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Goodman Mfg R-410A User's Manual

1. 20 zie came 22 COOLING HEAT PUMP SERVICE ANALYSIS GUIDE seen 21 5 1 CHECKING VOLTAGE ass 22 S 2 CHECKING WIRING uuu te cioe 23 5 3 CHECKING THERMOSTAT WIRING AND ANTICIPATOR 23 S 3A Thermostat and WO 23 9 98 sssrini 23 eas rune 23 5 4 CHECKING TRANSFORMER AND CONTROL CIRCUIT nennen niente nnne 24 5 7 CHECKING CONTACTOR AND OR RELAYS nnn nnne enitn nennen nnn nnn nnne 24 5 8 CHECKING CONTACTOR CONTACTS nnns sands nennt 24 INDEX S 11 CHECKING LOSS OF CHARGE PROTECTOR 25 5 15 CHECKING CAPACITOR vevcouvveecencddeussoceeececeusssenceccedeussenceusddavssecueccuceudvacececevdasyseuceusddavsacccesd 25 S 15A Resistance Check 26 59 158 C Deck 26 S 16 CHECKING MOTORS 2 27 S 16B Checking a
2. 44 OT18 60A OUTDOOR THERMOSTAT ee 44 OT18 60A OUTDOOR 45 BAT KITT 46 GPH13MED ECONOMIZER FOR 15 47 IMPORTANT INFORMATION Pride and workmanship go into every product to provide our customers with quality products Itis possible however that during its lifetime a product may require service Products should be serviced only by a qualified service technician who is familiar with the safety procedures required in the repair and who is equipped with the proper tools parts testing instruments and the appropriate service manual REVIEW ALL SERVICE INFORMATION IN THEAPPROPRIATE SERVICE MANUAL BEFORE BEGINNING REPAIRS IMPORTANT NOTICES FOR CONSUMERS AND SERVICERS RECOGNIZE SAFETY SYMBOLS WORDS AND LABELS 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 CERTIFED BY GOODMAN INSTALLATION AND REPAIR OF THIS UNIT SHOULD BE PERFORMED ONLY BY INDIVIDUALS MEETING THE REQUIREMENTS OF AN ENTRY PREVENT THE RISK OF PROPERTY DAMAGE PERSONAL INJURY OR DEATH LEVEL TE
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6. This draws in the normally open contact of the contactor starting the compressor and condenser fan motors At the same time energizing the X13 motor for models so equipped and energizing the VSTB for ECM equipped models starting the indoor fan motor When the thermostat is satisfied it opens its contacts break ing the low voltage circuit from R to Y amp G causing the com pressor contactor to open and de energizing the indoor blower motor shutting down the system If the room thermostat fan selector switch should be set to the on position then the indoor blower would run continu ous rather than cycling with the compressor APH and GPH models energize the reversing valve through the circuit in the room thermostat Therefore the revers ing valve remains energized as long as the thermostat sub base is in the cooling position HEATING CYCLE PH15 M41 Heat Pump Units On a call for first stage heat the contacts of the room ther mostat close This energizes terminals R to Y and R to G the low voltage circuit to the contactor is completed starting the compressor and outdoor fan motor This also energizes the indoor blower through the VSTB on delay on APH15 M series units and instantly on the GPH15 M series units with the GE X13 motor When the thermostat is satisfied breaking the circuit be tween R to Y and R to G the compressor and outdoor fan motor will stop The indoor blower will stop after the 60 sec
7. LINE VOLTAGE WIRING Power supply to the unit must be N E C Class 1 and must comply with all applicable codes The unit must be electrically grounded in accordance with the local codes or in their ab sence with the latest edition of the National Electrical Code ANSI NFPA No 70 or Canada Canadian Electrical Code C22 1 Part 1 A fused disconnected must be provided and sized in accordance with the unit minimum circuit ampacity The best protection for the wiring is the smallest fuse or breaker which will hold the equipment on line during normal operation without nuisance trips Such a device will provide maximum circuit protection DO NOT EXCEED THE MAXIMUM OVERCURRENT DEVICE SIZE SHOWN ON THE UNIT DATA PLATE All line voltage connections must be made through weather proof fittings All exterior power supply and ground wiring must be in approved weather proof conduit Low voltage wiring from the unit control panel to the thermostat requires coded cable The unit transformer is connected for 230V operation If the unit is to operate on 208V reconnect the transformer primary lead as shown on the unit wiring diagram If itis necessary for the installer to supply additional line volt age wiring to the inside of the package unit the wiring must comply with all local codes This wiring must have a minimum temperature rating of 105 C All line voltage splices must be made inside the unit or heat kit control box 15 SY
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9. motor The electric heat will be energized through the nor mally open contacts of the electric heat sequencers The indoor blower will be energized through W from the thermo stat DEFROST CYCLE Package Heat Pumps The defrosting of the outdoor coil is jointly controlled by the defrost control board and the defrost thermostat Solid State Defrost Control During operation the power to the circuit board is controlled by a temperature sensor which is clamped to a feeder tube entering the outdoor coil Defrost timing periods of 30 60 or 90 minutes may be selected by connecting the circuit board jumper to 30 60 or 90 respectively Accumulation of time for the timing period selected starts when the sensor closes approximately 34 F and when the room thermostat calls for heat At the end of the timing period the unit s defrost cycle will be initiated provided the sensor remains closed When the sensor opens approximately 60 F the defrost cycle is terminated and the timing period is reset If the de frost cycle is not terminated due to the sensor temperature aten minute override interrupts the unit s defrost period FAN OPERATION Continuous Fan Mode APH15 M Series ECM equipped models only If the thermostat calls for continuous fan the indoor blower will be energized through the VSTB at 3096 of selected sec ond stage cooling speed on APH15 units If the thermostat is not calling for heat or cool and the fan Swi
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11. ond off delay on the APH15 M series units and after the programmed 60 second off delay on GPH15 M series units with the GE X13 motor When auxiliary electric heaters are used a two stage heat ing two stage cooling thermostat would be installed Should the second stage heating contacts in the room ther mostat close which would be wired to W1 at the unit low voltage connections this would energize the coil s of the electric heat relay s Contacts within the relay s will close bringing on the electric resistance heaters If auxiliary electric heaters should be used they may be con trolled by outdoor thermostats OT18 60A or OT EHR18 60A Emergency Heat Mode Heat Pumps NOTE The following only applies if the unit has an approved electric heat kit installed for auxiliary heating SYSTEM APH15 Series ECM equipped models only With the thermostat set to the emergency heat position and a call for 2nd stage heat R to W1 will be energized This will energize the electric heat sequencers and also energize W1 on the Variable Speed Terminal Board to start the indoor blower motor When the normally open contacts of the heat sequencers close this will energize the electric resistance heat GPH15 M Series X13 equipped models only With the thermostat set to the emergency heat position and a call for 2nd stage heat to W1 will be energized This will energize the electric heat sequencers and the GE X13
12. D 22 3 4 109 22 1 4 169 4 E j Fd N P A R g 7 4 4214 A 4434 Y 4 7 x N lt 22 3 4 180 22 1 4 18 NO EM a c RETURN SUPPLY SQUARE ROUND HORIZONTAL APPLICATIONS a lt Measurements are in inches ACCESSORIES PH15 24 60 M4 ECONOMIZER GPH13MED103 DOWNFLOW APPLICATIONS Blockoff X External Hood Panel lt bs Louver Assembly ECONOMIZER PGEH102 103 HORIZONTAL APPLICATIONS 2 BC ae ZA p pm 2 16 1 8 E 2 get E f a gt Measurements inches ACCESSORIES PH15 24 60 M4 ROOF CURBS A R 15 8 14 1 2 13 8 MODEL A RETURN SUPPLY 101 102 103 46 1 4 393 8 141 2 12 1 2x23 15x 22 1 2 Inside Dimensions PRODUCT DESIGN LOCATION amp CLEARANCES In installations where the unit is installed above ground level and not serviceable from the ground Example Roof Top in stallations the installer must provide a service platform for the service person with rails or guards in accordance with local codes o
13. Identify the leads and using a Megger Hi Potential Ground Tester or other suitable instrument which puts out a volt age between 300 and 1500 volts check for a ground sepa rately between each of the three leads and ground such as an unpainted tube on the compressor Do not use a low voltage output instrument such as a volt ohmmeter 3 Ifa ground is indicated then carefully remove the compres sor terminal protective cover and inspect for loose leads or insulation breaks in the lead wires 4 fno visual problems indicated carefully remove the leads at the compressor terminals Carefully retest for ground directly between compressor terminals and ground 5 If ground is indicated replace the compressor 5 17 UNLOADER TEST PROCEDURE A nominal 24 volt direct current coil activates the internal unloader solenoid The input control circuit voltage must be 18 to 28 volt ac The coil power requirement is 20 VA The exter nal electrical connection is made with a molded plug assem bly This plug contains a full wave rectifier to supply direct current to the unloader coil INPUT 24V OUTPUT 24VDC RECTIFIER INSOE _ UNLOADER SOLENOID Molded Plug Unloader Test Procedure If it is suspected that the 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
14. 34 5 102 EVACUATION 34 klein 35 5 104 CHECKING COMPRESSOR EFFICIENCY 36 5 105 THERMOSTATIC EXPANSION VALVE NASAAN 36 S106 OVERFEEDING wa 37 SUNDERFEEDING anr E E ERES EX RN RE ER Vo Ner Ere 37 5 108 SUPERHEAT x Gern Lex ER XX RENE BER REB ERR 37 S 109 CHECKING SUBCOOLING ee 38 S 110 CHECKING EXPANSION VALVE OPERATION ee 41 5 112 CHECKING RESTRICTED LIQUID LINE ee 41 5 113 REFRIGERANT OVERCHARGE E 41 S 114 NON CONDENSABLES snas ann Ennan Ennn Aneena nnen ee 4 115 COMPRESSOR BURNOUT ncn SUR CUN RA ROB GO YR RR Ra oO NV aX 41 5 122 REVERSING VALVE REPLACEMENT 5553 2 252 5 6a aaa cocoa ra Ren 42 5 200 CHECKING EXTERNAL STATIC PRESSURE eee nnne nnne nennen nnn ninh 43 8 201 CHECKING TEMPERATURE RISE 5 daas Cen cre Y ERAS 43 WIRINGDIAGCRAMS
15. ADJUST 7 15 G FAN v1 4 2 COOL 5 13 EM 2 DELAY 4 12 24 Vac R f HEAT 2 10 BK PWM SPEED COMMON1 1 g O REV VALVE 16 PIN ECM HARNESS CONNECTOR If you do not read voltage and continuity as described the problem is in the control or interface board but not the motor If you register voltage as described the ECM power head is defective and must be replaced 27 440 Jewod unya Jo lddns paou ol Joud 440 Jewod JOJOUJ UI suld pejeesun INJD slpueH Jojoui Buroeuuoosip 440 Jewod uun 39Vd LXAN 4 peloedxeun eonpoud pue jonpoud sploA eui eloN peeds IND3 941 Ajeuonounj jueJeyip Alelelduoo yoo uang 101 Hope Aay souls 398 1100 BY esn eloN
16. GPH13MED103 DOWNFLOW ECONOMIZER nannte c 12 PGEH102 103 HORIZONTAL ECONOMIZER eres eene 12 PGC101 103 ROOF CURBS ua roii 13 PRODUCT DESIGN 13 LOCATION AND CLEARANCES 5 iine annot REN 13 COMPRESSEOR 14 INDOOR BLOWER MOTOR neon icc erui D NY RR Y RR RR cede 14 ELECTRICAL ll c 15 LINE VOLTAGE WIRING c M 15 SYSTEM OPERATION ete 16 COOLING 16 pellice 16 HEATING cR 16 DEFROST cect ccs T ee 17 17 AIRFLOW ADJUSTMENTS FOR INDOOR BLOWER MOTOR eene nennen nennen nnn 17 SCHEDULED MAINTENANCE 20 ONCE MONTH 20 20 TEST EQUIPMENT
17. PRESSURE CONTROL 4 WARNING HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT ey MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH The high pressure control capillary senses the pressure in the compressor discharge line If abnormally high condensing pres sures 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 pres sure control with wire removed If not continuous the con tacts are open 3 Attach a gauge to the dill valve port on the base valve With power ON LINE VOLTAGE NOW PRESENT 4 Startthe system and place a piece of cardboard in front of the condenser coil raising the condensing pressure 5 Check pressure at which the high pressure control cuts out If it cuts out at 610 PSIG 10 PSIG it is operating normally See causes for high head pressure in Service Problem Analy sis Guide If it cuts out below this pressure range replace the control 5 15 CHECKING CAPACITOR CAPACITOR RUN A run capacitor is wired across the auxiliary and main wind ings 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 ph
18. SERVICING These capacitors have a 15 000 ohm 2 watt resistor wired across its terminals The object of the resistor is to discharge the capacitor under certain operating conditions rather than having it discharge across the closing of the contacts within the switching device such as the Start Relay and to reduce the chance of shock to the servicer See the Servicing Section for specific information concerning capacitors RELAY START A potential or voltage type relay is used to take the start ca pacitor 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 volt age across the start winding will energize the start relay hold ing 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 dh 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 Discharge capacitor and remove wire leads DISCHARGE CAPACITOR THROUGH A 20 TO 30 OHM RESISTOR BEFORE HANDLING Volt Ohm Meter TESTING CAPACITOR RESISTANCE 26 2 Set an ohmmeter on its hi
19. THAN 80 FULL OF LIQUID REFRIGERANT NEVER ADD ANYTHING OTHER THAN R 22 TO AN R 22 CYLINDER OR R 410A 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 USE A CYLINDER AS A PLATFORM OR A ROLLER AVOID POSSIBLE EXPLOSION USE ONLY RETURNABLE NOT DISPOSABLE SERVICE CYLINDERS WHEN REMOVING REFRIGERANT FROM A SYSTEM ENSURE THE CYLINDER IS FREE OF DAMAGE WHICH COULD LEAD TO A LEAK OR EXPLOSION ENSURE THE HYDROSTATIC TEST DATE DOES NOT EXCEED 5 YEARS ENSURE THE PRESSURE RATING MEETS OR EXCEEDS 400 LBS WHEN IN DOUBT DO NOT USE CYLINDER d warning To AVOID POSSIBLE INJURY EXPLOSION OR DEATH PRACTICE SAFE HANDLING OF REFRIGERANTS In either of these instances an electrical short between the terminal and the compressor housing may result in the loss of integrity between the terminal and its dielectric embed ment This loss may cause the terminals to be expelled thereby venting the vaporous and liquid contents of the com pressor housing and system A venting compressor terminal normally presents no danger to anyone providing the terminal protective cover is properly in place If however the terminal protective cover is not properly in place a venting terminal may discharge a combination of a hotlubricating oil and refrigerant b flammable mixture if system is contaminated with air in a stream
20. X13 blower motor The GE X13 motor is a 3 Phase brushless DC single phase AC input ball bearing construction motor with an inte gral control module with an internal FCC B EMI filter The GE X13 motor is continuously powered with line voltage The switched 24 volt control signal is controlled by the thermo stat in the cooling and heat pump mode and the blower relay in the electric heat mode APH15 M series model package units use an ECM blower motor These motors offer greater airflow flexibility as well as dehumidification The airflow delivery for these models can be adjusted by changing the position of dip switches on a low voltage terminal board PRODUCT DESIGN ELECTRICAL WIRING The units are designedfor operation at the voltages and hertz as shown on the rating plate All internal wiring is complete Ensure the power supply to the compressor contactor is brought to the unit as shown on the supplied unit wiring diagram The 24V wiring must be connected between the unit control panel and the room thermostat TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK WIRING TO THE UNIT MUST BE PROPERLY POLARIZED AND GROUNDED dh WARNING HIGH VOLTAGE DISCONNECT ALL POWER BEFORE CHANGING ANY ELECTRICAL WIRING MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH TO AVOID THE RISK OF PROPERTY DAMAGE PERSONAL INJURY OR FIRE USE ONLY COPPER CONDUCTORS
21. adjustments TSUPPLY RISE SUPPLY RETURN Checking Temperature Rise 43 WIRING DIAGRAMS PACKAGE SYSTEM WIRING DIAGRAM 1 STAGE ELECTRIC HEAT TYPICAL HP SEE NOTE 1 ROOM THERMOSTAT 18 GAUGE 7 WIRE REQUIRED FOR PACKAGE UNIT HEAT PUMPS OO OOOO LOW VOLTAGE Nu JUNCTION BOX _Y YELLOW F 0 R g BLUE i p 2 1 OUTDOOR THERMOSTAT CLOSE ON TEMPERATURE FALL PACKAGE SYSTEM WIRING DIAGRAM 2 STAGE ELECTRIC HEAT ABOVE 10 KW TYPICAL HP SEE NOTE 1 ROOM THERMOSTAT 18 GAUGE 8 WIRE PACKAGE UNIT FOR HEAT PUMPS LOW VOLTAGE 62 OOO MOOO JUNCTION BOX poop _ LI Ig J O ORANGE SEE NOTE 2 lt a gt lt 2 o o c ul uj lt lt ta gt c ul Q c a ul o 2 lt x z o o 02 25 lt i E E 4 oc Za T Ex wo mo x c amp o a lt OF oz W WHITE BR BROWN BL BLUE OUTDOOR THERMOSTAT CLOSE ON TEMPERATURE FALL A WARNING NOTES Color Codes R Red Y Yellow 1 O and E used on heat pumps only BL Blue 2 Connect wire from terminal 1 on outdoor thermostat to the white BR Brow
22. being tested With power ON LINE VOLTAGE NOW PRESENT 22 Using a voltmeter measure the voltage across terminals L1 and L2 of the contactor for single phase units and L3 for 3 phase units No reading indicates open wiring open fuse s no power or etc from unit to fused disconnect service Repair as needed With ample voltage at line voltage connectors energize the unit Measure the voltage with the unit starting and operating and determine the unit Locked Rotor Voltage Locked Rotor Voltage is the actual voltage available at the compressor during starting locked rotor or a stalled condition Measured voltage should be above minimum listed in chart below To measure Locked Rotor Voltage attach a voltmeter to the run and common C terminals of the compres sor or to the T and T terminals of the contactor Start the unit and allow the compressor to run for several sec onds then shut down the unit Immediately attempt to restart the unit while measuring the Locked Rotor Volt age 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 208 230 Three phase units require balanced 3 phase power supply to operate If the percentage of voltage imb
23. modes rr TUI COOLING HEATING TXV VALVES Some TXV valves contain an internal check valve thus eliminat ing the need for an external check valve and bypass loop The three forces which govern the operation of the valve are 1 the pressure created in the power assembly by the feeler bulb 2 evaporator pressure and 3 the equivalent pressure of the su perheat spring in the valve 096 bleed type expansion valves are used on indoor and out door coils The 096 bleed valve will not allow the system pres sures High and Low side to equalize during the shut down period The valve will shut off completely at approximately 100 PSIG 30 bleed valves used on some other models will continue to allow some equalization even though the valve has shut off completely because of the bleed holes within the valve This type of valve should not be used as a replacement for a 096 bleed valve due to the resulting drop in performance The bulb must be securely fastened with two straps to a clean straight section of the suction line Application of the bulb to a horizontal run of line is preferred If a vertical installation can not be avoided the bulb must be mounted so that capillary tubing comes out at the top THE VALVES PROVIDED BY GOODMAN ARE DESIGNED TO MEET THE SPECIFICATION REQUIREMENTS FOR OP TIMUM PRODUCT OPERATION DO NOT USE SUBSTI TUTES 5 106 OVERFEEDING Overfeeding b
24. must be installed behind the return air grille s or provision must be made for a filter in an accessible location within the return air duct An internal filter rack GPH13MFR102 amp 103 and an external filter rack GPGHFR101 103 are also available as accessories 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 3 4 14 drain connector is provided for removal of con densate water from the indoor coil In order to provide proper condensate flow do not reduce the drain line size Refrigerant flow control is achieved by use of TXV These mod els use the FasTest Access Fitting System with a saddle that is either soldered to the suction and liquid lines or is fastened with a locking nut to the access fitting box core and then screwed into the saddle Do not remove the core from the saddle until the refrigerant charge has been removed Failure to do so could result in property damage or per sonal injury The single phase units use permanent split capacitors PSC design compressors Starting components are therefore not required Alow MFD run capacitor assists the compressor to start and remains in the circuit during operation 13 PRODUCT DESIGN The outdoor fan motors are single phase capacitor type mo tors Air for condensing cooling is drawn through the outdoor coil by a propeller fan a
25. not available on the traditional PSC motor These features include e Improved Efficiency Constant CFM e Start and Stop Improved Humidity Control Motor Speed Adjustment Each ECM blower motor has been preprogrammed for opera tion at 4 distinct airflow levels when operating in Cooling Heat Pump mode or Electric Heat mode These 4 distinct levels may also be adjusted slightly lower or higher if de sired The adjustment between levels and the trim adjust ments are made by changing the dip switch s either to an OFF or ON position Dip Switch Functions The ECM motor has an electronic control that contains eight 8 2 position dip switches The function of these dip switches is shown in Table 1 17 SYSTEM Electric Heat N A Indoor Thermostat Cooling amp Heat Pump CFM CFM Trim Adjust Table 1 CFM Delivery Tables 2 and 4 show the CFM output for dip switch combi nations 1 2 Electric Heat and 5 6 Cooling Heating Tables 3 shows the dip switch settings for 1 and 2 stage thermostats poner m Mm 1600 1400 Factory Table 2 Model Switch 3 Switch 4 Thermostat c Table 3 18 Switch 5 Switch 6 Cooling HP 1050 1250 eee 1100 Factory Table 4 Thermostat Only Mode During Fan Only Operations the CFM output is 3096 of the high stage cooling setting CFM Trim Adjust Minor adjustmen
26. 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 elec trically energized and or operated without having the terminal protective cover properly in place See Service Section S 17 for proper servicing PRODUCT IDENTIFICATION Brand G Goodman Brand or Distinctions A Amana Brand Minor Revision Major Revision Product Type Package Cooling Heating Voltage 1 208 230V 1ph 60Hz 3 208 230V 3ph 60Hz 4 460V 3ph 60Hz Refrigerant 4 R 410A Product Family C Cooling H Heat Pump Product Series 15 15 SEER Rating Configuration 24 24 000 BTUH M Multi Position 36 36 000 BTUH 48 48 000 BTUH 60 60 000 BTUH Single Phase Multiposition Package Heat Pumps Amana Goodman Package Heat Pump 15 Seer R410A Multiposition heat A GPH15 M41AA pump units Initial release __GPH15 M41 5 __ Chassis Models Chassis Models ACCESSORIES PH15 24 60 M4 Part Description FitsModels Horizontal Manual 2596 Fresh Air Damper Horizontal Manual 2596 Fresh Air Damper Horizontal Motorized 2596 Fresh Air Damper pi EM Outdoor Thermostat with Emergency Heat Relay All HKR15A CA GPH15 36 60 M41 HKRZOA GPHIS 49 G0 M4T MANA BRAND THERMOSTATS PH15 24 60 M4 ACCESSO
27. over charge condition DISCONNECT POWER SUPPLY BEFORE SERVICING 1 Disconnect the heater lead wires 2 Using an ohmmeter check heater continuity should test continuous if not replace 5 21 CHECKING REVERSING VALVE AND SOLENOID Occasionally the reversing valve may stick in the heating or cooling position or in the mid position When stuck in the mid position part of the discharge gas from the compressor is directed back to the suction side resulting in excessively high suction pressure An increase in the suc tion line temperature through the reversing valve can also be measured Check operation of the valve by starting the sys tem and switching the operation from COOLING to HEATING cycle If the valve fails to change its position test the voltage 24V at the valve coil terminals while the system is on the COOLING cycle If no voltage is registered at the coil terminals check the op eration of the thermostat and the continuity of the connecting wiring from the O terminal of the thermostat to the unit If voltage is registered at the coil tap the valve body lightly while switching the system from HEATING to COOLING etc If this fails to cause the valve to switch positions remove the coil connector cap and test the continuity of the reversing valve solenoid coil If the coil does not test continuous replace it If the coil test continuous and 24 volts is present at the coil terminals the valve is inopera
28. 3 Ifvoltage was present in steps 1 and 2 the motor has failed and will need to be replaced Note When replacing motor ensure the belly band is between the vents on the motor and the wiring has the proper drip loop to prevent condensate from entering the motor High Voltage Connections 3 16 X13 MOTOR CONNECTIONS 5 17 CHECKING COMPRESSOR WINDINGS 4 WARNING HERMETIC COMPRESSOR ELECTRICAL TERMINAL VENTING CAN BE DANGEROUS WHEN INSULATING MATERIAL WHICH SUPPORTS A HERMETIC COM PRESSOR OR ELECTRICAL TERMINAL SUDDENLY DISINTEGRATES DUE TO PHYSICAL ABUSE OR AS A RESULT OF AN ELECTRICAL SHORT BETWEEN THE TERMINAL AND THE COMPRESSOR HOUSING THE TERMINAL MAY BE EXPELLED VENTING THE VAPOR AND LIQUID CONTENTS OF THE COMPRES SOR HOUSING AND SYSTEM SERVICING If the compressor terminal PROTECTIVE COVER and gasket if required is not properly in place and secured there is a remote possibility if a terminal vents that the vaporous and liquid discharge can be ignited spouting flames several feet causing potentially severe or fatal injury to anyone in its path This discharge can be ignited external to the compressor if the terminal cover is not properly in place and if the discharge impinges on a sufficient heat source Ignition of the discharge can also occur at the venting terminal or inside the compressor if there is sufficient contaminant air present in the system and an electrical arc occurs as th
29. 4 R 2 x 3 4 BK JUN R 5 Mio p R y M2 2 R lt BK BK R ONE 1 ELEMENT ROWS L1 L2 TWO 2 ELEMENT ROWS U J Se NI N AN S amp S CN 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 HIGH VOLTAGE LN A wt oe gt o Y Jo M L1 L2 L1 12 THREE 3 ELEMENT ROWS LP FOUR 4 ELEMENT ROWS 15 KW 20 KW d WARNING SINGLE PHASE HKR HEAT KIT 46 PH15 M4 WIRING DIAGRAMS S19VINOO ONIHIM SAHS Hdx SLINN 4013004 YAZINONOOA GAWELHdS 13dO0MW 9NIHn LOV3nNVIN NVWOIOO9 NMOHS SV TIVLSNI NOILISOd AnANININ TWNOILdO H3L3INOLLN3 LOd S0L L 6 QV NVW3 109 W 1715 1 39VLIS ILETOIN QN3AWOO38 3 LON ania TIOHLNOO Ad IVH LN3 v 3LIHM 3ONVHO
30. 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 84 86 88 90 82 84 86 88 80 82 84 86 78 80 82 84 100 102 104 106 108 110 112 114 116 118 120 122 124 126 100 102 104 106 108 110 112 114 116 118 120 122 124 100 102 104 106 108 110 112 114 116 118 120 122 100 102 104 106 108 110 112 114 116 118 120 SERVICING 5 110 CHECKING EXPANSION VALVE OPERATION 1 Remove the remote bulb of the expansion valve from the suction line 2 Start the system and cool the bulb in a container of ice water closing the valve As you cool the bulb the suction pressure should fall and the suction temperature will rise 3 Next warm the bulb in your hand As you warm the bulb the suction pressure should rise and the suction tempera ture will fall 4 or pressure change is noticed the expan sion valve is operating If no change is noticed the valve is restricted the power element is faulty or the equalizer tube is plugged 5 Capture the charge replace the valve and drier evacuate and recharge 5 112 CHECKING RESTRICTED LIQUID LINE When the system is operating the liquid line is warm to the touch If the liquid line is restricted a definite temperature drop will be noticed at the point of restriction In severe cases frost will form at the restric
31. CHNICIAN AS SPECIFIED BY THE AIR CONDITIONING AND DO NOT STORE COMBUSTIBLE MATERIALS OR USE GASOLINE OR OTHER FLAMMABLE LIQUIDS OR VAPORS IN THE VICINITY OF THIS APPLIANCE REFRIGERATION INSTITUTE ARI ATTEMPTING TO INSTALL OR REPAIR THIS UNIT WITHOUT SUCH BACKGROUND MAY RESULT IN PRODUCT DAMAGE PERSONAL INJURY OR DEATH GOODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES YOU INSTALL OR PERFORM SERVICE ON THIS UNIT YOU ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMAGE WHICH MAY RESULT MANY JURISDICTIONS REQUIRE A LICENSE TO INSTALL OR SERVICE HEATING AND AIR CONDITIONING EQUIPMENT 4 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 CONSUMER INFORMATION LINE GOODMAN BRAND PRODUCTS TOLL FREE 1 877 254 4729 U S only email us at customerservice goodmanmfg com fax us at 713 856 1821 Not a technical assistance line for dealers Outside the U S call 1 713 861 2500 Not a technical assistance line for dealers Your telephone company will bill you for the call CONSUMERINFORMATION LINE AMANA BRAND PRODUCTS TOLL FREE 1 877 254 4729 U
32. ER BEFORE SERVICING OR INSTALLING THIS UNIT MULTIPLE POWER SOURCES FAILURE TO DO 50 CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH 1 Remove control panel cover or etc to gain access to trans former With power ON LINE VOLTAGE NOW PRESENT 2 Using a voltmeter check voltage across secondary voltage side of transformer R to 3 No voltage indicates faulty transformer bad wiring or bad splices 4 Check transformer primary voltage at incoming line voltage connections and or splices 5 voltage is present at the primary voltage side of the transformer and 24 volts is not present on the secondary side then the transformer is inoperative Replace S 7 CHECKING CONTACTOR AND OR RELAYS The compressor contactor and other relay holding coils are wired into the low or line voltage circuits When the control circuit is energized the coil pulls in the normally open contacts or opens the normally closed contacts When the coil is de energized springs return the contacts to their normal position DISCONNECT POWER SUPPLY BEFORE SERVICING 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 con tactor 24 5 8 CHECKING CONTACTOR CONTACTS DISCONNECT POWER SUPPLY BEFORE SERVICING SINGLE PHASE 1 Disconnect the wire leads from the terminal T side of t
33. ER PRESSURE FAILURE TO FOLLOW PROPER PROCEDURES MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH This is the most important part of the entire service procedure The life and efficiency of the equipment is dependent upon the thoroughness exercised by the serviceman when evacuating air non condensable and moisture from the system Air in a system causes high condensing temperature and pres sure resulting in increased power input and reduced perfor mance SERVICING Moisture chemically reacts with the refrigerant and oil to form corrosive hydrofluoric and hydrochloric acids These attack motor windings and parts causing breakdown The equipment required to thoroughly evacuate the system is a high vacuum pump capable of producing a vacuum 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 or run when under a high vacuum Motor damage could occur A WARNING SCROLL COMPRESSORS DO NOT FRONT SEAT THE SERVICE VALVE S WITH THE COMPRESSOR OPERATING IN AN ATTEMPT TO SAVE REFRIGERANT WITH THE SUCTION LINE OF THE COMPRESSOR CLOSED OR SEVERLY RESTRICT ED THE SCROLL COMPRESSOR WILL DRAW A DEEP VACUUM VERY QUICKLY THIS VACUUM CAN CAUSE INTERNAL ARCING OF THE FUSITE RESULTING INA DAMAGED OR FAILED COMPRESSOR 1 Connect the vacuum pump vacuum tight manifold set with high vacuum hoses thermocoup
34. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH DISCONNECT ALL POWER BEFORE uw ONCE A MONTH 1 Inspectthe return filters of the evaporator unit and clean or change if necessary NOTE Depending on operation conditions it may be necessary to clean or replace the filters more often If permanent type 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 oil ing TOAVOID PREMATURE MOTOR FAILURE DO NOT OIL 4 Manually rotate the outdoor fan and indoor blower to be sure they run freely 5 Inspectthe control panel wiring compressor connections and all other component wiring to be sure all connec tions are tight Inspect wire insulation to be certain that itis good 20 6 Check the contacts of the compressor contactor f they are burned or pitted replace the contactor 7 Using a halide or electronic leak detector check all piping and etc for refrigerant leaks 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 The
35. IAN MUST PERFORM THE INSTALLATION AND SERVICE OF THIS PRODUCT SHOULD QUESTIONS ARISE CONTACT YOUR LOCAL EPA OFFICE VIOLATIONS OF EPA REGULATIONS MAY RESULT IN FINES OR PENALTIES Awarnine SYSTEM CONTAMINANTS IMPROPER SERVICE PROCEDURE AND OR PHYSICAL ABUSE AFFECTING HERMETIC COMPRESSOR ELECTRICAL TERMINALS MAY CAUSE DANGEROUS SYSTEM VENTING The successful development of hermetically sealed refrig eration compressors has completely sealed the compressor s moving parts and electric motor inside a common housing minimizing refrigerant leaks and the hazards sometimes as sociated with moving belts pulleys or couplings Fundamental to the design of hermetic compressors is a method whereby electrical current is transmitted to the com pressor motor through terminal conductors which pass through the compressor housing wall These terminals are sealed in a dielectric material which insulates them from the housing and maintains the pressure tight integrity of the her metic compressor The terminals and their dielectric em bedmentare strongly constructed but are vulnerable to care less compressor installation or maintenance procedures and equally vulnerable to internal electrical short circuits caused by excessive system contaminants 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
36. OLTAGE 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 unit wiring from disconnect switch and wire a test cord to the disconnect switch NOTE The wire size of the test cord must equal the line wire size and the fuse must be of the proper size and type 2 With the protective terminal cover in place use the three leads to the compressor terminals that were disconnected at the nearest point to the compressor and connect the common start and run clips to the respective leads 3 Connect good capacitors of the right MFD and voltage rat ing into the circuit 4 With power ON close the switch LINE VOLTAGE NOW PRESENT A If compressor starts and continues to run the cause for failure is somewhere else in the system B Ifthe compressor fails to start replace SERVICING S 18 TESTING CRANKCASE HEATER Note Not all compressors use crankcase heaters The crankcase heater must be energized a minimum of four 4 hours before the compressor is operated Crankcase heaters are used to prevent migration or accumula tion of refrigerant in the compressor crankcase during the off cycles and prevents liquid slugging or oil pumping on start up Scroll Compressors are not equipped with a crankcase heat ers A crankcase heater will not prevent compressor damage due to a floodback or
37. RIES DUCT SIDE VIEW Requires 1 filter Measurement in inches Filter Size 16 x 25 x 2 DOWNFLOW FILTER RACK GPH13MFR TEE 7 PANEL SIDE VIEW FILTER PLATFO RON PRON S L SR EXTERNAL HORIZONTAL FILTER RACK GPGHFR101 103 727 EVAPORATOR _ RIGHT SIDE DOWNFLOW N DUCT OPENING COIL Filter Size 14 x 25 x 2 Requires 2 filters Measurement in inches ACCESSORIES PH15 24 60 M4 MOTORIZED MANUAL FRESH AIR DAMPERS DOWNFLOW APPLICATIONS lt 4 758 y 5 11 7 8 Manual Fresh Air Dampers 4 Motorized Fresh Air Dampers a MOTORIZED MANUAL FRESH AIR DAMPERS HORIZONTAL APPLICATIONS BOTTOM VIEW 5 3 4 NS F gt E BOTTOM VIEW SUN 53 4 11718 ES PGMDD101 102 Manual Fresh Air Dampers Motorized Fresh Air Dampers ACCESSORIES PH15 24 60 M4 SQUARE TO ROUND CONVERTER DOWNFLOW APPLICATIONS 42 1 4 4 14 3 4 lt 4 S N ED GE S
38. RY OR DEATH 1 Disconnect the 5 pin and the 16 pin connectors from the ECM power head 2 Remove the 2 screws securing the ECM power head and separate it from the motor 3 Disconnect the 3 pin motor connector from the power head and lay it aside 4 Using an ohmmeter check the motor windings for continu ity to ground pins to motor shell If the ohmmeter indi cates continuity to ground the motor is defective and must be replaced 5 Using an ohmmeter check the windings for continuity pin to pin If no continuity is indicated the thermal limit over load device may be open Allow motor to cool and retest 3 pin motor connector connector S 16D CHECKING GE X13 MOTORS GPH15M Series Only The GE X13 Motor is a one piece fully encapsulated phase brushless DC single phase AC input motor with ball bearing construction Unlike the ECM 2 3 2 5 motors the GE X137 features an integral control module Note The GE TECMate will not currently operate the GE X13 motor 1 Using voltmeter check 230 volts to the motor connec tions 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 30 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
39. Remove the leads from the compressor terminals SEE WARNINGS S 17 BEFORE REMOVING COMPRES SOR TERMINAL COVER 2 Using ohmmeter test continuity between terminals S R C R and C S on single phase units or terminals T1 T2 and T3 3 phase units OHMMETER TESTING COMPRESSOR WINDINGS If either winding does not test continuous replace the com pressor NOTE open compressor is indicated allow ample time for the internal overload to reset before replacing compressor 5 178 GROUND TEST If fuse circuit breaker ground fault protective device etc has tripped this is a strong indication that an electrical problem exists and must be found and corrected The circuit protective device rating must be checked and its maximum rating should coincide with that marked on the equipment nameplate With the terminal protective cover in place it is acceptable to replace the fuse or reset the circuit breaker ONE TIME ONLY to see if it was just a nuisance opening If it opens again DO NOT continue to reset Disconnect all power to unit making sure that all power legs are open 1 DO NOT remove protective terminal cover Disconnect the three leads going to the compressor terminals at the near est point to the compressor DAMAGE CAN OCCUR TO THE GLASS EMBEDDED TERMINALS IF THE LEADS ARE NOT PROPERLY REMOVED THIS CAN RESULT IN TERMINAL AND HOT OIL DISCHARGING COMPRESSOR GROUND TEST 31 SERVICING 2
40. S only email us at hac consumer affairs amanahvac com fax us at 931 438 4362 Not a technical assistance line for dealers Outside the U S call 1 931 433 6101 Not a technical assistance line for dealers Your telephone company will bill you for the call IMPORTANT INFORMATION SAFE REFRIGERANT HANDLING While these items will not cover every conceivable situation they should serve as a useful guide Awarnine 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 LAW ALL REFRIGERANTS MUST BE RECLAIMED AN INDOOR LEAK IS SUSPECTED THOROUGHLY VENTILATE THE AREA BEFORE BEGINNING WORK LiQUID REFRIGERANT CAN BE VERY COLD TO AVOID POSSIBLE FROST BITE OR BLINDNESS AVOID CONTACT WITH REFRIGERANT AND WEAR GLOVES AND GOGGLES LIQUID REFRIGERANT DOES CONTACT YOUR SKIN OR EYES SEEK MEDICAL HELP IMMEDIATELY ALwavs FOLLOW EPA REGULATIONS NEVER BURN REFRIGERANT AS POISONOUS GAS WILL BE PRODUCED A warninc THE UNITED STATES ENVIRONMENTAL PROTECTION AGENCY EPA HAS ISSUED VARIOUS REGULATIONS REGARDING THE INTRODUCTION AND DISPOSAL OF REFRIGERANTS INTRODUCED INTO THIS UNIT FAILURE TO FOLLOW THESE REGULATIONS MAY HARM THE ENVIRONMENT AND CAN LEAD TO THE IMPOSITION OF SUBSTANTIAL FINES THESE REGULATIONS MAY VARY BY JURISDICTION A CERTIFIED TECHNIC
41. STEM COOLING The refrigerant used the system is R 410A It is a clear colorless non toxic and non irritating liquid R 410A is a 50 50 blend of R 32 and R 125 The boiling point at atmospheric pressure is 62 9 F A few of the important principles that make the refrigeration cycle possible are heat always flows from a warmer to a cooler body Under lower pressure a refrigerant will absorb heat and vaporize at a low temperature The vapors may be drawn off and condensed 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 Heat is continually being transferred to the cool fins and tubes of the indoor evaporator coil by the warm system air This warming process causes the refrigerant to boil The heat re moved 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 reaching the compressor can weaken or break compressor valves The compressor increases the pressure of the gas thus add ing more heat and discharges hot high pressure superheated gas into the outdoor condenser coil In the condenser coil the hot refrigerant gas being warmer than the outdoor a
42. Service Instructions PH 15 SEER Multi Position Package Heat Pumps with R 410A Refrigerant amp Accessories SS SS SS 7 SN This manual is to be used by qualified professionally trained HVAC technicians only Goodman does not assume any responsibility for property damage or personal injury RS6300008 Rev 1 due to improper service procedures or services performed by an unqualified person November 2007 Copyright 2007 Goodman Manufacturing Company L P IMPORTANT INFORMATION euin n inire 4 PRODUCT IDENTIFICATION MA ee 6 ACCESSORIES 7 101 103 8 AR 9 PGMDD101 103 DOWNFLOW MANUAL FRESH AIR DAMPERS nennen nnne nnne nnns 10 PGMDMD102 103 DOWNFLOW MOTORIZED FRESH AIR DAMPERS eene nnns 10 PGMDH102 103 HORIZONTAL MANUAL FRESH AIR DAMPERS eene nnne rnnt 10 PGMDH102 103 HORIZONTAL MOTORIZED FRESH AIR DAMPERS eene nnne nnns 10 SQRPG101 103 SQUARE TO ROUND CONVERTER DOWNEFLOW nennen nennen nnne nnns 11 SQRPGH101 103 SQUARE TO ROUND CONVERTER HORIZONTAL _ 11
43. Temperature Pressure Chart on follow ing pages 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 atleast 10 minutes to allow pressure to sta bilize 2 Temporarily install thermometer on suction large line near suction line service valve with adequate contact and insulate for best possible reading 3 Referto 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 66 F To obtain the degrees temperature of superheat subtract 50 0 from 66 0 F The difference is 16 Superheat The 16 Superheat would fall in the range of allowable superheat See R410A Pressure vs Temperature chart on page 40 SUPERHEAT AND SUBCOOLING ADJUSTMENT ON TXV APPLICATIONS Single Speed Application PH1524 PH1536 1 Purge gauge lines Connect service gauge manifold to access fittings Run system at least 10 minutes to allow pressure to stabilize 2 Temporarily install thermometer on liquid small line near liquid line access fitting with adequate contact and insu late for best possible reading 3 Check s
44. alance exceeds 3 the unit must not be operated until the voltage condition is corrected Max Voltage Deviation Voltage From Average Voltage 100 Imbalance Average Voltage To find the percentage of imbalance measure the incoming power supply L1 L2 240V L1 L3 232V L2 L3 238V Total 710V To find Max deviation Avg V 710 236 7 3 240 236 7 3 3 232 236 7 4 7 238 236 7 1 3 Max deviation was 4 7V 4 7 236 7 If the percentage of imbalance had exceeded 3 it must be determined if the imbalance is in the incoming power supply or the equipment To do this rotate the legs of the incoming power and retest voltage as shown below Voltage Imbalance 1 99 L1 L2 240V L1 L3 227V L2 L3 238V Rotate all 3 incoming legs as shown L1 L2 227V L1 L3 238V L2 L3 240V By the voltage readings we see that the imbalance rotated or traveled with the switching of the incoming legs Therefore the power lies within the incoming power supply If the imbalance had not changed then the problem would lie within the equipment Check for current leakage shorted mo tors etc 5 2 CHECKING WIRING 4 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 Check wiring visually for signs of overheating damaged insu
45. and Controls S 26 S 27 Dirty Air Filter Inspect Filter Clean or Replace Dirty Indoor Coil Inspect Coil Clean Not enough air across Indoor Coil Check Blow er Speed Duct Static Press Filter 5 200 Too much air across Indoor Coil Reduce Blow er Speed S 200 Overcharge of Refrigerant Recover Part of Charge 5 113 Outdoor Coil Inspect Coil Clean Noncondensibles Recover Charge Evacuate Recharge Recirculation of Condensing Air Remove Obstruction to Air Flow Infiltration of Outdoor Air Check Window s Doors Vent Fans Etc Improperly Located Thermostat Relocate Thermostat Air Flow Unbalanced Readjust Air Volume Dampers System Undersized Refigure Cooling Load Broken Internal Parts eplace Compressor Broken Valves est Compressor Efficiency Inefficient Compressor est Compressor Efficiency Loose Hold dow n Bolts ighten Bolts Faulty Reversing Valve 2 eplace Valve or Solenoid S 21 122 Faulty Defrost Control Test Control Faulty Defrost Thermostat Test Defrost Thermostat Check Flow rator amp Seat or Replace Flow rator 5 25 S 111 Cooling or Heating Cycle Heat Pump Heating Cycle Only Heat Pump 21 SERVICING S 1 CHECKING VOLTAGE 4 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 doors control panel cover etc from unit
46. ant of liquid refrigerant continued flood back 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 suction and or discharge valves or scroll flanks on Scroll com pressors reducing the ability of the compressor to pump re frigerant vapor The condition of the valves or scroll flanks is checked in the following manner 1 Attach gauges to the high and low side of the system 2 Startthe system and run a Cooling Performance Test 36 If the test shows Below normal high side pressure Above normal low side pressure Low temperature difference across coil Lowamp 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 liquid refrigerant flow into an evaporator coil in exact proportion to the rate of evaporation of the refrigerant in the coil The amount of refrigerant entering the coil is regulated since the valve responds to temperature of the refrigerant gas leaving the coil feeler bulb contact and the pressure of the refrigerant in the coil This regulation of the flow prevents the return of liquid refrigerant to the compressor The illustration below shows typical heatpump TXV check valve operation in the heating and cooling
47. ase relationship between the capacitor current and voltage in conjunction with the motor windings so thatthe motor will give two phase operation when connected to a single phase circuit The capacitor also re duces the line current to the motor by improving the power factor CAPACITOR START SCROLL COMPRESSOR MODELS Hard start components are not required on Scroll compressor equipped units due to a non replaceable check valve located in the discharge line of the compressor However hard start kits are available and may improve low voltage starting characteris tics Only hard start kits approved by Goodman or Copeland should be used Kick Start and or Super Boost kits are not approved start assist devices This check valve closes off high side pressure to the compres sor after shut down allowing equalization through the scroll flanks Equalization requires only about one or two seconds during which time the compressor may turn backwards 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 elec trolytic type rather than metallized polypropylene as used in the run capacitor A switching device must be wired in series with the capacitor to remove it from the electrical circuit after the compressor starts to run Not removing the start capacitor will overheat the capacitor and burn out the compressor windings 25
48. cuate and recharge 5 115 COMPRESSOR BURNOUT When acompressor burns out high temperature develops caus ing the refrigerant oil and motor insulation to decompose form ing acids and sludge If a compressor is suspected of being burned out attach a refrigerant hose to the liquid line dill valve and properly remove and dispose of the refrigerant VIOLATION OF EPA REGULATIONS MAY RESULT IN FINES OR OTHER PENALITIES Now determine if a burn out has actually occurred Confirm by analyzing an oil sample using a Sporlan Acid Test Kit AK 3 or its equivalent Remove the compressor and obtain an oil sample from the suction stub If the oil is not acidic either a burnout has not occurred or the burnout is so mild that a complete clean up is not necessary If acid level is unacceptable the system must be cleaned by using the clean up drier method 4 CAUTION DO NOT ALLOW THE SLUDGE OR OIL TO CONTACT THE SKIN SEVERE BURNS MAY RESULT 41 NOTE The Flushing Method using R 11 refrigerant is no longer approved by Goodman Manufacturing Company L P Suction Line Drier Clean Up Method The POE oils used with R410A refrigerant is an excellent sol vent In the case of a burnout the POE oils will remove any burnout residue left in the system If not captured by the refrig erant filter they will collect in the compressor or other system components causing a failure of the replacement compres
49. e ter minal vents Ignition cannot occur at the venting terminal without the pres ence 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 at the time of manufacture and during servicing To reduce the possibility of external ignition all open flame electrical power and other heat sources should be extinguished or turned off prior to servicing a system If the following test indicates shorted grounded or open wind ings see procedure S 19 for the next steps to be taken S 17A RESISTANCE TEST Each compressor is equipped with an internal overload The line break internal overload senses both motor amperage and winding temperature High motor temperature or amper age heats the disc causing it to open breaking the common circuit within the compressor on single phase units The three phase internal overload will open all three legs Heat generated within the compressor shell usually due to recycling of the motor high amperage or insufficient gas to cool the motor is slow to dissipate allow at least three to four hours for it to cool and reset then retest a WARNING HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT MULTIPLE POWER SOURCES FAILURE TO DO 50 CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH 1
50. etal 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 main tain room temperature within 1 1 2 to 2 degree range The anticipator is supplied in the thermostat and is not to be replaced Ifthe anticipator should fail for any reason the ther mostat 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 follow ing for recommended heater anticipator setting To determine the proper setting use an amp meter to measure the amperage on the W wire going to the thermostat Use an amprobe as shown below Wrap 10 turns of thermostat wire around the stationary jaw of the amprobe and divide the reading by 10 10 TURNS OF THERMOSTAT WIRE From W on thermostat OF AMPROBE READS 4 AMPS CURRENT DRAW WOULD BE 4 AMPS Checking Heat Anticipator Amp Draw 23 SERVICING S 4 CHECKING TRANSFORMER AND CONTROL CIRCUIT A step down transformer 208 240 volt primary to 24 volt sec ondary is provided with each package unit This allows ample capacity for use with resistance heaters 4 WARNING HIGH VOLTAGE DISCONNECT ALL POW
51. ghest ohm scale and connect the leads to the capacitor A Good Condition indicator swings to zero and slowly returns to infinity Start capacitor will bleed resistor will not return to infinity It will still read the resistance of the resistor B Shorted indicator swings to zero and stops there replace C Open reading replace Start capacitor would read resistor resistance 5 158 CAPACITANCE CHECK DISCHARGE CAPACITOR THROUGH A 20 TO 30 OHM RESISTOR BEFORE HANDLING Using a hookup as shown below take the amperage and volt age readings and use them in the formula Capacitance MFD 2650 X Amperage Voltage Volt Ohm Meter 1 415 AMP FUSE TESTING CAPACITANCE SERVICING S 16 CHECKING MOTORS S 16B CHECKING FAN AND BLOWER MOTOR ECM MOTORS APH15 M Series An ECM is an Electronically Commutated Motor which offers many significant advantages over PSC motors The ECM has near zero rotor loss synchronous machine operation variable speed low noise and programmable air flow Because of the sophisticated electronics within the ECM motor some techni cians are intimated by the ECM motor however these fears are unfounded GE offers two ECM motor testers and with a VOM meter one can easily perform basic troubleshooting on ECM motors An ECM motor requires power line voltage and a signal 24 volts to operate The ECM motor stator contains permanent magnet As a
52. he contactor 2 With power ON energize the contactor LINE VOLTAGE NOW PRESENT VOLT OHM ac fortesting Coil Voltmeter testing contacts TESTING COMPRESSOR CONTACTOR Single Phase 3 Using a voltmeter test across terminals A L1toL2 No voltage Check breaker or fuses on main power supply If voltage present proceed to step B B 11 to T2 Meter should read the same as L1 to L2 in step A If voltage readings are not the same as step A replace contactor THREE PHASE Using a voltmeter test across terminals A L1 L2 L1 L3 and L2 L3 If voltage is present pro ceed to B If voltage is not present check breaker or fuses on main power supply B T1 T2 T1 T3 and T2 T3 If voltage readings are not the same as in A replace contactor SERVICING Ohmmeter for testing holding coil Voltmeter for testing contacts TESTING COMPRESSOR CONTACTOR Three phase S 11 CHECKING LOSS OF CHARGE PROTECTOR Heat Pump Models The loss of charge protector senses the pressure in the liquid line and will open its contacts on a drop in pressure The low pressure control will automatically reset itself with a rise in pressure The low pressure control is designed to cut out open at ap proximately 50 PSIG It will automatically close at approximately 95 PSIG Test for continuity using a VOM and if not as above replace the control 5 12 CHECKING HIGH
53. here 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 charg ing cylinder At this time you may still have some liquid refrigerant in the charging cylinder hose and will definitely have liquid in the liquid hose Reseat the liquid line core Slowly open the high side manifold valve and transfer the liquid refrigerant from the liquid line hose and charging cyl inder hose into the suction service valve port CAREFUL Watch so that liquid refrigerant does not enter the com pressor Final Charge Adjustment The outdoor temperature must be 60 F or higher Set the room thermostat to COOL fan switch to AUTO and set the tem perature control well below room temperature After system has stabilized per startup instructions compare the operating pressures and outdoor unit amp draw to the num bers listed in the technical manual If pressures and amp draw are too low add charge If pressures and amp draw are too high remove charge Check subcooling and superheat as de tailed in the following section 5 With the system still running remove hose and reinstall both valve caps 6 Check system for leaks Due to their design Scroll compressors are inherently more tolerant of liquid refrigerant NOTE Even though the compressor section of a Scroll com pressor is more toler
54. inclined manometer measure the static pressure of the return duct at the inlet of the unit Negative Pressure Total External Static 2 Measure the static pressure of the supply duct Positive Pressure 3 Addthe two readings together NOTE Both readings may be taken simultaneously and read directly on the manometer as shown in the illustration above if so desired 4 Consult proper table for quantity of air If the external static pressure exceeds the minimum or maxi mum allowable statics check for closed dampers dirty filters undersized or poorly laid out ductwork 5 201 CHECKING TEMPERATURE RISE Temperature rise is related to the BTUH output of the unit and the amount of air CFM circulated over the indoor coil All units are designed for a given range of temperature increase This is the temperature of the air leaving the unit minus the temperature of the air entering the unit The more air CFM being delivered through a given unit the less the rise will be sothe less air CFM being delivered the greater the rise The temperature rise should be adjusted in accordance to a given unit specifications and its external static pressure 1 Take entering and leaving air temperatures 2 Select the proper speed tap from the unit s blower perfor mance data in the Technical Manual for the specific unit 3 Take motor amperage draw to determine that the motor is not overloaded during
55. iquid is considered subcooled when its tempera ture is lower than the saturation temperature corresponding to its pressure The degree of subcooling equals the degrees of temperature decrease below the saturation temperature at the existing pressure 1 Attach an accurate thermometer or preferably a thermo couple type temperature tester to the liquid line close to the high pressure access fitting process tube 2 Install a high side pressure gauge on the high side liquid access fitting 3 Record the gauge pressure and the temperature of the line Review the technical information manual or specification sheet for the model being serviced to obtain the design subcooling 5 Compare the hi pressure reading to the Required Liquid Line Temperature chart Find the hi pressure value on the left column Follow that line right to the column under the design subcooling value Where the two intersect is the required liquid line temperature Alternately you can convert the liquid line pressure gauge reading to temperature by finding the gauge reading in Tem perature Pressure Chart and reading to the left find the temperature in the Column 6 The difference between the thermometer reading and pres sure to temperature conversion is the amount of subcooling Add charge to raise subcooling Recover charge to lower subcooling SUBCOOLING SAT LIQUID TEMP LIQUID LINE TEMP EXAMPLE a Liquid Line Pressure 417 b Corres
56. ir first loses its superheat by heat trans ferred from the gas through the tubes and fins of the coil The refrigerant now becomes saturated part liquid part vapor and then continues to give up heat until it condenses to a liquid alone Once the vapor is fully liquefied it continues to give up heat which subcools the liquid and it is ready to repeat the cycle HEATING The heating portion of the refrigeration cycle is similar to the cooling cycle By de energizing the reversing valve solenoid coil the flow of the refrigerant is reversed The indoor coil now becomes the condenser coil and the outdoor coil be comes the evaporator coil The check valve in the TXV at the indoor coil will open by the flow of refrigerant letting the now condensed liquid refrigerant bypass the indoor expansion device The check valve in the TXV at the outdoor coil will be forced closed by the refrigerant flow thereby utilizing the outdoor expansion device COOLING CYCLE On heat pump models when the thermostat is switched to cool this completes a circuit from R to O energizing the reversing valve solenoid When the contacts of the room thermostat close making terminals R to Y amp G the low voltage circuit of the transformer is completed Current now flows 16 PH15 24 60 M41 through the magnetic holding coils of the compressor contactor and fan motor for models with X13 motors and Variable Speed Terminal Board VSTB for models with ECM motors
57. ise a leak is present Repair and re evacuate 7 Close valve to thermocouple vacuum gauge and vacuum pump Shut off pump and prepare to charge 103 CHARGING dh WARNING REFRIGERANT UNDER PRESSURE DO NOT OVERCHARGE SYSTEM WITH REFRIGERANT DO NOT OPERATE UNIT IN A VACUUM OR AT NEGATIVE PRESSURE FAILURE TO FOLLOW PROPER PROCEDURES MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH 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 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 nameplates for the correct refrigerant charge An inaccurately charged system will cause future prob lems 1 Usinga calibrated set of refrigerant scales allow liquid re frigerant 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 Start the system and charge the balance of the refrigerant through the low side 35 SERVICING 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 T
58. ising the temperature of the control The defrost control should open at 60 F 5 F 4 f notas above replace control 5 50 CHECKING HEATER LIMIT CONTROL S OPTIONAL ELECTRIC HEATERS Each individual heater element is protected with an automatic rest limit control connected in series with each element to prevent overheating of components in case of low airflow This limit control will open its circuit at approximately 150 F to 160 F and close at approximately 110 F DISCONNECT ELECTRICAL POWER SUPPLY Remove the wiring from the control terminals 2 Using anohmmeter test for continuity across the normally closed contacts No reading indicates the control is open replace if necessary Make sure the limits are cool before testing IF FOUND OPEN REPLACE DO NOT WIRE AROUND 5 52 CHECKING HEATER ELEMENTS Optional electric heaters may be added in the quantities shown in the spec sheet for each model unit to provide electric resis tance heating Under no condition shall more heaters than the quantity shown be installed 33 SERVICING 4 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 Disassemble and remove the heating element s 2 Visually inspect the heater assembly for any breaks in the wire or broken insulators 3 Using an ohmmeter test the e
59. lation and loose connections 2 Use an ohmmeter to check continuity of any suspected open wires 3 If any wires must be replaced replace with comparable gauge and insulation thickness 5 3 CHECKING THERMOSTAT WIRING AND ANTICIPATOR S 3A THERMOSTAT AND WIRING LINE VOLTAGE NOW PRESENT With power ON and thermostat calling for cooling 1 Use a voltmeter to verify 24 volts present at thermostat wires C and R 2 f no voltage present check transformer and transformer wiring If 24 volts present proceed to step 3 3 Use avoltmeter to check for 24 volts at thermostat wires C and Y 4 No voltage indicates trouble in the thermostat wiring or external transformer source 5 Checkthe continuity of the thermostat and wiring Repair or replace as necessary Indoor Blower Motor With power ON LINE VOLTAGE NOW PRESENT 1 Use a voltmeter to verify 24 volts present at thermostat wires C and R 2 f no voltage present check transformer and transformer wiring If 24 volts present proceed to step 3 3 Setfan selector switch at thermostat to ON position 4 With voltmeter check for 24 volts at wires C and G 5 No voltage indicates the trouble is in the thermostat or wiring 6 Checkthe continuity of the thermostat and wiring Repair or replace as necessary S 3B COOLING ANTICIPATOR The cooling anticipator is a small heater resistor in the ther mostat During the off cycle it heats the bim
60. le vacuum gauge and charg ing cylinder as shown R 410A 7 MANIFOLD LOW SIDE HIGH SIDE GAUGE GAUGE AND VALVE AND VALVE T 800 PSI RATED HOSES d CHARGING CYLINDER AND SCALE VACUUM PUMP ADAPTER TO UNIT SERVICE VALVE PORTS TES VACUUM PUMP NN 2 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 off to a maxi mum of 25 microns A high vacuum pump can only pro duce a good vacuum if its oil is non contaminated 3 Ifthe vacuum pump is working properly close the valve to the vacuum thermocouple gauge and open the high and low side valves to the high vacuum manifold set With the valve on the charging cylinder closed open the manifold valve to the cylinder 4 Evacuate the system to at least 29 inches gauge before opening valve to thermocouple vacuum gauge 5 Continue to evacuate to a minimum of 250 microns Close valve to vacuum pump and watch rate of rise If vacuum does not rise above 1500 microns in three to five minutes system can be considered properly evacuated 6 Ifthermocouple vacuum gauge continues to rise and levels off at about 5000 microns moisture and non condensables are still present If gauge continues to r
61. lement for continuity no reading indicates the element is open Replace as neces sary 5 100 REFRIGERATION REPAIR PRACTICE 44 DANGER ALWAYS REMOVE THE REFRIGERANT CHARGE IN A PROPER MANNER BEFORE APPLYING HEAT TO THE SYSTEM These models use the FasTest Access Fitting System with a saddle that is either soldered to the suction and liquid lines or is fastened with a locking nut to the access fitting box core and then screwed into the saddle Do not remove the core from the saddle until the refrigerant charge has been removed Failure to do so could result in property dam age or personal injury When installing a new core or reinstalling the core after re moval itis very important note that before inserting the core into the saddle the core and saddle must be free of debris and the O Ring must have a thin coating of refrigerant oil applied to it The oil is to prevent the Ring from being deformed when the core is tightened completely The core should be torqued to 8 ft Ib When repairing the refrigeration system 1 Neveropen a system that is under vacuum Air and mois ture will be drawn in 2 Plug orcap all openings 3 Remove all burrs and clean the brazing surfaces of the tubing with sand cloth or paper Brazing materials do not flow well on oxidized or oily surfaces 4 Clean the inside of all new tubing to remove oils and pipe chips 5 When brazing sweep the tubing with dry nitrogen to p
62. mp Blower Motor ECM Motors 27 S 16C Checking ECM Motor Windings irn 30 16D Checking GEX13 Motors eoruni R ESS mau ua 30 S 17 CHECKING COMPRESSOR WINDINGS ee 31 Resistance Test 5 irr ER ERERER didia ransaka aka eR 31 5S 17B Ground Test 31 5 17 Unloader Test Procedure non nanc nERERRRRR SERRE RRRRRRRRRRR uA 32 S 17D Operation rre rper nit in nune er Eae Pe Era Ek aee FER Aa SUE YER RR XAR ANE 32 5 18 TESTING CRANKCASE HEATER ee 33 S 21 CHECKING REVERSING VALVE AND SOLENOID 33 S 24 TESTING DEFROST CONTROL ee 33 S 25 TESTING DEFROST nre cione n nnn ed cerra Enn er eek an EDT EDUC e X aua aas CEN Rye 33 S 50 CHECKING HEATER LIMIT CONTROL S ee 33 5 52 CHECKING HEATER ELEMENTS renean uo eon ann pan aeu e cR Ea Ranae 33 5 100 REFRIGERATION REPAIR PRACTICE ee 34 S 101 LEAK TESTING NITROGEN OR NITROGEN TRACED nnne nennen nnn t nnt nnne
63. n wire on package units if single stage indoor thermostat is used bag G Green OT18 60A OUTDOOR THERMOSTAT 44 WIRING DIAGRAMS PACKAGE SYSTEM WIRING DIAGRAM HEAT PUMPS ONLY TWO STAGE ELECTRIC HEAT ABOVE 10 kW TYPICAL H P ROOM THERMOSTAT 18 GAUGE 8 WIRE 3 PACKAGE PUMP FR EPI RED Du ET peel YELLOW OUTDOOR THERMOSTAT 2 lt USED SEE NOTE 1 i l5 p od 20o uc TN TN TN A a Ros wu xal a bemmeemmn O Ovo TEE DP a ME on pu LLL lt lt iR MEME c EM Qr BL j j j MEME quu DIM PE 2 4 oU T SE Pole dem MM MM BR om Y gt amp gt 3 3 P t amp BL BL was P a MEE Ses 241 mot OUTDOOR THERMOSTAT 1 LOW VOLTAGE amp CLOSE ON TEMPERATURE FALL JUNCTION BOX ES ior 5 gt T 8225 For outdoor temperatures below 0 F with 50 or higher relative humidity 20 0 5959 set outdoor thermostat at 0 NOTE 1 18 2 BE CONNECTED BETWEEN W2 THERMOSTAT AND BROWN WIRE IF DESIRED COLOR CODES R RED Y YELLOW BL BLUE lt BR BROWN ORANGE W WHITE G GREEN 18 60 OUTDOOR THERMOSTAT 45 WIRING DIAGRAMS PH15 M
64. nd is discharged vertically out the top of the unit The outdoor coil is designed for 0 static No addi tional restriction ductwork shall be applied Conditioned air is drawn through the filter s field installed across the evaporator coil and back into the conditioned space by the indoor blower COMPRESSORS The PH15 4 and 5 ton M series package heat pump units use a two stage scroll compressor The two step modulator has an internal unloading mechanism that opens a bypass port in the first compression pocket effectively reducing the displace ment of the scroll The opening and closing of the bypass port is controlled by an internal electrically operated solenoid Modulation Ring amp Bypass Seals Solenoid Coil Assembly The ZPS two step modulated scroll uses a single step of un loading to go from full capacity to approximately 67 capac ity A single speed high efficiency motor continues to run while the scroll modulates between the two capacity steps Bypass Ports Open 67 Capacity 100 Capacity A scroll is an involute spiral which when matched with a mat ing scroll form as shown generates a series of crescent shaped gas pockets between the two members During compression one scroll remains stationary fixed scroll while the other form orbiting scroll is allowed to orbit but not rotate around the first form 14 As this motion occurs the pockets between the two forms are slowly p
65. ool JOJON 28 SERVICING peloedxeun pue senueJJew 1 SPIOA Ionuoomolou eloN peeds W93 941 Ayyeuonouny 9 Alelelduoo juasayip yoo sepow 10 eours Jolouu lonuoo loeuoo eu esn eloN Sinnn rir swear nue nafhiPunianun IOI YAALA Alioedeo luelel 001 MOI 101 uleJp exesuepuoo si Jepun dool dup e6ueJuV enloejnueuwu lueudinbe Aq se JO pejueuo 9 0 3009 10 0UJ slpueH jueseud si Jolou sJnjslolN pue 91 9 0 4 Jamod Bunoeuuoosip pue soeldey sey Jo Joye JO euJnllej 440 Jewod peeds Jewmolq 1284100 snfpV SuolloJsel 2eJJoo JoeuD 440 Jewod Jeyn 1 42940
66. ponding Temp F 120 c Thermometer on Liquid line 113 F To obtain the amount of subcooling subtract 113 F from 120 F The difference is 7 subcooling which would fall in the range of allowable subcooling SERVICING Pressure vs Temperature Chart R 410A PSIG F PSIG F 420 0 _ 120 4220 121 4240 121 426 0 _ 121 428 0 122 430 0 122 432 0 _ 122 N 434 0 _ 123 436 0 123 438 0 123 440 0 124 4420 124 4440 124 446 0 125 448 0 _ 125 450 0 _ 126 452 0 126 454 0 _ 126 456 0 127 458 0 127 460 0 127 462 0 _ 128 464 0 128 466 0 _ 128 468 0 129 470 0 129 i ii N 472 0 129 4740 _ 130 476 0 130 478 0 130 480 0 131 4820 131 4840 131 486 0 132 488 0 132 490 0 132 4920 132 4940 _ 133 496 0 133 498 0 133 in 500 0 134 502 0 134 5040 134 506 0 135 508 0 135 510 0 135 512 0 136 1 514 0 136 516 0 136 518 0 137 520 0 137 3 Based on ALLIED SIGNAL Data 39 SERVICING REQUIRED LIQUID LINE TEMPERATURE AT SERVICE VALVE PSIG 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 40 8 10 12 14 16 18 58 60 62 64 66 68 70 72 74 76 78 80
67. r ordinances 12 MIN 36 MIN FOR SERVICE 12 MIN 36 MIN FOR SERVICE PH15 24 60 M41 NOTE Roof overhang should be no more than 36 and provisions made to deflect the warm discharge air out from the overhang Minimum clearances are required to avoid air recirculation and keep the unit operating at peak efficiency 4 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 Refer to Roof curb Installation Instructions for proper curb in stallation 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 7 7 SS Lh Roof Curb PH15 24 60 M4 PH Package Units are designed for outdoor installations only in either residential or light commercial applications The connecting ductwork Supply and Return can be connected for horizontal discharge airflow In the down discharge applica tions a matching Roof Curb PGC101 102 103 is recom mended for horizontal models only Areturn air filter
68. re vent the formation of oxides on the inside surfaces 6 Complete any repair by replacing the liquid line drier in the system evacuate and charge 34 At any time the system has been open for repair the factory installed liquid line filter drier must be replaced BRAZING MATERIALS Copper to Copper Joints Sil Fos used without flux alloy of 15 silver 80 copper and 5 phosphorous Recommended heat 1400 F Copper to Steel Joints Silver Solder used without a flux alloy of 30 silver 38 copper 32 zinc Recommended heat 1200 F 5 101 LEAK TESTING NITROGEN OR NITROGEN TRACED A WARNING TO AVOID THE RISK OF FIRE OR EXPLOSION NEVER USE OXYGEN HIGH PRESSURE AIR OR FLAMMABLE Eun FOR LEAK TESTING OF A REFRIGERATION YSTEM 4 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 5 102 EVACUATION dh WARNING REFRIGERANT UND
69. result the shaft feels rough when turned by hand This is a characteristic of the motor not an indication of defective bearings LINE VOLTAGE NOW PRESENT Disconnect the 5 pin connector from the motor 2 Using a volt meter check for line voltage at terminals 4 amp 5 at the power connector If no voltage is present 3 Check the unit for incoming power See section S 1 If line voltage is present reinsert the 5 pin connector and remove the 16 pin connector 5 Check for signal 24 volts at the transformer 6 Check for signal 24 volts from the thermostat to the G terminal at the 16 pin connector 7 Using an ohmmeter check for continuity from the 1 amp 3 common pins to the transformer neutral or C thermostat terminal If you do not have continuity the motor may func tion erratically Trace the common circuits locate and re pair the open neutral 8 Setthe thermostat to Fan On Using a voltmeter check for 24 volts between pin 15 and common 9 Disconnect power to compressor Set thermostat to call for cooling Using a voltmeter check for 24 volts at pin 6 and or 14 10 Setthe thermostat to a call for heating Using a voltmeter check for 24 volts at pin 2 and or 11 Lines 1 and 2 will be connected for 120VAC Power Connector applications only Gnd AC Line Connection AC Line Connection OUT 8 16 OUT
70. rmocouple type temperature meter measure dry bulb temperature 2 Sling psychrometer measure relative humidity and wet bulb temperature 3 Amprobe measure current 4 Volt Ohm Meter testing continuity capacitors motor windings and voltage 5 Accurate Leak Detector testing for refrigerant leaks 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 proper refrigerant charge 9 Inclined Manometer measure static pressure and pres sure drop across coils Other recording type instruments can be essential in solv ing abnormal problems however in many instances they may be rented from local sources Proper equipment promotes faster more efficient service and accurate repairs with less call backs SERVICING COOLING HEAT PUMP SERVICE ANALYSIS GUIDE System Operating Complaint No Cooling Unsatisfactory Cooling Heating Pressures POSSIBLE CAUSE Test Method Remedy DOTS IN ANALYSIS GUIDE INDICATE SYMPTOM POSSIBLE CAUSE System will not start Compressor will not start fan runs Comp and Cond Fan will not start Evaporator fan will not start Condenser fan will not start Compressor runs goes off on overload Compressor cycles on overload Too cool and then too warm Not cool enough on warm days Certain areas too cool others too warm Compressor is noisy System
71. runs blows cold air in heating Unit will not terminate defrost Unit will not defrost Low suction pressure Low head pressure High suction pressure High head pressure See Service Procedure Ref Pow er Failure Test Voltage Blow n Fuse Inspect Fuse Size amp Type Unbalanced Pow er 3PH Test Voltage Loose Connection nspect Connection Tighten Shorted or Broken Wires Test Circuits With Ohmmeter Open Fan Overload Test Continuity of Overload Faulty Thermostat est continuity of Thermostat amp Wiring Faulty Transformer Check control circuit w ith voltmeter Shorted or Open Capacitor Test Capacitor Internal Compressor Overload Open Test Continuity of Overload Shorted or Grounded Compressor Test Motor Windings S 17B Compressor Stuck Use Test Cord S 17D Faulty Compressor Contactor Test continuity of Coil amp Contacts S 7 S 8 Compressor High Stage Not Working Test Voltage to Unloader Plug Test Plug 17 Open Control Circuit Test Control Circuit w ith Voltmeter 5 4 S 11 S 12 Low Voltage est Voltage Faulty Evap Fan Motor Repair or Replace o o 2 18 o N gt Shorted Grounded Fan Motor est Motor Windings S 16A D Improper Cooling Anticipator Check resistance of Anticipator 5 38 Shortage of Refrigerant Test For Leaks Add Refrigerant 5 101 103 Restricted Liquid Line Remove Restriction Replace Restricted Part S 112 Open Element or Limit on Elec Heater Test Heater Element
72. s not exceed 6 PSIG NOTICE Regardless the cause for burnout must be deter mined and corrected before the new compressor is started 42 5 122 REVERSING VALVE REPLACEMENT Remove the refrigerant charge from the system When brazing a reversing valve into the system it is of ex treme importance that the temperature of the valve does not exceed 250 F at any time Wrap the reversing valve with a large rag saturated with water Re wet the rag and thoroughly cool the valve after each braz ing operation of the four joints involved The wet rag around the reversing valve will eliminate conduction of heat to the valve body when brazing the line connection The use of a wet rag sometimes can be a nuisance There are commercial grades of heat absorbing paste that may be sub stituted After the valve has been installed leak test evacuate and re charge SERVICING 5 200 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 in many cases this con stitutes a poorly designed system To determine proper air movement proceed as follows 1 Using a draft gauge
73. should go up or down least 25 percent 2 If step one does not give the expected results shut unit off Apply 18 to 28 volt ac to the unloader molded plug leads and listen for a click as the solenoid pulls in Remove power and listen for another click as the unloader returns to its original position 3 Ifclicks can t be heard shut off power and remove the con trol circuit molded plug from the compressor and measure the unloader coil resistance The resistance should be 32 to 60 ohms depending on compressor temperature 32 4 Next check the molded plug A Voltage check Apply control voltage to the plug wires 18 to 28 volt ac The measured dc voltage at the female connectors in the plug should be around 15 to 27 vdc B Resistance check Measure the resistance from the end of one molded plug lead to either of the two female connectors in the plug One of the connec tors should read close to zero ohms while the other should read infinity Repeat with other wire The same female connector as before should read zero while the other connector again reads infinity Reverse polarity on the ohmmeter leads and repeat The fe male connector that read infinity previously should now read close to zero ohms C Replace plug if either of these test methods doesn t show the desired results S 17D OPERATION TEST Ifthe voltage capacitor overload and motor winding test fail to show the cause for failure 4 amp WARNING HIGH V
74. sor and or spread contaminants throughout the system damag ing additional components Use brand part number RF000127 suction line filter drier kit This drier should be installed as close to the com pressor suction fitting as possible The filter must be acces sible and be rechecked for a pressure drop after the system has operated for a time It may be necessary to use new tub ing and form as required NOTE Atleast twelve 12 inches of the suction line immedi ately out of the compressor stub must be discarded due to burned residue and contaminates 1 Remove compressor discharge line strainer 2 Removethe liquid line drier and expansion valve 3 Purge all remaining components with dry nitrogen or car bon dioxide until clean Install new components including liquid line drier 5 Braze joints leak test evacuate and recharge system 6 Startup the unit and record the pressure drop across the drier 7T Continue to run the system for a minimum of twelve 12 hours and recheck the pressure drop across the drier Pres sure 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 Ifthe pressure drop becomes greater then it must be re placed and steps 5 through 9 repeated until it doe
75. tch on the thermostat is returned to the automatic posi tion the fan will stop after a 60 second delay on APH15 units PH15 24 60 M41 GPH15 M Series X13 equipped models only If the thermostat calls for continuous fan the indoor blower will be energized from the G terminal of the thermostat to the X13 blower motor If a call for heat or cool occurs during a continuous fan call the GE X13 motor will always recognize the call for the highest speed and ignore the lower speed call If the thermostat is not calling for heat or cool and the fan Switch on the thermostat is returned to the automatic posi tion the fan will stop after the programmed 60 second off delay on units with the GE X13 motor AIRFLOW ADJUSTMENTS FOR INDOOR BLOWER MOTOR APH15 M Series ECM equipped models only Dip switch 4 must be set to ON for APH1524 36 Dip switch 4 must be set to OFF for 2 stage compressor models APH1548 60 Dip switch 4 ON energizes Y1 signal to the ECM motor anytime Y Y2 is energized The indoor motor will not operate properly if switch is not set correctly for the model ECM Motor The ECM control board is factory set with the dip switch 4 in the ON position for single stage units and to the OFF position for the 2 stage units All other dip switches fac tory set in the position For most applications the settings are to be changed according to the electric heat size The ECM motor provides many features
76. tion and extend down the line in the direction of the flow Discharge and suction pressures will be low giving the ap pearance of an undercharged unit However the unit will have normal to high subcooling If a restriction is located replace the restricted part replace drier evacuate and recharge 5 113 REFRIGERANT OVERCHARGE An overcharge of refrigerant is normally indicated by exces sively high head pressure and or liquid return to the compres sor If high head pressure is not indicated an overcharge or a sys tem containing non condensables could be the problem If overcharging is indicated 1 Start the system 2 Remove small quantities of gas from the suction line dill valve until the head pressure is reduced to normal 3 Observe the system while running a cooling performance test if a shortage of refrigerant is indicated then the sys tem contains non condensables See S 114 Non Condensables S 114 NON CONDENSABLES Check for non condensables 1 Shut down the system and allow the pressures to equalize for a minimum of 15 minutes 2 Take a pressure reading 3 Compare this pressure to the temperature of the coldest coil since this is where most of the refrigerant will be If the pressure indicates a higher temperature than that of the coil temperature non condensables are present To remove the non condensables 1 Remove the refrigerant charge 2 Replace and or install liquid line drier 3 Eva
77. tive replace it 5 24 TESTING DEFROST CONTROL To check the defrost control for proper sequencing proceed as follows With power ON unit not running 1 Jumper defrost thermostat by placing a jumper wire across the terminals DFT and R at defrost control board 2 Connect jumper across test pins on defrost control board 3 Set thermostat to call for heating System should go into defrost within 21 seconds Immediately remove jumper from test pins 5 Using VOM check for voltage across terminals C amp O Meter should read 24 volts 6 Using VOM check for voltage across fan terminals DF1 and DF2 on the board You should read line voltage 208 230 VAC indicating the relay is open in the defrost mode 7T Using VOM check for voltage across W2 amp C terminals on the board You should read 24 volts If not as above replace control board 9 Setthermostat to off position and disconnect power before removing any jumpers or wires NOTE Remove jumper across defrost thermostat before re turning system to service 5 25 TESTING DEFROST THERMOSTAT 1 Install a thermocouple type temperature test lead on the tube adjacentto the defrost control Insulate the lead point of contact 2 Checkthe temperature at which the control closes its con tacts by lowering the temperature of the control The de frost control should close at 34 F 5 F 3 Check the temperature at which the control opens its con tacts by ra
78. ts can be made through the dip switch com bination of 7 8 Table 5 shows the switch position for this feature NOTE The airflow will not make the decreasing adjustment in Electric Heat mode cw _ Seien 10 oN OFF _ 15 oF Table 5 Humidity Control When using a Humidistat normally closed cut jumper PJ6 on the control board The Humidistat will only affect both low stage and high stage cooling airflow by adjusting the Airflow to 8596 Two Stage Heating When using staged electric heat cut jumper PJ4 on the con trol board Thermostat Wiring Use thermostat wiring diagrams provided with the thermostat when making these connections See Specification Sheet for APH model series for CFM vs ESP tables SYSTEM Typical Heat Pump System Cooling Reversing Valve Energized Reversing Valve De Energized 19 SCHEDULED MAINTENANCE Package heat pumps require regularly scheduled mainte nance to preserve high performance standards prolong the service life of the equipment and lessen the chances of costly failure In many instances the owner may be able to perform some of the maintenance however the advantage of a service con tract which places all maintenance in the hands of a trained serviceman should be pointed out to the owner 4 WARNING HIGH VOLTAGE SERVICING OR INSTALLING THIS UNIT MULTIPLE POWER SOURCES MAY BE PRESENT
79. ubcooling and superheat Systems with TXV ap plication should have a subcooling of 10 2 F and super heat of 15 to 18 F a Ifsubcooling and superheat are low adjust to 15 18 F then check subcooling b If subcooling is low and superheat is high add charge to raise subcooling 1010 2 F then check super heat c If subcooling and superheat are high adjust TXV valve to 15 18 F then check subcooling d If subcooling is high and superheat is low adjust TXV valve to 15 to 18 F superheat and remove charge to lower the subcooling to 10 2 F The TXV should NOT be adjusted at light load conditions 55 to 60 F under such conditions only the subcooling can be evaluated This is because suction pressure is dependent on 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 37 SERVICING SUBCOOLING SAT LIQUID TEMP LIQUID LINE TEMP SATURATED LIQUID PRESSURE TEMPERATURE CHART Saturated Liquid Pressure Temperature F Pse __ ___ 235 80 275 90 k Two Speed Application PH1548 PH1560 Run the unit on low stage cooling for 10 minutes until refriger ant pressures stabilize Follow the guidelines and methods below to check unit operation and ensure that the refrigerant charge is within limits Charge the unit on low stage 1 P
80. urge gauge lines Connect service gauge manifold to access fittings Run system at least 10 minutes to allow pressure to stabilize 2 Temporarily install thermometer on liquid small line near liquid line access fitting with adequate contact and insu late for best possible reading 3 Check subcooling and superheat Two stage systems run ning on low stage with TXV application should have a subcooling of 5 to 7 F and superheat of 15 to 18 F a If subcooling and superheat are low adjust to 15 to 18 F superheat then check subcooling NOTE To adjust superheat turn the valve stem clockwise to increase and counter clockwise to de crease b If subcooling is low and superheatis high add charge to raise subcooling to 5 to 7 F then check super heat c If subcooling and superheat are high adjust TXV valve to 15 to 18 F superheat then check subcooling 38 d If subcooling is high and superheat is low adjust TXV valve to 15 to 18 F superheat and remove charge to lower the subcooling to 5 to 7 F NOTE Do NOT adjust charge based on suction pres sure unless there is a gross undercharge 4 Disconnect manifold set installation is complete SUBCOOLING SAT LIQUID TEMP LIQUID LINE TEMP Heat Pump Heating Cycle The proper method of charging a heat pump in the heat mode is by weighing the charge according to the total charge listed on the rating plate 109 CHECKING SUBCOOLING Refrigerant l
81. ushed to the center of the two scrolls while simulta neously being reduced in volume When the pocket reaches the center of the scroll form the gas which is now at a high pressure is discharged out of a port located at the center During compression several pockets are being compressed simultaneously resulting in a very smooth process Both the suction process outer portion of the scroll members and the discharge process inner portion are continuous Some design characteristics of the Compliant Scroll compres Sor are Compliant Scroll compressors are more tolerant of liquid refrigerant NOTE Even though the compressor section of a Scroll compressor is more tolerant of liquid refrigerant continued floodback or flooded start conditions may wash oil from the bearing surfaces causing premature bearing failure e These Scroll compressors use POE or polyolester oil which is NOT compatible with mineral oil based lubricants like 3GS POE oil must be used if additional oil is re quired e Compliant scroll compressors perform quiet shutdowns that allow the compressor to restart immediately without the need for a time delay This compressor will restart even if the system has not equalized NOTE Operating pressures and amp draws may differ from standard reciprocating compressors This information can be found in the unit s Technical Information Manual INDOOR BLOWER MOTOR GPH15 M series model package units use a GE
82. y the expansion valve results in high suction pres sure cold suction line and possible liquid slugging of the com pressor If these symptoms are observed 1 Check for an overcharged unit by referring to the cooling performance charts in the servicing section 2 Check the operation of the power element in the valve as explained in S 110 Checking Expansion Valve Operation 3 Check for restricted or plugged equalizer tube 5 107 UNDERFEEDING Underfeeding by the expansion valve results in low system capacity and low suction pressures If these symptoms are observed 1 Check for a restricted liquid line or drier A restriction will be indicated by a temperature drop across the drier 2 Check the operation of the power element of the valve as described in S 110 Checking Expansion Valve Operation 5 108 SUPERHEAT The expansion valves are factory adjusted to maintain 15 to 18 degrees superheat of the suction gas Before checking the superheat or replacing the valve perform all the procedures outlined under Air Flow Refrigerant Charge Expansion Valve Overfeeding Underfeeding These are the most common causes for evaporator malfunction CHECKING SUPERHEAT Refrigerant gas is considered superheated when its tempera ture is higher than the saturation temperature corresponding to its pressure The degree of superheat equals the degrees of temperature increase above the saturation temperature at ex isting pressure See

Goodman Mfg R-410A User's Manual

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