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APG15 and 13 Service Manual

1. pa L2 INDUCER Li ODF ue LOW HIGH LOW PARK SO N K K6 fF Row KEY 8 2 C9 K7 Ut 92 Z un T s A NN 7X rad IN J V jJ U6 5 LAI A 4 07 3 2 04 VE ES E Le u m k2 U5 Ki N MZ w V y 1802 LL _ _ 2 SPEED UP 150 7 NONE Fi S FAULT BLOWER STAGE ECON RECALL OFF DELAY DELAY W1W2G 26 SYSTEM OPERATION Pin Voltage 24VAC Indoor Outdoor Thermostat IDT ODT Output 24 High Stage Compressor Output 24VAC Pressure Switch Loss of Charge Switch Input 24 Indoor Outdoor Thermostat IDT ODT Input 24VAC Pressure Switch Loss of Charge Switch Output 6 24VAC Low Stage Compressor Output Table 1 Circuit Definitions and Voltage Ratings for the 6 Circuit Connector Circuits Pim ose Function 2 Pressure Switch 2 Pressure Switch Input e unused Main Valve Low Table 2 Circuit Definitions and Voltage Ratings for the 9 Circuit Connector Circuits DI Low or Inducer Low Table 3 High
2. Internal Control Fault Micro Controller Detected Hardware Failure or Gas Valve Detected Energized When it Should be De energized Lockout Due to Excessive Retries Pressure Switch Stuck Closed Off Pressure Switch Stuck Open Open High Temperature Limit Flame Present Outside the Flame Same for Heat Indoor Thermostat Outdoor Thermostat Pressure Switch Loss of Charge Switch is Open Normal Red LED Fault Codes LED Flashes Status Flame Condition 2 Flame Present Outside the Flame Detect Mode Steady ON Low Flame Signal Current Steady ON Normal Flame No Flame Present Amber LED Flame Status Codes NOTE The flash rate is 0 25 seconds on 0 25 seconds off with a 2 second pause between codes NORMAL SEQUENCE OF OPERATION DSI Direct Spark Ignition System PCBAG123 Board 1 Thermostat calls for heat by energizing W The control checks the pressure switch for open condition If the pressure switch is closed the control will flash code 3 and wait for the pressure switch to open 2 The induced draft motor is energized and the control flashes code 2 and waits for the pressure switch to close Once the pressure switch is closed the LED stops flashing andthe control begins timing the 15 second pre purge 62 Blower Delay Settings 22 speed up COOL HEAT UNUSED u a Di p I H B
3. A n d 14 ACCESSORIES SQUARE TO ROUND CONVERTER DOWNFLOW APPLICATIONS ao gt 12 1 4 143 4 22 3 4 16 0 22 1 4 160 y 1 12 1 4 74 143 4 7 y 22 3 4 180 22 1 4 180 N Y SQUARE TO ROUND CONVERTER HORIZONTAL APPLICATIONS LA LE Measurements are in inches 15 ACCESSORIES GPGHFR101 103 EXTERNAL HORIZONTAL FILTER RACK PRODUCT DESIGN Locations and Clearances NOTE To ensure proper condensate drainage unit must be installed in a level position In installations where the unit is installed above ground level and not serviceable from the ground Example Roof Top installations the installer must provide a service platform for the service person with rails orguards in accordance with local codes or ordinances or in their absence with the latest edition ofthe National Fuel Gas Code ANSI Z223 1 12 MIN 36 FOR SERVICE 36 MIN FOR SERVICE NOTE Roof overhang should be no more than 36 Minimum clearances are required to avoid air recirculation and keep the unit operating at pea
4. aun i 051 Control Board 3 Thecontrol energizes the spark igniter and gas valve for 7 seconds If flame is established the control goes into a 30 second heat on delay 4 Theindoor blower is energized at the heat speed after a 30 second on delay 5 The control monitors the safety circuit inputs flame and thermostat during operation 6 When the thermostat is satisfied the gas valve is de energized and the induced draft blower remains on for a 29 second post purge The indoor blower remains on for the selected heat blower off delay 90 120 or 150 seconds Indoor blower off timing begins when thermo stat call for heat ends Testing Direct Spark Ignition DSI systems Thermostat calling for heat 15 second prepurge time and 7 second trial for ignition 1 Checkfor230 VAC fromL 1 terminal of control module to L2 No voltage check wire connections continuity etc 2 Check for 24 at R to C thermostat terminals Novoltage check3 amp automotive type fuse on control board A blown fuse would indicate a short in the 24 VAC circuit thermostat or limit circuit b Voltage Present check limit auxiliary limit and rollout S 300 S 301 and S 302 If limit auxiliary limit and rollout are closed then check for 24 atthe gas valve terminals No 24 VAC at gas valve replace Control board SERVICING B1809918 Ignition Board Fault Codes Off Main Limit Switc
5. 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 1 Remove the wires from the auxiliary limit control termi nals 2 Using an ohmmeter test for continuity across the two terminals Noreading indicates the controlis open Push the red reset button test again if still open replace the control SERVICING VOLT OHM METER RED RESET BUTTON mc lt IDENTIFYING TAB TESTING AUXILIARY LIMIT CONTROL 5 302 CHECKING FLAME ROLLOUT SWITCH APG GPG units are equipped with a temperature activated manual reset control This control is mounted to the manifold assembly and is wired in series with the auxiliary limit and gas valve The control is designed to open should a flame roll out occur An over firing condition or flame impingement on the heat shield can also cause the control to open If the rollout control has opened the circuit between the ignition control and gas valve will be interrupted and the ignition control module will go into lockout The servicer should reset the ignition control by opening and closing the thermostat circuit The servicer should look for the ignitor glowing which indicates there is power to the ignition control The servicer should measure the voltage between each side of the rollout control and ground w
6. e 1 rest Votage Replace Vers Remove restriction or replace expansion device Bub Bra Tighten SERVICING GAS HEATING ANALYSIS CHART Complaint No Heat nsatisfactory Heat POSSIBLE CAUSE DOTS IN ANALYSIS GUIDE INDICATE amp POSSIBLE CAUSE 5 2 2 SYMPTOM 2 S Pow er Failure Blow Fuse oose Connection Shorted Broken Wires FaiyTemesst proper Sting improper Thermostat Location Faulty Limit or Rol Out Swich Fame Sensor Conr Valve or Gas Supply Shuto induced Draft 1 Dirty Flame Sensor Low uA _ Flame Sensor notin Low V FautyGasVave Figh Stage Heat Stage Ony DwenawdeUmt improper Air Locking out on Main Lit Delayedigniton Flashback Orifice Size Cracked Heat Exchanger Stuck Gas Valve Furnace Undersized PTT TT TTT TTT TTT TTT 5 PTET TEE EET TT et gt oo oo oo 000 pes Test Method Remedy e t Pre Sw itc See Service Procedure Reference S 1 5 4 5 2 5 3 5 4 5 3 5 4 5 313 5 3 5 300 5 301 5 302 5 314 5 313 5 304 5 303 5 314 5 314 5 304
7. 1 Discharge capacitor and remove wire leads WARNING Discharge capacitor through a 20 to 30 OHM resistor before handling CAPACITOR TESTING CAPACITOR RESISTANCE 2 Setanohmmeter 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 VOLTMETER NM CAPACITOR TESTING CAPACITANCE 41 SERVICING WARNING Discharge capacitor through a 20 to 30 OHM resistor before handling Capacitance MFD 2650 X Amperage Voltage S 16A CHECKING FAN AND BLOWER MOTOR WINDINGS PSC MOTORS The auto reset fan motor overload is designed to protect the motor against high temperature and high amperage condi tions by breaking the common circuit within the motor similar to the compressor internal overload However heat gener ated within the motoris faster to dissipate than the compres sor allow at least 45 minutes for the overload to reset then retest WARNING HIGH VOLTAGE Disconnect ALL power before servicing
8. ME 1 Ad WHLNA 3LIHM 2 LN31VAIQO3 021 06 LHO 4OINO 19154 39 18 NMOHS SV TIVLSNI NOILISOd IWNOLLdO HALAWOILNALOd S01 L 6 QV H38HVH lVISONWH3HI 10103501 UNIT MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH o I Lr 2 l lt oc gt amp oc LL m oc l lt 2 2 o HIGH VOLTAGE AVIS ME SLOVLNOO AV I3 ME MOTI3A 389 A warnine ACCESSORIES WIRING DIAGRAMS Wiring is subject to change Always refer to the wiring diagram on the unit for the most up to date wiring 64 ACCESSORIES WIRING DIAGRAMS ECONOMIZER HIGH VOLTAGE WARNING 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 ul 5 9 5 gt WIRING DIAGRAM FOR USE WITH ECONOMIZERS BUILT SINCE MARCH 2008 JUMPER C7150B MIXED AIR DISCHARGE lt SENSOR 0 2 10VDC INDOOR AIR SENSOR 5 Y CONTACTOR C7400 O
9. These Scroll compressors use POE or polyolester oil which is NOT compatible with mineral oilbased lubri cants like 3GS POE oil must be used if additional oil is required 18 Compliantscroll 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 Operating pressures and amp draws may differ from standard reciprocating compressors This information may be found in the Cooling Performance Data section Some models of the A GPG15 series package units use a 2 stage scroll compressor The basic scroll design has been modified with the addition of an internal unloading mechanism that opens a by pass port in the first compression pocket effectively reducing the displacement of the scroll The opening and closing of the by pass port is controlled by an internal electrically operated solenoid Modulation Ring amp Bypass Seals Solenoid Coil Assembly The ZPS 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 Bypass Ports Closed 100 Capacity Bypass Ports Open 67 Capacity A scroll is an involute spiral which when matched with a mating scroll form as shown generates a series of crescent shaped gas pocket
10. 24 BRAND MINOR Goodman REVISION Brand or REFRIGERANT Distinctions A Amana PRODUCT Brand SERIES MAJOR 15 Up to 15 SEER REVISION HEATING INPUT 070 69 000 BTUH 090 92 000 BTUH 115 115 000 BTUH 140 138 000 BTUH PRODUCT TYPE Single Package Cooling Heating VOLTAGE 1 208 230V 1ph 60Hz 3 208 230v 3ph 60Hz 4 460v 3ph 60Hz PRODUCT FAMILY G Gas Electric NOMINAL CAPACITY 24 24 000 BTUH 30 30 000 BTUH 36 36 000 BTUH 37 36 000 BTUH 42 42 000 BTUH 48 48 000 BTUH 49 48 000 BTUH 60 60 000 BTUH PRODUCT IDENTIFICATION Package Gas Units Single Phase A GPG1524 60 1AA Brand Goodman Brand Package Gas up to 15 Seer R410a gas electric units Initial release Amana Brand Goodman Brand Package Gas up to 15 Seer R410a A GPG1536 60 1AB gas electric units Sound improvements Change condenser motor and blade A GPG1530 1AA D A GPG1537 1AA Brand Goodman Brand Package Gas up to 15 Seer R410a A GPG1542 4AA gas electric units Initial release of 8 models that will complete 2009 Tax A GPG15 24 30 36 42 49 1AB Brand Goodman Brand Package Gas up to 15 Seer R410a A GPG15 36 48 60 1AC gas electric units Drain pan material change A GPG15 24 30 37 42 49 1AC Amana Brand Goodman Brand Package Gas up to 15 Seer R410a A GPG1560 1AD gas electric units Release of models with
11. 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 51 SERVICING 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 atthe restriction and extend down the line inthe 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 Anevaporator 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 u
12. WHEN SIZING A TRUNK LINE PER THE TABLES INCLUDE ALL APPLIANCES ON THAT LINE THAT COULD BE OPERATED SIMULTANEOUSLY The gas pipe supplying the unit mustbe properly sized based onthe cubicfeet per hour of gas flow required specific gravity ofthe gas andlength ofthe run The gaslineinstallation must comply with local codes or in the absence of local codes with the latest edition of the National Fuel Gas Code ANSI Z223 1 NATURAL GAS CAPACITY OF PIPE IN CUBIC FEET OF GAS PER HOUR CFH LENGTH OF NOMINAL BLACK PIPE SIZE 5 00 ww s 79 3 2 9 99 BTUH FURNACE INPUT 7 CALORIFIC VALUE OF GAS CONNECTING THE GAS PIPING NATURAL GAS 1 Use black iron or steel pipe and fittings for the building piping 2 Usepipejointcompound on male threads only Pipe joint compound must be resistantto the action of the fuel used 3 Use ground joint unions 4 Installadriplegtotrapdirtand moisture before itcan enter the gas valve The drip leg must be a minimum of three inches long 5 Use two pipe wrenches when making connection to the gas valve to keep it from turning 6 Installa manual shutoff valve This shutoff valve should be conveniently located within six 6 feet ofthe unit and between the meter and unit 7 Tighten all joints securely PRODUCT DESIGN 8 Connect the unit to the building piping by one of the following methods a metall
13. or installing this unit Multiple power sources may be present Failure to do so may cause property damage personal m or death 1 Remove the motor leads from its respective connection points and capacitor if applicable 2 Checkthe 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 Ifthe windings do nottest continuous ora reading is obtained from lead to ground replace the motor S 16C CHECKING ECM MOTOR WINDINGS WARNING 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 m or death 1 Disconnectthe 5 pin and the 16 pin connectors from the ECM power head 2 Removethe2 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 42 4 Using an ohmmeter check the motor windings for conti nuity to ground pins to motor shell If the ohmmeter indicates continuity to ground the motoris 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 overload device may be open Allow motor to cool and retest Motor Connector 3 Motor OK when gt 100k ohm 3 pin WINDING TEST S 16D
14. steady heat STEADY HEAT Control inputs are continuously monitored to ensure limit and pressure switches are closed flame is established and the thermostat call for heat remains POST PURGE When the thermostat demand for heat is satisfied the control immediately deenergizes the gas valve The inducer output remains on for a 29 second post purge period Heat Blower Off Delay The indoor blower motor is de energized after the selected blower off delay time Blower timing begins when the thermostat is satisfied Blower Off Delay Settings 5 wi Transformer 29 SYSTEM OPERATION Typical Package Cooling or Package Gas Indoor Outdoor Coil Coil Thermostatic Expansion Valve Restrictor Orifice Assy Either a thermostatic expansion valve or restrictor orifice assembly may be used depending on model refer to the parts catalog for the model being serviced Restrictor Orifice Assembly in Cooling 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 30 SCHEDULED MAINTENANCE Package gas units require regularly scheduled maintenance to preserve high performance standards prolongthe service life of the equipment and lessen the chances of costly failure In many i
15. 5 When brazing sweep the tubing with dry nitrogen to prevent the formation of oxides on the inside surfaces 6 Complete any repair by replacing the liquid line drier in the system evacuate and charge BRAZING MATERIALS Copper to Copper Joints Sil Fos used without flux alloy of 15 silver 80 copper and 5 phosphorous Recom mended heat 1400 F Copper to Steel Joints Silver Solder used without a flux alloy of 3096 silver 38 copper 32 zinc Recommended heat 1200 F 45 SERVICING S 101 LEAK TESTING NITROGEN OR NITROGEN TRACED WARNING To avoid the risk of fire or explosion never use oxygen high pressure air or flammable gases for leak testing of a refrigeration system WARNING To avoid possible explosion the line from the nitrogen cylinder must include a pressure regulator and a pressure relief 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 REFRIGERANT UNDER PRESSURE Failure to follow proper procedures may caus
16. CHECKING EEM MOTORS Applies to PG15 41A The EEM motor is a one piece fully encapsulated 3 phase brushless DC single phase AC input motor with ball bearing construction Unlike the ECM 2 3 2 5 motors the EEM features an integral control module Note The GE TECMate will not currently operate the EEM motor 1 Using a voltmeter check for 230 volts to the motor connections L and N If 230 volts is present proceed to step 2 If 230 volts is not present check the line voltage circuit to the motor 2 Using a voltmeter check for 24 volts from terminal C to either terminal 1 2 3 4 or 5 depending on which tap is being used at the motor If voltage present proceed to Step 3 If no voltage check 24 volt circuit to motor 3 If voltage was present in steps 1 and 2 the motor has failed and will need to be replaced Note Whenreplacing motor ensurethe belly band is between the vents on the motor andthe wiring has the proper drip loop to prevent condensate from entering the motor SERVICING High Voltage Connections 3 16 Low Voltage Connections EEM MOTOR CONNECTIONS S 17 CHECKING COMPRESSOR WARNING Hermetic compressor electrical terminal venting can be dangerous When insulating material which supports a hermetic compressor or electrical terminal suddenly disintegrates due to physical abuse or as a result of an electrical short between the terminal and the compressor housing the terminal ma
17. Voltage Terminals 27 SYSTEM OPERATION 2 Seconds within Flame Stabilization Period Flame Failure Response Time TEST 2 Seconds or Per ANSI Z21 20 Outside of Flame Stabilization Period Low to High Stage Delay Selectable 5 minutes or 10 minutes Default 10 minutes Heat ON Delay 30 Seconds Table 4 Control Timings coor Function Len rlashesistatus Normal Intrnal Gas Valve Fault Lockout Pressure Switch Stuck Closed Pressure Switch Stuck Open Open High Temperature Limit Flame Detected with Gas Valve De Energized Compressor Short Cycle Delay Active Limit Opened 5 Times in Same For Heat Indoor Thermostat Outdoor Thermostat is Open Pressure Switch Loss of Charge Switch is Open 5 Normal ff No Flame Present Low Flame Current Flame Detected with Gas Valve De energized Table 5 LED Status Codes and Corresponding System Condition Off 28 SYSTEM OPERATION PCBAG123 IGNITION CONTROL SEQUENCE OF OPERATION Continous Fan 1 When the thermostat calls for continuous fan G with out a call for heat or cooling the indoor the fan has a 7 second delay on make and energizes the HEAT speed The fan remains energized as long as the call forfan remains withouta call for heat or cooling The fan call G has a 60 second delay on break Note When the Configuration tab is broken the continuous fan mode will have a 7 second delay on make and a 60 second
18. do so may cause property damage personal m or death 1 Disconnect the motor wire leads from its connection point at integrated ignition control module 2 Using andohmmeter testfor 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 Ifthe windings do nottest continuous or a reading is obtained to ground replace the motor 4 After completing check and or replacement of induced draft blower motor 5 Turnonelectrical power and verify proper unit operation 5 304 TESTING GAS VALVE Direct Spark Ignition DSI Systems A combination redundant operator type gas valve which provides all manual and automatic control functions required for gas fired heating equipment is used on 13 SEER models Atwo stage combination redundant operatortype gas valve which provides all manual and automatic control functions required for gas fired heating equipmentis used on 15 SEER models The valve provides control of main burner gas flow pressure regulation and 100 percent safety shut off 56 WARNING 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 7 Ensure gas valve main gas supply 2 Using a voltmeter check from the purple and blue wires on 1 stage gas
19. faut proc der des operations d entretien 3 Pousse le levier du contr le du gaz ARRET position Ne pas forcer 4 Remettre en place le panneau d acc s 0140F00000P 15 11 ACCESSORIES ROOF CURBS 4 22 m d 15 8 4 a SUPPLY DOWNFLOW FILTER RACK PGFR101 102 103 ide 4 go 3 2 EP a 26 1 2 Filter Size 14 x 25 x 2 Measurement in inches NOTE PGFR cannot be used with downflow economizers 12 ACCESSORIES PGED103 DOWNFLOW ECONOMIZER PGED103 16 18 14 X 25 FILTER ATTACHMENT 16 X 20 x 2 FILTER 16 20 MIST ELIMINATOR ECONOMIZER HORIZONTAL APPLICATIONS Measurement in inches lt MODEL p FiLter ACCESSORIES MOTORIZED MANUAL FRESH AIR DAMPERS HORIZONTAL APPLICATIONS B A 7 5 8 CO 5 3 4 A 11 7 8 2 1 MANUAL amp ye MOTORIZED gt b E MOTORIZED MANUAL FRESH AIR DAMPERS DOWNFLOW APPLICATIONS BOTTOM VIEW 5 3 4 1178 2 F PGMDD103 125736 BOTTOM VIEW im 11718 PGMDD101 102 MANUAL A MOTORIZED
20. instructions If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life If you cannot reach your gas supplier call the fire department C Use only your hand to move the gas control switch or knob Never use tools If the gas control switch or knob will not operate don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion D Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS 1 STOP Read the safety information above on this label 2 Set the thermostat to lowest setting 3 Turn off all electric power to the appliance 4 This appliance is equipped with an automatic ignition system which automatically lights the burners Do not try to light the burners by hand 5 Remove control access panel 6 Move the gas control switch or knob GAS CONTROL SWITCH SHOWN IN ON POSITION 7 Wait five 5 minutes to clear out any Ras If you then smell gas STOP ollow B in the safety information above on this label If you don t smell gas go to the next step 8 Move the gas control switch or knob to ON 9 Replace control access panel 10 Turn on all electric powe
21. off to a maximum of 25 microns A high vacuum pump can only produce a good vacuum if its oil is non contaminated R 410A MANIFOLD LOW SIDE HIGH SIDE GAUGE GAUGE AND VALVE AND VALVE P 800 PSI 74 HOSES P4 a CHARGING CYLINDER AND SCALE VACUUM PUMP TO ADAPTER UNIT SERVICE VALVE PORTS VACUUM PUMP AUF EVACUATION Ifthe vacuum 1 working properly closethe 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 valveto the cylinder Evacuate the system to at least 29 inches gauge before opening valve to thermocouple vacuum gauge Continue to evacuate to a maximum of 250 microns Close valve to vacuum pump and watch rate of rise If vacuum does notrise above 1500 microns in three to five minutes system can be considered properly evacuated If thermocouple vacuum gauge continues to rise and levels off at about 5000 microns moisture and non condensables are still present If gauge continues to rise aleak is present Repair and re evacuate Close valve to thermocouple vacuum gauge and vacuum pump Shut off pump and prepare to charge SERVICING 5 103 CHARGING WARNING REFRIGERANT UNDER PRESSURE Do not overcharge system with refrigerant Do not operate unit in a vacuum
22. or at negative pressure Failure to follow proper procedures may cause property damage personal injury or death CAUTION Use refrigerant certified to ARI standards Used refrigerant may cause compressor damage and will void the warranty Most portable machines cannot clean used refrigerant to meet ARI standards CAUTION Operating the compressor with the suction valve closed will void the warranty and cause serious compressor damage Charge the system with the exact amount of refrigerant Refer to the specification section or check the unit name plates forthe correct refrigerant charge An inaccurately charged system will cause future prob lems 1 Using a quality set of charging scales weigh the proper amount of refrigerantforthe system Allow liquid refriger ant only to enter the high side 2 Afterthe system will take all it will take close the valve on the high side of the charging manifold 3 Startthesystem and charge the balance ofthe 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 cyli
23. units are designed for a given range of temperature increase This is the temperature of the air leaving the unit minus the temperature of the air entering the unit The more air CFM being delivered through a given unit the less the rise willbe so the less air CFM being delivered the greater the rise The temperature rise should be adjusted in accordance to a given unit specifications and its external static pressure 1 Check BTUH input to unit do not exceed input rating stamped on rating plate 2 Take entering and leaving air temperatures 3 Select the proper speed tap or dip switch setting for direct drive units 4 Take motor amperage draw to determine that the motor is not overloaded during adjustments SUPPLY SS x Yun TSUPPLY lt lt lt gt 1 SA TRETURN RISE TSUPPLY TRETURN Checking Temperature Rise 53 SERVICING 5 300 TESTING PRIMARY LIMIT CONTROL APG GPG units use a snap disk type primary limit device Sometimes referred to as stat on a stick The limit setting is fixed and must not be readjusted in the field COLOR IDENTIFYING Volt Ohm SLEEVES Meter TESTING PRIMARY LIMIT CONTROL Refertothe specification section to determine the proper limit cutout temperature for the model being serviced In all instances the limit control is wired in series with the ignition control If the temperature w
24. which shows that ninety 90 cubic feet of gas will be consumed in one 1 hour Let s assume the local gas utility has stated thatthe calorific value of the gas is 1025 BTU per cubic foot Multiplying the ninety 90 cubic feet by 1025 BTU fP gives us an input of 92 250 BTU hr Checking the BTU input on the rating plate of the unit being tested EXAMPLE GPG153609041 INPUT 92 000 BTU HR OUTPUT 72 900BTU HR Should the figure you calculated not fall within five 5 percent of the nameplate rating of the unit adjust the gas valve pressure regulator or resize orifices Inno case should the input exceed that shown on the rating plate 4 CAUTION ALWAYS CONNECT A MANOMETER TO THE 1 8 PIPE TAP AT THE GAS VALVE BEFORE ADJUSTING THE PRESSURE REGULATOR IN NO CASE SHOULD THE FINAL MANIFOLD PRESSURE VARY MORE THAN PLUS OR MINUS 3 INCHES WATER COLUMN FROM 3 5 INCHES WATER COLUMN FOR NATURAL GAS OR 10 INCHES WATER COLUMN FOR PROPANE GAS To adjust the pressure regulator on the gas valve turndown clockwise to increase pressure and input and out counter clockwise to decrease pressure and input Since propane gas is not normally installed with a gas meter clocking will be virtually impossible The gas orifices used with propane are calculated for 2500 BTU gas per cubic foot and with proper inlet pressures and correct piping size full capacity will be obtained With propane gas no unit gas valve regulator is use
25. 3 Check for 24 volts at thermostat terminals C and Y1 a No voltage checkthermostat wiring and thermo stat Voltage present check pressure switch circuit If pressure switch circuit checks closed proceed to step 4 4 Check for 24 volts at contactor coil a b No voltage check 6 pin connector and wires from contactor coil to 6 pin connector on control board If wires and connector check good replace con trol Voltage present replace contactor Testing High Stage Cooling Operation with Low Stage Cooling Operating 1 Board set for 2 stage thermostat a Check for 24 volts at thermostat terminals C and Y2 on control board No voltage check thermostat and thermostat wiring Voltage present check pressure switch circuit If pressure switch circuit checks closed proceed to next step Check for 24 volts to compressor unloader sole noid If no voltage present check 6 pin connector and wires from compressor unloader solenoid to 6 pin connector on board If connector and wires check good replace control 2 Board set for 1 stage thermostat a Wait the selected delay time either 5 or 10 minutes depending on jumper setting Check for 24 volts at compressor unloader sole noid No voltage check 6 pin connector and wires from compressor unloader solenoid to 6 pin connector on board If connector and wires check good replace control 61 SERVICING LED m Flashes Status system
26. 304 0 508 0 135 680 0 159 204 0 70 306 0 510 0 _ 135 684 0 160 206 0 71 308 0 512 0 136 688 0 160 208 0 72 310 0 514 0 136 692 0 161 2100 72 312 0 516 0 136 696 0 161 212 0 73 314 0 518 0 137 2140 738 316 0 520 0 _ 137 3 i i PSIG F 522 0 137 524 0 137 c OIRIOIO I inn 3 o Oo nro oo o co o1 02 gt EN oj 09 oA iin o 491 ji ji ololNj jajojN N M Based ALLIED SIGNAL Data 48 SERVICING 5 106 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 Checkforanovercharged unitby referring to the cooling performance charts in the servicing section 2 Checkthe operation of the power elementin the valve as explained in S 110 Checking Expansion Valve Opera tion 3 Checkfor restricted or plugged equalizer tube 5 107 UNDERFEEDING Underfeeding by the expansion valve results in low system capacity and low suction pressures If these symptoms are observed 1 Checkforarestricted liquid line or drier A restriction will be indicated by a temperature drop across the drier 2 Checkthe operation ofthe power element ofthe valve as described in S 110 Checking Expansion Valve Opera tio
27. 5 3 5 313 5 304 5 301 5 300 5 308 5 309 5 306 5 307 5 302 5 304 5 310 5 310 5 302 5 310 35 SERVICING 5 1 5 3 5 5 3 5 3 5 7 5 8 5 9 5 12 5 13 5 15 5 15 5 15 5 16 5 16 5 160 17 S 17A 5 17 S 17C S 17D S 18 S 100 S 101 S 102 S 103 36 Table of Contents Checking Voltage 37 Checking Wiring seen 38 Checking Thermostat Wiring amp Anticipator 38 Thermostat amp Wiring sess 38 Cooling Anticipator 38 Heating 38 Checking Transformer amp Control Circuit 39 Checking Contactor and or Relays 39 Checking Contactor Contacts 39 Checking Fan Relay Contact 40 Checking High Pressure Control 40 Checking Low Pressure Control 40 Checking 40 Resistance 41 Capacitance 41 Checking Fan amp Blower Motor Windings PSC Motors 42 Checking ECM Motor Windings 42 Checking EEM Motors 42 Checking Compressor Windings 43 Resis
28. 55 47 56 47 56 48 57 48 58 49 58 45 55 __ 4887 INPUT BURNER HIGH ALTITUDE U S BURNER ORIFICE 02 CANADA BURNER ORIFICE S 313 TESTING IGNITION CONTROL MODULE NOTE Failure to earth ground the unit ora high resistance connection in the ground may cause the control to lockout due to failure to flame sense WARNING To avoid personal injury or death due to electric shock wiring to the unit must be properly grounded Disconnect power before installing or servicing 12 INDUCER ODF LOW LOW PARK 1 FS K3 K5 T2 __ co 92 7 KA 2 U6 5 lal 4 u7 3 8 04 2 A 4l MU u5 V M ar FX heo 2 Es Es E DS SPEEDUP 150 2 None Fi ly ere ers ers es le es QD Kr Ku FAULT BLOWER STAGE ECON FR W1W2G Y1 Y2 IRECALL OFF DELAY DELAY 22 500 BTUH NAT 20 000 BTUH L P
29. 854 1 115 1 887 2 904 1 577 3 298 988 1 672 2 574 1 398 2 923 D 896 1 515 2 332 1 267 2 649 824 1 394 2 146 1 165 2 437 767 1 297 1 996 1 084 2 267 719 1 217 1 873 1 017 2 127 679 1 149 1 769 961 2 009 546 923 1 421 772 1 613 467 790 1 216 660 1 381 414 700 1 078 585 1 224 4 WARNING e ss so ium 345 584 898 488 1 020 321 543 836 454 949 IF YOUR PROPANE GAS APPLIANCE IS INSTALLED IN To convert to Capacities at 15 PSIG Settings Multiply by 1 130 AN EXCAVATED AREA OR A CON FINED SPAC E WE To convert to Capacities at 5 PSIG Sutiings Multiply by 0 879 STRONGLY RECOMMENDED THAT YOU CONTACT YOUR PROPANE SUPPLIER ABOUT INSTALLING A GAS DETECTING WARNING DEVICE THAT WOULD ALERT YOU A GAS LEAK PROPANE GAS IS HEAVIER THAN AIR AND ANY LEAKING GAS CAN SETTLE IN ANY LOW AREAS Sizing Between Single or Second Stage Regulator and Appliance Maximum Propane Capacities Listed are Based on 1 2 W C Pressure Drop at OR CONFINED SPACES 11 W C Setting Capacities in 1 000 BTU HR PROPANE GAS ODORANT MAY FADE MAKING PIPE OR THE GAS UNDETECTABLE EXCEPT WITH A LEN TUBING SIZE O D TYPE L SCHEDULE40 WARNING DEVICE d AN UNDETECTED GAS LEAK WILL CREATE A FEET 3 8 1 2 5 8 3 4 7 8 1 2 3 4 1 1 1 4 1 1 2 DANGER OF EXPLOSION OR FIRE IF YOU SUSPECT 2 RER Sew RE THE PRESENCE OF GAS FOLLOW THE INSTRUCT 2 IONS
30. Broad Ocean Package Unit ID Blowers Amana Brand Goodman Brand Package Gas up to 15 Seer R410a A GPG15 24 30 37 42 49 60 1BA gas electric units Initial release of models with 2 row 5mm condenser coil and aluminum evaporator coil Amana Brand Goodman Brand Package Gas up to 15 Seer R410a A GPG15 24 30 37 42 49 60 1CA gas electric units Initial release of models with Broad Ocean Digi blower motor These units have R410A refrigerant ACCESSORIES ACCESSORIES Description Part Number Propane Conversion Kit PG13 LPT 00A may be used on models with AA revisions LPT 03 LPT 03 can be used with either White Rodgers or Honeywell gas valve LPM 05 Propane Conversion Kit PG15 HA 02 High Altitude Kit PGC101 102 103 Roof Curb PGED1 01 1 02 Downflow Economizer Small and Medium Chassis PGED103 Downflow Economizer Large Chassis PGEH1 01 102 Horizontal Economizer Small and Medium Chassis PGEH1 03 Horizontal Economizer Large Chassis PGMDD 1 01 102 Manual 2596 Fresh Air Damper Downflow Application Small and Medium Chassis PGMDD 1 03 Manual 25 Fresh Air Damper Downflow Application Large Chassis PGMDH 1 01 Manual 2596 Fresh Air Damper Horizontal Application Small Chassis PGMDH 1 02 Manual 2596 Fresh Air Damper Horizontal Application Medium Chassis PGMDH 1 03 Manual 2596 Fresh Air Damper Horizontal Application Large Chassis PGMDMD101 102 Motorized 25 Fresh Air Damper Downflow Application Small and Med
31. ELEVATION ABOVE SEA LEVEL FEET 2000 3000 4000 4500 5000 6000 7000 8000 44 55 44 55 45 56 45 56 46 57 47 58 47 58 HIGH ALTITUDE INPUT BURNER KIT U S BURNER ORIFICE HAO2 CANADA BURNER ORIFICE 44 55 47 57 25 000 BTUH NAT 20 000 BTUH L P ELEVATION ABOVE SEA LEVEL FEET 2000 3000 4000 4500 5000 6000 7000 8000 43 55 53 55 44 56 44 56 44 56 45 57 45 57 INPUT BURNER FIIGH AETITUDE U S BURNER ORIFICE CANADA BURNER ORIFICE 02 43 55 46 57 60 100 051 Control Board SERVICING Testing Direct Spark Ignition DSI Systems PCBAG100 Board Heating Mode Indoor thermostat calling for heat 15 second prepurge time and 7 second trial for ignition 1 Check for 230 volts from 1 terminal of control module to L2 Novoltage check wire connections continuity etc 2 Check for 24 volts at R to C thermostat terminals a d No voltage check 3amp automotivetype fuse on control board Ablown fuse could indicate a short in the 24 volt circuit thermostat or limit circuit Voltage Present check limit and rollout S 301 and S 302 If limit and rollout are closed then check for 24 VAC at the gas valve terminals No 24 VAC at gas valve check 9 pin connector and wires from ignition control to gas valve If wires and connections at 9 pin connector check good replace ignition c
32. G 189 195 202 208 215 222 229 236 243 251 259 266 274 283 291 299 308 317 326 335 345 354 364 374 384 395 406 416 427 439 450 462 474 486 499 511 50 16 14 w 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 122 124 126 128 REQUIRED SUBCOOLING TEMPERATURE F 100 102 104 106 108 110 112 114 116 118 120 122 124 126 100 102 104 106 108 110 112 114 116 118 120 122 124 100 102 104 106 108 110 112 114 116 118 120 122 100 102 104 106 108 110 112 114 116 118 120 SERVICING 5 109 CHECKING SUBCOOLING Refrigerantliquidis considered subcooled when its tempera ture is lowerthanthe saturation temperature corresponding toits 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 thermo couple type temperature tester to the liquid line close to the pressure switch 2 Installahigh side pressure gauge onthe high side liquid service valve atthe front of the unit 3 Record the gauge pressure and the temperature of the line 4 Compare the hi pressure reading to the Required Liquid Line Temperature chart on the following page Find the hi pressure value onthe left column Follow thatline right tothe column
33. GAS VALVE 58 Pressure Regulator under cap screw Open to Atmosphere Open to Atmosphere H 6 Pressure Inlet Pressure Tap Tap Gas Valve On Off Selector Switch Manifold Inlet Pressure Pressure HONEYWELL MODEL VR8215 1 STAGE GAS VALVE MEASURING INLET AND MANIFOLD GAS PRESSURE With Power ON WARNING Line Voltage now present 3 Put furnace into heating cycle and turn on all other gas consuming appliances For NATURAL GAS a Inlet pressure should be a nominal 7 w c b 2stage heat models only Manifold pressure on low stage should be 2 0 w c 3 w c c Manifold pressure for 1 stage heat models and high stage for 2 stage heat models should be 3 5 3 W C For PROPANE GAS a Inlet pressure should be a nominal 11 w c b 2stage heat models only Manifold pressure on low stage should be 6 w c c Manifold pressure for 1 stage heat models and high stage for 2 stage heat models should be 10 w c Manifold Gas Pressure 3 5 w c Natural Gas Single Stage Manifold Gas Pressure Gas Range Nominal Low Stage 1 6 2 2 w c 10 0 w c High Stage 3 2 3 8 w c 5 7 6 3 W C High Stage 9 7 10 3 w c Two Stage SERVICING If operating pressures differ from above make necessary pressure regulator adjustments check piping size etc and or consult with local uti
34. Hz 3 208 230v 3ph 60Hz 4 460V 3ph 60Hz MINOR REVISION PRODUCT IDENTIFICATION Single Phase Package Gas Units A GPG13 24 60 M41AA Amana Brand Goodman Brand Package Gas up to 13 Seer 410 gas electric unit Initial release A GPG13 24 60 M41AB Amana Brand Goodman Brand Package Gas up to 13 Seer 410 gas electric unit Release of models with Honeywell Valve A GPG13 24 60 M41 AC Brand Goodman Brand Package Gas up to 13 Seer 410 gas electric unit Drain pan material change Amana Brand Goodman Brand Package Gas up to 13 Seer R410A A GPG13 24 60 M41AD l gas electric unit Release of models with Broad Ocean Package Unit ID Blowers A GPG1336045M41CA Amana Brand Goodman Brand Package Gas up to 13 Seer R410A A GPG1336070M41CA gas electric unit Release of models with a2 row 5 16 condenser with a liquid A GPG1336090M41CA manifold Amana Brand Goodman Brand Package Gas up to 13 Seer R410A AGP G1 3 24 60 M41BA gas electric unit Initial release of models with 2 row 5mm condenser coil and aluminum evaporator coil AIGPG13 24 30 42 48 60 M41CA Amana Brand Goodman Brand Package Gas up to 13 Seer R410A PG1 336 Md DA gas electric unit Initial release of models with 2 row 5mm condenser coil and copper evaporator coil Amana Brand Goodman Brand Package Gas up to 13 Seer 410 A GPG13 48 60 M41DA gas electric unit Initial release of models wit
35. ON PAGES 9 11 FAILURE TO DO SO COULD 20 e RESULT IN SERIOUS PERSONAL INJURY OR DEATH 40 ON DONT nd o ASE D RN 50 20 46 86 146 224 122 255 480 985 1 476 60 19 42 78 132 203 110 231 436 892 1 337 80 16 36 67 113 174 94 198 372 764 1 144 100 14 32 59 100 154 84 175 330 677 1 014 125 12 28 52 89 137 74 155 292 600 899 PROPANE TANK SIZING MINIMUM 150 11 26 48 80 124 67 141 265 544 815 TANK SIZE REQUIRED IF LOWEST OUTDOOR 200 10 22 41 69 106 58 120 227 465 697 MAXIMUM GAS TEMPERATURE AVG FOR 24 HOURS REACHES 250 9 19 36 61 94 51 107 201 412 618 NEEDED TO 300 8 18 33 55 85 46 97 182 374 560 VAPORIZE 350 7 16 30 51 78 43 89 167 344 515 125 BTU HR 400 7 15 28 47 73 40 83 156 320 479 50 250K BTU HR 100 CFH 375K BTU HR 150 CFH 500K BTU HR 200 CFH 750K BTU HR 300 CFH AVERAGE RATE HOUR WITHDRAWL IN 8 HOUR PERIOD IN ACCORDANCE WITH PAMPHLET NO 54 22 SYSTEM OPERATION COOLING The refrigerant used in the system is R 410A It is a clear colorless non toxic and non irritating liquid R 410A is a 50 50 blend of R 32 and R 125 The boiling point at atmo spheric 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 pressur
36. RING AND ANTICIPATOR THERMOSTAT WIRE SIZING CHART MIN COPPER WIRE GAUGE AWG 25 feet 18 LENGTH OF RUN 50 feet 16 75 feet 14 100 feet 14 125 feet 12 150 feet 12 S 3A THERMOSTAT AND WIRING WARNING Line Voltage now present With power ON thermostat calling for cooling 1 Useavoltmeterto check for 24 volts at thermostat wires C and Y in the condensing unit control panel 2 Novoltage indicates trouble in the thermostat wiring or externaltransformer source 3 Checkthe continuity ofthe thermostat and wiring Repair or replace as necessary Indoor Blower Motor With power ON 38 WARNING Line Voltage now present 1 Setfan selector switch at thermostat to ON position 2 With voltmeter check for 24 volts at wires C and G No voltage indicates the trouble is in the thermostat or wiring 4 Checkthe continuity ofthe thermostat and wiring Repair or replace as necessary S 3B COOLING ANTICIPATOR The cooling anticipator is a small heater resistor in the thermostat During the off cycle it heats the bimetal element helping the thermostat call for the next cooling cycle This prevents the room temperature from rising too high before the system is restarted A properly sized anticipator should maintain room temperature within 1 1 2 to 2 degree range The anticipator is supplied in the thermostat and is notto be replaced If the anticipator should fail for any reason the thermos
37. S 303 Testing Inducer 56 S 304 Testing Gas Valve 56 S 305 Checking Main Burners 57 5 306 Checking 57 S 307 Checking Gas Pressure 58 5 308 Checking For Delayed Ignition 59 5 309 Checking for 59 5 310 Checking Pressure Control 59 S 311 High Altitude Application 60 S 813 Testing Ignition Control Module 60 S 314 Checking Flame 63 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 SERVICING S 1 CHECKING VOLTAGE WARNING 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 7 1 Remove doors control panel cover etc from unit being tested With power ON LA WARNING Line Voltage now present 2 Usingavoltmeter measurethe voltage across terminals L1 and L2 ofthe contactor for single phase units and L3 for 3 phase units 3 Noreading indicates op
38. STAGE COMPRESSORS ONLY 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 INPUT 24V AC DC OUTPUT 24VDC RECTIFIER INSIDE _ UNLOADER SOLENOID Molded Plug Unloader Test Procedure Ifitis suspected thatthe unloader is not working the following methods may be used to verify operation 1 Operate the system and measure compressor current Cycle the unloader ON and OFF at 10 second intervals The compressor amperage should go up or down atleast 25 percent 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 andlisten 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 SERVICING 4 Next check the molded plug A Voltage check Apply control voltage to the plug wires 18to 28 volt ac The measured dc voltage at the female connectors in the plug should be aroun
39. Service Instructions 13 and 15 Gas Electric Package Units with R 410A Refrigerant amp Accessories D LISTED Intertek This Forced Air Central Unit Design Complies With Requirements Embodied in The American National Standard National Standard of Canada Shown Below ANSI Z21 47 CSA 2 3 Central Furnaces This manual is to be used by qualified professionally trained HVAC technicians only Goodman does not assume any responsibility for property damage or RS6300007r15 personal injury due to improper service procedures or services performed by August 201 3 an unqualified person Copyright 2007 2013 Goodman Manufacturing Company L P TABLE CONTENTS IMPORTANT INFORMATION 2 3 SCHEDULED MAINTENANCE 31 33 PRODUCTION IDENTIFICATION 4 5 TROUBLESHOOTING CHARTS 34 35 ACCESSORIES eria t 8 16 SERVICING TABLE OF CONTENTS 36 PRODUCT DESIGN 17 22 34 63 SYSTEM OPERATION 23 30 ACCESSORIES WIRING DIAGRAMS 64 65 IMPORTANT INFORMATION Pride and workmanship go into every productto provide our customers with quality products Itis possible however thatduringits lifetime a product may require service Products should be serviced only by aqualified service technician who is familiar with the safety p
40. Thermostat G input is removed Air circulation blower is immediately de energized Control returnsto Standby and awaits next thermostat request 25 SYSTEM OPERATION PCBAG100 CONTROL BOARD The following tables list the functions for the connectors DESCRIPTION and terminals the timings and the fault codes for the 100 control board The ignition control is designedforuse in gas heating electric cooling package equipment rooftop applications and oper ates with a two stage heat and two stage cooling system It 4 is adirectspark ignition system that uses a 22 000 volt spark HIGH VOLTAGE to ignite the burners A flame sensor is used to monitor the Disconnect ALL power before servicing flame or installing this unit Multiple power The board has the option of using a single or two stage ther sources may be present Failure to do so mostat The board also controls the indoor blower and has a property damage personal injury an adjustable heat fan off delay There is also a fault recall button for recalling the last 5 fault codes To recall the fault codes depress the fault recall but ton for at least 2 seconds but not more than 4 seconds To clear the fault code memory depress the fault recall button for at least 5 seconds
41. UTDOOR AIR ENTHALPY SENSOR COLOR CODES P PURPLE G 5 MYELLOW 6 2 TSTAT 2 W7212 M7215 ECONOMIZER GOODMAN GAS PACK WITH PACKAGE 2 YXR YELLOW RED Y1 TSTAT 1 4 COMMON GPC13MED102 amp 103 FOR PG13 8 15 4 WIRING DIAGRAM FOR USE WITH ECONOMIZERS BUILT SINCE MARCH 2008 Wiring is subject to change Always refer to the wiring diagram on the unit for the most up to date wiring 65
42. a call for cooling the call for heat shall proceed as normal except the fan remains energized on cool speed Heat Mode 1 CALL FOR HEAT The thermostat calls for heat by energizing the W terminal The control checks to see ifthe end switch is open If the end switch is closed the control will flash code 3 on the LED and wait indefi nitely for the end switch to open The control will lockout the call for heat if the end switch is closed before the induced draft motor is energized A GPG13 PRE PURGE The control energizes the induced draft motor flashes code 2 on LED and waits for the pressure switch to close When the pressure switch has closed the control stops flashing the LED and begins timing the 15 second pre purge period Note Under normal operation the LED will not flash if the pressure switch closes immediately after energizing the induced draft motor IGNITION The control energizes the gas valve and spark If flame is not established within 7 seconds the gas valve and spark is de energized and the control goes to an inter purge If flame is established the spark is de energized and the control goes to heat blower on delay Heat Blower On Delay The control waits for 30 second heat fan on delay andthen energizes the indoor blower heat speed Ifthe blower is already energized by a call for cooling or continuous fan or in a blower off delay period the on delay is skipped and control goes to
43. accessible location within the return air duct The minimum filter area should not be less than those sizes listed in the Specification Section Under no circumstances should the unit be operated without return air filters 17 PRODUCT DESIGN A 3 4 14 NPT drain connector is provided for removal of condensate water from the indoor coil In order to provide proper condensate flow do not reduce the drain line size NOTE Tighten drain to a maximum torque of 10 in Ibs Refrigerant flow control is achieved by use of thermostatic expansion valves TXV or flowrator The single phase models use permanent split capacitors PSC design compressors Starting components are there fore not required A low MFD run capacitor assists the compressor to start and remains in the circuit during opera tion A GPG three phase units use three phase compressors Starting components and run capacitors are therefore not required A GPG Package Gas Units are designed for outdoor instal lations only in either residential or light commercial applica tions and are available 2 2 5 3 3 5 4 amp 5 ton sizes They are designed for 208 230 volt single phase applications or 208 230 volt 3 phase applications The connecting ductwork Supply and Return can be con nected for either horizontal or vertical airflow In the vertical application a matching Roof Curb is recommended A return air filter must be installed behind the return air grille s o
44. before placing in operation Because of the danger of explosion or fire never use a match or open flame to test for leaks Never exceed specified pressure for testing Higher pressure may damage the gas valve and cause overfiring which may result in heat exchanger failure This unit must be isolated from the gas supply system by closing its individual manual shutoff valve during any pres sure testing of the gas supply piping system at test pres sures equal to or less than 1 2 psig 3 48 kPa TANKS AND PIPING PROPANE UNITS 4 amp WARNING PERSONAL INJURY HAZARD IRON OXIDE RUST CAN REDUCE THE LEVEL OF ODORANT IN PROPANE GAS A GAS DETECTING DEVICE IS THE ONLY RELIABLE METHOD TO DETECT A PROPANE GAS LEAK CONTACT YOUR LOCAL PROPANE SUPPLIER ABOUT INSTALLING A GAS DETECTING WARNING DEVICE TO ALERT YOU IN THE EVENT THAT A GAS LEAK SHOULD DEVELOP FAILURE TO DETECT A PROPANE GAS LEAK COULD RESULT IN AN EXPLOSION OR FIRE WHICH COULD CAUSE SERIOUS PERSONAL INJURY OR DEATH All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters See NBFU Manual 58 or Natural Standards of Canada B149 2 Installation Code for Propane Gas Burning Appliances and Equipment For satisfactory operation propane gas pressure must be 10 inch W C at the unit manifold with all gas appliances in operation Maintaining proper gas pressure depends on three main factors 1 Vaporization rate which depends
45. burnout must be deter mined and corrected before the new compressor is started S 200 CHECKING EXTERNAL STATIC PRESSURE The minimum and maximum allowable duct static pressure is found in the Technical Information Manual Too great of an external static pressure will result in insuffi cient air that can cause icing of the coil whereas too much air can cause poor humidity control and condensate to be pulled off the evaporator coil causing condensate leakage Too much air can cause motor overloading and many cases this constitutes a poorly designed system To determine proper air movement proceed as follows 1 Using a draft gauge inclined manometer measure the static pressure of the return duct at the inlet of the unit Negative Pressure INCLINED MANOMETER N 4 RETURN lt Total External Static 2 Measurethe static pressure ofthe supply duct Positive Pressure 3 Addthe two readings together NOTE Bothreadings may be taken simultaneously and read directly on the manometer if so desired 4 Consult proper table for quantity of air If the external static pressure exceeds the minimum or maximum allowable statics check for closed dampers dirty filters undersized or poorly laid out ductwork 5 201 CHECKING TEMPERATURE RISE Temperature riseis related to the BTUH output of the unit and the amount of air CFM circulated over the heat exchanger All
46. d however the second stage supply line pressure regulator should be adjusted to give 11 water column with all other gas consuming appliances running The dissipation of the heat transferred to the heat exchanger is now controlled by the amount of air circulated over its surface The flow rate CFM of air circulated is governed by the external static pressure in inches of water column of duct work cooling coil registers and etc applied externally to the unit versus the motor speed tap A properly operating unit must have the BTU input and flow rate CFM of air within the limits shown to prevent short cycling of the equipment As the external static pressure goes up the temperature rise will also increase Consultthe proper tables for temperature rise limitation 33 SERVICING Complaint POSSIBLE CAUSE DOTS IN ANALYSIS GUIDE INDICATE POSSIBLE CAUSE Pow er Failure Blow n Fuse Loose Connection Shorted or Broken Wires Open Overload Faulty Thermostat Faulty Transformer Shorted or Open Capacitor Shorted or Grounded Compressor Compressor Stuck Faulty Compressor Contactor 2nd Faulty Ignition Control Open Control Circuit Low Voltage Faulty Evap Fan Motor Shorted or Grounded Fan Motor Improper Cooling Anticipator Shortage of Refrigerant Restricted Liquid Line Dirty Air Filter Dirty Indoor Coil Not enough air across Indoor Coil Too much air across Indoor Coil Overcharge of Refrigerant Dirty Outdo
47. d 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 ofthe connec tors should read close to zero ohms while the other should read infinity Repeat with other wire The samefemale connector as before should read zero while the other connector again reads infinity Reverse polarity on the ohmmeter leads and re peat The female connector that read infinity previ ously should now read close to zero ohms C Replaceplugifeitherofthese 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 WARNING 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 1 Removeunit wiring from disconnect switch and wire atest cord to the disconnect switch NOTE Thewire size ofthetestcord must equal the line wire size and the fuse must be of the proper size and type 2 Withthe protective terminal cover in place use the three leads to the compressor terminals that were discon nected at the nearest point to the compressor and connect the common start and run clips to the respective leads 3 Connect good capacitors of the right MFD and voltage rating into the circuit as shown 4 With powe
48. delay on break and the COOL speed tap will beenergized If a call for cool Y occurs during continuous fan the blower will switch over to COOL speed Ifacallforheat W occurs during continuous fan the blower will remain energized through the heat cycle or until G is de energized The continuous fan operation will function while the control is in heat mode lockout Cool Mode 1 When the thermostat calls for cooling Y the control energizes the cooling speed fan after a 7 second on delay The control provides a 3 minute anti short cycle protection for the compressor If the compressor has been offfor 3 or more minutes the compressor imme diately energizes whenthe thermostat calls for cool If the compressor has not been off for atleast 3 minutes when a call for cool occurs the control waits until 3 minutes has elapsed from the time the compressor was last de energized before re energizing the com pressor When the thermostat removes the for cooling Y the compressor is deenergized and the control deenergizes the cooling speed fan after a cooling off delay period of 60 seconds A call for cooling has priority over continuous fan If G is energized while Y is energized during the cooling fan on delay the fan will remain off until the delay is over Note The cooling fan operation will continue to function while the control is in heat lockout Note If a call for heat exist with
49. during low stage heating Thermostat W1 input is removed Low stage gas valve is de energized Induced draft blower remains energized at low speed for post purge period Air circulating blower remains energized at low heat speed for heat OFF delay Heat OFF delay begins when W1 input is removed Control returns to Standby and awaits next thermostat request A GPG15 B Heating Operation High stage heat 10 TE 12 13 Thermostat type is to two stage Thermostat W1 and W2 inputs initiate high stage heating Induced draftbloweris energized at high speed forthe pre purge period Pre purge timer begins after control recognizes pressure switch has closed Trial for ignition period begins after pre purge period expires Low and high stage gas valves are energized along with the igniterfortrial for ignition period Igniter is de energized when flame is detected Flameis achieved and detected during trial for ignition period Flame stabilization period begins when flame is detected Gas valve and induced draft blower remain at high stage and high speed Air circulating blower is energized at high heat speed after heat ON delay time expires Heat ON delay timer begins when flame is detected Control monitors thermostat flame limit and pres sure switch inputs during high stage heating Thermostat W1 and W2 inputs are removed High and low stage gas valves are de energized Induced d
50. e a refrigerant will absorb heat and vaporize at a low temperature The vapors may be drawn off and condensed ata higher pressure and tempera ture 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 pres sures 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 Heatis 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 Thatis it absorbs more heat than is necessary to vaporize it This is assurance that only dry gas will reach the compressor Liquid reachin
51. e property damage personal injury or death This is the mostimportant 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 systemis ahigh vacuum pump capable of producing a vacuum equiva lent 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 orrunwhen under ahigh 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 46 Connect the vacuum pump vacuum tight manifold set with high vacuum hoses thermocouple vacuum gauge and charging cylinder as shown Startthe 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
52. e now present 2 Using a voltmeter check voltage across secondary voltage side of transformer R to C 3 Novoltage indicates faulty transformer bad wiring or bad splices 4 Check transformer primary voltage at incoming line voltage connections and or splices 5 voltage available at primary voltage side of trans former and wiring and splices good transformer is inop erative Replace S 7 CHECKING CONTACTOR AND OR RELAYS WARNING HIGH VOLTAGE Disconnect ALL power before servicing or installing this unit Multiple power sources may be present Failure to do so may cause property damage personal injury or death The 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 5 8 CHECKING CONTACTOR CONTACTS SINGLE PHASE WARNING HIGH VOLTAGE Disconnect ALL power before servicing or installing this unit Multiple power sourc
53. e side of the meter is to the wire and the positive of the meter is to terminal FS 4 Turnon Power Tx WARNING Line Voltage now present 5 With Power ON Place the unit into a heating cycle As soon as is established microamp reading should be evidentonce proof of flame microamp reading is established the hot surface ignitor will be de ener gized 7 The nominal microamp reading is 4 microamps 8 If the microamp current is less than 0 5 microamp the control will lockout and flash a code of 1 flash after attempting to reestablish flame sense 9 Ifthe microamp reading is less than the minimum fied check for high resistance wiring connections the distance 3 16 between the sensor and burner flame sensor connections dirty flame sensor or poor ground ing 10 If no reading check for continuity on all components and if good replace ignition control module NOTE Contaminated fuel or combustion air can create a nearly invisible coating on the flame sensor This coating works as an insulator causing a loss in the flame sense signal If this situation occurs the flame sensor must be cleaned with steel wool Do not use sand paper the silicone in sand paper will further contaminate the sensor 63 HO 021 061HO OINO 1VIS L ADVLS ILINW QN3ININOO3H 3LON ECONOMIZER INVHOVIG H3ZIINONOO3 201 L0L H d3Od TSGOW ONIHNLOVANNVAN NVINIOOO
54. e sizing drills 3 Ifresizing is required a new orifice of the same physical size and angle with proper drill size opening should be installed 57 SERVICING S 307 CHECKING GAS PRESSURE Gas inlet and manifold pressures should be checked and adjusted in accordance to the type of fuel being consumed WARNING Disconnect gas and electrical power supply 1 Connect a water manometer or adequate gauge to the inlet pressure fitting of the gas valve 2 Remove the pressure tap fitting at the manifold if provided or check at the gas valve outlet fitting and connect another manometer or gauge Gas Valve Manometer On Off _ Inlet Pressure ose Switch Tap 10 Low Pressure Atmosphere Rust fa Ve Outlet 2 1 4 Inlet High Pressure ji JH Adjust E Open to Atmosphere Outlet Pressure d Manometer S Manometer WHITE ROGERS MODEL 36G 2 STAGE GAS VALVE Pressure Regulator Adjustment Under Cap Screw Open to Atmosphere Outlet Pressure Open to Tap Atmosphere D OUTLET Inlet Pressure On Off Tap Selector Switch Manifold Pressure Inlet Pressure WHITE ROGERS MODEL 36G 1 STAGE
55. ed must be provided and sized in accordance with the unit minimum circuit ampacity The best protection for the wiring is the smallest fuse or breaker which will hold the equipment on line during normal operation without nuisance trips Such a device will provide maximum circuit protection dh WARNING DO NOT EXCEED THE MAXIMUM OVERCURRENT DEVICE SIZE SHOWN ON THE UNIT DATA PLATE All line voltage connections must be made through weather proof fittings All exterior power supply and ground wiring must be in approved weather proof conduit Low voltage wiring from the unit control panel to the thermostat requires coded cable See the following figures for ground level and rooftop wiring Note Junction box location shown is optional and is for illustration purposes only ne JUNCTI Electrical Power Directly To Junction Box Electrical Power Routed Through Bottom of Unit The unit transformer is connected for 230V operation If the unitis to operate on 208V reconnectthe transformer primary lead and the induced draft blower leads as shown onthe unit wiring diagram 19 PRODUCT DESIGN WARNING TO AVOID THE RISK OF PROPERTY DAMAGE PERSONAL INJUSRY OR FIRE USE ONLY COPPER CONDUCTORS All line voltage connections must be made through weather proof fittings All exterior power supply and ground wiring must be in approved weather proof conduit Low voltage If it is necessary for the installer to suppl
56. element is faulty or the equalizer tube is plugged 5 Capture the charge replace the valve and drier and evacuate S 111 FIXED ORIFICE RESTRICTOR DEVICES Thefixedorifice restrictor device flowrator used in conjunc tion with the indoor coil is a predetermined bore I D Itis 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 Inthe cooling cycle when the outdoor air temperature rises the high side condensing pressure rises Atthe 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 tempera ture 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 Astrainer is placed onthe entering side of the tube to prevent any foreign material from becoming lodged inside the fixed orifice restriction device If arestriction should become evident proceed as follows 1 Recover refrigerant charge 2 Remove the orifice or tube strainer assembly and re place 3 Replace liquid line drier evacuate and recharge
57. en wiring open fuse s no power or etc from unit to fused disconnect service Repair as needed 4 With ample voltage at line voltage connectors energize the unit 5 Measure the voltage with the unit starting and operating and determine the unit Locked Rotor Voltage Locked Rotor Voltage is the actual voltage available at the compressor during starting locked rotor or a stalled condition Measured voltage should be above minimum listed in chart below To measure Locked Rotor Voltage attach a voltmeter to the R and common C terminals ofthe compressor ortothe T and T terminals of the contactor the unit andallow the compressorto run for several seconds then shut down the unit Immediately attempt to restart the unit while measuring the Locked Rotor Voltage 6 Voltmeter should read within the voltage tabulation as shown If the voltage falls below the minimum voltage check the line wire size Long runs of undersized wire can cause low voltage If wire size is adequate notify the local power company in regards to either low or high voltage Unit Supply Voltage Voltage Three phase units require a balanced 3 phase power supply to operate If the percentage of voltage imbalance exceeds 396the unit must not be operated until the voltage condition is corrected Max Voltage Deviation From Average Voltage X 100 Average Voltage 96 Voltage lt Imbalance Tofindthe percentage of imbalance measure
58. es W C of that listed on the nameplate for the fuel used At all altitudes and with either fuel the air temperature rise must be within the range listed on the unit nameplate Refer to the Installation Manual provided with the LP kit for conversion from natural gas to propane gas and for altitude adjustments When this package unit is installed at high altitude the appropriate High Altitude orifice kit must be installed As altitude increases there is a natural reduction in the density of both the gas fuel and combustion air This kit will provide the proper design certified input rate within the specified altitude range High altitude kits are not approved for use in Canada For installations above 2 000 feet use kit HA 02 The HA 02 kit is used for both Natural and LP gas at high altitudes Use LPM 05 2 stage heat models or LPT 03 1 stage heat models propane conversion kit for propane conversions at altitudes below 2000 feet Natural gas installations below 2000 feet do not require a kit LPT 00A may be used on models with AA revisions LPT 03 is compatible with both the White Rodgers and the Honeywellgas valves For propane conversions above 2000 feet high altitude kit HA 02 is required in addtion to the propane conversion kit Natural gas and LP gas installations at altitudes gt 2000 ft 20 000 BTUH NAT 20 000 BTUH L P ELEVATION ABOVE SEA LEVEL FEET 2000 3000 4000 4500 5000 6000 7000 8000 45 55 47
59. es may be present Failure to do so may cause property damage personal m gy or death 1 Disconnectthe wire leads from the terminal T side ofthe contactor 2 With power ON energize the contactor WARNING LINE VOLTAGE NOW PRESENT VOLT OHM METER Ohmmeter for testing holding coil Voltmeter for testing contacts TESTING COMPRESSOR CONTACTOR Single Phase 3 Using a voltmeter test across terminals L1 L2 Novoltage Check breaker orfuses on main power supply L2 T1 No voltage indicates CC1 contacts open If ano voltage reading is obtained replace the contactor 39 SERVICING THREE PHASE Using a voltmeter test across terminals A L1 L2 L1 L3 and L2 L3 If voltage is present proceedtoB 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 VOLT OHM Ohmmeter for testing holding coil Voltmeter for testing contacts TESTING COMPRESSOR CONTACTOR ThreePhase 5 9 CHECKING FAN RELAY CONTACTS The fan relays are incorporated into the control board See section S 313 for checking control board 5 12 CHECKING HIGH PRESSURE CONTROL WARNING 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 m or death The hi
60. ever in many instances they may be rented from local sources Proper equipment promotes faster more efficient service and accurate repairs with less call backs HEATING PERFORMANCE TEST Before attempting to diagnose an operating fault run a Heating Performance Test and apply the results to the Service Problem Analysis Guide Toconducta heating performance test the BTU inputtothe package gas unit must be calculated After the heating cycle has been in operation for at least fifteen minutes and with all other gas appliances turned off the gas meter should be clocked To find the BTU input multiply the number of cubic feet of gas consumed per hour by the heating value of the gas being used The calorific value of the gas being used is found by contacting your local utility 31 SCHEDULED MAINTENANCE 1 Million 100 Thousand 10 Thousand 1 Thousand CUBIC GAS RATE CUBIC FEET PER HOUR Size of Test Dial Size of Test Dial Seconds 1 4 1 2 1 2 Seconds 1 4 1 2 1 2 for One cu ft cu ft cu ft cu ft for One cu ft cu ft cu ft cu ft Revolution Revolution 32 SCHEDULED MAINTENANCE Example It takes forty 40 seconds on the gas meter for the hand the cubic foot dial to make one complete revolution with all appliances off except the unit Using the gas rate chart observe the forty 40 seconds locate and read across to the one 1 cubic foot dial column There you will find the number 90
61. g from improper service or service procedures If you perform service on your own product you assume responsibility for any personal injury or property damage which may result WARNING 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 To locate an authorized servicer please consult your telephone book or the dealer from whom you purchased this product For further assistance please contact GOODMAN BRAND PRODUCTS AMANA BRAND PRODUCTS TOLL FREE TOLL FREE 1 877 254 4729 U S only 1 877 254 4729 U S only email us at customerservice goodmanmfg com email us at customerservice goodmanmfg com fax us at 713 856 1821 fax us at 713 856 1821 Not a technical assistance line for dealers 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 IMPORTANT INFORMATION SAFE REFRIGERANT HANDLING While these items will not cover every conceivable situation they should serve as a useful guide WARNING Refrigerants are heavier than air They can push out the oxygen in your lungs or in any enclosed space To avoid possible difficulty in breathing or death Never purge refrigerant into an enclosed room or space By law all refrigerants
62. g 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 super heated 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 trans ferred from the gas through the tubes andfins ofthe 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 vaporis fully liquefied it continues to give up heat which subcools the liquid and it is ready to repeat the cycle HEATING The heating cycle is accomplished by using aunique tubular design heat exchanger which provides efficient gas heating on either natural gas or propane gas fuels The heat exchangers compacttubular construction provides excellent heattransfer for maximum operating efficiency Inshottype gas burners with integral cross lighters are used eliminating the need for adjustable air shutters The same burner is designed for use on either natural or propane gas fuels Theinduced draftblower draws fuel and combustion air into the burners and heat exchanger for proper combustion A pressure switch is used in conjunction with the D blower to detect a blocked flue condition Blower operation is controlled by the ignition control module The module allows for field adjustment ofthe blower de
63. gh pressure control senses the pressure in the liquid 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 40 4 Startthe system and place a piece of cardboard in front ofthe condenser coil raising the condensing pressure 5 Checkpressure at which the high pressure control cuts out If it cuts out at610 PSIG 10 PSIG itis operating normally See causes for high head pressure in Service Problem Analysis Guide If it cuts out below this pressure range replace the control The control should reset at 420 PSIG 25 PSIG 5 13 CHECKING LOW PRESSURE CONTROL Thelow pressure control senses the pressure inthe suction line and will open its contacts on a drop pressure Thelow pressure control will automatically reset itself with a rise in pressure The low pressure control is designed to cut out open at approximately 7 PSIG 3 PSIG It will automatically cut in close at approximately 25 PSIG 5 PSIG Testfor continuity using a VOM andif notas above replace the control 5 15 CHECKING CAPACITOR CAPACITOR RUN A run capacitor is
64. h Open Sticking Gas Valve 3 Minute Compressor Anti Cycle Timer Normal Operation No Power Check Input Power Check Fuse on Control Internal Control Fault Replace Control Check Flame Sensor Check Flame Rollout 4 Blinks Switch 5 Blinks False Flame Sensed S 314 CHECKING FLAME SENSOR Aflame sensing device is used in conjunction with the ignition Check Gas Flow Ignition Failure Check Gas Pressure Open Rollout Switch t Blink or Open Aux Limit Switch Check Aux Limit 2 Blinks Pressure Switch Check Pressure Switch Open 6 Blinks Compressor Output Delay NOTE The flash rate is 0 25 seconds on 0 25 seconds control module to prove combustion If a microamp signalis not present the control will de energize the gas valve and Status Light Equipment Status Check Check Gas Valve 3 Blinks WIEN Check Pressure Switch Closed Open Main Limit off with a 2 second pause between codes retry for ignition or lockout DSI Direct Spark Ignition Systems WARNING 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 7 1 Disconnectthe sensor wire from terminal FS ofthe ignition control module Flame Sensor Flame Sensor 2 Connect a microamp meter in series with this wire and terminal FS 3 Besure the negativ
65. h a Broad Ocean Digi blower motor GPG1324 M41DA Amana Brand Goodman Brand Package Gas up to 13 Seer R410A gas electric unit Initial release of 2 ton models with a Rechi compressor 13240 45 70 41 DA A GPG13420 70 90 M41DA Amana Brand Goodman Brand Package Gas up to 13 Seer R410A NGPG13480 70 90 M41EA gas electric unit 2Changing from 5mm to 5 16 condenser coils A GPG1348115M41EA Three Phase Package Gas Units Model Description GPG 1336 48 60 M43AA Goodman Brand Package Gas up to 13 Seer R410A gas electric unit 208 230 3 60 Initial release Goodman Brand Package Gas up to 13 Seer R410A gas electric unit 208 PG1 208 230 3 60 Release of models with Honeywell Valve GPG1336 48 60 M43AC Goodman Brand Package Gas up to 13 Seer R410A gas electric unit 208 230 3 60 Drain pan material change x Goodman Brand Package Gas up to 13 Seer R410A gas electric unit 208 PG1336 4 M43AD 230 3 60 Release of models with Broad Ocean Package Unit ID Blowers Goodman Brand Package Gas up to 13 Seer R410A gas electric unit 208 GPG1348 60 M43BA 230 3 60 Release of models with Broad Ocean Digi blower motor These units have R410A refrigerant PRODUCT IDENTIFICATION The model number is used for positive identification of component parts used manufacturing Please use this number when requesting service or parts information Ga 15
66. hile the ignition control is try to power the gas valve VOLT OHM METER ___ COLOR IDENTIFYING CHECKING FLAME ROLLOUT SWITCH Limit Switch Operation Applies to Primary Auxiliary and Roll Out Limits DSI systems If a limit switch opens the indoor blower is energized on heat speed and the induced draft blower is energized The LED on the control flashes 4 to indicate an open limit switch The blower and inducer remain on while the limit switch is open The gas valve is de energized Power to the thermo stat R is removed while the limit switch is open When the limit switch re closes the induced draft motor runs through its post purge and the indoor blower goes through the heat off delay If a call for heat exists when the limit switch re closes the control goes through a pre purge period and then makes an ignition attempt The indoor blower remains on forthe delay off time during the re ignition attempt 1 If no voltage is measured on either side of control it indicates ignition control or wiring to control problem 2 If voltage is measured on one side of the control and not the other it indicates the control is open 3 If voltage is measured on both sides of the control the wiring to gas valve or valve is at fault Servicing procedure with furnace not firing 1 Confirm that the outer door was in place and all screws tightened No leaks under the door 2 Check to see if a
67. hing device must be wired in series with the capacitor to remove it from the electrical circuit after the compressor starts to run Not removing the start capacitor will overheat the capacitor and burn out the compressor windings These capacitors have a 15 000 ohm 2 watt resistor wired across its terminals The object ofthe resistor is to discharge the capacitor under certain operating conditions rather than having it discharge across the closing of the contacts within the switching device such as the Start Relay and to reduce the chance of shock to the servicer See the Servicing Section for specific information concerning capacitors RELAY START A potential or voltage type relay is used to take the start capacitor out of the circuit once the motor comes up to speed This type of relay is position sensitive The normally closed contacts are wired in series with the start capacitor and the relay holding coil is wired parallel with the start winding As the motor starts and comes up to speed the increase in voltage across the start winding will energize the start relay holding coil and open the contacts to the start capacitor Two quick ways to test a capacitor are a resistance and a capacitance check S 15A RESISTANCE CHECK d WARNING 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
68. ic pipe and fittings b Semi rigid metallic tubing and metallic fittings Aluminum alloy tubing shall not be used in exterior locations Listed gas appliance connectors used in accor dance with the terms of their listing that are completely in the same room as the equipment NOTE n b and c the connector or tubing must be installed so as to be protected against physical and thermal damage Aluminum alloy tubing and connectors must be coated to protect against external corrosion where they are in contact with masonry plaster or insulation or are subject to repeated wettings by such liquids as water except rain water detergents or sewage MANUAL SHUT OFF VALVE DRIP LEG MI 17 _ GROUND JOINT UNION INSTALLED AHEAD OF GAS VALVE GROMMET NOTE The unit gas supply entrance is factory sealed with plugs Keep plugs in place until gas supply is ready to be installed Once ready replace the plugs with the supplied grommets and install gas supply line CHECKING THE GAS PIPING 4 CAUTION TO AVOID THE POSSIBILITY OF PROPERTY DAMAGE PERSONAL INJURY OR FIRE THE FOLLOWING INSTRUCTIONS MUST BE PERFORMED REGARDING GAS CONNECTIONS AND PRESSURE TESTING Theunitandits gas connections must be leak tested
69. ing 52 S 115 COMPRESSOR BURNOUT When acompressor burns out high temperature develops causing the refrigerant oil and motor insulation to decom pose forming acids and sludge If acompressor 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 AK 3 or its equivalent Remove the compressor and obtain an oil sample from the suction stub Ifthe 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 AX CAUTION Do not allow the sludge or oil to contact the skin Severe burns 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 Inthe case of aburnout 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
70. ithin the furnace should exceed this setting the control will open de energizing the ignition control which in turn will open the electrical circuitto the gas valve The control will automatically reset when the temperature within the combustion chamber is sufficiently lowered WARNING 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 1 Remove electrical power to unit Some units may have more than one source of power 2 Remove the wires from the limit control terminals 3 Using an ohmmeter test for continuity across the two terminals 4 limit test open allow unit to cool and retest 5 If still open replace the control 54 S 301 TESTING AUXILIARY LIMIT The auxiliary limit control is a preset nonadjustable control mounted in the blower compartment area It is connected in series with the rollout switch wiring to the gas valve Ifits temperature should be exceeded it will open interrupting the voltage to the gas valve causing it to open An additional limit primary limit control is required for safety control of high temperature within the furnace or ductwork AUX LIMIT
71. ium Chassis PGMDMD103 Motorized 25 Fresh Air Downflow Application Large Chassis PGMDMH101 Motorized 25 Fresh Air Damper Horizontal Application Small Chassis PGMDMH102 Motorized 25 Fresh Air Damper Horizontal Application Medium Chassis PGMDMH103 Motorized 25 Fresh Air Damper Horizontal Application Large Chassis SQRPG1 01 102 Square to Round Adapter w 16 Round Downflow Application Small and Medium Chassis SQRPG1 03 Square to Round Adapter w 18 Round Downflow Application Large Chassis SQRPGH1 01 102 Square to Round Adapter w 16 Round Horizontal Application Small and Medium Chassis SQRPGH1 03 Square to Round Adapter w 18 Round Horizontal Application Large Chassis PGFR101 102 103 Internal Filter Rack All Chassis Extemal Horizontal Filter Rack for Goodman Amana Gas Electric GPGHFR101 103 amp Multi position Package Units All Chassis CDK36 Flush Mount Concentric Duct Kit CDK36515 Flush Mount Concentric Duct Kit w Filter CDK36530 Step Down Concentric Duct Kit CDK36535 Step Down Concentric Duct Kit w Filter CDK48 72 Flush Mount Concentric Duct Kit CDK48 725 15 Flush Mount Concentric Duct w Filter CDK4872530 Step Down Concentric Duct Kit CDK4872535 Step Down Concentric Duct Kit w Filter NOTE Complete lineup of thermostats can be found in the Thermostat Specification Sheets 8 LIGHTING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING WARNING A This appliance does not have a pi
72. k efficiency A minimum 12 inch clearance is required to the condenser coil NOTE The flue outlet hood is packaged separately inside the unit and must be installed prior to operation amp WARNING TO PREVENT POSSIBLE DAMAGE THE UNIT SHOULD REMAIN IN AN UPRIGHT POSITION DURING ALL RIGGING AND MOVING OPERATIONS TO FACILITATE LIFTING AND MOVING IF A CRANE IS USED PLACE THE UNIT IN AN ADEQUATE CABLE SLIDE IMPORTANT NOTE If using bottom discharge with roof curb ductwork should be attached to the curb prior to installing the unit Refer to Roof curb Installation Instructions for proper curb installation Curbing must be installed in compliance with the National Roofing Contractors Association Manual Lower unit carefully onto roof mounting curb While rigging unit center of gravity will cause condenser end to be lower than supply air end NOTE roof curb be used to utilize bottom discharge APG GPG Package Units are designed for outdoor installa tions only in either residential or light commercial applica tions NOTE To ensure proper condensate drainage unit must be installed in a level position The connecting ductwork Supply and Return can be con nected for either horizontal or down discharge airflow In the downdischarge applications a matching Roof Curb is recom mended Areturn airfilter mustbe installed behind the return air grille s or provision must be made for afilterin an
73. l y compris pr s du plancher pour d celer une odeur de gaz i c est le cas ROBI NET A GAZ ARR TEZ Passer l etape B des instructions de securite MANUEL EN POS sur la portion superieure de cette etiquette MARCHE s il n y a pas d odeur de gaz passer l et pe suivante 7 pousse le levier du contr le du gaz power to the appliance DU GAZ Set thermostat to desired setting If the appliance will not operate MANUAL GAS instructions intitul es Comment couper l admission follow the instructions To Turn LEVER SHOWA de gaz de l appareil et appeler un technicien Off Gas To Appliance and call your N ON qualifi ou le fournisseur de gaz service technician or gas company 2 position 8 Remettre en place le panneau d acc s 9 Mettre l appareil sous tension 10 R gler le thermostat la temp rature d sir e 11 Si l appareil ne se met pas en marche suivre les EE TURN OFF GAS TO APPLIANCE 1 2 3 Set the thermostat to lowest setting Turn off all electric power to the appliance 2 Couper l alimentation lectrique de l appareil s il if service is to be performed Push the gas control lever to OFF Position Do not force Replace control access panel POUR COUPER L ADMISSION DE GAZ DE L APPAREIL 1 R gler le thermostat la temp rature la plus bass
74. lay at the end of the heating cycle The range of adjustment is for 90 120 1500r 180 seconds The factory delay setting is 30 seconds delay on 150 seconds delay off Direct Spark Ignition DSI Systems APG GPG units are equipped with a direct spark ignition system Ignition is provided by 22 000 volt electronic spark A flame sensor then monitors for the presence of flame and closes the gas valve if flame is lost 23 SYSTEM OPERATION IGNITION CONTROL SEQUENCE OF OPERATION A Heating Operation Low stage heat 10 dis 12 13 24 Thermostat type is set to two stage Thermostat W1 input initiates low stage heating Induced draftbloweris energized athigh speedforthe pre purge period Pre purgetimer begins after control recognizes pressure switch has closed Trial for ignition period begins after pre purge period expires Low and high stage gas valves are energized along with the igniter for trial for ignition period Igniter is de energized when flame is detected Flame is achieved and detected during trial for ignition period Flame stabilization period begins when flame is detected De energize high stage gas valve and switch induced draft blower to low speed within five seconds of flame detection Air circulating blower is energized at low heat speed after heat ON delay time expires Heat ON delay timer begins when flame is detected Control monitors thermostat flame limit and pres sure switch inputs
75. lectric 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 proce dures and equally vulnerable to internal electrical short circuits caused by excessive system contaminants WARNING To avoid possible explosion Never apply flame or steam to a refrigerant cylinder If you must heat a cylinder for faster charging partially immerse it in warm water Never fill a cylinder more than 80 full of liquid refrigerant Never add anything other than R 22 to an R 22 cylinder or R 410A to an R 410A cylinder The service equipment used must be listed or certified for the type of refrigerant used Store cylinders in a cool dry place Never cylinder as a platform or a roller AA WARNING To avoid possible explosion use only returnable not disposable service cylinders when removing refrig erant from a system Ensure the cylinder is free of damage which could lead to a leak or explosion Ensure the hydrostatic test date does not exceed 5 years Ensure the pressure rating meets or exceeds 400 Ibs When in doubt do not use cylinder In either of these instances an electrical short between the terminal and the compressor housing may result in the loss of integrity between
76. lier This furnace must be installed in accordance with the manufacturers instructions and local codes In the absence of local codes follow the National Fuel Gas Code ANSI 7223 1 For outdoor installation only WARNING If not installed operated and maintained in accordance with the manufacturer s instructions this product could expose you to substances in fuel combustion which can cause death or serious illness and which are known to the State of California to cause cancer birth defects or other reproductive harm This product contains fiberglass insulation Fiberglass insulation contains a chemical known by the State of California to cause cancer FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance B14933 239 LIGHTING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING WARNING A This appliance does not have a pilot It is equipped with an ignition device which automatically lights the burners Do not try to light the burners by hand B BEFORE OPERATING smell around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS o Do not try to light any appliance o Do not touch any electric switch do not use any telephone in your building o call your pole from a neighbor s phone Follow the gas suppliers
77. liquid refrigerantflow 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 ofthe refriger ant in the coil This regulation of the flow prevents the return of liquid refrigerantto the compressor The three forces which govern the operation ofthe valve are 1 the pressure created in the power assembly by the feeler bulb 2 evaporator pressure and 3 the equivalentpressure ofthe superheat spring in the valve 096bleed type expansion valves are usedon the indoor coils The 0 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 Pressure Good thermal contact between the feeler bulb and the suction line is essential to satisfactory valve control and performance The bulb must be securely fastened 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 should be mounted so that the capillary tubing comes out at the top THE VALVES PROVIDED ARE DESIGNED TOMEET THE SPECIFICATION REQUIREMENTS FOR OPTIMUM PROD UCT OPERATION DO NOT USE SUBSTITUTES 47 SERVICING Pressure vs Temperature Cha
78. lity 5 308 CHECKING FOR DELAYED IGNITION Delayed ignition is a delay in lighting a combustible mixture of gas and air which has accumulated in the combustion chamber When the mixture does ignite it may explode and or rollout causing burning in the burner venturi If delayed ignition should occur the following should be checked 1 Improper gas pressure adjustto proper pressure See 5 307 2 Improper burner positioning burners should be inlocat ing slots level front to rear and left to right 3 Carry over lighter tube or cross lighter obstructed clean 4 Main burner orifice s deformed or out of alignment to burner replace 5 309 CHECKING FOR FLASHBACK Flashback will also cause burning in the burner venturi butis caused by the burning speed being greater than the gas air flow velocity coming from a burner port Flashback may occur atthe moment of ignition after a burner heats up or when the burner turns off The latter is known as extinction pop Since the end results of flashback and delayed ignition can be the same burning in the burner venturi a definite attempt should be made to determine which has occurred If flashback should occur check for the following 1 Improper gas pressure adjust to proper pressure See S 307 2 Checkburner for proper alignment and or replace burner 33 Improper orifice size check orifice for obstruction S 310 CHECKING PRESSURE CONTROL A pressure co
79. lot It is equipped with an ignition device which automatically lights the burners Do not try to light the burners by hand B BEFORE OPERATING smell around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any telephone in your building your supplier from a neighbor s phone Follow the gas suppliers instructions If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life If you cannot reach your gas supplier call the fire department C Use only your hand to move the gas control switch or knob Never use tools If the gas control switch or knob will not operate don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion D Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS 1 STOP Read the safety information above on this label 2 Set the thermostat to lowest setting 3 Turn off all electric power to the appliance 4 This appliance is equipped with an automatic igniti
80. must be reclaimed If an indoor leak is suspected thoroughly ventilate the area before beginning work Liquid refrigerant can be very cold To avoid possible frostbite or blindness avoid contact with refrigerant and wear gloves and goggles If liquid refrigerant does contact your skin or eyes seek medical help immediately Always follow EPA regulations Never burn refrig erant as poisonous gas will be produced WARNING To avoid possible injury explosion or death practice safe handling of refrigerants WARNING The compressor POE oil for R 410A units is extremely susceptible to moisture absorption and could cause compressor failure Do not leave system open to atmosphere any longer than necessary for installation WARNING System contaminants improper service procedure and or physical abuse affecting hermetic compressor electrical terminals may cause dangerous system venting The successful developmentof hermetically sealed refrigera tion 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 sealedin a die
81. n 5 108 SUPERHEAT The expansion valves are factory adjusted to maintain 12 to 15 degrees superheat of the suction gas Before checking the superheat or replacing the valve perform all the proce dures outlined under Air Flow Refrigerant Charge Expan sion Valve Overfeeding Underfeeding These arethe most common causes for evaporator malfunction CHECKING SUPERHEAT Refrigerant gas is considered superheated when itstempera ture is higher than the saturation temperature corresponding toits pressure The degree of superheat equals the degrees of temperature increase above the saturation temperature at existing pressure See Temperature Pressure Chart on following page CAUTION To prevent personal injury carefully connect and disconnect manifold gauge hoses Escaping liquid refrigerant can cause burns Do not vent refrigerant to atmosphere Recover during system repair or final unit disposal 1 Run system at least 10 minutes to allow pressure to stabilize 2 Temporarily install thermometer on suction large line near compressor with adequate contact and insulate for best possible reading 3 Refer to the superheat table provided for proper system superheat Add charge to lower superheat or recover charge to raise superheat Superheat Formula Suct Line Temp Sat Suct Temp EXAMPLE a Suction Pressure 143 b Corresponding Temp F 50 c Thermometer on Suction Line 61 F To obtain
82. nder Atthis time you may still have some liquid refrigerant in the charging cylinder hose and will definitely have liquid in the liquid hose Reseatthe 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 Dueto their design Scroll compressors are inherently more tolerant of liquid refrigerant NOTE Even though the compressor section of a Scroll compressor is more tolerant of liquid refrigerant continued floodback or flooded start conditions may wash oil from the bearing surfaces causing premature bearing failure 5 104 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 5 105 THERMOSTATIC EXPANSION VALVE The expansion valve is designed to control the rate of
83. nstances the owner may be able to perform some of the maintenance however the advantage of a service contract which places all maintenance in the hands of a trained serviceman should be pointed out to the owner WARNING 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 7 es A MONTH Inspectthe return filters ofthe evaporator unit and clean orchange if necessary NOTE Depending on operation conditions it may be necessary to clean or replace the filters more often If permanenttype filters are used they should be washed with warm water and dried 2 When operating on the cooling cycle inspect the con densate line piping from the evaporator coil Make sure the piping is clear for proper condensate flow ONCE A YEAR QUALIFIED SERVICE PERSONNEL ONLY 1 Clean the indoor and outdoor coils 2 Clean the cabinet inside and out 3 Motors are permanently lubricated and do not require oiling TO AVOID PREMATURE MOTOR FAILURE DO NOTOIL 4 Manually rotate the outdoor fan and indoor blower to be sure they run freely 5 Inspect the control panel wiring compressor connec tions and all other component wiring to be sure all connections are tight Inspect wire insulation to be certain that it is good 6 Checkthe contacts of the compressor contactor If they are burned or pit
84. ntrol device is used to measure negative pressure at the induced draft blower motor inlet to detect a partial or blocked flue Pressure Switch Operation DSI Direct Spark System The pressure switch is ignored unless there is a call for heat When the control receives a call for heat the control checks to see that the pressure switch is open If the control sees that the pressure switch is closed before the induced draft blower is energized the LED will flash a code of 2 to indicate the pressure switch is stuck closed and the inducer will remain off until the pressure switch opens If the pressure switch opens before the ignition period the induced draft blower will remain on and the control will stay in pre purge until the pressure switch is closed for an entire 15 second pre purge period The LED will flash a code of 3 to indicate open pressure switch If the pressure switch opens after the gas valve has been energized the control will de energize the gas valve and run the indoor blower through the heat off delay The inducer stays on until the pressure switch re closes Then the control makes another ignition attempt WARNING 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 m or death 1 Remove wires from the electrical terminals 2 Using a VOM check from Common to NO Normally Open sh
85. ny damage was done to the furnace especially the wiring 3 Confirmthat heat exchangeris not obstructed by feeling fordischarge airfrom the flue hood when the combustion blower is running but the unit is not firing Ifthe above steps do notsuggestthe reason the control has tripped the furnace should be fired 1 Removethe heating compartment door 2 Turn of the power or open the thermostat circuit 3 Resetthe rollout control 4 Turn power on and put the unit into a call for heating CAUTION Flame rollout could occur Keep face and hands a safe distance from burner area 55 SERVICING 5 Look under the heat shield as the unit is running Flames should be drawn into firing tubes a Ifonly one burners flame is not drawn into the tube that tube is restricted b f without the air circulation blower running all flames are not drawn into the tubes either the collector box combustion blower or flue outlet is obstructed Ifthe combustion blower or flue outlet is obstructed the pressure switch should have opened preventing the unitfrom firing also inspect the unit pressure switch and wiring c Ifthe burner flame is not drawn into the tube only when the air circulation blower is running then a cracked heat exchanger tube is present 5 303 TESTING INDUCER MOTOR WARNING HIGH VOLTAGE Disconnect ALL power before servicing or installing this unit Multiple power sources may be present Failure to
86. on a temperature of the liquid and b wetted surface area of the container or containers 2 Proper pressure regulation Two stage regulation is recommended from the standpoint of both cost and efficiency 3 Pressure dropin lines between regulators and between second stage regulator and the appliance Pipe size required will depend on length of pipe run and total load of all appliances Complete information regarding tank sizing for vaporization recommended regulator settings and pipe sizing is avail able from most regulator manufacturers and propane gas suppliers Propaneis an excellentsolvent and special pipe dope must beused when assembling piping forthis gas as it will quickly dissolve white lead or most standard commercial com pounds Shellac base compounds resistant to the actions of liquefied petroleum gases such as Gasolac Stalactic Clyde s or John Crane are satisfactory 21 PRODUCT DESIGN TYPICAL PROPANE PIPING PROPANE GAS PIPING CHARTS 5 to 15 PSIG First Stage 20 PSIG Max Sizing Between First and Second Stage Regulator Regulator Continuous Maximum Propane Capacities listed are based on 1 PSIG Pressure Drop at 10 11 W C PSIG Setting Capacities in 1 000 BTU HR PIPE OR 1 TUBING TUBING SIZE O D TYPEL NOMINAL PIPE SIZE SCHEDULE 40 LENGTH 200 PSIG Second Stage FEET Maximum Regulato 5 8 3 4 7 8 1 2 3 4 1 303 2 205 3 394 1 843 3
87. on system which automatically lights the burners Do not try to light the burners by hand 5 Remove control access panel 6 Move the gas control switch or knob to OFF GAS CONTROL SWITCH SHOWN IN ON POSITION GAS CONTROL __ KNOB 7 Wait five 5 minutes to clear out any es If you then smell gas STOP ollow in the safety information above on this label If you don t smell gas go to the next step 8 Move the gas control switch or knob to ON 9 Replace control access panel 10 Turn on all electric power to the appliance 11 Set the thermostat to the desired setting 12 If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier 7 GAS CONTROL SWITCH SHOWN IN ON L POSITION TO TURN OFF GAS TO APPLIANCE 1 Set the thermostat to its lowest setting 2 Turn off all electric power to the appliance if service is to be performed 3 Remove control access panel 4 Move the gas control switch or knob to OFF Do not force 5 Replace control access panel PG13 M AA WARNING Improper installation adjustment alteration service or maintenance can cause injury or property damage Refer to the user s information manual provided with this furnace For assistance or additional information consult a qualified installer service agency or the gas supp
88. ontrol Voltage present at gas valve replace gas valve Testing High Stage Heat Operation with Low Stage Heat Operating 1 Board set for 2 stage thermostat a Check for 24 Volts thermostat terminals W2 and C on the control board No voltage check thermostat and thermostat wiring Voltage present check for 24 volts at gas valve terminals C and HI No voltage presentatvalve check 9 pin connector andwires from ignition control to gas valve If wires and connections at 9 pin connector check good replace ignition control Voltage present at gas valve replace gas valve 2 Board set for 1 stage thermostat a Wait the selected delay time either 5 or 10 minutes depending on jumper setting Check for 24 volts at gas valve terminals C and HI No voltage present check 9 pin connector and wires from ignition control to gas valve If wires and connections at 9 pin connector check good replace ignition control Voltage present at gas valve terminals C and HI replace valve Cooling Mode Indoor thermostat calling for cool 1 Check for 230 volts from L1 terminal of control module to L2 No voltage check wire connections continuity etc 2 Check for 24 volts at R and C thermostat terminals on ignition control a b No voltage check 3 amp automotive type fuse on control board A blown fuse could indicate a short in the 24 volt circuit Voltage present proceed to step 3
89. or Coil Noncondensibles Recirculation of Condensing Air Infiltration of Outdoor Air Improperly Located Thermostat Air Flow Unbalanced System Undersized Broken Internal Parts Inefficient Compressor High Pressure Control Open Unbalanced Pow er 3PH Wrong Type Expansion Valve Expansion Device Restricted Expansion Valve Bulb Loose Inoperative Expansion Valve Loose Hold dow n Bolts 34 SYMPTOM System will not start Stage Compressor Not Energized COOLING ANALYSIS CHART Pressures 5 2 gt a 2 24 o o 5 S eo gt wn gt s 5 o 2 D 9 o gt 5 gt 2186 19 23 2 21018 S LE S S o o IS o Die siz g D Sic ilo gt Compressor will not start fan runs 2 IL sre Test Method 5 8 gt 54 Test Unloader Solenoid 2 stage compressor only Inspect Ffer Clean or Replace Inspect Col een _ nspectCol Clean Remove obstruction o Ak ow Check Window s Doors Vent Fans Ee COO T A
90. ould read open If switch reads as noted proceed to Step 3 otherwise replace control 3 Removethe pressure control hose from the control and interconnect with an inclined manometer as shown HOSE TO J TUBE N PRESSURE SWITCH INCLINED MANOMETER Reconnect wires to the Common and NO terminals With Power ON T WARNING Line Voltage now present 4 Energize furnace for heating cycle The induced draft blower motor will begin to run The inclined manometer should read approximately 1 2 0 3 W C with no combustion 5 Remove and checkthe two electrical wires and using the VOM check from Common to NO Normally Open it should read closed with 1 0 motor running If not as above replace pressure control 6 Reconnect all wires to the control and place in heating cycle 7 Astheunitfires on high stage the inclined manometer negative pressure will drop to 1 0 0 3 W C 8 If notas listed replace control Note the pressure switch must be mounted with the diaphragm in a vertical position 59 SERVICING S 311 HIGH ALTITUDE APPLICATION High Altitude Derate U S Installations Only IMPORTANT NOTE The gas electric units naturally derate with altitude Do not attempt to increase the firing rate by changing orifices or increasing the manifold pressure This can cause poor combustion and equipment failure At all altitudes the manifold pressure must be within 0 3 inch
91. oved Control returnsto Standby and awaits nextthermostat request B Cooling Operation High stage cool Thermostat type is set to two stage Thermostat Y 1 and Y2 or Y 1 Y2 and inputs initiate high stage cooling IDT ODT Pressure Loss of Charge Switch circuits are checked for closed condition Cooling operation can proceed only if these circuits are closed A GPG15 Low and high stage compressor outputs are ener gized Condenser fan motor is energized at high speed Air circulating blower is energized at high cool speed after cool ON delay expires Cool ON delay timer begins when thermostat inputs are detected Control monitors thermostat gas valve flame and IDT ODT Pressure Loss of Charge Switches during high stage cooling operation Thermostat Y 1 and Y2 or Y1 Y2 and inputs are removed Low and high stage compressor outputs are de energized High speed condenser fan motor is de energized Air circulating blower switches to low cool speed for the cool OFF delay Cool OFF delay timer begins when thermostat input is removed Control returnsto Standby and awaits next thermostat request A Continuous Fan Operation 1 Thermostat G input initiates Continuous Fan opera tion Air circulation blower shall be immediately energized at the continuous fan speed For purposes of this specification the continuous fan speed shall be the low heat speed
92. r ON close the switch 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 5 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 usedto prevent migration or accumu lation of refrigerant in the compressor crankcase during the off cycles and prevents liquid slugging or oil pumping on start up Acrankcase heater will not prevent compressor damage due to a floodback or over charge condition FA WARNING UU 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 5 100 REFRIGERATION REPAIR PRACTICE DANGER Always remove the refrigerant charge in a proper manner before applying heat to the system When repairing the refrigeration system WARNING eis Disconnect ALL power before servicing 1 Never open a system that is under vacuum Air and moisture will be drawn in 2 Plug or cap all openings 3 Remove all burrs and clean the brazing surfaces of the tubing with sand cloth or paper Brazing materials do not flow well on oxidized or oily surfaces 4 Cleanthe inside of all new tubing to remove oils and pipe chips
93. r provision mustbe made for afilterin an accessible location within the return air duct 3 phase models have an internal downflow filter rack The minimum filter area should not be less than those sizes listed in the Specification Section Under no circumstances should the unit be oper ated without return air filters A GPG model units use either PSC or EEM type indoor blower motors EEM motors are constanttorque motors with very low power consumption and are energized by a 24V signal from the ignition control board The EEM motors feature an integrated control module Air for condensing cooling cycle is drawn through the outdoor coil by a propeller fan and is discharged vertically out the top of the unit The outdoor coil is designed for 0 static No additional restriction ductwork shall be applied Conditioned air is drawn through the filter s field installed across the coil and back into the conditioned space by the indoor blower Most A GPG series package units use the Compliant Scroll compressor there are a number of design characteristics which are different from the traditional reciprocating com pressor Dueto their design Scroll compressors are inherently more tolerant of liquid refrigerant NOTE Even though the compressor section of a Scroll compressor is more tolerant of liquid refrigerant continued flood back or flooded start conditions may wash oil from the bearing surfaces causing premature bearing failure
94. r to the appliance 11 Set the thermostat to the desired setting 12 the appliance will not follow the instructions To Gas To Appliance and call your service technician or gas supplier TO TURN OFF GAS TO APPLIANCE 1 Set the thermostat to its lowest setting 2 Turn off all electric power to the appliance if service is to be performed 3 Remove control access panel 4 Move the gas control switch or knob to OFF Do not force 5 Replace control access panel 13 WARNING Improper installation adjustment alteration service or maintenance can cause injury or property damage Refer to the user s information manual provided with this furnace For assistance or additional information consult a qualified installer service agency or the gas supplier This furnace must be installed in accordance with the manufacturers instructions and local codes In the absence of local codes follow the National Fuel Gas Code ANSI Z223 1 WARNING If not installed operated and maintained in accordance with the manufacturer s instructions this product could expose you to substances in fuel combustion which can cause death or serious illness and which are known to the State of California to cause cancer birth defects or other reproductive harm This product contains fiberglass insulation Fiberglass insulation contains a chemical known by the State of California
95. r will not push im or turn C Ne pousser ou tourner manette d admission du gaz hand don t try to repair it call a qualified service qu la main jamais emploer d outil cette Fin technician Force or attempted repair may result in a fire Si la manette reste coinc e ne tenter pas de or explosion Do not use this appliance if any part has been underwater tente de forcer la manette ou de la r parer peut Immediately call a qualified service technician to inspect the appliance and to replace any part of the control TET System and any gas control which has been underwater D Ne pas se servir de cet appareil s il a t plong dans entrainant des dommages mat riels des lesions Cet appareil ne comporte pas de veilleuse Il est muni d un dispositif d allumage qui allume B AVANT DE LE FAIRE FONCTTONNER renifler tout autour de l appariel pour dec ler une odeur de gaz Renifler pr s du plancher car certains gaz sont plus lourds l air et peuvent s accumuler au niveau du sol QUE FAIRE S IL Y A UNE ODEUR DE GAZ Ne pas tenter d allumer d appareils o Ne toucher aucun interrupteur ne pas vous servir des t l phones dans le b timent o Appelez imm diatement votre fournisseur de gaz depuis un voisin Suivez les instructions du fournisseur de gaz o Si vous ne pouvez rejoindre le fournisseur de gaz r parer appelez un technicien qualifi Quiconque provoquer une explosion o
96. raft blower switches from high speed to low speed and remains energized for post purge period Air circulating blower remains energized at high heat speed for High Stage Heat OFF Delay period then switches to low heat speed for the remainder of the selected heat OFF delay Heat OFF delay begins when W1 and W2 inputs are removed Control returnsto Standby and awaits nextthermostat request SYSTEM OPERATION IGNITION CONTROL SEQUENCE OF OPERATION CONT A Cooling Operation Low stage cool ale 2 10 11 Thermostat type is set to two stage Thermostat Y1 or thermostat Y1 and G input initiates low stage cooling IDT ODT Pressure Loss of Charge Switch circuits are checked for closed condition Cooling operation can proceed only if these circuits are closed Low stage compressor output is energized Condenser fan motor is energized at low speed Air circulating blower is energized at low cool speed after cool ON delay expires Cool ON delay timer begins when thermostat inputs are detected Control monitors thermostat gas valve flame and IDT ODT Pressure Loss of Charge Switches during low stage cooling Thermostat Y 1 or Y 1 and inputs are removed Low stage compressor output is de energized Low speed condenser fan motor is de energized Air circulating blower remains energized at low cool speed for the cool OFF delay Cool OFF delay timer begins when thermostat input is rem
97. rocedures required 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 SERVICEMANUAL BEFORE BEGINNING REPAIRS IMPORTANT NOTICES FOR CONSUMERS AND SERVICERS RECOGNIZE SAFETY SYMBOLS WORDS AND LABELS WARNING This unit should not be connected to or used in conjunction with any devices that are not design certified for use with this unit or have not been tested and approved by Goodman Serious property damage or personal injury reduced unit performance and or hazardous conditions may result from the use of devices that have not been approved or certified by Goodman A warnine ONLY INDIVIDUALS MEETING AT A MINIMUM THE REQUIREMENTS OF AN ENTRY LEVEL TECHNICIAN AS SPECIFIED BY THE AIR CONDITIONING HEATING AND REFRIGERATION INSTITUTE AHRI MAY USE THIS INFORMATION ATTEMPTING TO INSTALL OR REPAIR THIS UNIT WITHOUT SUCH BACKGROUND MAY RESULT IN PRODUCT DAMAGE PERSONAL INJURY OR DEATH WARNING Do not store combustible materials or use gasoline or other flammable liquids or vapors in the vicinity of this appliance as property damage or personal injury could occur Have your contractor point out and identify the various cut off devices switches etc that serves your comfort equipment WARNING Goodman will not be responsible for any injury or property damage arisin
98. rt R 410A oF PSIG F PSIG F 216 0 74 3 420 0 120 2180 74 9 4220 121 220 0 75 5 4240 121 526 0 138 2220 76 1 426 0 121 528 0 138 2240 76 7 4280 1224 530 0 138 226 0 77 2 430 0 122 532 0 139 228 0 77 8 432 0 _ 122 534 0 139 230 0 434 0 123 536 0 139 232 0 436 0 123 538 0 140 234 0 438 0 123 540 0 140 236 0 4400 124 544 0 141 238 0 442 0 124 548 0 141 240 0 444 0 124 552 0 142 242 0 446 0 125 556 0 142 244 0 f 448 0 125 560 0 143 246 0 450 0 126 564 40 143 248 0 452 0 126 568 0 144 250 0 1 4540 126 572 0 145 252 0 456 0 127 576 0 _ 145 254 0 458 0 _ 127 580 0 146 256 0 2 460 0 127 584 0 146 258 0 462 0 128 588 0 147 260 0 1 464 0 128 592 0 147 262 0 466 0 128 596 0 148 264 0 468 0 _ 129 600 0 149 266 0 470 0 129 604 0 149 268 0 472 0 129 608 0 150 1 270 0 474 0 130 612 0 150 272 0 476 0 130 616 0 151 274 0 478 0 130 620 0 _ 151 276 0 480 0 131 624 0 152 278 0 482 0 131 628 0 152 280 0 4840 131 632 0 153 282 0 486 0 132 636 0 153 284 0 488 0 _ 132 640 0 154 286 0 490 0 132 644 0 155 288 0 5 492 0 132 648 0 155 290 0 494 0 133 652 0 156 190 0 66 292 0 496 0 133 656 0 156 192 0 67 294 0 498 0 133 660 0 157 194 0 67 296 0 500 0 134 664 0 157 196 0 68 298 0 502 0 134 668 0 158 198 0 68 300 0 504 0 134 672 0 158 200 0 69 302 0 506 0 135 676 0 159 202 0 70
99. s BECKETT BURNER WARNING Disconnect gas and electrical power supply In checking main burners lookfor signs of rust oversized and undersized carry over ports restricted with foreign material etc 5 306 CHECKING ORIFICES A predetermined fixed gas orifice is used in all of these furnaces That is an orifice which has a fixed bore and position A The length of Dimension A determines the angle of Gas Stream Defraction B A dent or burr will cause severe deflection of gas stream No resizing should be attempted until allfactors are taken into consideration such as inlet manifold gas pressure align ment and positioning specific gravity and BTU content of the gas being consumed The only time resizing is required is when areduction in firing rate is required for an increase in altitude Orifices should be treated with care in order to prevent damage They should be removed and installed with a box end wrench in order to prevent distortion In no instance should an orifice be peened over and redrilled This will change the angle or deflection of the vacuum effect or entraining of primary air which will make it difficult to adjust the flame properly This same problem can occur if an orifice spud of a different length is substituted AX WARNING Disconnect gas and electrical power supply 1 Check orifice visually for distortion and or burrs 2 Check orifice size with orific
100. s 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 PRODUCT DESIGN 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 ina very smooth process Both the suction process outer portion of the scroll members andthe discharge process inner portion are continuous ELECTRICAL WIRING Theunits are designed for operation on 60 hertz current and at voltages as shown on the rating plate internal wiring is complete Ensure the power supply to the compressor contactor is brought to the unit as shown on the supplied unit wiring diagram The 24V wiring must be connected between the unit control panel and the room thermostat LINE VOLTAGE WIRING Power supply to the unit must be N E C Class 1 and must comply with all applicable codes The unit must be electri cally grounded in accordance with the local codes or in their absence with the latest edition of the National Electrical Code ANSI NFPA No 70 orin Canada Canadian Electrical Code 22 1 Part 1 Afused disconnect
101. s 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 atleast three to four hours for it to cool and reset then retest Fuse circuit breaker ground fault protective device etc has not tripped WARNING 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 m or death 1 Remove the leads from the compressor terminals WARNING See warnings S 17 before removing compressor terminal cover 2 Usinganohmmeter testcontinuity between terminals S R C R and C S on single phase units or terminals T1 T2 and T3 on phase units TESTING COMPRESSOR WINDINGS 43 SERVICING If either winding does not test continuous replace the compressor NOTE If an open compressor is indicated allow ample time forthe internal overloadto reset before replacing compressor 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 equipmen
102. sing a fixed orifice restrictor device flowrator metering device could allow refrigerantto return to the compressor under extreme overcharge conditions Also with a fixed orifice restrictor device flowrator metering device extreme cases of insufficient indoor air can cause icing of the indoor coil and liquid return to the compressor but the head pressure would be lower There are other causes for high head pressure which may be found in the Service Problem Analysis Guide If other causes check out normal overcharge or a system containing non condensables would be indicated If this system is observed 1 Start the system 2 Remove and capture small quantities of refrigerant as from the suction line access fitting until the head pressure is reduced to normal 3 Observethe 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 Ifthe pressure indicates a highertemperature than that ofthe 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 recharg
103. t nameplate Withthe terminal protective cover in place itis acceptable to replace the fuse orresetthe circuit breaker ONE TIME ONLY to see if it was just a nuisance opening Ifitopens again DO NOT continue to reset mz WARNING E Disconnect ALL power before servicing Disconnect all power to unit making sure that all power legs are open 1 DO NOT remove protective terminal cover Disconnect the three leads going to the compressor terminals at the nearest point to the compressor 2 Identify the leads and using a Megger Hi Potential Ground Tester or other suitable instrument which puts out a voltage between 300 and 1500 volts check for a ground separately between each of the three leads and ground such as an unpainted tube on the compressor Do notuse alow voltage output instrument such as a volt ohmmeter COMPRESSOR GROUND TEST ground is indicated then carefully remove the com pressor terminal protective cover and inspect for loose leads or insulation breaks in the lead wires 4 fnovisualproblems indicated carefully remove the leads at the compressor terminals 44 WARNING Damage can occur to the glass embedded terminals if the leads are not properly removed This can result in terminal and hot oil discharging Carefully retestfor ground directly between compressor terminals and ground 5 If groundis indicated replace the compressor S 17C UNLOADER TEST PROCEDURE 2
104. tance 43 Ground TEST 44 Unloader Test 44 Operation TeSt sens iniecit vie ctis 45 Testing Crankcase Heater optional item 45 Refrigeration Repair Practice 45 46 VACUATION 46 47 WARNING HIGH VOLTAGE 5 104 Checking Compressor Efficiency 47 5 105 Thermostatic Expansion Valve 47 106 Overfeeding 49 S 107 2 2 0 4004402200 49 5108 49 5 109 Checking Subcooling 51 S 110 Checking Expansion Valve Operation 51 S 111 Fixed Orifice Restriction Devices 51 S 112 Checking Restricted Liquid Line 52 5 113 RefrigerantOvercharge 52 5 114 52 S 115 Compressor Burnout 52 5 200 Checking Extedrnal Static Pressure 53 S 201 Checking Temperature Rise 53 5 300 Testing Primary 54 5 301 Testing Auxiliary 54 S 302 Checking Flame Rollout Switch 55
105. tat must be changed S 3C HEATING ANTICIPATOR The heating anticipator is a wire wound adjustable heater which is energized during the ON cycle to help prevent overheating of the conditioned space The anticipator is a part of the thermostat and if it should fail for any reason the thermostat must be replaced See the following for recommended heater anticipator setting To determine the proper setting use an ammeter to measure the current on the W wire going to the thermostat Use an amprobe as shown below Wrap 10 turns of thermo stat wire aroundthe stationary jaw of the amprobe and divide the reading by 10 10 TURNS OF THERMOSTAT WIRE From W on thermostat READS 4 AMPS CURRENT DRAW WOULD BE 4 AMPS Checking Heat Anticipator Amp Draw SERVICING S 4 CHECKING TRANSFORMER AND CON TROL CIRCUIT WARNING 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 7 step down transformer 208 240 volt primary to 24 sec ondary is provided with each indoor unit This allows ample capacity for use with resistance heaters The outdoor sec tions do not contain a transformer WARNING Eus Disconnect ALL power before servicing 1 Remove control panel cover or etc to gain access to transformer With power ON WARNING Line Voltag
106. ted replace the contactor 7 Using a halide or electronic leak detector check all piping and etc for refrigerant leaks 8 Check the combustion chamber Heat Exchanger for Soot scale etc Inspect all burners for lint and proper positioning 9 Startthe system usingthe proper instrumentation check gas inlet and manifold pressures burner flame and microamp signal Adjust if necessary 10 Startthe system and run a Heating Performance Test If the results of the test are not satisfactory see the Service Problem Analysis Guide for the possible cause TEST EQUIPMENT Proper test equipment for accurate diagnosis is as essen tial as regular hand tools The following is a must for every service technician and service shop 1 Thermocouple type temperature meter measure dry bulbtemperature 2 Sling psychrometer measure relative humidity and wet bulbtemperature 3 Amprobe measure current 4 Volt Ohm Meter testing continuity capacitors motor windings and voltage 5 Accurate Leak Detector testing for refrigerant leaks 6 High Vacuum Pump evacuation Electric Vacuum Gauge Manifold Gauges and high vacuum hoses to measure and obtain proper vacuum 8 Accurate Charging Cylinder or Electronic Scale mea sure properrefrigerant charge 9 Inclined Manometer measure static pressure and pressure drop across coils Other recording type instruments can be essential in solving abnormal problems how
107. the system damaging additional components Use part number RF000127 suction line filter drier kit This drier should be installed as close to the compressor suction fitting as possible The filter must be accessible and be rechecked for a pressure drop after the system has operated for a time It may be necessary to use new tubing and form as required NOTE At least twelve 12 inches of the suction line immediately out of the compressor stub must be discarded due to burned residue and contaminates 1 Remove compressor discharge line strainer 2 Remove the liquid line drier and expansion valve 3 Purge all remaining components with dry nitrogen or carbon dioxide until clean Install new components including liquid line drier 5 Braze all joints leak test evacuate and recharge sys tem SERVICING 6 Startup 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
108. 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 ONTXV APPLICATIONS 1 Run system at least 10 minutes to allow pressure to stabilize 2 Temporarily install thermometer on liquid small line near pressure switches 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 12 15 F Ifsubcooling and superheatare low adjust to 9 3 F then check subcooling b If subcooling is low and superheat is high add charge to raise subcooling to 10 F then check superheat c lfsubcoolingand superheat are high adjust TXV valve to 12 15 F then check subcooling d lfsubcoolingis high and superheatis low adjust TXV valve to 12 15 F superheat and remove charge to lower the subcooling to 2 15 F The TXV should NOT be adjusted atlightload conditions 55 to 60 F under such conditions only the subcooling can be evaluated This is because suction pressure is dependentonthe 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 49 SERVICING REQUIRED LIQUID LINE TEMPERATURE AT SERVICE VALVE PSI
109. the incoming power supply L1 L2 240V L1 L3 232V Avg V 710 236 7 L2 L3 238V 3 Total 710V 240 236 7 3 3 232 236 7 4 7 238 236 7 1 3 To find Max deviation Max deviation was 4 7V Voltage Imbalance 4 7 1 99 236 7 If the percentage of imbalance had exceeded 3 it must be determined if the imbalance is in the incoming power supply orthe equipment To do this rotate the legs of the incoming power and retest voltage as shown below L1 L2 240V L1 L3 227V L2 L3 238V Rotate all 3 incoming legs as shown 11 12 227 L1 L3 238V L2 L3 240V By the voltage readings we see thatthe imbalance rotated or traveled with the switching ofthe incoming legs Therefore the imbalance lies within the incoming power supply 37 SERVICING Ifthe imbalance had not changed then the problem would lie within the equipment Check for current leakage shorted motors etc 5 2 CHECKING WIRING WARNING 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 m 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 If any wires must be replaced replace with comparable gauge and insulation thickness S 3 CHECKING THERMOSTAT WI
110. the terminal and its dielectric embed ment This loss may cause the terminals to be expelled thereby venting the vaporous and liquid contents of the compressor housing and system Aventing compressorterminal 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 hotlubricating oil and refrigerant b flammable mixture if system is contaminated with air inastream 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 The model numberis usedfor positive identification of component parts used in manufacturing Please usethis number when requesting service or parts information Distinctions A Amana Brand PRODUCT TYPE Single Package Cooling Heating PRODUCT SERIES 13 Up to 13 SEER HEATING INPUT 070 69 000 BTUH 090 92 000 BTUH 115 115 000 BTUH 140 138 000 BTUH 24 24 000 BTUH 30 30 000 BTUH 36 36 000 BTUH 37 36 000 BTUH 42 42 000 BTUH 48 48 000 BTUH 49 48 000 BTUH 60 60 000 BTUH VOLTAGE MAJOR REVISION 1 208 230V 1ph 60
111. to cause cancer FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance 0140F00688 Rev A LIGHTING INSTRUCTIONS LIRE AVANT DE METTRE D BEFORE OPERATING i EN MARCHELIRE pu exact WARNING If you do not follow these instructions AVERTISSEMENT Quiconque ne respecte pas a fire or explosion may result causing property la lettre les instructions dans le pres nt manuel damage personal injury or loss of life risque de d clencher un incendie ou une explosion A This appliance does not have a pilot It is equipped corporelles ou la perte de vies humaines with an ignition device which automatically lights the burner Do not try to light the burner by hand BEFORE OPERATING smell all around the appliance automatiquement le br leur Ne pas tenter area for gas Be sure to smell next to the floor d allumer le br leur manuellement because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance o Do not touch any electric switch do not use any phone in your building o Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions o Tf you cannot reach your gas supplier call the fire department Use only your hand to push im or turn the gas control lever appelez le service des incendies Never use tools If the leve
112. u un incendie l eau m me partiellement Faire inspecter l appareil par un technicien qualifi et remplacer toutr partie du Syst me de contr le et toute commande qui ont t plong es dans l eau Push gas control lever ET to ON Replace access panel gt i Turn on all electric ARRI VEE 10 11 B OPERATING INSTRUCTIONS STOP Read the safety information above on this label Set the thermostat to lowest setting Turn off all electric power to the appliance This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand Push the gas control lever to OFF Position Do not force Wait five 5 minutes to clear out any gas Then 6 Attendre cing 5 minutes pour laisser echapper tout le smell for gas including near the floor If you then smell gas STOP Follow in the safety information above on this label if you don t smell gas go to next step RS 15 CCE NEN 1 ARR TEZ Lisez les instructions de s curit dans la section sup rieure de cette tiquette 2 R gler le thermostat la temp rature la plus basse 3 Couper l alimentation lectrique de l appareil 4 Cet appareil menager etant dote d un systeme d allumage automatique ne pas essayer allumer br leur manuellement 5 pousse le levier du contr le du gaz a OFF ARRET position gaz Renifler tout autour de l apparei
113. under the design subcooling value Where the two intersect is the required liquid line temperature Alternately you can convert the liquid line pressure gauge reading to temperature by finding the gauge reading in Temperature Pressure Chart and reading to the left find the temperature in the F Column 5 The difference between the thermometer reading and pressure to temperature conversion is the amount of subcooling 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 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 110 CHECKING EXPANSION VALVE OPERA TION 1 Removethe remote bulb ofthe 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 suctiontemperature will rise 3 Nextwarmthe bulbin your hand As you warm the bulb the suction pressure should rise and the suction tem perature will fall 4 f a temperature or pressure change is noticed the expansion valve is operating If no changeis noticed the valve is restricted the power
114. valves and from C and M on 2 stage gas valves for 24 volts to gas valve 3 If24 volts are present and no gas flows through the valve replace valve Gas Valve On Off Switch Inlet Pressure lt nie Outlet Pressure Tap W R 36G54 238 WHITE ROGERS MODEL 36G 2 STAGE GAS VALVE Pressure Regulator Outlet Pressure _ Adjustment Tap Under Cap Screw ER X kx CD st au 1 Inlet Pressure l Tap Gas Valve On Off Selector Switch D OUTLET W R 36G22 202 WHITE ROGERS MODEL 36G 1 STAGE GAS VALVE SERVICING Pressure Regulator Inlet under cap screw Pressure Outlet Tap Pressure 2 5 j INLET OUTLET d 5 Gas Valve On Off Selector Switch HONEYWELL MODEL VR8215 1 STAGE GAS VALVE 5 305 CHECKING MAIN BURNERS The main burners are used to provide complete combustion of various fuels in a limited space and transfer this heat of the burning process to the heat exchanger Proper ignition combustion and extinction are primarily due to burner design orifice sizing gas pressure primary and secondary air vent and proper seating of burner
115. 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 betweenthe capacitor current and voltage in conjunction with the motor windings so that the motor will give two phase operation when connected to a single phase circuit The capacitor also reduces the line current to the motor by improving the power factor CAPACITOR START SCROLL COMPRESSOR MODELS Hard start components are not required on Scroll compres sor equipped units due to a non replaceable check valve located in the discharge line of the compressor However hard start kits are available and may improve low voltage starting characteristics This check valve closes off high side pressure to the com pressor after shut down allowing equalization through the scroll flanks Equalization requires only about one or two seconds during which time the compressor may turn back wards SERVICING Your unitcomes with a 180 second anti short cycle to prevent the compressor from starting and running backwards MODELS EQUIPPED WITH A HARD START DEVICE A start capacitor is wired in parallel with the run capacitor to increase the starting torque The start capacitor is of the electrolytic type rather than metallized polypropylene as used in the run capacitor A switc
116. y additional line voltage wiring to the inside of the package unit the wiring must comply with all local codes This wiring must have a minimum temperature rating of 105 C and must be routed away from the burner compartment All line voltage splices must be made inside the unit control box GAS SUPPLY AND PIPING 4 amp CAUTION THIS PACKAGE GAS UNIT IS FACTORY SET TO OPERATE ON NATURAL GAS AT THE ALTITUDES SHOWN ON THE RATING PLATE IF OPERATION ON PROPANE IS REQUIRED OBTAIN AND INSTALL THE PROPER CONVERSION KIT S BEFORE OPERATING THIS UNIT FAILURE TO DO SO MAY RESULT IN UNSATISFACTORY OPERATION AND OR EQUIPMENT DAMAGE The rating plate is stamped with the model number type of gas and gas input rating Make sure the unit is equipped to operate on the type of gas available Inlet Gas Pressure Min 5 0 W C Max 10 0 W C Min 11 0 W C Max 13 0 W C Inlet Gas Pressure Must Not Exceed the Maximum Value Shown in the table above The minimum supply pressure must not be varied downward because this could lead to unreliable ignition In addition gas input to the burners must not exceed the rated input shown on the rating plate Overfiring of the unit could result in premature heat exchanger failure 20 GAS PIPING CAUTION TO AVOID POSSIBLE UNSATISFACTORY OPERATION OR EQUIPMENT DAMAGE DUE TO UNDERFIRING OF EQUIPMENT DO NOT UNDERSIZE THE NATURAL GAS PROPANE PIPING FROM THE METER TANK TO THE FURNACE
117. y be expelled venting the vapor and liquid contents of the compressor housing and system Ifthe 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 ifthe discharge impinges on a sufficient heat source Ignition ofthe discharge can also occur at the venting terminal orinside the compressor ifthere 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 essen tial atthe time of manufacture and during servicing Toreduce the possibility of external ignition all open flame electrical power and other heat sources should be extin guished or turned off prior to servicing a system 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 amper age heat

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