4. Low voltage wiring. Verify low voltage wiring size is adequate for the length used since it will be increased in a long line application.

System Charging

R22 condensers are factory charged for 15 feet of line set. To calculate the amount of extra refrigerant (in ounces) needed for a line set over 15 feet, multiply the additional length of line set by 0.6 ounces. Note for the formula below, the linear feet of line set is the actual length of liquid line (or suction line, since both should be equal) used, not the equivalent length calculated for the suction line.

Extra refrigerant needed =

(Linear feet of line set – 15 ft) x X oz/ft.

Where X = 0.6 for 3/8" liquid tubing

Remember, for condensers with a liquid valve connection

less than 3/8" diameter, 3/8" liquid tubing is required for a

line set longer than 25 feet.

S-202 DUCT STATIC PRESSURES AND/OR

STATIC PRESSURE DROP ACROSS COILS

This minimum and maximum allowable duct static pressure for the indoor sections are found in the specifications section.

Tables are also provided for each coil, listing quantity of air (CFM) versus static pressure drop across the coil.

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

SERVICING

S-203 AIR HANDLER EXTERNAL STATIC

To determine proper air movement, proceed as follows:

1. Using a draft gauge (inclined manometer), measure the static pressure of the return duct at the inlet of the unit, (Negative Pressure).

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

3. Add the two readings together.

TOTAL EXTERNAL STATIC

NOTE: Both readings may be taken simultaneously and read

directly on the manometer if so desired.

4. Consult proper table for quantity of air.

If external static pressure is being measured on a furnace to determine airflow, supply static must be taken between the "A" coil and the furnace.

S-204 COIL STATIC PRESSURE DROP

1. Using a draft gauge (inclined manometer), connect the positive probe underneath the coil and the negative probe above the coil.

2. A direct reading can be taken of the static pressure drop across the coil.

3. Consult proper table for quantity of air.

STATIC PRESSURE DROP

If the total external static pressure and/or static pressure drop exceeds the maximum or minimum allowable statics, check for closed dampers, dirty filters, undersized or poorly laid out duct work.

TOTAL EXTERNAL STATIC

ACCESSORIES WIRING DIAGRAMS

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

ALL FUEL SYSTEM AFE18-60A CONTROL BOARD

POWER SUPPLY INPUT

FURNACE DEMAND OUTPUT

BLOW ER FAN DEMAN D OUTPUT

POWER SUPPLY INPUT (COMMON)

SECOND STAGE FURNACE DEMAND OUTPUT

COMPRESSOR OUTPUT

SECOND STAGE COMPRESSOR OUTPUT

REVERSING VALVE OUTPUT

POWER SUPPLY OUT TO THERMOSTAT

CALL FOR REVERSING VALVE

CALL FOR COMPRESSOR

CALL FOR EMERGENCY HEAT

CALL FOR BLOW ER FAN

CALL FOR FURN AC E HEAT

POWER SUPPLY COMMON OUT TO THERMOSTA T

CALL FOR 2ND STAGE FURN AC E HEAT

CALL FOR 2ND STAGE COMPRESSOR

POWER SUPPLY OUT TO HP CONTROL

HP CALL FOR FUR NACE (DURING DEFROST)

REVERSING VALVE OUTPUT

COMPRESSOR CONTACTOR OUTPUT

POWER SUPPLY COMMON OUT TO HP CONTROL

ODT (OUTDOOR THERMOSTAT)

2ND STAGE COMPRESSOR DEMAND OUTPUT

F U R N A C E

T H E R M O S T A T

H E A T

P U M P

R W1 G C W2 Y Y2 O

R O Y E G W1 C W2 Y2

R W2 O Y

C OT-NO OT-NC OT-C

P1-8

P1-7

P1-4

P1-6

P1-5

P1-2

P1-3

P1-1

P2-2

P2-1

P2-7

P2-8

P2-5

P2-9

P2-3

P2-4

P2-6

P3-9

P3-8

P3-7

P3-2

P3-6

P3-3

P3-1

P3-4

P3-5

24VAC

POWER SUPPLY

1.0K

6.8K

+5VDC

E/W1

+VDC +5VDC

+VDC

MICROPROCESSOR

24VAC

+VDC

W1-FURN W2-HP

G-STAT

G-FURN

Y2-HP

Y2-STAT Y2-FURN

Y-STAT Y-FURN

Y-HP

BREAK F OR O DT

1 2

ALL FUEL SYSTEM CONTROL BOARD - AFE18-60A

This wiring diagram is for reference only. Not all wiring is as shown above.

Refer to the appropriate wiring diagram for the unit being serviced.

(For use with Heat Pumps in conjunction with 80% or 90% Single-Stage or Two-Stage Furnaces)

ACCESSORIES WIRING DIAGRAMS

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

10kw and Below, One Stage Electric Heat

From Air Handler

CGW2 R

BLUE

WHITE

BROWN

BLACK

RED

HITE

EMERGENCY

HEAT

RELAY

THERMOSTAT

OT/EHR18-60

15kw and Above, Two Stage Electric Heat

BLUE

WHITE

BROWN

BLACK

RED

CRW2OY

ORANGE

WHI

From Outdoor Unit

From Air Handler

OWN

BLUE

GREEN

CGW2 R

Indoor Thermostat

SEE NOTE

RED

EMERGENCY

HEAT

RELAY

THERMOSTAT

OT/EHR18-60

CRW2OY

Note:

When us ing a Thermost at with only one stage for el ect ri c hea t (W2) , tie wh it e an d

From Outdoor Unit

brown wires from air handler together.

Typical Wiring Schematics for OT/EHR18-60 (Outdoor Thermostat & Emergency Heat Relay).

This wiring diagram is for reference only. Not all wiring is as shown above.

Refer to the appropriate wiring diagram for the unit being serviced.

HIT

LOW

Indoor Thermostat

ACCESSORIES WIRING DIAGRAMS

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

15kw and Above with Two OT/EHR18- 60 ' s, Two Stage Electric H eat and Two Stage Therm ostat

From Air Handler

OT/EHR18-60 #1

BLUE

WHITE

BROWN

BLACK RED

EEN

HITE

BLUE

CGW2 R

BROWN

W2 W3

EMERGENC Y

HEAT

RELAY

THERMOSTAT

OT/EHR18-60 #2

EMERGENC Y

HEAT

RELAY

THERMOSTAT

BLUE

WHITE

BROWN

BLACK RED

CRW2OY

WHITE

ORANGE

LOW

From Outdoor Unit

Indoor Thermostat

Typical Wiring Schematics for OT/EHR18-60 (Outdoor Thermostat & Emergency Heat Relay).

This wiring diagram is for reference only. Not all wiring is as shown above.

Refer to the appropriate wiring diagram for the unit being serviced.

ACCESSORIES WIRING DIAGRAMS

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

L2L1 L1 L2

208/240 VOLTS

SEE NOTE 1

HTR1

HTR2

HTR3

HTR4

M1 M2

M5 M6

PLM

PLF

EBTDR

COM

PLM

PLF

TLHTR2

HTR1 TL

M1M2M3

L2L1

EQUIPMENT GROUND

USE COPPER OR ALUMINUM WIRE

GRD

4 5 678 9

4 5WH67489

SEE

NOTE

L2 L 1 L2

HTR1

HTR2

HTR3

PLM

PLF

HTR1

L1 L2

ONE (1) ELEMENT ROWS TWO (2) ELEMENT ROWS THREE (3) ELEMENT ROWS FOUR (4) ELEMENT ROWS

NOTE: WHEN INSTALLING HEATER KIT, ENSURE SPEED TAP DOES NOT EXCEED MINIMUM BLOWER SPEED (MBS) SPECIFIED FOR THE AIRHANDLER/HEAT ER

KIT COMBINATION ON THIS UNIT'S S&R PLA TE. AFTER INSTALLING OPTIONAL HEAT KIT, MARK AN "X" IN THE PROVIDED ABOVE. MARK ACCORDING TO NUMBER OF HEATER ELEMENT ROWS INSTALLED. NO MARK INDICATES NO HEAT KIT INSTALLED.

TERMINAL BLOCK SHOW N

FOR 50HZ MO DELS ONLY

RD GR

SEE

NOTE

XFMR-R

XFMR-C

SPEEDUP

COPPER OR ALUMINUM

POWER SUPPLY

(SEE RATING PLATE )

USE MIN. 75°C FIELD WIRE

THREE SPEED MOTOR WIRING

(SE LE C T M ODEL S ONLY)

IF REP L AC E M ENT O F THE OR IGINAL WIRE S SUPPLIED WITH THIS ASSEMBLY IS NECESSARY, USE WIRE THAT CONFORMS TO THE NATIONAL ELECTRIC CODE.

EBTDR

SEE NOTE 3

SEE NOTE 5

COM

SEE

NOTE

R G

(M1) RD LOW

(M2)

MEDIUM

(COM) BK

(TR 1)

HIGH

3 SPEED

1 2

24V

SEE NOTE 1

240

COLOR CODE

BLACK

RED YELLOW

BLYLBLUE

COMPONENT CODE

EVAPORATOR MOTOR

RUN CAPACITOR

STRAI N RELIEF

RRELAY

ELECTRONIC BLOWER TIME

EBTDR

Notes:

1) Red wires to be on transformer terminal "3" for 240 volts and on terminal "2" for 208 volts.

2) See c omposite wiring diagrams in installation instructions for proper low voltage wiring connections.

3) Confirm speed tap selected is appropriate for appl ication. If speed tap needs

to be changed, connect appropriate motor wire (Red for low, Blue for medium, and Black for high speed) on "COM" connection of the EBTDR. Inactive motor wires should be connected to "M1 or M2" on EBTDR.

4) Brow n and white wires are used with Heat Kits only.

EBTDR has a 7 second on delay when "G" is energized and a 65 second off delay when "G" is de-energized.

DELAY RELAY

EBTDR

24V

WH6BR

GREEN

PURPLE

BROWN WHITEWH

PLF

WIRING CODE

FACT ORY WIRING HIGH VOLTAGE LOW VOLTAGE

FIELD WIRI NG HIGH VOLTAGE LOW VOLTAGE

TRANSFORMER FEMALE PLUG CONNECTOR

PLF

MALE PLUG CONNECTOR

PLM

FL FUSE LINK

THERMAL LIMIT

HTR HEAT ELEMENTS

EBTDR

NOTE 2

0140M00037

Typical Wiring Schematic ADPF, ARPF, ARUF with Electric Heat.

This wiring diagram is for reference only. Not all wiring is as shown above.

Refer to the appropriate wiring diagram for the unit being serviced.

ACCESSORIES WIRING DIAGRAMS

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

HTR2

FL HTR3

FL HTR4 TL

RS2

208/240

24V

EBTDR

XFMR-R XFMR-C

COM

SPEEDUP

L1 L2

EQUIPMENT GROUND

USE COPPER OR ALUMINUM WIRE

BRSRPK

Typical Wiring Schematic MBR Blower with Electric Heat.

This wiring diagram is for reference only. Not all wiring is as shown above.

Refer to the appropriate wiring diagram for the unit being serviced.

ACCESSORIES WIRING DIAGRAMS

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

PJ4

HTR2

HTR3

HTR4

L2L1 L1 L2

TO LOW VOLTAGE TERMINAL BOARD

PL2

YCON

IN4005

DIODE

Y1YY2

SEE NOTE 1

F A CT O R Y WI R I NG HIGH VOL T AG E LOW VOLTAGE FIELD W IRIN G HIGH VOL T AG E LOW VOLTAGE

THERM AL LIMIT

HEAT ELEMENT

HTR

RELAY

TLHTR1

BL BK

NOTE DIODE ON VSTB

M5 M6

SEE

NOTE 4

*SEE N OTE 7

IRING CODE

M7 M8

PL1

1PL2

PL2

01 40A0 0000 P

HTR1

L1 L 2

ONE (1) ELEMEN T RO WS TWO (2) ELEMENT ROWS THREE (3) ELEMENT ROWS FOUR (4) EL EMEN T ROWS

AFTER INSTALLING OPTIO N AL HEAT KIT, MARK AN "X" IN THE PROVIDED ABOVE.

* SEE NOTE 7

LOW VOLTAGE

FIELD CON NEC TION

BOX

PN. B1368270 REV. A

R YCON

HUM

PJ6

DS1

COPPER

POWER SUPPLY

(SEE RATING PLATE)

CONTROLS SHOWN WITH UTILITIES IN "ON" POSITION AND THERMOSTAT IN "OFF" POSITION. IF REPLACEMENT OF THE ORIGINAL W IRES SUPPLIED WITH THIS ASSEMBLY IS NECESSARY, USE 105°C . WIRE. SIZE TO CONFORM TO THE NATIONA L ELECTRIC CODE.

CONDE NSER

OT2

OT1

COM W 2OED

HEATPUMP

PJ2

PJ4

HEATER

24 VAC

J3J2

CONDENSER

W/W2

OTC OT1 COT2OE\W1

OUTDO OR

THERMOST

R Y1 G

Y/Y2

HUMIDISTAT

HUM

YCON R

R PU

THERMOSTAT

W2 R

EQUIPMENT GROUND

HTR2

HTR1

M1M2M3

L2L1

MARK ACCORDING TO NUMBER OF HEATER ELEMENT ROWS INSTALLED

NO MARK INDICATES NO HEAT KIT INSTALLED

L2 L1 L2

HTR1

HTR2

HTR3

Y1C

Y/Y2

PUW

RYG

USE COPPER WIRE

1R23

PL1

PL2

SEE NOTE 8

4567 89

312

456789

240

208

COM

24V

OTES:

1. FOR HEAT PUMP APPLICATIONS REMOV E ORANGE JUMPER WIRE BETWEEN O & Y1.

2. FOR TWO STAGE ELECTRIC HEAT APPLICATIONS CUT PJ4. (USE ONLY ON 15 & 20 KW MODELS).

3. FOR OUTDOOR THERMOSTAT OPERATION OF SECOND STAGE HEAT, CUT PJ2 & ADD OT18-60 TO OTC & OT2.

4. FOR SINGLE STAGE COOLING APPLICATIONS CONNECT THERMOSTAT TO Y/Y2 ONL Y, TAPE OR REMOVE Y1 CONNECTI ON. CONNECT CONDENSING UNIT TO YCON & C.

5. W HEN HUMIDSTAT IS PROVIDED CUT PJ6. THERMOSTAT OPENS ON HUMIDITY RISE.

6. RED WIRES TO BE ON TRANSFORMER TERMINAL 3 FOR 240 VOLTS AND ON TER MINAL 2 FOR 208 VOLTS.

7. SEE COMPOSITE WIRING D IA GRAMS IN INS TALLATION INSTRUCTIONS FOR PROPER LOW VOLTAGE

CONNECTIONS AND DETAILS ON COMPATIBLE THERMOSTATS AND THEIR CONNECTIONS.

8. DISCARD ORIGINAL "PL1" PLUG CONNECTOR WHEN INSTALLING OPTIONAL HEAT KIT.

SEE NOTE 5

PJ6

HUM

SEE NOTE 3

PL1 PL2

5 PL2

PJ2

2OT1

PJ2,PJ4,PJ6

W WHITE R

Y BL

EM PL

FL FUSE LINK

2 2

24 VOL T

SEE NOTE 2

COLOR COD E

BLACKBK RED YELLOW BLUE

EVAPORATOR MOTOR PLUG PROGRAM JUMPER

GREENG

PU PURPLE

BROWNBR ORANGE

PINK

COMP

VARIABLE SPEED TRANSFORMERVSTB TR

TERMINAL BOARD

208/240 VOL TS

W2W E

ONENT CODE

Typical Wiring Schematic AEPF with Electric Heat.

This wiring diagram is for reference only. Not all wiring is as shown above.

Refer to the appropriate wiring diagram for the unit being serviced.

ACCESSORIES WIRING DIAGRAMS

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

L2L1

24V

240

PN. B1368270 REV. A

TLHTR2

HTR1 TL

HKR Heat Kit

8 9

4 5

PL 1

Y/Y2

Y1C

THERMOSTAT

YCON

CONDENSER

456789

312

PL2

208

CONDENSER

YCON

OT1 OT2

HUM

W/W2

COMW2O

COM

HEATPUMP

OTC OT1 COT2OE\W1

OUTDOOR

THERMOSTATS

PJ4 PJ2 PJ6

HEATER

HUMIDISTAT

24 VAC

RY1

HUM

Y/Y2

J3J2

DS1

VSTB

Blower Section

Typical Wiring Schematic MBE Blower with Electric Heat.

This wiring diagram is for reference only.

Not all wiring is as shown above.

Refer to the appropriate wiring diagram for the unit being serviced.

ACCESSORIES WIRING DIAGRAMS

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

HTR1

L1 L2

ONE (1) E LEMENT ROWS TWO (2) ELEMENT ROWS THREE (3) ELEMENT ROWS FOUR (4) ELEMENT ROWS

NOTE: WH EN INSTALLI NG HEATE R KI T, ENSU R E SPEED TAP D OES NOT EXCEED MINIMUM BLOWER SPEED (MBS) SPECIFIED FOR THE AIRHANDLER/HEAT ER

XFMR-R

COM

EBTDR

XFMR-C

COPPER OR ALUMINUM

POWER SUPPLY

(SEE RA T ING PLATE )

USE MIN. 75°C F IELD WIRE

IF REPLACEMENT OF THE ORIGINAL W IRES SUPPLIED WITH THIS ASSEMBLY IS NECESSARY , USE WIRE THAT CONFORMS TO THE NATIONAL ELECTRIC CODE .

NO NC

TLHTR2

PLM

SEE NOTE 3

PLF

HTR1 TL

L2L1

KIT C OMBINATION ON THIS UNIT'S S&R PLATE. AFTER INSTALLING OPTION AL HEAT KIT , MARK AN "X" IN THE PROVIDED ABOVE. MARK ACCORDING T O NUMBER OF HEA T E R ELEMENT ROWS INSTALLED. NO MARK INDICATES NO HEA T KIT INSTALLED.

TERMINAL BLOCK SHOWN

SEE NOTE 2

RCG W1W2 Y2Y1 O

FOR 50HZ MODELS ONLY

BR WH

41 32 5DH

A B

M1M2M3

GRD

1 2 3

EQUIPMENT GROUND

USE COPPER OR ALUMINUM WIRE

4 5 678 9

4 5WH6789

24V

SEE NO TE 1

240

SEE NOTE 4

21 43 5

NC GL

HTR1

HTR2

HTR3

L2 L1 L2

M1 M2

208/240 VOLTS

PLM

PLF

C LGN

SEE NOTE 1

24V

PLF

W2R W1C G 4Y1 OY2 1DH 32 5

COLOR C O DE

GREEN

BLACK

RED

YELLOW

BLYLBLUE

COM PONENT CODE

EVAPORATOR MOTOR

TER MINA L BO ARD

RELAY

CR CONTROL RELAY

EBTDR

ELECTRONI C BLOWER TIME DELAY RELAY

Notes:

1) Red wires to b e on transformer terminal "3" for 240 volts and on terminal " 2" for 208 v olts.

2) See composite wiring diagrams in installati on instructions for proper l ow voltage wiring connections.

3) Confirm speed tap selected is a ppropriate for application . If speed tap needs to be changed, co nnect red wire from termi nal 4 of CR relay t o appropriate tap at TB

4) Brown and white wires are used with Heat Kits only.

PURPLE BROWN WHITEWH

FACTO RY WIRING HIGH VOL TAGE LOW VOL TAGE

FIELD WIRI NG HIGH VOL TAGE LOW VOL TAGE

PLF

PLM

FL FUSE LINK

TL THERMAL LIMIT

HTR HEAT ELEMENTS

PLM

PLF

WIRING CODE

TRANSFORMER FEMALE PLUG CONNECTOR MALE PL UG CONNECTOR

L2L1 L1 L2

7 4

HTR1

HTR2

HTR3

HTR4

XFMR-R

XFMR-C

COM

EBTDR

NO NC

1 2

3 4

0140A00034

Typical Wiring Schematic ASPF****16A* with Electric Heat.

This wiring diagram is for reference only. Not all wiring is as shown above.

Refer to the appropriate wiring diagram for the unit being serviced.

ACCESSORIES WIRING DIAGRAMS

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

Typical Wiring Schematic ASPF****16B* with Electric Heat.

This wiring diagram is for reference only. Not all wiring is as shown above.

Refer to the appropriate wiring diagram for the unit being serviced.

Goodman Mfg RT6100004R13 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual