Goodmans ASX, SSX, DSZ, GSZ, DSX User Manual

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Service Instructions

SSX, ASX, GSX, DSX Condensing Units,

SSZ, ASZ, GSZ DSZ Split System Heat Pumps

with R-410A 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.

RS6200006r11

April 2009

IMPORTANT INFORMATION

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

PRODUCT IDENTIFICATION .....................................4 - 11

ACCESSORIES......................................................13 - 23

PRODUCT DESIGN ................................................25 - 27

SYSTEM OPERATION ...........................................28 - 32

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

BEGINNING REPAIRS.

IMPORTANT NOTICES FOR CONSUMERS AND SERVICERS

RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS

WARNING

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

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

TROUBLESHOOTING CHART .......................................33

SERVICE TABLE OF CONTENTS.................................34

SERVICING ............................................................35 - 72

ACCESSORIES WIRING DIAGRAMS ....................73 - 80

GOODM A N.

WARNING

O PREVENT THE RISK OF PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH, DO NOT STORE COMBUSTIBLE MATER IALS OR USE GASOLINE OR OTHER FLAMMABLE LIQUIDS OR VAPORS IN THE VICINITY OF THIS APPL IANCE.

WARNING

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

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

MAY RESU LT.

ANY JURISDICTIONS REQU IRE A LICENSE TO INSTALL OR SERV ICE HEATING AND AIR CONDITIONING EQUIPMENT.

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

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.)

Outside the U.S., call 1-713-861-2500.

(Not a technical assistance line for dealers.)

Your telephone company will bill you for the call.

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

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 1-931-433-6101.

(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

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

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

EVER PURGE REFRIGERANT INTO AN ENCLOSED ROOM OR SPACE. BY

•

LAW, ALL REFRIGERANTS MUST BE RECLAIMED.

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

• BEFORE BEGINNING WORK.

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

•

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

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

LWAYS FOLLOW

• AS POIS ONOUS GA S WILL BE PRODUC ED.

F LIQUID REFRIGERANT DOES CONTACT YOUR

EPA

REGULATIONS. NEVER BURN REFRIGERANT,

O AVO ID

WARNING

HE UNITED STATES ENVIRONME NTAL PROTECTION AGENCY ( "

HAS ISSUED VARIOUS REGULATIONS REGARDING THE INTRODUCTION AN D DISPOSA L OF REFRI GERANTS INTRODUC ED INTO T HIS UNIT . FOLLOW T HESE REGU LATIONS MAY HARM TH E ENVIRON MENT AND CAN LEAD TO THE H IMPOSI TION O F SUBSTAN TIAL FIN ES. MAY VARY BY JURISDICTION.

EPA OFFICE.

LOCAL

SHOULD QUEST IONS ARI SE, CO NTACT YOUR

THESE REGULATIONS

EPA

AILURE TO

WARNING

TO AVOID POSSIBLE EXPLOSION:

EVER APPL Y FLAME O R STEA M TO A REFR IGERAN T CYLINDE R. IF YOU

•

MUST HEA T A CYLIND ER FOR FAS TER CHARG ING, PARTI ALLY IMME RSE IT IN WARM WATER.

NEVER FILL A CYLINDER MORE THAN 80% FULL OF LIQUID REFRIG ERANT.

•

NEVER ADD ANYTHING OTHER T HAN R-22 TO AN R-22 CYLINDER OR

•

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

BE LISTED OR CERTIFIED FOR THE TYPE OF REFRIGERANT USED.

TORE CYLIN DERS IN A COOL, DRY PL ACE. NEVER US E A CYLIND ER

•

AS A PLATFORM OR A ROLLER.

WARNING

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

SERVICE CYLINDERS WHEN REMOVING REFRIGERANT FROM A SYSTEM.

•

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

LEAK OR EX PLOS ION.

•

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

•

ENSURE THE PRESSURE RATING MEETS OR EXCEEDS 400 LBS.

WHEN IN DOUBT, DO NOT USE CYLINDER.

WARNING

SYSTEM CONTAMINANTS, IMPROPER SERVICE PROCEDURE AND/OR PHYSICAL

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

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

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

O AVOID POSSIBLE INJURY, EX PLOSION OR DEATH, PRACTICE SAFE

HANDLING OF RE FRIGERANTS.

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 Heat Pum ps R410A

Model # De sc r ipti on

oodman Spli t Z R4 10A Heat Pump 13 Seer R410A heat pum p u nits . Initial

GSZ1 3**1AA

GSZ1 3**1AB

SSZ140**1AA

SSZ140**1AB

SSZ140**1AC

releas e with Reg al Beloit motor .

oodman Spli t Z R4 10A Heat Pump 13 Seer R410A heat pum p u nits . Initial

releas e with Br oad Ocean mo tor.

pecial High Featu re Split Z R410A heat pump 14 S eer heat pum p units. I nitial

releas e of Goodman 14 S E E R Heat Pump R410A .

pecial High Featu re Split Z R4 1 0A he at pu mp 14 See r h ea t pu m p uni t s.

Intr oduc es new revis ions have scr ew locations mov ed i n the t op panel, bas e pans , louver s , and c ontr ol box covers.

pecial High Featu re Split Z R410A heat pump 14 Seer heat pump units. Models

contain B r oad Ocean motors .

SSZ140181AC

SSZ 140241AF

SSZ140301AD

SSZ 140361AF

SSZ140421AD

SSZ140[48-60]1AE

SSZ160**1AA

SSZ160**1AB

SSZ160[24-48]1AC

SSZ160601AD

SSZ160**1AC

DSZ160**1AA

pecial High Featu re Split Z R4 1 0A he at pu mp 14 See r h ea t pu m p uni t s.

Introduces new revisions adding mufflers to the discharge line.

pecial High Featu re Split revisions replace TXV & compensator with flowrator & accum ulator; adds mufflers on SSZ14036` , 421, 481, 601.

pecial High Featu re Split Z R410A heat pump 16 S eer heat pum p units. I nitial

releas e of Goodman 16 S E E R Heat Pump R410A .

pecial High Featu re Split Z R4 1 0A he at pu mp 16 See r h ea t pu m p uni t s.

Intr oduc es new revis ions have scr ew locations mov ed i n the t op panel, bas e pans , louver s , and c ontr ol box covers.

pecial High Featu re Split Z R4 1 0A he at pu mp 16 See r h ea t pu m p uni t s.

Introduces new revisions adding mufflers to the discharge line.

pecial High Featu re Split Z R4 1 0A he at pu mp 16 See r h ea t pu m p units.Int roduc es mo dels contain i ng the B road Ocean mo tor and added Mu ffler and standar dized TXV, Compensator us ing the ASZ18 Se er weldment to the SSZ160601AC.

eluxe Split Z He at Pump 16 S eer heat pump units . I ntr oduces Goodm an 2-stage

16 SEER heat pumps with R-410A.

R 410A heat pump 14 S eer heat pump

units . New

PRODUCT IDENTIFICATION

Split System Heat Pumps R410A

Mod e l # D e scr i p t ion

mana® Brand Split Z R410A he at pump 13 Seer heat pump uni ts . I n itial rel eas e

ASZ130**1AA

ASZ140**1AA

ASZ140**1AB

ASZ140**1AC

ASZ140181AD

ASZ140[24-36]1AE

ASZ14[42-48]1AD

ASZ140601AE

ASZ160**1AA

ASZ160**1AB

of Aman a® B r and 13 S E E R Heat Pum p R410A .

mana® Brand Split Z R410A he at pump 14 Seer heat pump uni ts . I n itial rel eas e

of Aman a® B r and 14 S E E R Heat Pum p R410A .

mana® Brand Split Z R410A heat pu mp 14 Seer heat pump units. Introdu ces new revisions hav e s c r ew locations mo v ed in the to p panel, bas e pans, louver s , and con trol box covers.

mana® Brand Split Z R410A he at pump 14 Seer heat pum p u nits. New rev ision s have hor izontal sty le louv ers .

mana® Brand Split Z R410A he at pump 14 Seer heat pump uni ts . Adds ne w st eel

muff ler, and su c tion tubes w/sh oc k loop .

mana® Brand Split Z R410A he at pump 16 Seer heat pump uni ts . I n itial rel eas e of Aman a® B r and 16 S E E R Heat Pum p R410A .

mana® Brand Split Z R410A heat pu mp 16 Seer heat pump units. Introdu ces new revisions hav e s c r ew locations mo v ed in the to p panel, bas e pans, louver s , and con trol box covers.

ASZ160**1AC

ASZ160**1AD

ASZ160241AD

ASZ160[36-60]AE

ASZ180**1AB

mana® Brand Split Z R410A he at pump 16 Seer heat pum p u nits. New rev ision s

have hor izontal sty le louv ers .

mana® Brand Split Z R410A he at pump 16 Seer heat pum p u nits. New rev ision s

add ed Muffl er and s tanda r diz ed TXV, Compensator using t he A S Z18 Seer wel dm ent.

mana® Brand Split Z R410A he at pump 16 Seer heat pump uni ts . Adds ne w st eel muff ler, and su c tion tubes w/sh oc k loop .

mana® Brand Split Z R410A he at pump 18 Seer heat pump uni ts . I n itial rel eas e of Aman a® B r and 18 S E E R Heat Pum p R410A .

PRODUCT IDENTIFICATION

Split System Air Conditioners R410A

M ode l # Des c ri pt io n

GSX 130**1AA

oodman Split

SEER R-410A Condensers with Regal Beloit motors

Con de ns er 13 S eer condens ing units . Introduction of G o odm a n 13

GSX 130**1AB

GSX 130**1BA

SSX140**1AA

SSX140**1AB

SSX14018,241AC

SSX140301AC

SSX14036-601AC

SSX14030,361AD

SSX140421AD

oodman Spli

SEER R-410A Condensers with Broad Ocean mot ors.

oodman Split SEER R-410A Condensers, using Quant um Leap coils. Units will have new louver s becaus e units ar e s ma ller. Pisto n si z e c hange. Other comp o nen t s unc h ang ed.

pecial High Feature Split

Good m an 14 S E E R A C 410A.

pecial High Feature Split

scre w locations mov ed in the top panel, base pans, louvers, an d contr ol box covers.

pecial High Feature Split

coils by removing [1] haripin.

pecial High Feature Split

Broad Ocean motor 0131M00060

pecial High Feature Split

Broad Ocean motor 0131M00061

pecial High Feature Split

coils by removing [1] haripin.

pecial High Feature Split

SSX140421A in 29" base pan

Co ndenser 13 Se er c ondensi ng uni t s . I ntr oduction of Goodma n 13

t X

Con de ns er 13 S eer condens ing units . Introduction of G o odm a n 13

Condens er 14 Seer condensing unit s . Initial release of

on denser 14 Seer condensi ng units. Revi si ons ha ve

Condenser 1 4 Seer condens ing units . Revised condense r

Con d enser 14 Seer condens ing units. Mo del c ontain the

Condenser 1 4 Seer condens ing units . Revised condense r

Condens er 14 S eer condensing unit s. I ntroduces

SSX140421BA

SSX14030-421AE

SSX140[18-36]1BA

SSX140421CA

SSX160**1AA

SSX160**1AB

DSX160**1AA

pecial High Feature Split

SSZ140421B * in 29 b as e pan and it will the re duce the unit c har ge from 1 80 oz. to 170 oz. and replace the 1/ 4 h p outdo or unit motor with 1/ 6 h p mot or.

pecial High Feature Split

coils by removing [1] haripin.

pecial High Feature Split

Good m an 14 S E ER R-410A Condensers , u s ing Quantum Le ap Coils .

pecial High Feature Split

16 SEER AC 410A

pecial High Feature Split

scre w locations mov ed in the top panel, base pans, louvers, an d contr ol box covers.

pecial High Feature Split

scre w locations mov ed in the top panel, base pans, louvers, an d contr ol box covers.

eluxe Split X Condenser 16 Seer condensing units. Introduces Goodman 2-stage, 16

SEER condensi ng units with R-410A.

Condens er 14 S eer condensing unit s. Revision for

Condenser 1 4 Seer condens ing units . Revised condense r

Condenser 1 4 S eer condens i ng units . Int roducti o n of

Condens er 16 S eer condensing unit s. I ntroduces Goodman

Con d ens er 16 S eer condens ing units . New re v is ions hav e

PRODUCT IDENTIFICATION

Split System Air Conditioners R410A

M ode l # Des c ri ption

ASX130* *1AA

ASX130* *1BA

ASX140* *1AA

ASX140* *1AB

ASX140**1AC

ASX14018-361AD

ASX140421AD

ASX1404 21BA

Aman a® Brand

of Aman a® Brand Deluxe 13 SEER AC R410A conditioners.

Aman a® Brand

Brand 13 SEER R-410A Condensers, using Quantum Leap Coils. Units will have new louvers since unit s are small er. Piston size change; other components unch anged.

Aman a® Brand

of Aman a® Brand Deluxe 14 SEER AC R410A conditioners.

Aman a® Brand

scre w locations moved in the top pa nel, bas e pans, louv ers , and c ontr ol box c ov ers.

Aman a® Brand

horizontal style louvers.

Aman a® Brand

by re mov ing (1) hair pin.Reduce R410A quantity by 6 ounc es

Aman a® Brand

in 29 " bas e pan

Aman a® Brand

in 29" platfor m. It will t he reduce the unit charge from 180 o z . to 170 oz . and replace the 1/4 hp ou td oor unit mo to r wit h 1/6 hp motor.

plit X Co ndenser 13 Se er co ndens ing unit s . Ini ti al r ele ase new models

plit X Co ndenser 13 Se er co ndens ing unit s . Intr oduction of Am ana®

plit X Co ndenser 14 Se er co ndens ing unit s . Ini ti al r ele ase new models

plit X Co ndenser 14 Seer co ndens in g unit s . New r ev is ions hav e

plit X Co ndenser 14 Seer co ndens in g units . The new r ev is ions hav e

plit X Co ndenser 14 Se er co ndens ing unit s . Rev ised cond ens er coils

plit X Co ndenser 14 Se er co ndens ing unit s . Intr oduces AS X 140421A

plit X Co ndenser 14 Se er co ndens ing unit s . Rev ision for A SX 1 40421

ASX140[18-36]1BA

ASX140421CA

ASX160* *1AB

ASX160**1AC

ASX180* *1AB

Aman a® Brand

Brand 14 SEER R-410A Condensers, using Quantum Leap Coils.

Aman a® Brand

scre w locations moved in the top pa nel, bas e pans, louv ers , and c ontr ol box c ov ers.

Aman a® Brand

horizontal style louvers.

Aman a® Brand

of Aman a® Brand Deluxe 16 SEER AC R410A conditioners.

plit X Co ndenser 14 Se er co ndens ing unit s . Intr oduction of Am ana®

plit X Co ndenser 16 Seer co ndens in g unit s . New r ev is ions hav e

plit X Co ndenser 16 Seer co ndens in g units . The new r ev is ions hav e

plit X Co ndenser 18 Se er co ndens ing unit s . Ini ti al r ele ase new models

PRODUCT IDENTIFICATION

Single Piece Air Handlers

Model # Description

Single Piece R Multi-Position PSC Motor Unpainted Flowrater Introducation

ARUF****16AA

ARUF364216AB

ARUF486016AB

ARUF364216AC

ARUF****16BA

ARUF****1BA

of new 13 SEER Air Handler Models. All Models will be suitable for use with R22 and R-410A

Single Piece R Multi-Position PSC Motor Unpainted Flowrater.Revision replaces the current spot welded blower housing with the same cinched or crimped design used on the 80% furnace line.

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

replaces all ARUFcoils using wavy fin with louver enhanced fin.

Single Piece R Multi-Position PSC Motor Unpainted Flowrater Introducation

of R-22 Only Air Handlers.

ARPF****16AA

ARPF364216AB

ARPF486016AB

ARPF****16BA

ARPF****1BA

ADPF****16AA

ADPF364216AB

ADPF486016AB

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

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

Single Piece R Multi-Position PSC Motor Painted Flowrater. Revision replaces the current spot welded blower housing with the same cinched or crimped design used on the 80% furnace line.

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

replaces all ARPFcoils using wavy fin with louver enhanced fin.

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

R-22 Only Air Handlers.

Single Piece Downflow PSC Motor Unpainted Flowrater. Introducation of

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

Single Piece Downflow PSC Motor Unpainted Flowrater. Revision replaces the current spot welded blower housing with the same cinched or crimped design used on the 80% furnace line.

Single Piece Downflow PSC Motor Unpainted Flowrater. Revision replaces

ADPF304216AC

ADPF****1BA

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

Single Piece Downflow PSC Motor Unpainted Flowrater Revision replaces

all ARPFcoils using wavy fin with louver enhanced fin.

PRODUCT IDENTIFICATION

S ing le Pie ce Air Ha n dl ers

Mode l # De s cription

Single Piece E Multi- P os ition Var iable- S pe ed Painted Flowrator. Introducation of

AEPF****16AA

AEPF****16BA

AEPF****16BB

AEPF****16CA

AEPF****1BA

new 13 S EER A ir Han dler Models . A ll M odels will b e s uitable for use with R- 22 and R-410A

Single Piece E Multi- P os ition Var iable- S pe ed Painted Flowrator. Revision

introduc es new m odels adding l ower kw hit kits on the S& R plate

Single Piece E Multi- P os ition Var iable- S pe ed Painted Flowrator. Revision

replaces t he c ur rent spot welded blower housin g w ith the sam e cinc h ed o r crimped design use d on the 80% furnace l ine.

Single Piece E Multi- P os ition Var iable- S pe ed Painted Flowrator. Revision

replaces all A R P Fc oils us i ng wavy fin with louver enha nced fin.

Single Piece E Multi- P os ition Var iable- S pe ed 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 Multi- P os ition Var iable- S pe ed Painted Flowrator Sin gle Piece S Mult i -Position EEM mo tor Painted Flowrator 3-Ton Air H andler u nits with 3-row co i l.

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

ASPF Air Handlers

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

modi fied AS P F control sc hem e, t o ensure blower operation during and aft er ca ll for hea t on units with heat k its and replac ing wavy fin with louv er enhanc ed fi n on c oil

Single Piece Air Handler Wal l Mount Unpainted Flo wrator. In troduc es 13 SEER

Dayton w all moun t air handlers

Single Piece Air Handler Wal l Mount Unpainted Flo wrator. In troduc es 13 SEER

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

Single Piece Air Handler Wal l Mount Unpainted Flo wrator. In troduc es 13 SEER

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

Single Piece Air Handler Wal l Mount Unpainted Flowr ator . Revis i on replaces

cur r ent w avey fin design with new louv e r ed fin desi g n

Single Piece Air Handler Wal l Mount Unpainted Flowrator. Introduction of

AWUF37 Air Handler s for us e with R-22 and R410A .

and

AWUF****16BA

ACNF****1AA

ACNF****16AA

ACNF****1BA

AH**-1*

Single Piece Air Handler Ceiling Mount N Un ca s ed Flow rater. Revis ion has

louv er fins & re places c opper tube ha ir pins with aluminum hairpins .

Single Piece Air Handler Ceiling Mount N Un ca s ed Flow rater. Revis ion release

all mo de ls o f 13 SEE R Day ton u nc a s ed air handlers.

Single Piece Air Handler Ceiling Mount N Un ca s ed Flow rater. Revis ion release

all mo dels of 13 SEE R Day ton u nc a s ed air handlers.All Models will be suitable fo r use wit h R- 22 and R-410A

Single Piece Air Handler Ceiling Mount N Un ca s ed Flow rater. Revis ion re plac es

cur r ent w avey fin design with new louv e r ed fin desi g n

Single Piece Air Handler Hydronic Air Handler. Revis ion replaces the time delay r e lay in the AH a ir ha ndl er s w it h t he UTE C t ime del ay co ntr ol bo ar d.

PRODUCT IDENTIFICATION

MBR/MBE Air Handler s

Mo del # Descripti on

odular Blower R Mul ti-Position PSC Motor. Intro duce s module blower w ith PSC

MBR****AA-1AA

MBE****AA-1AA

MBE****AA-1BA

Mo del # Descripti on

CAUF*****6AA

CAUF*****6BA

bl ow er mo tor .

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

variable speed blower m otor.

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

adding l ower kw hit ki ts on the S &R plate

Evaporator Coils

Ind oor Coil A Upfl ow/Downflow Uncased Flo wr ator . Introduce s 13 S E ER CAUF

Dayton Upflow/Downflow coils.

Ind oor Coil A Upfl ow/Downflow Uncased Flo wr ator . Rev ision releases Bur r Oak

Lou ver ed Fin in place of the Wavy Fin curr ently in p roduction.

CAPF*****6AA

CAPF*****6BA

CAPF/CAUF36***CA

CHPF*****6AA

CHPF*****6BA

CHPF2430B6CA CHPF3636B6CA

CHPF3642[ C-D]6CA

CHPF3743C6BA CHPF3743D6CA

CSCF*****6AA

Ind oor Coil A Upfl ow/Downflow Painted Flowra tor . Introduces 13 S E ER CAPF

Dayton Upflow/Downflow coils.

Ind oor Coil A Upfl ow/Downflow Painted Flowr ator. Revis ion re leases B ur r Oak

Lou ver ed Fin in place of the Wavy Fin curr ently in p roduction.

Ind oor Coil A Upfl ow/Downflow [Painted or Uncased] Flow rator. Re vision

redesign s for perf or m anc e im pr o vement from 2 r ow to 3 row.

Ind oor Coil Horizontal A Coil Painted Flowrator. Release 13 SEER CHPF

hori zontal A coil.

Ind oor Coil Horizontal A Coil Painted Flowrator. Release 13 SEER CHPF horizontal A coil. Revision releases Burr Oak Louvered Fin in place of the Wa vy Fin c urrently in product i on . The r ows change by one, (i.e. 4 row to 3 ro w; 3 r o w to 2 row) where applicab le.

Ind oor Coil Horizontal A Coil Painted Fl owrator . 13 SEE R CHPF horiz ontal A coil, r evis ion has louv er f i ns & re places co pper tube hair pi ns with a l uminum hairpins.

Ind oor Coil S Horizontal Slab Coil C Upainted Flowrator. Rele ase 13 SEER CSCF sla b h or izontal coil.

CSCF*****6BA

Ind oor Coil S Horizontal Slab Coil C Upainted Flowrator. Revision releases Burr Oak Louver ed Fin in p l ac e o f the Wavy F in curr ently in pr oduct ion. The r ows chan ge by one, ( i. e. 4 row t o 3 row; 3 r ow to 2 row ) whe r e app licable.

PRODUCT IDENTIFICATION

SSZ14361AA

BRAND:

G: Go odman

(Standa rd

Fe ature Set)

S: Goodman®

(High Fe ature Set)

: Amana® Brand Deluxe D: Deluxe Go odman®

PRODUCT FAMILY:

S: Split System

SEER:

SEER Rating

NO MINAL CAP ACITY:

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 R EVISIO N:

: Init ial Release

MAJOR REVISI ON:

: Initial Release

PRODUC T TYPE:

X: Cond ens er R-4 10A Z: Heat P ump R- 410A

ELECTRICAL:

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

PRODUCT IDENTIFICATION

C A P F 1824 A 6 A

PRODUCT

TYPE:

C: Indoor Coil

APPLICATION

A: U pflow/D ownflow C oil H: Horizontal A Coil S: Ho r izontal Slab Coil

EXPA NSION DEVICE:

F: Flowrater

CABINET FINISH:

U: Unpai nted P: Painte d N: Unpain ted Case

REVISION

A: Revision

REFRIGERANT CHARGE:

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

NOMINAL WI DTH FOR GAS FURNACE

A: Fits 14" Fur nace Cabinet B: Fits 17 1 /2" F ur nace Cabi net C: Fits 21 " Fu rnac e Cabi net D: F its 24 1/ 2" Furnace Cabinet N: Does Not Apply (Horizon tal S lab Coils )

NOMINAL CAPACITY RANGE @ 13 SEER

1824: 1 1/ 2 to 2 T on s 3030: 2 1/ 2 Ton s 36 36 : 3 To ns 3642 : 3 to 3 1/2 Tons 48 60 : 4 & 5 T on s

MB R 8 00 A A 1

DESIGN SERIES:

MB: Modular Blower

MOT OR TY PE:

R: Constant Spe ed

E: Variable Speed

FACTORY HEAT

00: No Hea t

AIRFL OW DE LIV E RE D

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

ELECTRICA L SUPPLY:

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

D ESIGN SERIES

A: First Series

CIRCUIT BREAKER

A: No Circuit Breaker B: Circuit Breaker

PRODUCT IDENTIFICATION

A W U F 3642 1 6 A A

EXPA NSION

PRODUCT

TYPE:

A: Air Handler

CABINE T FINIS H :

U: Unpainted P: Paited N: Uncased

A PPLICATION

C: C eiling M ount P S C Motor D: Downflow PSC Motor E: Mul ti-P os ition Varible-Speed M otor S: Ene rgy-Efficient Motor R: Multi-Position PSC Motor T: Coated Coils W: Wall Mount PSC Motor

DEVI CE :

F: Flowrater T: TXV (Expansion Device)

MINOR REVISION*

MAJOR REVISION*

RE FRIGE RANT CHA RGE:

No Digit: R-22 Only 6 : R-41 0A or R-22

ELECTRICAL:

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

NOMINAL CAPACITY RAN GE:

@ 13 SEER Dedic at ed Applic at ion 3 6 36: 3 To ns

Multi-Position & Downflow Applications 3 1 37: 3 To ns 364 2: 3 - 3 1/2 Tons 1830: 1 1/2 - 3 1/2 Tons @10 SEER 1729: 1 1/2 - 2 1/2 Tons (for export systems)

Ceiling Mount & Wall Mount Applications (Nominal Cooling Capacity/Electric Heat kW) 1805: 1 1/2 Tons Cooling / 5 kW Electric Heat 2405 : 2 To ns Co o lin g / 5 kW E le c tr i c He at 3608 : 3 To ns Co o lin g / 8 kW E le c tr i c He at 3705 : 3 To ns Co o lin g / 5 kW E le c tr i c He at 3708 : 3 To ns Co o lin g / 8 kW E le c tr i c He at

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

ACCESSORIES

ASX13

Model Description

ASX13

018

ASC01Anti-Short Cycle Kit XXXXXXX CSR-U-1 Hard-start Kit X X X X CSR-U-2 Hard-start Kit X X X X CSR-U-3 Hard-start Kit XX

FSK01A

Freeze Protection Kit XXXXXXX TX2N4³ TXV Kit X TX3N4 TX5N4

TXV Kit XXX

GSX13

Model Description

ASC01Anti-Short Cycle Kit XXXXXXX CSR-U-1 Hard-start Kit X X X X CSR-U-2 Hard-start Kit X X X X CSR-U-3 Hard-start Kit XX

FSK01A

Freeze Protection Kit XXXXXXX TX2N4³ TXV Kit X TX3N4 TX5N4

TXV Kit XXX

GSX13

018

ASX13

024

GSX13

024

ASX13

030

GSX13

030

ASX13

036

GSX13

036

ASX13

042

GSX13

042

ASX13

0418

GSX13

0418

ASX13

060

GSX13

060

SSX14

Model Description

SSX14

018

ASC01Anti-Short Cycle Kit XXXXXXX CSR-U-1 Hard-start Kit X X X X CSR-U-2 Hard-start Kit X X X X CSR-U-3 Hard-start Kit XX

FSK01A

Freeze Protection Kit XXXXXXX TX2N4³ TXV Kit X TX3N4

TX5N4

TXV Kit XXX

SSX14

024

SSX14

030

SSX14

036

SSX14

042

SSX14

048

SSX14

060

ASX14

Model Description

ASC01 Anti-Short Cycle Kit CSR-U-1 Hard-start Kit

ASX14

018

XXXXXXX

XXXX CSR-U-2 Hard-start Kit CSR-U-3 Hard-start Kit

FSK01A TX2N4³ TXV Kit

Freeze Protection Kit XXXXXXX

X TX3N4³ TXV Kit TX5N4³ TXV Kit

Installed on indoor coil

Required for heat pump applications where ambient temperatures fall below 0°F with 50% or higher relative humidy.

³ Field-installed, non-bleed, expansion valve kit — Condensing units and heat pumps with reciprocating compressors require the use of

ASX14

024

ASX14

030

ASX14

036

XXXX

XXX

ASX14

042

ASX14

048

ASX14

060

XXX

ACCESSORIES

DSX/SSX16

Model Description

ASC 01 An ti - Sh o rt Cy cl e Ki t CSR - U -1 Ha r d -sta r t Ki t

D/SSX16

024

XXXXXX XXX

D/SSX16

030

D/SSX16

036

D/SSX16

042

D/SSX16

048

D/SSX 16

CSR - U -2 Ha r d -sta r t Ki t X X X X CSR - U -3 Ha r d -sta r t Ki t

FSK01A TX2N4³ TXV Kit

TX3N4³ TXV Kit TX5N4³ TXV Kit

Installed on indoor coil

Required for heat pump applications where amb ient temperatures fall be low 0°F with 50% or higher relative humidy. ³ Field-installed, non-bleed, expansion valve kit — Condensing units and heat pumps with reciprocating compressors require th e use of start-assist components when used in conjunction with an indoor coil using a non-bleed thermal expansion valve refrigerant meter ing device.

Freeze Pr otec t ion Kit X X X X X X

XXX

ASX16

Model Description

ASC 01 Anti- S ho r t Cycle Ki t CSR-U - 1 Har d- sta r t K i t

ASX16

024

XXXXXX

XXX CSR-U - 2 Har d- sta r t K i t X X X X CSR-U - 3 Har d- sta r t K i t

FSK01A TX2N4³ TXV Kit

Freeze Protection Kit X X X X X X

X TX3N4³ TXV Kit TX5N4³ TXV Kit

Installed on indoor coil

Required for heat pump applications where ambient temperatures fall below 0°F with 50% or higher relative humidy. ³ Field-installed, non-bleed, expansion valve kit — Condensing units and heat pumps with reciprocating compressors require the use of start-assist components when used in conjunction with an indoor coil using a non-bleed thermal expansion valve refrigerant meter ing device.

ASX1 6

030

ASX16

036

ASX16

042

ASX1 6

048

ASX16

XXX

060

ACCESSORIES

ASX18

Model Description

ASC01 Anti-Short Cycle Kit CSR-U-1 Hard-start Kit CSR-U-2 Hard-start Kit CSR-U-3 Hard-start Kit

FSK01A TX2N4³ TXV Kit

TX3N4³ TXV Kit TX5N4³ TXV Kit

Installed on indoor coil

Required for heat pump applications where ambient temperatures fall below 0°F with 50% or higher relative humidy. ³ Field-installed, non-bleed, expansion valve kit — Condensing units and heat pumps with reciprocating compressors req uire the use of start-assist components when used in conjunction with an indoor coil using a non-bleed thermal expansion valve refrigerant metering device.

Freeze Protection Kit

ASX18

036

XXX X XXX

XXX

ASX18

048

ASX18

060

ACCESSORIES

ASZ13

Model Description

AFE18-60A All-Fuel Kit XXXXXXX ASC01 Anti-Short Cycle Kit XXXXXXX CSR-U-1 H ard-start Kit X X X X CSR-U-2 H ard-start Kit XXXX CSR-U-3 H ard-start Kit XX

FSK01A OT/EHR18-60 Emergency Heat Relay kit X X X X X X X OT18-60A² Outdoor Thermostat w/ Lockout Stat X X X X X X X TX2N4³ TXV Kit X TX3N4³ TXV Kit XXX TX5N4³ TXV Kit XXX

Freeze Protection Kit XXXXXXX

ASZ13

018

GSZ13

Model Description

AFE18-60A All-Fuel Kit XXXXXXX ASC01 Anti-Short Cycle Kit XXXXXXX

CSR-U-1 H ard-start Kit X X X X CSR-U-2 H ard-start Kit XXXX CSR-U-3 H ard-start Kit XX

FSK01A OT/EHR18-60 Emergency Heat Relay kit X X X X X X X OT18-60A² Outdoor Thermostat w/ Lockout Stat X X X X X X X TX2N4³ TXV Kit X

TX3N4³ TXV Kit XXX TX5N4³ TXV Kit XXX

Freeze Protection Kit XXXXXXX

GSZ13

018

SSZ14

Model Description

SSZ14

018

ASZ13

024

GSZ13

024

SSZ14

024

ASZ13

030

GSZ13

030

SSZ14

030

ASZ13

036

GSZ13

036

SSZ14

036

ASZ13

042

GSZ13

042

SSZ14

042

ASZ13

048

GSZ13

048

SSZ14

048

ASZ13

060

GSZ13

060

SSZ14

060

AFE18-60A All-Fuel Kit XXXXXXX ASC01 Anti-Short Cycle Kit XXXXXXX

CSR-U-1 H ard-start Kit X X X X CSR-U-2 H ard-start Kit XXXX CSR-U-3 H ard-start Kit XX

FSK01A OT18-60A

OY-EHR18-60Emergency Heat Relat Kit XXXXXXX TX2N4³ TXV Kit X TX3N4³ TXV Kit XXX

TX5N4³

Freeze Protection Kit XXXXXXX Outdoor Thermostat XXXXXXX

TXV Kit XXX

ASZ14

Model Description

AFE18-60A All-Fuel Kit XXXXXXX ASC01 Anti-Short Cycle Kit XXXXXXX CSR-U-1 H ard-start Kit X X X X CSR-U-2 H ard-start Kit XXXX CSR-U-3 H ard-start Kit XX

FSK01A OT18-60A

OY-EHR18-60Emergency Heat Relat Kit XXXXXXX TX2N4³ TXV Kit X TX3N4³ TXV Kit XXX

TX5N4³

Installed on indoor coil

Required for heat pump applications where ambient temperatures fall below 0°F with 50% or higher relative humidy.

Condensing units and heatp pumps with reciprocating compressors require the use of start-assist components when used in conjunction with an indoor coil using a

Freeze Protection Kit XXXXXXX Outdoor Thermostat XXXXXXX

TXV Kit XXX

ASZ14

018

ASZ14

024

ASZ14

030

ASZ14

036

ASZ14

042

ASZ14

048

ASZ14

060

ACCESSORIES

DSZ/SSZ16

Model Description

AFE18-60A All-Fuel Kit X X X X X X ASC01 Anti-Short Cycle Kit X X X X X X CSR-U-1 Hard-start Kit X X X CSR-U-2 Hard-start Kit X X X X CSR-U-3 Hard-start Kit XX

FSK01A OT/EH R18-60 E m e rg e ncy He at Rel ay K i t X X X X X X OY/EH R18- 60 Em e rg e ncy He at Rel ay K i t X X X X X X OT18-60A² Outdoor T hermostat w/ Lockout Stat X X X X X X TX2N 4³ TXV Kit X TX3N 4³ TXV Kit X X TX5N 4³ TXV Kit XXX

Installed on indoor coil

Required for heat pump applications where ambient temperatures fall below 0°F with 50% or higher relative humidy.

Field-ins talled, non -ble ed , exp ansion valve k it — Condensin g units and heat pum ps with reciproca ting co mpressors require the use of start-assist

comp onents when used in conjunction with an indoor c oil using a non-bleed thermal ex pansion valve refrigerant metering device.

Fre eze Prot ec tion Ki t X X X X X X

D/SSZ 16

024

D/SSZ16

030

D/SSZ16

036

D/SSZ16

042

D/SSZ16

048

D/SSZ16

060

ASZ16

Model Description

ASZ16

024

ASZ16

030

ASZ16

036

ASZ16

042

ASZ16

048

ASZ16

060

AFE18-60A All-Fuel Kit X XXXXX ASC01 Anti-Short Cycle Kit XXXXXX CSR-U-1 Hard-start Kit X X X CSR-U-2 Hard-start Kit X XXX CSR-U-3 Hard-start Kit XX

FSK01A

Freeze Protection Kit X XX XXX

OT/EHR18-60Emergency Heat Relay Kit XXXXXX OY /E H R 18- 60 Em e rgen c y H eat Rel ay K it X X X X X X OT 18-6 0A² Outdoor Therm os tat w/ Lockout Sta t X X X X X X TX2 N4³ TXV Ki t X TX3 N4³ TXV Ki t X X TX5 N4³ TXV Ki t XXX

Installe d on in door coi l

Required for heat pump applications where ambient temperatures fall below 0°F with 50% or higher relative hu midy.

Field-installed, non-bleed, expansion valve k it — Condensing units and heat pumps with reciprocating compressors require the use of start-assist

components when used in conjunction with an indoor coil using a non-bleed thermal expansion valve refrigerant metering device.

ACCESSORIES

ASZ18

Model Description

AFE18-60A All-Fuel Kit X X X ASC01 Anti-Short Cycle Kit X X X CSR-U-1 Hard-start Kit X CSR-U-2 Hard-start Kit X X X CSR-U-3 Hard-start Kit X X

FSK01A OT/EHR18-60 Emergency Heat Relay Kit X X X OY/EH R18-60 Emergency Heat Relay Kit X X X OT18-60A² Outdoor Thermostat w/ Lockout Stat X X X TX2N4³ TXV Kit TX3N4³ TXV Kit X TX5N4³ TXV Kit X X

Installed on indoor coil

Required for heat pump applications where ambient temperatures fall below 0°F with 50% or higher relative humidy.

Field-installed, non-bleed, expansion valve kit — Condensing units and heat pumps with reciprocating compressors require the use of start-assist

components when used in conjunction with an indoor coil using a non-bleed thermal expansion valve refrigerant metering device.

Freeze Protection Kit X X X

ASZ18

036

ASZ18

048

ASZ18

060

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 RELA Y

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

SHOR T CYCLE

Y1Y2R1

PROTECTOR

Install Line

Thermostat

Here

Wire Nut

ELLOW 1

CONTACTOR

BLACK 1

T2 T1

BLACK 1

THERMOSTAT WIRE

UNIT

TERMINAL

BOARD

ACCESSORIES

COIL MODEL TX2N4 TXV KIT TX3N4 TXV KIT TX5N4 TXV KIT FSK01A FREEZE PROTECTION KIT

CA*F18246* CA*F30306* XX

CA*F36426* XX X CHPF18246* XX CHPF30306* XX CHPF36426* XX

CSCF1824N6*

CSCF303N6* XX

CSCF3642N6* XX X

COIL ACCESSORIES

XX X

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-----XX---MBE2000AA-1AA - - - - - X X X - - MBE1200AA-1BA - X X X X X X - - - MBE1600AA-1BA - X X X X X X - - - MBE2000AA-1BA- XXXXXXX- - -

X = Allowable combinations

- = Restricted combinations

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

^ = Circuit 1: Single Phase for Air Handler Motor * = Revision level that my or may not be designated Circuit 2: 3-Phase for HKR3 Heater Kits C = Circuit Breaker option

ELECTRIC HEAT KIT

ELECTRIC HEAT KIT APPLICATIONS - ARPF

ARPF1824

1/16

HKR-03* X X X X X X HKR-05*, HKR-05C* X X X X X X HKR-06* X X X X X X HKR-08*, HKR-08C* X HKR-10*, HKR-10C* X HKR-15C* X

HKR-20C* X HKR-21C* X ^ HKR3-15* X ^ HKR3-20* X

* Revision level that may or may not be designated C Circuit breaker option ^ Heat kit requires three-phase power supply

ARPF1931

1/16

ARPF3030

1/16

ARPF3642

1/16

ARPF3743

1/16

ARPF4860

1/16

XXXX

¹ Air handler must either be on medium or high speed ² Air handler must be on high speed ³ For static pressure of 0.6 or higher, air handler must be on

XXX

X X X X X

ACCESSORIES

ELECTRIC HEAT KIT APPLICATIONS - ARUF

ARUF1729

1/16

ARUF1824

1/16

ARUF1931

1/16

ARUF3030

1/16

ARUF3642

1/16

ARUF3743

1/16

ARUF4860

1/16

HKR-03* XXXXXXX

HKR-05*, HKR-05C* XXXXXXX

HKR-06* XXXXXXX

HKR-08*, HKR-08C* X

HKR-10*, HKR-10C* X

HKR-15C* X

HKR-20C* X

HKR-21C* X

^ HKR3-15* X

^ HKR3-20* X

* Revision level that may or may not be designated C Circuit breaker option ^ Heat kit requires three-phase power supply

Air handler must either be on medium or high speed

Air handler must be on high speed

For static pressure of 0.6 or higher, air handler must be on medium or high speed

ARUF024-

00A1A

ARUF032-

00A1B

ARUF042-

00A1B

XXXX

ARUF049-

00A1B

XXX

ARUF061-

00A1B

HKR-03* XXXXX

HKR-05*, HKR-05C* XXXXX

HKR-06* XXXXX

HKR-08*, HKR-08C* X X

HKR-10*, HKR-10C* X

HKR-15C* X

HKR-20C* X

HKR-21C* X

^ HKR3-15* X

^ HKR3-20* X

XXX

* Revision level that may or may not be designated C Circuit breaker option ^ Heat kit requires three-phase power supply

Air handler must either be on medium or high speed

Air handler must be on high speed

For static pressure of 0.6 or higher, air handler must be on medium or high speed

ACCESSORIES

ELECTRIC HEAT KIT APPLICATIONS - AEPF

AEPF183016 AEPF303616 AEPF313716 AEPF426016

HKR-05*, HKR-05C* X X HRK-08*, HKR-08C X X X HKR-10*, HKR-10C

X HKR-15C* HKR-20C* HKR-21C

Revision level that may or may not be designated

C Circuit Breaker option

This heater kit can be used ONLY for 1000 CFM or higher applications

This heater kit can be used ONLY for 1200 CFM or higher applications

XXX

ELECTRIC HEAT KIT APPLICATIONS - ASPF

ASPF183016 ASPF303616 ASPF313716 ASPF426016

HKR-03* XXXX HKR-05*, HKR-05C* X X X X HKR-06* XXXX HRK-08*, HKR-08C* HKR-10*, HKR-10C* HKR-15C* HKR-20C* HKR-21C* +HKR3-15* +HKR3-20*

Revision level that may or may not be designated

C Circuit Breaker option + Heat kit requires 3-phase power supply

Air handler must be on speed tap 2, 3, 4 or 5

Air handler must be on speed tap 4 or 5

Air handler must be on speed tap 3, 4 or 5

X X

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

The condenser air is pulled through the condenser coil by a direct drive propeller fan. This condenser air is then discharged out of the top of the cabinet. These units are designed for free air discharge, so no additional resistance, like duct work, shall be attached.

The suction and liquid line connections on present models are of the sweat type for field piping with refrigerant type copper. Front seating valves are factory installed to accept the field run copper. The total refrigerant charge for a normal installation is factory installed in the condensing unit.

GSX, GSZ, ASX, ASZ, SSX, SSZ and DSX, DSZ models are available in 1 1/2 through 5 ton sizes and use R-410A refrigerant. They are designed for 208/230 volt single phase applications.

ASX, ASZ, DSX and DSZ R-410A model units use the Copeland Scroll "Ultratech" Series compressors which are specifically designed for R-410A refrigerant. These units also have Copeland

GSX, GSZ, SSX and SSZ R-410A model units use the Copeland Scroll "Ultratech" Series compressors which are specifically designed for R-410A refrigerant.

There are a number of design characteristics which are different from the traditional reciprocating and/or scroll compressors.

"Ultractech" Series scroll compressors will not have a discharge thermostat. Some of the early model scroll compressors required discharge thermostat.

"Ultratech" Series scroll compressors use "POE" or polyolester oil which is NOT compatible with mineral oil based lubricants like 3GS. "POE" oil must be used if additional oil is required.

ComfortAlert diagnostics.

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.

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.

PRODUCT DESIGN

The ASX [16 & 18], ASZ [16 & 18], DSX16 and DSZ16 series split system units use a two-stage scroll compressor. The two-step modulator has an internal unloading mechanism that opens a bypass port in the first compression pocket, effectively reducing the displacement of the scroll. The opening and closing of the bypass port is controlled by an internal electrically operated solenoid.

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

FIGURE A

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

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

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

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

Some design characteristics of the Compliant Scroll compressor are:

• Compliant Scroll compressors are more tolerant of liquid refrigerant.

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

• Compliant Scroll compressors use white oil which is compatible with 3GS. 3GS oil may be used if additional oil is required.

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

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

PRODUCT DESIGN

CAPACITY CONTROL

During the compression process, there are several pockets within the scroll that are compressing gas. Modulation is achieved by venting a portion of the gas in the first suction pocket back to the low side of the compressor thereby reducing the effective displacement of the compressor. See Figure A. Full capacity is achieved by blocking these vents, increasing the displacement to 100%. A solenoid in the compressor, controlled by an external 24-volt ac signal, moves the slider ring that covers and uncovers these vents. The vent covers are arranged in such a manner that the compressor operates somewhere around 67% capacity when the solenoid is not energized and 100% capacity when the solenoid is energized. The loading and unloading of the two step scroll is done “on the fly” without shutting off the motor between steps. See Figure B below. The unloaded mode default was chosen for two reasons:

1. It is expected that the majority of run hours will be in the low capacity, unloaded mode.

2. It allows a simple two-stage thermostat to control capacity through the second stage in both cooling and possibly heating if desired.

UNLOADER SOLENOID

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

FIGURE B

SYSTEM OPERA TION

COOLING

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

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

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

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.

HEATING

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

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

The restrictor orifice used with the CA*F, CHPF and CH**FCB coils 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.

GSZ, ASZ, SSZ and DSZ models 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.

SYSTEM OPERA TION

DEFROST CYCLE

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

Solid State Defrost Control

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

TEST

90 60 30

JUMPER WIRE

CY W2 R R DFT

DF2

DF1

HEATING CYCLE

The reversing valve on the GSZ, SSZ, ASZ and DSZ 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.

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® Brand Heat Pump products

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

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

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

Com p laint

POSSIBLE CAUSE

DOTS IN ANALYSIS

GUIDE INDICATE

"POS SIBL E CAUSE"

Pow er Failure Blow n Fuse Unbalanced Power, 3PH Loose Connection Shorted or Broken Wires Open Fan Overload Faulty Thermostat Faulty Transformer Shorted or Open Capacitor Internal Compressor Overload Open Shorted or Grounded Compressor Compre s sor Stuc k 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 Conden sing Air Infiltration of Outdoor Air Improperly Lo cated Thermostat Air Flow Unbalanced System Undersized Broken Internal Parts Broken Valves Ineff icient 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

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

Unsatis facto r y

Cooling/Heating

System runs continuously - little cooling/htg

Too cool and then too warm

•

•••

••••••

••

••• •

••

•••••

•

••

•••

•

•••

••

•• •• •

♦♦

••• •

•• •

••

•• •

•••

••

•• ••

•

••• • ••

••• • •• •

••

••• • •

•• •

•

• Cooling or Heating Cycle (Hea t Pum p)

•••

System

Ope rating

Pressures

Not cool enough on warm days

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

♦

•

♦

••

♦

••

♦ ♦ ♦

•

••

•

♦

••

•

♦♦♦ ♦♦♦ ♦♦♦♦♦ ♦ ♦♦♦♦♦♦♦

Heating Cycle Only (Heat Pump)

♦

Test Method

Re medy

See Service Procedure Ref.

Test Voltage S-1 Inspect Fuse Size & Type S-1 Test Voltage S-1 Inspe ct Connec tion - Tighten S-2, S-3 Test Circuits With Ohmmeter S-2, S-3 Test Continuity of Ov erload S-17A Test Continuity of Thermostat & Wiring S-3 Check Control Circuit w ith Voltmeter S-4 Test Capacitor S-15 Test Continuity of Ov erload S-17A Test Motor Windings S-17B Use Tes t Cord S-17D Test Continuity of Coil & Contacts S-7, S-8 Test Continuity of Coil And Contacts S-7 Test Control Circuit w ith 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 Blow er Spe ed S-200 Recov er Part of Charge S-113 Inspect Coil - Clean Recov er Charge, Evac u ate , Rech a rge S-114 Remove Obstruction to Air Flow Check Window s , Doors, Vent Fans , Etc. Relocate Thermostat Readjust Air Volume Dampers Refigure Cooling Load Replace Compresso r S-115 Test Compressor Efficiency S-104 Test Compressor Efficiency S-104 Replace V alv e S-110 Remove Restriction or Replace Expansion Device S-110 Replace V alv e Replace V alv e Tighten Bulb Bracket S-105 Check Valve Operation S-110 Tigh ten B olts Replace Valve or Solenoid S-21, 122 Test Contro l S-24 Test Defrost Thermostat S-25 Check Flowrator & Seat or Replace Flowrator S-111

SERVICING

S-1 Checking Voltage .......................................... 35

S-2 Checking Wiring............................................ 35

S-3 Checking Thermostat, Wiring & Anticipator .. 35

S-3A Thermostat & Wiring ..................................... 35

S-3B Cooling Anticipator........................................ 36

S-3C Heating Anticipator........................................ 36

S-3D Checking Encoded Thermostats ................... 36

S-4 Checking Transformer & Control Circuit ....... 37

S-5 Checking Cycle Protector ............................. 37

S-6 Checking Time Delay Relay ..........................37

S-7 Checking Contactor and/or Relays................ 38

S-8 Checking Contactor Contacts ....................... 38

S-9 Checking Fan Relay Contact ........................ 38

S-10 Copeland Comfort™ Alert Diagnositics ......... 39

S-11 Checking Loss of Charge Protector............... 41

S-12 Checking High Pressure Control ................... 41

S-13 Checking Low Pressure Control .................... 41

S-15 Checking Capacitor....................................... 41

S-15A Resistance Check......................................... 42

S-15B Capacitance Check....................................... 4 2

S-16A Checking Fan & Blower Motor

Windings (PSC Motors) ............................... 43

S-16B Checking Fan & Blower Motor (ECM Motors) 4 3

S-16C Checking ECM Motor Windings .................... 46

S-16D ECM CFM Adjustments................................ 46

S-16E Blower Performance Data.............................. 48

S-16F Checking GE X13™ Motors .......................... 48

S-17 Checking Compressor Windings ................... 49

S-17A Resistance Test............................................ 49

S-17B Ground Test .................................................. 49

S-17C Unloader Test................................................ 50

S-17D Operation Test .............................................. 50

S-18 Testing Crankcase Heater (optional item) ..... 51

S-21 Checking Reversing Valve and Solenoid........ 51

S-24 Testing Defrost Control.................................. 51

S-25 Testing Defrost Thermostat ........................... 51

S-26 Checking Heater Limit Control(s) .................. 52

S-27 Checking Heater Elements ............................... 52

S-40 MBR/ARUF Electronic Blower Time Delay

with Single Stage Air Conditioners

& Heat Pumps .................................................. 52

S-41 MBE/AEPF with GSX, SSX, ASX, DSX

Air Conditioners ................................................ 54

S-41A MBE/AEPF with GSZ, SSZ, ASZ

Heat Pumps...................................................... 5 5

S-60 Electric Heater (optional item)........................... 58

S-61A Checking Heater Limit Control(S)...................... 59

S-61B Checking Heater Fuse Line............................... 59

S-62 Checking Heater Elements ............................... 59

S-100 Refrigeration Repair Practice.............................60

S-101 Leak Testing ..................................................... 60

S-102 Evacuation ........................................................ 60

S-103 Charging............................................................ 61

S-104 Checking Compressor Efficiency ...................... 6 2

S-105A Piston Chart - ASX13, GSX13, SSX14,

ASX14, ASZ13, GSZ13 Units............................ 63

S-105B Thermostatic Expansion Valve .......................... 63

S-106 Overfeeding ....................................................... 66

S-107 Underfeeding ..................................................... 66

S-108 Superheat ......................................................... 66

S-109 Checking Subcooling ........................................ 66

S-109A Two Speed Application...................................... 6 7

S-109B Heat Pump Heating Mode ................................. 67

S-110 Checking Expansion Valve Operation ............... 6 7

S-111 Fixed Orifice Restriction Devices ...................... 67

S-112 Checking Restricted Liquid Line........................ 68

S-113 Refrigerant Overcharge ...................................... 68

S-114 Non-condensables ............................................ 68

S-115 Compressor Burnout ......................................... 68

S-120 Refrigerant Piping.............................................. 69

S-202 Duct Static Pressure

& Static Pressure Drop Across Coils ................ 71

S-203 Air Handler External Static ............................... 71

S-204 Coil Static Pressure Drop ................................. 72

HIGH VOLTA GE! 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.

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.

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.

UNIT SUPPLY VOLTAGE

VOLTAGE MIN. MAX.

460 437 506

208/230 198 253

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.

S-2 CHECKING WIRING

HIGH VOLTAGE! Disconnect A LL power befor e servicing or installing. Multiple power sources may be pres ent. Fai lure to do so ma y caus e pro pe r ty dam a ge, pe r son al in ju r y or death.

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 W I RE SIZI NG CHART

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:

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

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

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.

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.

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.

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.

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.

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.

1. Remove wire from Y1 terminal.

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

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

TESTING COIL CIRCUIT

SERVICING

S-7 CHECKING CONTACTOR AND/OR RELAYS

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

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

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

1. Remove the leads from the holding coil.

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

contactor.

S-8 CHECKING CONTACTOR CONTACTS

WARNING

Disconnect ALL power before servicing.

VOLT/OHM

METER

L1L2

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

TESTING COMPRESSOR CONTACTOR

(Single Phase)

THREE PHASE

Using a voltmeter, test across terminals:

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

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

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

the same as in "A", replace contactor.

T3L3T2

VOLT/OHM

METER

SINGLE PHASE:

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

2. With power ON, energize the contactor.

WARNING

Line Voltage now present.

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.

Ohmmeter for testing holding coil Voltmeter for testing contacts

TESTING COMPRESSOR CONTACTOR

(Three-phase)

S-9 CHECKING FAN RELAY CONTACTS

HIGH VOLT AGE! 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.

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.

SERVICING

WARNING

Line V oltage 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.

S-10 COPELAND COMFORT ALERT™ DIAGNOSTICS

Applies to ASX /ASZ and DSX/DSZ units

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” Ope n Run Circ uit

Flash Code 7

Yellow “ALERT” Welded Contactor

Flash Code 8

Yellow “ALERT” Low Vol tage

Flash Code 9

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

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

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

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

Thermostat demand signal 1. Compressor protector is open Y1 is present, but the 2. Outdoor unit power disconnect is open compressor is not 3. Compressor circuit breaker or fuse(s) is open running 4. Broke n 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 coil poor air circulation (dirty, blocked, damaged) pressure out of limits or 3. Condenser fan is not running compressor overloaded 4. Return air duct has substantial leakage

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

Current only in run circuit 2. Open circuit in compress or st art 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 (con tact utility if voltage at discon nect 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 21 PSIG. It will automatically cut-in (close) at approximately 50 PSIG.

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

S-12 CHECKING HIGH PRESSURE CONTROL

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

HIGH VOL TAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause pr ope rty dam age , pe rs onal inju ry or death.

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

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

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

With power ON:

WARNING

Line Voltage now present.

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

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

S-13 CHECKING LOW PRESSURE CONTROL

The low pressure control senses the pressure in the suction 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 21 PSIG. It will automatically cut-in (close) at approximately 50 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® brand or Copeland should be used. "Kick Start" and/or "Super Boost" kits are not approved start assist devices.

SERVICING

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.

START

CAPACITO R

VIOLET 20

YELLOW 12

RED 10

START RELAY

OHMMETER

CAPACIT O R

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).

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:

ORANGE 5

RUN

CAPACITOR

T2 T1

L1L2

CONTACTOR

HARD START KIT WIRING

S-15A RESISTANCE CHECK

HIGH VOLT AGE! 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.

1. Discharge capacitor and remove wire leads.

WARNING

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

VOLTMETER

15 AMP

FUSE

AMMETER

CAPACITOR

TESTING CAPACITANCE

WARNING

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

Capacitance (MFD) = 2650 X Amperage

Voltage

SERVICING

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.

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.

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.

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.

1 2 3

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

}

applications only

Gnd

S-16B CHECKING FAN AND BLOWER MOTOR

AC Line Connection

(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

OUT - OUT +

technicians are intimated by the ECM motor; however, these fears are unfounded. GE offers two ECM motor testers, and

DJUST +/-

with a VOM meter, one can easily perform basic troubleshooting on ECM motors. An ECM motor requires power (line

Y1 Y/Y2

voltage) and a signal (24 volts) to operate. The ECM motor stator contains permanent magnet. As a result, the shaft

COOL

feels "rough" when turned by hand. This is a characteristic of the motor, not an indication of defective bearings.

WARNING

Line Voltage now present.

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

DELAY

COMMON2

W/W1

COMMON1 O (REV VALVE)

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.

If you do not read voltage and continuity as described, the

16-PIN ECM HARNESS CONNECTOR

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.

AC Line Connection

816

G (FAN)

EM Ht/W2

24 Vac (R)

HEAT

BK/PWM (SPEED)

SERVICING

(

)

ity)

Check

for

undercharged

condition

Check

and

plug

leaks

return

ducts

cabinet

different

have completel

- Turn power OFF prior to re pair .

Wait 5 minutes after

disconnecting power before

opening motor.

- Handle electronic motor/control with care.

- Check 230 Vac power at motor.

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

- Check low voltage connections

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

- Check for unseated pins in connectors

on motor harness .

- Turn power OFF prior to re pair .

Wait 5 minutes after

disconnecting power before

opening motor.

- Handle electronic motor/control with care.

- Test with a temporary jumper between R - G.

- Check motor for tight shaft.

- Check for loose motor mount.

- Make sure blower wheel is tight on shaft.

- Perform mot or /control replacement check ,

ECM motors only.

- Turn power OFF prior to re pair .

- Check line voltage for variation or "sag".

- Check low voltage connections

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

motor, unseated pins in motor

harness connect or s .

- Check-out system controls - Thermostat.

- Perform Moisture Check.*

- Turn power OFF prior to re pair .

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.

- Does removing panel or filter

reduce "puffing"?

- Check/replace filter.

- Check/correct duct restrictions.

- Adjust to corr ec t blower speed setting.

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

door switch open.

- Blown fuse or circuit breaker.

- 24 Vac wires miswired.

- Unseated pins in wiring

harness connect ors.

- Bad motor/control module.

- Moisture present in motor or control module.

- Loose motor mount.

- Blower wheel not tight on motor shaft.

- Bad motor/control module.

- Variation in 230 Vac to motor.

- Unseated pins in wiring harness

connectors.

- Erratic CFM command from

"BK" terminal.

- Improper thermostat connection or setting.

- Moisture present in motor/control module.

- Incorrect or dirty filter(s).

- Incorrect s upply or return ductwork.

- Incorrect blower speed setting.

Troubleshooting Chart for ECM Variable Speed Air Circulator Blower Motors

equipment manufacturer

e vo u

mo ro

con or

. -

or as recommended b

- This is normal start-up for

variable speed motor.

- No movement.

- Motor rocks,

but won't start.

- It is normal for motor to

oscillate with

no load on shaft.

- Varies up and down

or intermittent.

- "Hunts" or "puffs" at

high CFM (speed).

u n p

ra e

ensa

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

s con

*Moisture Check

- Motor won't

- Motor rocks

slightly

when starting.

start.

- Motor

oscillates up &

down while

being tested

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 repa ir .

Wait 5 minutes after

disconnecting power before

opening motor.

- Handle electronic motor/control

with care.

- Turn power OFF prior to repa ir .

Wait 5 minutes after

disconnecting power before

opening motor.

- Handle electronic motor/control

with care.

- Turn power OFF prior to repa ir .

- Check low voltage (Ther mostat)

wires and connections.

- Verify fan is not in delay mode -

wait until delay complete.

- Perform mot or/control replacement

check, ECM motors only.

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

- Perform mot or/control replacement chec k, ECM

motors only.

- Check for Triac s witched t'stat

or solid state r elay .

- Turn power OFF prior to repa ir .

- Check/replace filter.

- Check/correct duct restrictions.

- Adjust to correct blower speed setting.

CHART CONTINUED FROM PREVIOUS PAGE.

- 24 Vac wires miswired or loose.

- "R" miss ing/not connected at motor.

Troubleshooting Chart for ECM Variable Speed Air Circulator Blower Motors

- Fan in delay mode.

- Stays at low CFM despite

system call for cool

or heat CFM.

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

- "R" miss ing/not connected at motor.

- Fan in delay mode.

- Stays at high CFM.

- Motor starts,

but runs

erratically.

- Current leakage from controls

into G, Y, or W.

- High static c r eating high blower speed.

- Incorrect s upply or return ductwork.

- Incorrect or dirty filter(s).

- Incorrect blower speed setting.

- Blower won't shut off.

- Air noise.

have completel

- Turn power OFF prior to repa ir .

- Check for loos e blower housing,

panels, etc.

- Check for air whist ling thru seams in

ducts, cabi nets or panels.

- Check for cabi net/duct deformation.

- Turn power OFF prior to repa ir .

- Does removing panel or filter

reduce "puffing"?

- Check/replace filter.

- Check/correct duct restrictions.

- Turn power OFF prior to repa ir .

Wait 5 minutes after

disconnecting power before

opening motor.

- Handle electronic motor/control

with care.

capac

look alike, different modules ma

, en a

h the

oo muc ow

modes. Even thou

ow a or

e harnesses with "drip loop" under motor.

- Adjust to correct blower speed setting.

- Replace motor and perform

Moisture Check.*

resu e

uce unexpec

rammed for specific operatin

pro

.- Arran

es an

are factor

warran uc

pro s a

- Loose blower housing, panels, etc.

- High static c r eating high blower

speed.

- Air leaks in ductwork, cabinets,

or panels.

- High static c r eating high blower speed.

- Incorrect or dirty filter(s).

- Incorrect s upply or return ductwork.

- Incorrect blower speed setting.

- Moisture in motor/control module.

equipment manufacturer

e vo u

mo ro

con or

. -

or as recommended b

- Noisy blower or cabinet.

- "Hunts" or "puf fs" 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

S-16C CHECKING ECM MOTOR WINDINGS

HIGH VOLT AGE! 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.

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

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

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

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

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

3-pin motor connector

16-pin connector

The MBE/AEPF products use a General Electric ECM

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.

DIPSWITCH FUNCTIONS

The MBE / AEPF air handler motors have 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

Elec tric H e a t

N/A

Indoor Thermostat

Cooling & Heat Pump CFM

CFM Trim Adjust

Table 1

CFM DELIVERY

Tables 2, 3, 5 and 6 show the CFM output for dipswitch

combinations 1-2, and 5-6.

5-pin connector

S-16D ECM CFM ADJUSTMENTS MBE / AEPF

MBE MOTOR

This section references the operation characteristics of the MBE/AEPF models 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/AEPF are 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.

Electric Heat Operation

Model Switch 1 Switch 2 CFM

MBE1200

MBE1600

MBE2000

OFF

OFF OFF

ON OFF OFF

ON OFF

OFF

Table 2

1,200 1,000

800

600 1,600 1,400 1,200 1,000 2,000 1,800

1,600 1,200

SERVICING

Cooling/Heat Pump Operation

Model Sw i tch 5 Switch 6 CFM

MBE1200

MBE1600

MBE2000

OFF

OFF OFF

ON OFF OFF

ON OFF

OFF

1,200 1,000

800

600 1,600 1,400 1,200 1,000 2,000 1,800

1,600 1,200

Table 3

THERMOST AT “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 FF O N

Table 4

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 ST AGE HEATING

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

AEPF DIPSWITCH FUNCTIONS

Dipswitch 1/2 & 7/8 AEPF 183

Heating

Element

(kw)

UP TO 10 OFF OFF OF F OFF 1 100 1210 UP TO 10 ON OFF OF F OFF 890 935

5 OFF ON OFF OFF 700 770

AEPF3036 / 3137 / 4260

Heating

Element

(kw)

UP TO 20 OFF OFF OF F OFF 2 050 2150 UP TO 20 ON OFF OF F OFF 1 750 1835 UP TO 15 OFF ON OFF OFF 1600 1680 UP TO 10 ON ON OFF OFF 1200 126 0 UP TO 10 ON ON OFF ON 1020 107 0

Dipswitc h 5/6 & 7/8 AEPF 18 30

Switch

Position

5678CoolingHeat Pump

OFF OFF OFF OFF 1100 1100

ON OFF OFF OFF 800 800

OFF ON OFF OFF 600 600

AE PF3036 / 313 7 / 4 260

Switch

Position

5678CoolingHeat Pump

OFF OFF OFF OFF 1800 1800

ON OFF OFF OFF 1 580 1580

OFF ON OFF OF F 1480 1480

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

Switch

Position

1278

Switch

Position

1278

Switch

Position

Switch

Position

Switch

Position

Switch

Position

Emergen cy

Backup

Emergen cy

Backup

Indoor Airflow

Hea t Pump

Wit h Back up

Hea t Pump

Wit h Back up

SERVICING

S-16E BLOWER PERFORMANCE DATA

SPE ED STATIC

0.1 1,240 1,500 1,800 2,160

0.2 1,170 1,460 1,740 2,080

HIGH

MEDIUM

LOW

NOTE: External static is for blower @ 230 Volts. It does not include Coil, Air Filter or Electric Heaters.

0.3 1,120 1,360 1,680 1,990

0.4 1,060 1,280 1,610 1,890

0.5 980 1,200 1,520 1,790

0.6 900 1,110 1,430 1,690

0.1 900 1,380 1,540 1,730

0.2 850 1,320 1,490 1,670

0.3 790 1,270 1,450 1,590

0.4 740 1,200 1,400 1,520

0.5 680 1,140 13,560 1,420

0.6 605 1,040 1,280 1,320

0.1 650 1,170 1,130 1,520

0.2 590 1,130 1,100 1,450

0.3 540 1,080 1,070 1,360

0.4 500 1,020 1,030 1,290

0.5 430 950 990 1,200

0.6 330 830 930 1,090

MBR800** -*

SCFM

MBR1200** -*

SCFM

MBR1600**-*

SCFM

MBR2000**-*

SCFM

S-16F 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.

Note: The GE TECMate will not currently operate the GE X13TM 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”

GE X13TM MOTOR CONNECTIONS

SERVICING

S-17 CHECKING COMPRESSOR

WARNING

Hermetic compressor electrical terminal venting can be dangerous. When insulating mat erial whic h supports a hermeti c compresso r or electr ical t erminal suddenly disintegrates due to physical abuse or as a result of an electrical short between the terminal and the compressor housing, the terminal may be expelled, venting the vapor an d liquid contents of the compres sor ho us ing an d sy stem .

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 -

HIGH VOLT AGE! 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.

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 S-R, C-R, and C-S, on single phase units or terminals T2, T2 and T3, on 3 phase units.

OHMMETER

TESTING COMPRESSOR WINDINGS

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

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

COMP

S-17B GROUND TEST

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

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

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

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

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).

SERVICING

Do not use a low voltage output instrument such as a voltohmmeter.

HI-POT

COMPRESSOR GROUND TEST

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

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

WARNING

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

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

5. If ground is indicated, replace the compressor.

S-17C UNLOADER TEST PROCEDURE

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

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

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

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

4. Next check the molded plug.

A. Voltage check: Apply control voltage to the plug

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

B. Resistance check: Measure the resistance from

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

C. Replace plug if either of these test methods

doesn’t show the desired results.

S-17D OPERATION TEST

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

UNLOADER SOLENOID

Unloader Test Procedure

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

(Molded Plug)

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.

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.

SERVICING

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.

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.

MONTH

WARNING

SERIAL

NUMBER

PLANT

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

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

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

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

S-24 TESTING DEFROST CONTROL

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

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

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

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

4. Immediately remove jumper from test pins.

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

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

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

8. If not as above, replace control board.

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

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

S-25 TESTING DEFROST THERMOSTAT

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

2. Check the temperature at which the control closes its contacts by lowering the temperature of the control. 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.

SERVICING

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.

S-26 CHECKING HEATER LIMIT CONTROL(S)

(OPTIONAL ELECTRIC HEATERS)

Each individual heater element is protected with an automatic rest limit control connected in series with each element to prevent overheating of components in case of low airflow. This limit control will open its circuit at approximately 150°F. to 160°F and close at approximately 110°F.

WARNING

Disconnect ALL power before 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. Make sure the limits are cool before testing.

IF FOUND OPEN - REPLACE - DO NOT WIRE AROUND.

S-27 CHECKING HEATER ELEMENTS

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

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.

HIGH VOLTAGE! Discon nect ALL power befo r e serv icin g or installing. Multiple power sources may be present. Failure to do so may cause pr o perty dam age, pe rson al inju ry or death.

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

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

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

S-40 MBR/AR*F ELECTRONIC BLOWER

TIME DELAY RELAY

The MBR/AR*F 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.

SEQUENCE OF OPERATION

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

MBR/AR*F WITH SINGLE STAGE CONDENS-

ERS

1.0 Cooling Operation

1.1 On a demand for cooling, the room thermostat ener-

gizes “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”.

SERVICING

1.4 The compressor and condenser fan are turned off and

after a 65 second delay off, the relay on the EBTDR board is de-energized 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 3 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.

and 4th heater elements if available.

MBR/AR*F 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.

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.

SERVICING

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 MBE/AEPF WITH GSX, SSX, ASX, DSX

MBE ELECTRONIC BLOWER TIME DELA Y RELA Y AEPF AIR HANDLER

SEQUENCE OF OPERATION

tions and wiring diagrams provided with the MBE/AEPF for specific wiring connections, dip switch settings and system configuration.

MBE/AEPF WITH SINGLE STAGE GSX, ASX AND SSX CONDENSERS

When used with a single stage GSX, SSX and ASX condensers, dip switch #4 must be set to the on position on the VSTB inside the MBE/AEPF. 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/AEPF 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/AEPF unit. The VSTB inside the MBE/AEPF 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 MBE/AEPF removes 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 MBE/AEPF 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 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/AEPF 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

SERVICING

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 MBE/AEPF WITH SINGLE STAGE

GSZ, SSZ, & ASZ HEAT PUMPS

When used with a single stage GSZ, SSZ or ASZ heat pumps, 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/AEPF must be removed.

3.0 COOLING OPERA TION

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

4.0 HEA TING OPERATION

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/AEPF. 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/AEPF. 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/AEPF 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/AEPF. 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/AEPF. 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/AEPF. 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/AEPF. 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.

SERVICING

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.

SEQUENCE OF OPERA TION

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 outdoor unit and 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.

MBE/AEPF WITH TWO STAGE ASX & DSX CONDENSERS

1.0 COOLING OPERATION

When used with the ASX & DSX two stage condensers, dip switch #4 must be set to the OFF position on the VSTB inside the MBE/AEPF. The “Y1” output from the indoor thermostat must be connected to the

purple wire labeled “Ylow/Y1” inside the wire bundle marked “Thermostat” and the purple wire labeled “Ylow/

Y1” inside the wire bundle marked “Outdoor Unit” must be connected to “Ylow/Y1” at the condenser. The “Y2” 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/Y2” at the condenser. The orange

jumper wire from terminal “Y1” to terminal “O” on the VSTB inside the MBE/AEPF must remain connected.

1.1 On a demand for cooling, the room thermostat energizes

“G” and “Y1” and 24Vac is supplied to “G” and “Ylow/Y1” of the MBE/AEPF unit. The VSTB inside the MBE/AEPF will turn on the blower motor and the motor will ramp up to 60% of the speed programmed in the motor based on the settings for dip switch 5 and 6. The VSTB will supply 24Vac to “Ylow/Y1” at the condenser and the compressor and condenser fan starts in low speed operation.

1.2 If first stage cooling cannot satisfy the demand, the room thermostat will energize “Y2” and supply 24Vac to the MBE/AEPF unit. The blower motor will change to the cfm for high speed operation and the VSTB will supply 24Vac to “Y/Y2” at the condenser and the compressor and condenser fan will change to high speed operation. When the “Y2” demand is satisfied, the thermostat will remove the “Y2” demand and the VSTB will remove the 24Vac from “Y/Y2” at the condenser. The blower will drop to 60% of the programmed cfm and the compressor and condenser fan will change to low speed. On most

digital/electronic thermostats, “Y2” will remain energized until the first stage cooling demand “Y1” is satisfied and then the “G”, “Y1” and “Y2” demands will be removed.

1.3 When the first stage cooling demand, “Y1”, is satisfied,

the room thermostat removes the 24Vac from “G” and “Y1”. The MBE/AEPF removes the 24Vac from “Ylow/ Y1’ 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

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.

SERVICING

For the 3rd and 4th heater elements to operate on a second stage heat demand, the PJ4 jumper on the VSTB inside the MBE/AEPF must be cut. With the PJ4 jumper

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

MBE/AEPF WITH TWO ST AGE ASZ & DSZ HEAT PUMP UNITS

3.0 Cooling Operation When used with the ASZ & DSZ two stage heat

pumpS, dip switch #4 must be set to the OFF position on the VSTB inside the MBE/AEPF. The “Y1” output

from the indoor thermostat must be connected to the purple wire labeled “Ylow/Y1” inside the wire bundle marked “Thermostat” and the purple wire labeled “Ylow/ Y1” inside the wire bundle marked “Outdoor Unit” must be connected to “Y” at the heat pump. The “Y2” 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/ Y2” at the heat pump. The orange jumper wire from

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

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 “Y1” and 24Vac is supplied to “G” and “Ylow/Y1” of the MBE unit. The VSTB inside the MBE will turn on the blower motor and the motor will ramp up to 60% of 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 heat pump and the compressor and outdoor fan starts in low speed operation.

3.2 If first stage cooling cannot satisfy the demand, the room thermostat will energize “Y2” and supply 24Vac to “Y/ Y2”of the MBE unit. The blower motor will change to the cfm for high speed operation and the VSTB will supply 24Vac to “Y2” at the heat pump. The compressor and outdoor fan will change to high speed operation. When the “Y2” demand is satisfied, the thermostat will remove the “Y2” demand and the VSTB will remove the 24Vac from “Y2” at the heat pump. The blower will drop to 60% of the programmed cfm and the compressor and outdoor fan will change to low speed operation. On most digital/

electronic thermostats, “Y2” will remain energized until the first stage cooling demand “Y1” is satisfied and then the “G”, “Y1” and “Y2” demands will be removed.

3.3 When the first stage cooling demand, “Y1”, is satisfied,

the room thermostat removes the 24Vac from “G” and “Y1”. The VSTB removes the 24Vac from “Y’ at the heat pump and the compressor and outdoor fan are turned off. The blower motor will ramp down to a complete stop based on the time and 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 “G” and “Y1” and 24Vac is supplied to “G” and “Ylo/Y1” of the MBE/AEPF. The VSTB will turn on the blower motor and the motor will ramp up to 60% of 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. The

compressor will start on high speed and outdoor fan will start on low speed on a “Y1” heating demand but the blower motor will deliver only 60% of the programmed cfm for high speed heating operation.

4.2 If a thermostat that provides a “Y2” demand in heating is

used and first stage heating cannot satisfy the demand, the room thermostat will energize “Y2” and supply 24Vac to “Y/Y2” of the MBE unit. The blower motor will change to the cfm for high speed heating operation and the VSTB will supply 24Vac to “Y/Y2” at the heat pump.

SERVICING

The outdoor fan will change to high speed operation. If the “Y2” demand is present and becomes satisfied, the thermostat will remove the “Y2” demand and the VSTB will remove the 24Vac from “Y/Y2” at the heat pump. The blower will drop to 60% of the programmed cfm and the outdoor fan will change to low speed. On most digital/ electronic thermostats, “Y2” will remain energized until the first stage heating demand “Y1” is satisfied and then the “G”, “Y1” and “Y2” demands will be removed.

4.3 If the heat pump operation cannot satisfy the demand, the room thermostat energizes “W2/W3” and 24Vac is supplied to terminal “E/W1” of the VSTB inside the MBE/ AEPF unit. The VSTB will supply 24Vac to heat sequencer HR1 on the electric heater assembly.

4.4 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 auxiliary heat demand, the PJ4 jumper on the VSTB inside the MBE/AEPF must be cut. If the “W2/

W3” demand cannot be satisfied by the heat pump, the temperature indoors will continue to drop. The room thermostat will then energize “W3/W4” 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/W4” demand is satisfied, the room thermostat will remove the 24Vac from “W/W2” of the MBE/AEPF. 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/W4” will remain energized until the first stage demand “Y1” is satisfied and then the “G”, “Y1”, “Y2” “W2/W3” and “W3/W4” demands will be removed.

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

where the “W2/W3” demand is satisfied. When this happens, the room thermostat will remove the 24Vac from “E/W1” of the MBE/AEPF. The contacts on HR1 will open between 30 to 70 seconds and turn off the 1st and 2nd heater elements. If the “Y2” demand is present and becomes satisfied the room thermostat will remove the 24Vac from “Y/Y2” of the MBE and the blower motor will change to 60% of the programmed cfm. The VSTB will remove the 24Vac from “Y/Y2” at the heat pump and the outdoor fan will change to low speed operation. The heat pump remains on along with the blower motor because the “Y1” demand for first stage heat will still be present.

4.6 When the first stage heat demand “Y1” is satisfied, the room thermostat will remove the 24Vac from “G” and “Ylo/ Y1” of the MBE/AEPF. The VSTB removes the 24Vac from “Ylo/Y1” at the heat pump and the compressor and outdoor fan are 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.

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 installation.

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

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

SERVICING

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 on the right.

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

4.8KW7.2KW9.6KW14.4KW19.2KW24.0KW28.8 KW

ELECTRIC HEATER CAPACITY BTUH

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

BTUH 10200 16200 20400 23800 32400 48600 66500 71600

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.

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.

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 A LL power before servicing.

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

SERVICING

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 A LL 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.

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-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:

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.

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

2. Plug or cap all openings.

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

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

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

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

S-101 LEAK TESTING

(NITROGEN OR NITROGEN-TRACED)

WARNING

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

WARNING

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

Pressure test the system using dry nitrogen and soapy water to locate leaks. If you wish to use a leak detector, charge the system to 10 psi using the appropriate refrigerant then use nitrogen to finish charging the system to working pressure, then apply the detector to suspect areas. If leaks are found, repair them. After repair, repeat the pressure test. If no leaks exist, proceed to system evacuation.

S-102 EVACUATION

WARNING

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

SERVICING

IMPORTANT NOTE: Because of the potential damage to compressors, do not allow suction pressure at service valve to drop below 20 PSIG when pumping unit system down for repair. Outdoor section, depending on line set length and amount of charge in system, may not be able to hold the entire system charge.

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.

WARNING

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

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.

LOW SIDE

GAUGE

AND V ALVE

800 PSI

RATED

HOSES

UNIT SERVICE

VALVE PORTS

HIGH SIDE

GAUGE

AND V ALVE

VACUUM PUMP

ADAPTER

VACUUM PUMP

CHARGING

CYLINDER

AND SCALE

EVACUATION

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 pump. Shut off pump and prepare to charge.

S-103 CHARGING

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 refrigerant cert if ied to AHRI standards. Use d refrigerant may cause compressor damage an d will void the warranty. Most portable machines cannot clean used refrigera nt to meet AHRI standards .

CAUTIO N

Operating the compressor with the suction valve closed will vo id 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.

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

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

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

6. Check system for leaks.

Do not charge a remote condensing unit with a non-matching evaporator coil, or a system where the charge quantity is unknown. Do not install or charge R410A condensers matched with coils having capillary tubes or flow control restrictors. AHRI rated Coil combinations with thermostatic expansion valves (TEV's) should be charged by subcooling. See "Checking Subcooling and Superheat" sections in this manual. Subcooling values for "Ultron" system are found in the Technical Information manuals for "Ultron" outdoor units.

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

S-104 CHECKING COMPRESSOR

EFFICIENCY

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

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

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

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

If the test shows: a. Below normal high side pressure. b. Above normal low side pressure. c. Low temperature difference across coil. d. Low amp draw at compressor. And the charge is correct. The compressor is faulty - replace

the compressor.

Final Charge Adjustment

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

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

SERVICING

S-105A PISTON CHART FOR ASX13, GSX13,

SSX14, ASX14, ASZ13, GSZ13 units

Remote

Condenser

A/GS X1 30181A

A/GSX130181B

A/GS X1 30241A

A/GSX130241B

A/GSX130301

A/GSX130301B

A/GS X1 30361A

A/GSX130361B

A/GS X1 30421A

A/GSX130421B

A/GS X1 30481A

A/GSX130481B

A/GSX130601

SSX140181A SSX140241A SSX140301A SSX140361A SSX140421A SSX140421B SSX140481A

SSX140601A A/SSX140181B A/SSX140241B A/SSX140301B A/SSX140361B

Orifice

Size

0.049

0.051

0.053

0.057

0.059

0.061

0.068

0.070

0.074

0.076

0.080

0.092

0.049

0.057

0.063

0.067

0.074

0.079

0.088

0.052

0.055

0.065

0.070

Remote

Heat Pump A/GSZ130181 A/GSZ130241

A/GSZ130301 A/GSZ130361 A/GSZ130421 A/GSZ130481 A/GSZ130601 SSZ140361A * SSZ140421A * SSZ140481A * SSZ140601A *

Orifice

0.049

0.057

0.063

0.068

0.074

0.078

0.088

0.071

0.076

0.080

0.088

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

COOLING HEATING

TXV VALVES

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

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

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

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

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

SERVICING

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

°F

-37.7

-34.7

-32.0

-29.4

-36.9

-24.5

-22.2

-20.0

-17.9

-15.8

-13.8

-11.9

-10.1

-8.3

-6.5

-4.5

-3.2

-1.6

0.0

1.5

3.0

4.5

5.9

7.3

8.6

10.0

11.3

12.6

13.8

15.1

16.3

17.5

18.7

19.8

21.0

22.1

23.2

24.3

25.4

26.4

27.4

28.5

29.5

30.5

31.2

32.2

33.2

34.1

35.1

35.5

36.9

PSIG

100 102 104 106 108 110 112

PSIG

114.0

116.0

118.0

120.0

122.0

124.0

126.0

128.0

130.0

132.0

134.0

136.0

138.0

140.0

142.0

144.0

146.0

148.0

150.0

152.0

154.0

156.0

158.0

160.0

162.0

164.0

166.0

168.0

170.0

172.0

174.0

176.0

178.0

180.0

182.0

184.0

186.0

188.0

190.0

192.0

194.0

196.0

198.0

200.0

202.0

204.0

206.0

208.0

210.0

212.0

214.0

Pressure vs. Temperature Chart

R-410A

°F

37.8

38.7

39.5

40.5

41.3

42.2

43.0

43.8

44.7

45.5

46.3

47.1

47.9

48.7

49.5

50.3

51.1

51.8

52.5

53.3

54.0

54.8

55.5

56.2

57.0

57.7

58.4

59.0

59.8

60.5

61.1

61.8

62.5

63.1

63.8

64.5

65.1

65.8

66.4

67.0

67.7

68.3

68.9

69.5

70.1

70.7

71.4

72.0

72.6

73.2

73.8

PSIG

216.0

218.0

220.0

222.0

224.0

226.0

228.0

230.0

232.0

234.0

236.0

238.0

240.0

242.0

244.0

246.0

248.0

250.0

252.0

254.0

256.0

258.0

260.0

262.0

264.0

266.0

268.0

270.0

272.0

274.0

276.0

278.0

280.0

282.0

284.0

286.0

288.0

290.0

292.0

294.0

296.0

298.0

300.0

302.0

304.0

306.0

308.0

310.0

312.0

314.0

316.0

°F

74.3

74.9

75.5

76.1

76.7

77.2

77.8

78.4

78.9

79.5

80.0

80.6

81.1

81.6

82.2

82.7

83.3

83.8

84.3

84.8

85.4

85.9

86.4

86.9

87.4

87.9

88.4

88.9

89.4

89.9

90.4

90.9

91.4

91.9

92.4

92.8

93.3

93.8

94.3

94.8

95.2

95.7

96.2

96.6

97.1

97.5

98.0

98.4

98.9

99.3

99.7

PSIG

318.0

320.0

322.0

324.0

326.0

328.0

330.0

332.0

334.0

336.0

338.0

340.0

342.0

344.0

346.0

348.0

350.0

352.0

354.0

356.0

358.0

360.0

362.0

364.0

366.0

368.0

370.0

372.0

374.0

376.0

378.0

380.0

382.0

384.0

386.0

388.0

390.0

392.0

394.0

396.0

398.0

400.0

402.0

404.0

406.0

408.0

410.0

412.0

414.0

416.0

418.0

°F

100.2

100.7

101.1

101.6

102.0

102.4

102.9

103.3

103.7

104.2

104.6

105.1

105.4

105.8

106.3

106.6

107.1

107.5

107.9

108.3

108.8

109.2

109.6

110.0

110.4

110.8

111.2

111.6

112.0

112.4

112.6

113.1

113.5

113.9

114.3

114.7

115.0

115.5

115.8

116.2

116.6

117.0

117.3

117.7

118.1

118.5

118.8

119.2

119.6

119.9

120.3

PSIG

420.0

422.0

424.0

426.0

428.0

430.0

432.0

434.0

436.0

438.0

440.0

442.0

444.0

446.0

448.0

450.0

452.0

454.0

456.0

458.0

460.0

462.0

464.0

466.0

468.0

470.0

472.0

474.0

476.0

478.0

480.0

482.0

484.0

486.0

488.0

490.0

492.0

494.0

496.0

498.0

500.0

502.0

504.0

506.0

508.0

510.0

512.0

514.0

516.0

518.0

520.0

°F

120.7

121.0

121.4

121.7

122.1

122.5

122.8

123.2

123.5

123.9

124.2

124.6

124.9

125.3

125.6

126.0

126.3

126.6

127.0

127.3

127.7

128.0

128.3

128.7

129.0

129.3

129.7

130.0

130.3

130.7

131.0

131.3

131.6

132.0

132.3

132.6

132.9

133.3

133.6

133.9

134.0

134.5

134.8

135.2

135.5

135.8

136.1

136.4

136.7

137.0

137.3

PSIG

522.0

524.0

526.0

528.0

530.0

532.0

534.0

536.0

538.0

540.0

544.0

548.0

552.0

556.0

560.0

564.0

568.0

572.0

576.0

580.0

584.0

588.0

592.0

596.0

600.0

604.0

608.0

612.0

616.0

620.0

624.0

628.0

632.0

636.0

640.0

644.0

648.0

652.0

656.0

660.0

664.0

668.0

672.0

676.0

680.0

684.0

688.0

692.0

696.0

°F

137.6

137.9

138.3

138.6

138.9

139.2

139.5

139.8

140.1

140.4

141.0

141.6

142.1

142.7

143.3

143.9

144.5

145.0

145.6

146.2

146.7

147.3

147.9

148.4

149.0

149.5

150.1

150.6

151.2

151.7

152.3

152.8

153.4

153.9

154.5

155.0

155.5

156.1

156.6

157.1

157.7

158.2

158.7

159.2

159.8

160.3

160.8

161.3

161.8

*Based on ALLIED SIGNAL Data

SERVICING

REQUIRED LIQUID LINE TEMPERATURE

LIQUID PRESSURE

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

189 58 56 54 52 50 48 195 60 58 56 54 52 50 202 62 60 58 56 54 52 208 64 62 60 58 56 54 215 66 64 62 60 58 56 222 68 66 64 62 60 58 229 70 68 66 64 62 60 236 72 70 68 66 64 62 243 74 72 70 68 66 64 251 76 74 72 70 68 66 259 78 76 74 72 70 68 266 80 78 76 74 72 70 274 82 80 78 76 74 72 283 84 82 80 78 76 74 291 86 84 82 80 78 76 299 88 86 84 82 80 78 308 90 88 86 84 82 80 317 92 90 88 86 84 82 326 94 92 90 88 86 84 335 96 94 92 90 88 86 345 98 96 94 92 90 88 354 100 98 96 94 92 90 364 102 100 98 96 94 92 374 104 102 100 98 96 94 384 106 104 102 100 98 96 395 108 106 104 102 100 98 406 110 108 106 104 102 100 416 112 110 108 106 104 102 427 114 112 110 108 106 104 439 116 114 112 110 108 106 450 118 116 114 112 110 108 462 120 118 116 114 112 110 474 122 120 118 116 114 112 486 124 122 120 118 116 114 499 126 124 122 120 118 116 511 128 126 124 122 120 118

REQUIRED SUBCOOLING TEMPERATURE (°F)

SERVICING

S-106 OVERFEEDING

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

If these symptoms are observed:

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

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

3. Check for restricted or plugged equalizer tube.

S-107 UNDERFEEDING

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

If these symptoms are observed:

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

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

S-108 SUPERHEAT

The expansion valves are factory adjusted to maintain 8 to 12 degrees superheat of the suction gas. Before checking the superheat or replacing the valve, perform all the procedures outlined under Air Flow, Refrigerant Charge, Expansion Valve

- Overfeeding, Underfeeding. These are the most common

causes for evaporator malfunction.

CHECKING SUPERHEAT

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

CAUTION

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

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

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

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

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

EXAMPLE:

a. Suction Pressure = 143 b. Corresponding Temp. °F. = 50 c. Thermometer on Suction Line = 61°F.

To obtain the degrees temperature of superheat, subtract

50.0 from 61.0°F. The difference is 11° Superheat. The 11° Superheat would fall

in the ± range of allowable superheat.

SUPERHEAT AND SUBCOOLING ADJUSTMENT ON TXV APPLICATIONS

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

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

3. Check subcooling and superheat. Systems with TXV application should have a subcooling and superheat of 7 ± 2ºF.

a. If subcooling and superheat are low, adjust TXV

to 7 - 9ºF then check subcooling.

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

charge to raise subcooling to 7 ± 2ºF then check superheat.

c. If subcooling and superheat are high, adjust TXV

valve to 7 ± 9ºF then check subcooling.

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

TXV valve to 7 to 9ºF superheat and remove charge to lower the subcooling to 7 ± 2ºF.

The TXV should NOT be adjusted at light load conditions 55º to 60ºF, under such conditions only the subcooling can be evaluated. This is because suction pressure is dependent on the indoor coil match, indoor airflow, and wet bulb temperature. NOTE: Do NOT adjust charge based on suction pressure unless there is a gross undercharge.

4. Disconnect manifold set. Installation is complete.

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.

SERVICING

4. Review the technical information manual or specification sheet for the model being serviced to obtain the design subcooling.

5. Compare the hi-pressure reading to the "Required Liquid Line Temperature" chart (page 43). Find the hi-pressure value on the left column. Follow that line right to the column under the design subcooling value. Where the two intersect is the required liquid line temperature.

Alternately you can convert the liquid line pressure gauge reading to temperature by finding the gauge reading in Temperature - Pressure Chart and reading to the left, find the temperature in the °F. Column.

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

Add charge to raise subcooling. Recover charge to lower subcooling.

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

EXAMPLE:

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

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

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

S-109A TWO SPEED APPLICATION

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

1. Purge gauge lines. Connect service gauge manifold to base-valve service ports. Run system at least 10 minutes to allow pressure to stabilize.

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

3. Check subcooling and superheat. Systems with TXV application should have a subcooling of 5 to 7 ºF and superheat of 7 to 9 ºF.

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

7 to 9 ºF superheat, then check subcooling. NOTE: To adjust superheat, turn the valve stem

clockwise to increase and counter clockwise to decrease.

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

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

c. If subcooling and superheat are high, adjust TXV

valve to 7 to 9 ºF superheat, then check subcooling.

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

TXV valve to 7 to 9 ºF superheat and remove charge to lower the subcooling to 5 to 7 ºF.

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

4. Disconnect manifold set, installation is complete.

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

S-110 CHECKING EXPANSION VALVE

OPERATION

1. Remove the remote bulb of the expansion valve from the suction line.

2. Start the system and cool the bulb in a container of ice water, closing the valve. As you cool the bulb, the suction pressure should fall and the suction temperature will rise.

3. Next warm the bulb in your hand. As you warm the bulb, the suction pressure should rise and the suction temperature will fall.

4. If a temperature or pressure change is noticed, the expansion valve is operating. If no change is noticed, the valve is restricted, the power element is faulty, or the equalizer tube is plugged.

5. Capture the charge, replace the valve and drier, evacuate and recharge.

S-111 FIXED ORIFICE RESTRICTOR DEVICES

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

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

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

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

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

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

A strainer is placed on the entering side of the tube to prevent any foreign material from becoming lodged inside the fixed orifice restriction device.

If a restriction should become evident, proceed as follows:

1. Recover refrigerant charge.

SERVICING

2. Remove the orifice or tube strainer assembly and replace.

3. Replace liquid line drier, evacuate and recharge.

CHECKING EQUALIZATION TIME

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

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

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

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

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

S-112 CHECKING RESTRICTED LIQUID LINE

When the system is operating, the liquid line is warm to the touch. If the liquid line is restricted, a definite temperature drop will be noticed at the point of restriction. In severe cases, frost will form at the restriction and extend down the line in the direction of the flow.

Discharge and suction pressures will be low, giving the appearance of an undercharged unit. However, the unit will have normal to high subcooling.

Locate the restriction, replace the restricted part, replace drier, evacuate and recharge.

S-113 OVERCHARGE OF REFRIGERANT

An overcharge of refrigerant is normally indicated by an excessively high head pressure.

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

An evaporator coil, using a capillary tube metering device, could allow refrigerant to return to the compressor under extreme overcharge conditions. Also with a capillary tube metering device, extreme cases of insufficient indoor air can cause icing of the indoor coil and liquid return to the compressor, but the head pressure would be lower.

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

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

If this system is observed:

1. Start the system.

2. Remove and capture small quantities of gas from the suction line dill valve until the head pressure is reduced to normal.

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

S-114 NON-CONDENSABLES

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

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

S-115 COMPRESSOR BURNOUT

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

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

NOTICE

Violation of EPA regulations may result in fines or other penalties.

Now determine if a burn out has actually occurred. Confirm by analyzing an oil sample using a Sporlan Acid Test Kit, AK3 or its equivalent.

Remove the compressor and obtain an oil sample from the suction stub. If the oil is not acidic, either a burnout has not occurred or the burnout is so mild that a complete clean-up is not necessary.

If acid level is unacceptable, the system must be cleaned by using the clean-up drier method.

CAUTIO N

Do no t allow the slud ge or oil to con tact the skin . Severe bu rns may result.

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

longer approved by Amana® Brand Heating-Cooling.

Suction Line Drier Clean-Up Method

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

Use AMANA® 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.

SERVICING

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.

2. For all line set applications over 80 feet a TXV is recommended. The subcooling should be 6º ± 2º.

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 4 &

5) and recalculated system capacity.

Equivalent length =

Length horizontal + Length vertical + Losses from bends (see Tables 4 & 5)

Example using ¾” elbow:

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.

POE oils maintain a consistent viscosity over a large temperature range which aids in the oil return to the compressor; however, there will be some installations which require oil return traps. These installations should be avoided whenever possible, as adding oil traps to the refrigerant lines also increases the opportunity for debris and moisture to be introduced into the system. Avoid long running traps in horizontal suction line.

LONG LINE SET APPLICATION R-410A

This long line set application guideline applies to all AHRI listed R-410A 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 80 feet in actual length.

Accessories for lines greater than 80 feet:

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 required for any long line application (50 watt minimum).

150 feet of straight tubing + (four short radius elbows x 1.7) + (2 long radius elbows x 1.5) = 150 + 3.4 +3 =

156.4 equivalent feet.

2. For any residential split system installed with a long line set, 3/8" liquid line size must be used. 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 life-span.

3. Single Stage Condensing Unit: The maximum length of tubing must not exceed 150 feet.

•80 feet is the maximum recommended vertical difference between the condenser and evaporator when the evaporator is above the condenser. Equivalent length is not to exceed 150 feet.

•The vertical difference between the condenser and evaporator when the evaporator is below the condenser can approach 150 feet, as long as the equivalent length does not exceed 150 feet.

•The distance between the condenser and evaporator in a completely horizontal installation in which the indoor and outdoor unit do not differ more than 10 feet in vertical distance from each other can approach 150 feet, as long as the equivalent length does not exceed 150 feet.

SERVICING

4. Two-Stage Condensing Unit: The maximum length of tubing must not exceed 80 feet where 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. Most refrigerant tubing kits are supplied with 3/8"-

thick insulation on the vapor line. For long line installations over 80 feet that pass through a high ambient temperature, ½”-thick suction line insulation is recommended to reduce loss of capacity. Insulate the liquid line if it passes through an area of 120°F or greater. Do not attach the liquid line to any non-insulated portion of the suction line.

6. 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 vibrationisolating hardware when mounting line set to adjacent structure.

Table 4 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 5 lists the equivalent length gained from adding bends to the suction line. Properly size the suction

line to minimize capacity loss.

T ABLE 4. CAP ACITY MUL TIPLIERS AS A FUNCTION OF

SUCTION LINE SIZE & EQUIV ALENT LENGTH

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

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

Nominal

capacity

18,000 3/4 24,000 3/4 30,000 3/4

36,000

42,000

48,000

60,000

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.

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.

Fig 6. Evaporator unit with inverted vapor loop

3. An oil trap is required at the evaporator if the condenser is above the evaporator. Depending on the vertical rise of the line set, oil traps are required in the suction line. Oil traps should be installed at equal intervals along the suction line. Install 1 oil trap for a height difference of 15–25 feet between indoor and outdoor units. Install 2 oil traps for a difference of 26-50 ft, 3 for 51-100 ft, and 4 for 101-150 ft. 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 5).

T ABLE 5. LOSSES FROM SUCTION LINE ELBOWS

(EQUIV ALENT 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.)

SERVICING

Mounting the condensing unit above the evaporator coil will require oil traps at equal intervals along the suction line. Install 1 oil trap for a height difference of 15-25 feet between indoor and outdoor units.

Install 2 oil traps for a difference of 26-50 feet, 3 for 51-100 feet, and 4 for 101-150 feet.

Fig 7. Oil Trap Placement

Remember, 3/8" liquid tubing is required for all long line set applications.

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.

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.

Oil Trap Construction

Long Radius Street Ell

45 °

Ell

45°

Street

Ell

Short Radius

Street Ell

Fig 8. 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.

Initial System Charging

R-410A 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.

NO ADDITIONAL COMPRESSOR OIL IS NEEDED FOR LONG LINE SET APPLICATIONS ON RESIDENTIAL SPLIT SYSTEMS.

S-202 DUCT STATIC PRESSURES AND/OR

STATIC PRESSURE DROP ACROSS COILS

This minimum and maximum allowable duct static pressure for the indoor sections are found in the specifications section.

Tables are also provided for each coil, listing quantity of air (CFM) versus static pressure drop across the coil.

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

S-203 AIR HANDLER EXTERNAL STATIC

To determine proper air movement, proceed as follows:

1. Using a draft gauge (inclined manometer), measure the static pressure of the return duct at the inlet of the unit, (Negative Pressure).

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

Use subcooling as the primary method for final system charging of long line set system application.

Extra refrigerant needed =

(Linear feet of line set – 15 ft.) x X oz./ft.

Where X = 0.6 for 3/8" liquid tubing

SERVICING

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.

TOTAL EXTERNAL STATIC

S-204 COIL STATIC PRESSURE DROP

1. Using a draft gauge (inclined manometer), connect the positive probe underneath the coil and the negative probe above the coil.

2. A direct reading can be taken of the static pressure drop across the coil.

3. Consult proper table for quantity of air.

STATIC PRESSURE DROP

If the total external static pressure and/or static pressure drop exceeds the maximum or minimum allowable statics, check for closed dampers, dirty filters, undersized or poorly laid out duct work.

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 THERMOSTAT

CALL FOR 2ND STAGE FURN AC E HEAT

CALL FOR 2ND STAGE COMPRESSOR

POWER SUPPLY OUT TO HP CONTROL

HP CALL FOR FURNACE (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 FOR ODT

1 2

ALL FUEL 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 Heat and Two Stage Thermostat

From Air Handler

OT/EHR18-60 #1

BLUE

WHITE

BROWN

BLACK RED

ITE

EEN

BLUE

CGW2 R

BROWN

W2 W3

EMERGENCY

HEAT

RELAY

THERMOSTAT

OT/EHR18-60 #2

EMERGENCY

HEAT

RELAY

THERMOSTAT

BLUE

WHITE

BROWN

BLACK RED

CRW2OY

RED

RANGE

YEL

ITE

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

WH6BR

HTR1

HTR2

HTR3

HTR4

M5 M6

COM

SEE NOTE 1

EBTDR

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 TL

THERMAL LIMIT

HTR HEAT ELEMENTS

M7 M8

PLM

PLF

EBTDR

NOTE 2

0140M00037

PLM

PLF

TLHTR2

HTR1 TL

M1M2M3

L2L1

EQUIPMENT GROUND

USE COPPER OR ALUMINUM WIRE

GRD

4 5 678 9

4 5WH67489

SEE

NOTE

L2 L1 L2

HTR1

HTR2

HTR3

PLM

PLF

HTR1

L1 L2

ONE (1) ELEMENT ROWS TWO (2) ELEMENT ROWS THREE (3) ELEMENT ROWS FOUR (4) ELEMENT ROWS

NOTE: WHEN INSTALLING HEATER KIT, ENSURE SPEED TAP DOES NOT EX CEED 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

R G

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 WIRES 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

(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 composite wiring diagrams in installation instructions for proper low voltage wiring connections.

3) Confirm speed tap selected is appropriate for application. 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) Brown 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

GREEN

PURPLE

BROWN WHITEWH

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.

L2L1 L1 L2

TO L OW VOLTAGE TERMINAL BOARD

PL2

PJ4

ONENT CODE

HTR

HTR2

HTR3

HTR4

M1 M2

YCON

IN4005

DIODE

Y1YY2

SEE NOTE 1

FACTORY W IRING HIGH VOLTAGE LOW VO LTAGE FIELD W IRING HIGH VOLTAGE LOW VO LTAGE

THE RM AL LIMIT HEAT ELEM ENT RELAY

TLHTR1

BL BK

NOTE DIODE ON VSTB

IRING CODE

M5 M6

SEE

NOTE 4

*SEE N O TE 7

PL1

1PL2

PL2

01 40A0 0000 P

HTR1

L1 L2

ONE (1) ELEMEN T R OWS TWO (2) ELEMENT ROWS THREE (3) ELEMENT ROWS FOUR (4) EL EMENT ROWS

AFTER INSTALLING OPTIONAL HEAT KIT, MARK AN "X" IN THE PROVIDED ABOVE.

* SEE NOTE 7

LOW VOLTAGE

FIELD CON NECTION

BOX

PN. B136 8270 REV. A

R YCON

HUM

PJ6

DS1

COPPER

POWER SUPPLY

(SE E R AT IN G PL ATE )

CONTR O LS SHOW N WITH UTILITIES IN "ON" POS ITION AND TH E RM OSTAT IN "OFF" POSITION. IF REPLACEMENT OF THE ORIGINAL WIRES SUPPLIED WITH THIS ASSEMBLY IS NECESSARY, USE 105°C. WIRE. SIZE TO CONFORM TO THE NATIONA L E L ECT RI C C ODE.

CONDE NSER

OT2

OT1

COM W 2OED

HEATPUMP

PJ2

PJ4

HEATER

24 VAC

J3J2

CONDENSER

THERMOSTAT

YCON

W2 R

W/W2

OTC OT1 COT2OE\ W1

OUTDO OR

THERMOST

R Y1 G

R PU

Y/Y2

HUMIDISTAT

HUM

EQUIPMENT GROUND

HTR2

HTR1

M1M2M3

L2L1

MARK ACCORDING TO NUMBER OF HEATER ELEM ENT ROWS INST ALLED

NO MARK INDICATES NO HEAT KIT INSTALLED

L2 L1 L2

HTR1

HTR2

HTR3

Y1C

Y/Y2

PUW

RYG

USE COPPER WIRE

PL1

PL2

1R23

312

SEE NOTE 8

4567 89

456789

240

208

COM

24V

OTES:

1. FOR HEAT PUMP APPLICATION S REMOVE 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 TH ERMOSTAT TO Y/Y2 ONLY, TAPE OR REMOVE Y1 CONNECTION. CONNECT CONDENSING UNIT TO YCON & C.

5. WHEN HUMIDSTAT IS PROVIDED CUT PJ6. THERMOSTAT OPEN S ON HUM IDITY RISE.

6. RED WIRES TO BE ON TRANSFORMER TERM INAL 3 FOR 240 VOLTS AND ON TERMINAL 2 FOR 208 VOLTS.

7. SEE COMPOSITE WIRING DIAGRAMS IN INSTALLATION INSTRUCTIONS FOR PROPER LOW VOLTAGE

CONNECTIONS AND DETAILS ON COMPATIBLE THERM OSTATS AND THEIR CONNECTIONS.

8. DISCARD ORIGINAL "PL1" PLUG CONNECTOR WHEN INSTALLING OPTI ONAL 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

W2W E

SEE NOTE 2

COLOR CODE

BLACKBK RED YELLOW BLUE

EVAPORATOR MOTOR PLUG PROGRAM JUMPER

VARIABLE SPEED TRANSFORMERVSTB TR

PU PURPLE 0

COMP

TERMINAL BOARD

GREENG BROWNBR

ORANGE PINK

208/240 VOLTS

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

YCON

W/W2

CONDENSER

COMW2O

OT1 OT2

HUM

COM

OTC OT1 COT2OE\W1

HEATPUMP

OUTDOOR

PJ4 PJ2 PJ6

THERMOSTATS

HEATER

RY1

24 VAC

VSTB

HUMIDISTAT

HUM

Y/Y2

J3J2

DS1

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) ELEMEN T ROWS THREE (3) ELEMENT RO WS FOUR (4) ELEMENT ROWS

NOTE: WH EN INSTALLING HEATER KI T, ENSU R E SPEED TAP DOES NOT EXC EE D MINIM UM BLOWER SPEED (MBS) SPECIFIED FOR THE AIRHANDLER/HEAT ER

RCG W1W2 Y2Y1 O

XFMR-R

COM

EBTDR

XFMR-C C

COPPER OR ALUMINUM

POWER SUPPLY

(SEE RA T ING PL ATE)

USE MIN. 75°C F IELD WIRE

IF REPLACEMENT OF THE ORIGINAL WIRES SUPPLIED WITH THIS ASSEMBLY IS N ECESSARY, USE WIRE THAT CO NFORMS TO THE NATIONAL ELECT RIC CO DE .

NO NC

TLHTR2

PLM

SEE NOTE 3

PLF

HTR1 TL

L2L1

KIT COMBINATION ON TH IS UNIT'S S&R PLATE. AFTER INSTALLING OPTIONAL HEAT KIT, MARK AN "X" IN THE PROVIDED ABOVE. MARK ACCORDING TO NUMBER OF HEATER ELEMEN T ROWS INSTALLED. NO MARK INDICATES NO HEAT KIT INSTALLED.

TERMINAL BLOCK SHOWN

SEE NOTE 2

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

SEE NOTE 4

SEE NO TE 1

240

24V

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 M OTOR

EM TB

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 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.

Goodmans ASX, SSX, DSZ, GSZ, DSX User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual