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GPH13H Service Man

1. RR RD 40 OT18 60A OUTDOOR one reru utto Ran RR RR a RR n enu 41 SINGLE PHASE HKR HEAT KITS erento eren unn nen aan inue eren ec Pre nua cesses svevsieradecsseeversdh 42 PGE ECONOMIZER d 43 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 APPROVE
2. 30 5 17 RESISTANCE ec H 30 5 17 31 5 170 Operation TeSt 31 5 18 TESTING CRANKCASE HEATER rh RE Pau ER XXX RRRRRRYR 31 5 21 CHECKING REVERSING VALVE AND SOLENOID 32 5 24 TESTING DEFROST CONTROL scence 32 5 25 DEFROST THERMOSTAT ae 32 5 50 CHECKING HEATER LIMIT CONTROL 32 5 52 CHECKING HEATER ELEMENTS aAA EE a EEEE ERENER 32 5 100 REFRIGERATION REPAIR nnn nr nns nnne nnn 33 S101 LEAK TESTING aa A Eaa Eaa aaea aaa a 33 SA02 EVACUATION a a a aiaa 33 5 103 CHARGING titre
3. su so svecsanancebsasedeenaedeesetediececcesvedednavccassandedesccaccdecareessreziaceds 34 104 CHECKING COMPRESSOR EFFICIENCY nennen nennen nnn nne nnns sanas nna nns 35 92108 SUPERHFHEAT tonne rto ree aeuo RR REN RRRRRRRRREMSRBRRRRRRRRRRRRRR RES 35 5 109 CHECKING SUB COOLING reuera nn t tno aen ansa ee ERE e eX Pru oh ua ces eves aen RR RINREN uuu 36 111 FIXED ORIFICE RESTRICTION DEVICES erre enne p nananana adnada nanana Kansra saaan dun us 37 S 112 CHECKING RESTRICTED LIQUID LINE 37 S 113 REFRIGERANT OVERCHARGE nns nnns ansa t nas nni 37 S 114NON CONDENSABLES inne UE 37 S 115 COMPRESSOR BURNOUT 37 5 122 REVERSING VALVE REPLACEMENT 38 200 CHECKING EXTERNAL STATIC PRESSURE 39 2 201 CHECKING TEMPERATURE RISE RRARRES M nne FER To 39 WIRING DIAGRAMS ae 40 OT18 60A OUTDOOR THERMOSTAT
4. 2 BLUE IN YELLOW Y Te 1K RELAY CONTACTS 1K RELAY COMPRESSOR LOCKOUT UNIT T THERMOSTAT Bue PINK soF 3 w YELLOW BARBER COLEMAN AD 931 105 POTENTIOMETER OPTIONAL ORANGE MINIMUM DAMPER POSITION A INSTALL AS SHOWN TSTAT AIO S ORANGE P 27 p 2 Y2 used only with D WHITE odo kK NS 2 Stage Cool T stat ln A al I ya ENTHALPY 2 Y2 CMS 1K RELAY f KCN ORAN t YT e R i 9 GOODMAN MANUFACTURING CO ION i BH MODEL 101 103 ECONOMIZER ROOFTOP UNITS GPH GPC SERIES WIRING DIAGRAM NOTE RECOMMEND MULTI STAGE T STAT SINVHOVIG SNIHIM xL H LHd9 2d9
5. 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 pre 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 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 8096 copper and 5 phosphorous Recommended heat 1400 F Copper to Steel Joints Silver Solder used without a flux alloy of 3096 silver 38 copper 32 zinc Recommended heat 1200 F 101 LEAK TESTING Refrigerant leaks are best detected with a halide or electronic leak detector However on outdoor installed systems provisions must be made to shield the copper element of an halide torch from the sun and wind conditions in order to be able to see the element properly NOTE The flame of the halide detector will glow green in the presence of R 22 refrigerant For a system that contains a refrigerant charge and is sus pected of having a leak stop the operation and hold the explor ing tube of the detector as close to the tube as possible check all piping and fittings If a leak is
6. couple type temperature tester to the suction line at a point at least 6 from the compressor 2 Install a low side pressure gauge on the suction line ser vice valve at the outdoor unit Record the gauge pressure and the temperature of the line 4 Convertthe suction pressure gauge reading to temperature by finding the gauge reading in Temperature Pressure Chart and reading to the left find the temperature in the F Column 5 The difference between the thermometer reading and pres sure to temperature conversion is the amount of super heat EXAMPLE a Suction Pressure 84 b Corresponding Temp F 50 c Thermometer on Suction Line 63 F To obtain the degrees temperature of superheat subtract 50 0 from 63 0 F The difference is 13 Superheat For charging in the warmer months 10 F superheat at the compressor is required at conditions 95 F outdoor ambient dry bulb temperature 80 F dry bulb 67 F wet bulb indoor ambient approximately 50 96 humidity This superheat varies when conditions vary from the conditions described A superheat charge chart is provided below for other operating conditions Use itto provide the correct superheat at the conditions the unit is being charged at After superheat is adjusted it is recommended to check unit sub cooling at the condenser coil liquid line out Ambient Condenser Inlet Temp F Drybulb Return Air Temp F Drybulb O 0 s b
7. DB wB PSIG PSIG 3 36 Operating Pressures Temp F Gauge Pressure Gauge Pressure PSIG Freon 22 PSIG Freon 22 TEMPERATURE PRESSURE R 22 SERVICING S 111 FIXED ORIFICE RESTRICTION DEVICES The fixed orifice restriction device flowrator used in conjunc tion with the indoor coil is a predetermined bore 1 0 It is designed to control the rate of liquid refrigerant flow into an evaporator coil The amount of refrigerant that flows through the fixed orifice restriction device is regulated by the pressure difference be tween the high and low sides of the system In the cooling cycle when the outdoor air temperature rises the high side condensing pressure rises At the same time the cooling load on the indoor coil increases causing the low side pressure to rise but at a slower rate Since the high side pressure rises faster when the tempera ture increases more refrigerant flows to the evaporator increas ing the cooling capacity of the system When the outdoor temperature falls the reverse takes place The condensing pressure falls and the cooling loads on the indoor coil decreases causing less refrigerant flow If a restriction should become evident proceed as follows 1 Recover refrigerant charge 2 Remove the orifice assembly and clean or replace 3 Replace liquid line drier evacuate and recharge CHECKING EQUALIZATION TIME During the OFF cycle the high side pressure bleeds
8. across the evaporator coil and back into the conditioned space by the indoor blower COMPRESSORS Some GPC GPH series package units use the Compliant Scroll compressor instead of traditional reciprocating compressors Still other models use reciprocating compressors A scroll is an involute spiral which when matched with a 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 one As this motion occurs the pockets between the two forms are slowly pushed 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 e 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 fro
9. A WARNING NOTES Color Codes R Red Y Yellow 1 and used heat pumps only BL Blue 2 Connect wire from terminal 1 on outdoor thermostat to the white BR Brown wire on package units if single stage indoor thermostat is used Green 18 60 OUTDOOR THERMOSTAT 40 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 2 PACKAGE HEAT PUMP i 1 1 1 yl P P EATER LR RED Du ET peel i M Ld gc YELLOW OUTDOOR THERMOSTAT 2 G o F USED SEE 1 d 4 i Bow 4 fX ozo NE EU S3Ek War pu lt lt iR MEME c EM Qr PR W BL MEME quu DIM PE go ees oU T Pt de BR Sat gt amp xu lt 0 3 BL BL P a 27 1 OUTDOOR THERMOSTAT 1 LOW VOLTAGE amp CLOSE ON TEMPERATURE FALL JUNCTION BOX ES amp Ou T 3 Z25 For outdoor temperatures below 0 F with 50 or higher relative humidity 20 0 5912 set outdoor thermostat at 0 2 NOTE 1 OTI8 2 CAN BE CONNECTED BETWEEN W2 OF THERMOSTAT AND BROWN WIRE IF DESIRED COLOR CODES
10. BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH SERVICING 1 Disassemble and remove the heating element s 2 Visually inspect the heater assembly for any breaks in the wire or broken insulators 3 Using an ohmmeter test the element for continuity no reading indicates the element is open Replace as neces sary 100 REFRIGERATION REPAIR PRACTICE 4 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 to note that before inserting the core into the saddle the core and saddle must be free of debris and the O Ring must have a thin coating of refrigerant oil applied to it The oil is to prevent the 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 Plug or cap all openings
11. E 2 5 3 e o 8 T 5 5 5 ai 8 2 e 5 sie Lig e 5 5 5 Test Method 1989 a 6 S 3 v CIS 5 5 2 8 5 15 5 5 9 8 gt 2 5 2 z 5 15 218 213 88 o Slo 5 18 2 1 ala 5 5 5 2 5 5 5 5 o SiS 8 2 8 E lall lz 8 155 5 5 8 0 51515 gt o 2 BIE ls 5 5 8 GIG 2 8 o 5 15 3 4 JI fe per 5 2 5 3 ee 5 2 5 3 Li je LLL t LIII jeje LI LLL e 2s 1 ss fete I tT tT tet I LI LI fet tT L LLL _ fej leje 1 ILLI 5 1 fet 111 a Lu L 1 5 3 LT 5 107 103 LI LI eje 1 5 112 TestHeater Elementand Controls 5 265 27 le eje e e mspectFiter CleanorReplace L LI fe e
12. F Part 0130M00001P which is used on 3 thru 5 ton units should close at 31 F 3 F 3 Checkthe temperature at which the control opens its con tacts by raising the temperature of the control Part 0130M00009P which is used on 2 and 2 5 ton units should open at 60 F 5 F Part 0130M00001P which is used on 3 thru 5 ton units should open at 75 F 6 F 4 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 an ohmmeter test for continuity across the normally closed contacts No reading indicates the control is open replace if necessary Make sure the limits are cool before testing IF FOUND OPEN REPLACE DO NOT WIRE AROUND 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 4 WARNING HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT MULTIPLE POWER SOURCES MAY
13. R RED z Y YELLOW BL BLUE lt BR BROWN O ORANGE W WHITE G GREEN 18 60 OUTDOOR THERMOSTAT 41 WIRING DIAGRAMS R 2 x 3 4 BK 5 Mio p R y 2 2 R lt BK BK 4 R ONE 1 ELEMENT ROWS L1 L2 TWO 2 ELEMENT ROWS U lt J Se 7 EX 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 JN A A wt oe os o nm L1L2L1L2 THREE 3 ELEMENT ROWS FOUR 4 ELEMENT ROWS 15 KW 20 KW Ay WARNING SINGLE PHASE HKR HEAT KIT 42 b Hsx LHd9 Dd9 YAZIINONODA 32d ev HIGH VOLTAGE WARNING DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH
14. 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 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 of spray which may be dangerous to anyone in the vicinity Death or serious bodily injury could occur Under no circumstances
15. TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK WIRING TO THE UNIT MUST BE PROPERLY POLARIZED AND GROUNDED 15 PRODUCT DESIGN 4 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 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 No 70 or in Canada Canadian Electrical Code C22 1 Part 1 A fused disconnected must be provided and sized in accordance with the unit minimum circuit ampacity 16 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 transforme
16. and 50 or higher relative humidity E ue 7 SQRPC101 and SQRPC102 103 must be used with PCP101 103 Downflow Plenum kit and PCCP101 103 Roof Curb ACCESSORIES GPC GPH13 24 60 H21 PCCP101 103 ROOF CURB NEM Roof 14 Curb PCP101 103 DOWNFLOW PLENUM Use with PCCP Roof Curb 1 Flange 28 3 4 GPC GPH13 24 60 H21 PCEF101 103 ELBOW AND FLASHING KIT ACCESSORIES PCE101 103 ECONOMIZER DOWNFLOW APPLICATIONS 20 3 8 Fa M 5 2 E ud ue Must be used with PCP101 103 Iter ACCESSORIES GPC GPH13 24 60 H21 PCMD101 103 DOWNFLOW MANUAL DAMPER USED WITH PCP101 103 DOWNFLOW PLENUM j 29 3 4 GPHMD101 103 HORIZONTAL MOTORIZED DAMPER WITH DUCT FLANGE ye e ACCESSORIES GPC GPH13 24 60 H21 SQRPC SQUARE TO ROUND CONVERTER DOWNFLOW APPLICATIONS 1 FLANGES 1 1 2 SQRPCH SQUARE TO ROUND CONVERTER HORIZONTAL APPLICATIONS SQUARE TO ROUND DUCT CONVERTER PANEL OUTERFLANGE BEAD STARTER FLANGE D 2212 2412 2412 2412 2412 ACCESSORIES GPC GPH13 24 60 H21 PCFR101 103 EXTERNAL FILTER KIT HORIZONTAL APPLICATIONS PRODUCT DESIGN 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
17. can be essential in solving abnormal problems however in many instances they may be rented from local sources Proper equipment promotes faster more efficient service and accurate repairs with less call backs SERVICING COOLING HEAT PUMP SERVICE ANALYSIS GUIDE Complaint POSSIBLE CAUSE DOTS IN ANALYSIS GUIDE INDICATE POSSIBLE CAUSE SYMPTOM Pow er Failure Blow n Fuse Unbalanced Pow er 3PH Loose Connection Shorted or Broken Wires Open Fan Overload Faulty Thermostat Faulty Transformer Shorted or Open Capacitor Internal Compressor Overload Open Shorted or Grounded Compressor Compressor Stuck Faulty Compressor Contactor Faulty Fan Control Open Control Circuit Low Voltage Faulty Evap Fan Motor Shorted or Grounded Fan Motor Improper Cooling Anticipator Shortage of Refrigerant Restricted Liquid Line Open Element or Limit on Elec Heater Dirty Air Filter Dirty Indoor Coil Not enough air across Indoor Coil Too much air across Indoor Coil Overcharge of Refrigerant Dirty Outdoor Coil Noncondensibles Recirculation of Condensing Air Infiltration of Outdoor Air Improperly Located Thermostat Air Flow Unbalanced System Undersized Broken Internal Parts Broken Valves Inefficient Compressor Loose Hold dow n Bolts Faulty Reversing Valve Faulty Defrost Control Faulty Defrost Thermostat Flow rator Not Seating Properly System will not start No Cooli Unsatisfactory
18. contacts of the blower relay When the thermostat is satisfied this breaks the circuit from R to W This will turn off the electric heaters and the indoor blower after the programmed 60 second off delay on 5 ton units with the GE X13 motor GPC 5 ton units AB Revision Models With the thermostat set to the heat position and a call for heat R to W will be energized This will energize the electric heat sequencers and the GE X13 motor The electric heat will be energized through the normally open contacts of the electric heat sequencers The indoor blower will be energized through W from the thermostat When the thermostat is satisfied this breaks the circuit from R to W This will turn off the electric heaters and the indoor blower after the programmed 60 second off delay on 5 ton units with the GE X13 motor 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 normally open contacts of the EBTDR after a 7 second on delay on 2 thru 4 ton units and instantly on 5 ton 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 EBTDR 65 second off delay
19. detected do not attempt to apply more brazing to the joint Remove and capture the charge unbraze the joint clean and rebraze For a system that has been newly repaired and does not con tain a charge connect a oylinder of refrigerant through a gauge manifold to the liquid and suction line dill valves and or liquid line dill valve and compressor process tube NOTE Refrigerant hoses must be equipped with dill valve de pressors or special adaptor used Open the valve on the cylin der and manifold and allow the pressure to build up within the System Check for and handle leaks as described above After the test has been completed remove and capture the leak test refrigerant 102 EVACUATION 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 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 lentto 25 microns absolute and a thermocouple vacuum gauge to give a true reading of the vacuum
20. due to a floodback or over charge condition 31 SERVICING 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
21. 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 or Distinctions Product Type Package Cooling Heating Product Family C Cooling H Heat Pump Product Series 13 13 SEER Rating Nominal Capacity Minor Revision Major Revision Voltage 1 208 230V 1ph 60Hz 3 208 230V 3ph 60Hz 4 460V 3ph 60Hz Refrigerant 2 R 22 4 R 410A 24 000 BTUH 30 000 BTUH 36 000 BTUH 42 000 BTUH 48 000 BTUH 60 000 BTUH __ GPH13 H 1 Chassis Models 2 2 5 Ton Medium 13 3 5 Configuration H Horizontal PRODUCT IDENTIFICATION GPH13 H21A Amana Goodman Package Heat Pump 13 Seer horizontal heat pump units Initial release GPH1360H21AA Amana Goodman Package Heat Pump 13 Seer horizontal heat pump units Added minor revision to model number No change to units GPH1324 48H21AB Sr Package Heat Pump 13 Seer horizontal Added interlock Amana Goodman Package Heat Pump 13 Seer horizontal Sound Improvements Changed to 8 pole condenser motor and changed fan blade GPH1324 30H21AC GPH1348 60H21AC Amana Goodman Package Heat Pump 13 Seer horizontal Improve Control GPH1336 42H21AD Panel Fit by having 4 screws across the bottom in place of 3 screws
22. the coil terminals the valve is inoperative 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 Using VOM check for voltage across terminals amp 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 7 Using VOM check for voltage across W2 amp C terminals on the board You should read 24 volts 8 Ifnotas above replace control board 9 Setthermostat to off position and disconnect power before removing any jumpers or wires 32 NOTE Remove jumper across defrost thermostat before re turning system to service 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 Part 0130M00009P which is used on 2 and 2 5 ton units should close at 34 F 5
23. the heat sequencers close this will ener gize the electric resistance heat and also the 240 volt coil on the isolation isolation relay in the control panel The normally open contacts of the isolation relay will close energizing the indoor blower motor through the normally closed contacts of the EBTDR GPH 5 ton units A and AA Revision Models 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 the blower relay The electric heat will be energized through the normally open contacts of the electric heat sequencers The indoor blower will be energized through the normally open contacts of the blower relay GPH 5 ton units AB Revision Models 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 the GE X13 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 De
24. the system 10 If the pressure drop becomes greater then it must be re placed and steps 5 through 9 repeated until it does not exceed 6 8 PSIG NOTE The cause for burnout MUST be determined and cor rected BEFORE the new compressor is started 38 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 ca
25. 2 Using an ohmmeter test across the coil terminals 1 and 3 If the coil does not test continuous replace the relay Testing relay contacts DISCONNECT POWER SUPPLY BEFORE SERVICING Turn power off 1 Using a VOM test resistance across relay terminals 2 and 4 Should read open 2 Turn power on LINE VOLTAGE NOW PRESENT 3 Apply 240 volts to coil terminals 1 and 3 4 Using a VOM check for 240 volts from terminals 3 and 1 of relay Should read 240 volts In no voltage check wiring from heater kit to relay If voltage present proceed to step 5 5 Using VOM check for 240 volts from L1 at contactor to terminal 4 of relay Should read 240 volts Next check from L1 at contactor to terminal 2 of relay Should read 240 volts If not as above replace relay 27 SERVICING 5 Ton Units A and AA Revision NOTE The 5 Ton AB revision models do not have a relay On the A and AA revision 5 ton units with the GE X13 motor a standard fan relay is used DISCONNECT POWER SUPPLY BEFORE SERVICING Turn power off Testing relay holding coil 1 Remove the leads from the holding coil 2 Using an ohmmeter test across the coil terminals 1 and 3 If the coil does not test continuous replace the relay Testing relay contacts DISCONNECT POWER SUPPLY BEFORE SERVICING Turn power off 1 Using a VOM test resistance across relay terminals 2 and 4 Should read open 2 Turn power on LINE VOLTA
26. 2 thru 4 ton units and after the programmed 60 second off delay on 5 ton units with the GE X13 motor Continuous Fan Mode AB Revision 5 Ton 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 19 SYSTEM OPERATION Typical Package Cooling Chatleff Orifice Restrictor Orifice Assembly in Cooling Operation In the cooling mode the orifice is pushed into its seat forcing refrigerant to flow through the metered hole in the center of the orifice 20 SYSTEM OPERATION Typical Heat Pump System in Cooling Reversing Valve Energized Reversing Valve De Energized 21 SCHEDULED MAINTENANCE The owner should be made aware of the fact that as with any mechanical equipment the Package Cooling and Heat Pump units require regularly scheduled maintenance to preserve high performance standards prolong the service life of the equip ment and lessen the chances of costly failure In many instances the owner may be able to perform som
27. 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 POWER BEFORE SERVICING OR INSTALLING THIS UNIT MULTIPLE POWER SOURCES MAY PRESENT FAILURE TO DO SO MAY 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 cont
28. AC input motor with ball bearing construction Unlike the ECM 2 3 2 5 motors the GE X13 features an integral control module Note The GE TECMate will not currently operate the GE X13 motor 1 Using a voltmeter check for 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 29 SERVICING 2 Using a voltmeter check for 24 volts from terminal C to either terminal 1 2 3 4 or 5 depending on which tap is being used at the motor If voltage present proceed to step 3 If no voltage check 24 volt circuit to motor 3 If voltage was present in steps 1 and 2 the motor has failed and will need to be replaced Note When replacing motor ensure the belly band is between the vents on the motor and the wiring has the proper drip loop to prevent condensate from entering the motor High Voltage Connections 1 3 16 GE X13 MOTOR CONNECTIONS 5 17 CHECKING COMPRESSOR WINDINGS 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 ASA 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 If the compressor terminal PROTECTIVE C
29. D 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 TECHNICIAN AS SPECIFIED BY THE AIR CONDITIONING AND DO NOT STORE COMBUSTIBLE MATERIALS OR USE GASOLINE OR OTHER REFRIGERATION INSTITUTE ARI ATTEMPTING TO INSTALL OR FLAMMABLE LIQUIDS OR VAPORS IN THE VICINITY OF THIS APPLIANCE 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 O
30. ER 12 PCFR101 103 HORIZONTAL FILTER EAT ENIAN STEENSENS EENES 13 PRODUC 14 ELECTRICAL WIRING cheat Ee tei e eni tessera imis ecrit a I rre buc 15 B lzdehrczulicm 16 SYSTEM OPERATION tT 17 GPC GPH13 24 60 H21 con c 17 COOLING CY CEE onere 17 FIEATING CYCLE 17 DEFROST CY CUE iMi E E E EEE 18 FAN OPERATION p 19 SCHEDULED MAINTENANCE codon eaae re e er errema aeaaea eaaa 22 ONCE A MONTH m 22 E E E E E T A E T 22 TEST EQUIPMENT M 22 cg errcgqeemc 23 COOLING HEAT PUMP SERVICE ANALYSIS GUIDE 23 5 1 CHECKING VOLTAGE 24 5 2 CHECKING WIRING 25 5 3 CHECKING TH
31. ERMOSTAT WIRING AND 25 S 3A Thermostat and 25 S 3B Cooling AntICIpator ssi ERRARE AANE RE 25 S 3C Heating Anticipatot iniret rcr DX 25 5 4 CHECKING TRANSFORMER AND CONTROL CIRCUIT esee nnne nennt nnne tennis 26 5 7 CHECKING CONTACTOR AND OR RELAYS 26 5 8 CHECKING CONTACTOR CONTACTS 26 5 9 CHECKING FAN RELAY 27 S 11 CHECKING LOSS OF CHARGE PROTECTOR eese 28 S 15 CHECKING CAPACITOR cR 28 S 15A RESISTANCE CHECK WR 29 5 158 CHECK 29 9 16 CHECKING MOTORS 29 S 16A CHECKING FAN AND BLOWER MOTOR WINDINGS PSC MOTORS 29 S 16D CHECKING GE X13 MOTORS nennen 29 5 17 CHECKING COMPRESSOR WINDINGS
32. F 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 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
33. FORE 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 insulation and loose connections 2 Use an ohmmeter to check continuity of any suspected open wires 3 If any wires must be replaced replace with comparable gauge and insulation thickness S 3 CHECKING THERMOSTAT WIRING AND ANTICIPATOR S 3A THERMOSTAT AND WIRING 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 andR 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 Checkt
34. GE NOW PRESENT 3 Apply 24 volts to coil terminals 1 and 3 Using a VOM check for 24 volts from terminals 3 and 2 of relay Should read 24 volts If no voltage check low voltage wiring from transformer to relay If voltage present proceed to step 5 5 Using a VOM check for 24 volts from terminals 3 and 4 of relay Should read 24 volts If not as above replace relay 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 7 PSIG It will automatically cut in close at ap proximately 25 PSIG Test for continuity using a VOM and if not as above replace the control 28 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 phase relationship between the capacitor current and voltage in conjunction with the motor windings so that the motor will give two phase operation when connected to a single phase circuit The capacitor also re duces the line current to the motor by improving t
35. Horizontal Package Coolers GPC43 H21A Amana Goodman Package Cooler 13 Seer horizontal cooling units Initial release GPC1360H21AA Amana Goodman Package Cooler 13 Seer horizontal cooling units Added minor revision to model number No change to units GPC1324 48H21AB Amana Goodman Package Cooler 13 Seer horizontal cooling units Added interlock relay GPC1348H21BA Amana Goodman Package Cooler 13 Seer horizontal cooling units Changed from a 2 row condenser coil to a 1 row Amana Goodman Package Cooler 13 Seer horizontal cooling units Sound CPi nero Improvements Changed to 8 pole condenser motor and changed fan blade GPC1324H21AC GPC1348H21BB Amana Goodman Package Cooler 13 Seer horizontal cooling units Improve GPC1360H21AC Control Panel Fit by having 4 screws across the bottom in place of 3 screws GPC1330 42H21AD ACCESSORIES GPC GPH13 24 60 H21 PartNumber Description Fits Models Downflow Manual 2596 Fresh Air Damper Horizontal Motorized 2596 Fresh Air Damper Horizontal Fiter SQRPCH101 Horizontal Square to Round Adapter Small Chassis SQRPCH102 103 Horizontal Square to Round Adapter Med Large Chassis SQRPC101 Downflow Square to Round Adapter Small Chassis SQRPC102 103 Downflow Square to Round Adapter Med Large Chassis CDK1 2 Concentric Duct Kit Small Chassis CDK3 Concentric Duct Kit Med Large Chassis OT18 60A Outdoor Thermostat Required for heat pumps with outdoor ambient
36. ORE 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 being tested With power ON LINE VOLTAGE NOW PRESENT 24 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 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
37. OVER 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 30 This discharge can be ignited external to the compressor if the terminal cover is not properly in place and if the discharge impinges on a sufficient heat source Ignition of the discharge can also occur at the venting terminal or inside the compressor if there is sufficient contaminant air present in the system and an electrical arc occurs as the 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 heat
38. Service Instructions GPH13 PACKAGE HEAT PUMPS GPC13 PACKAGE COOLING HORIZONTAL MODELS 4 This manual is to be used by qualified professionally trained HVAC technicians RS6300009Rev 1 Good only Goodman does not assume any responsibility for property damage a personal injury due to improper service procedures or services performed by an November 2007 unqualified person Copyright 2007 Goodman Manufacturing Company L P IMPORTANT INFORMATIQN 4 PRODUCT IDENTIFICATION GPC GPH13 H21 6 7 P 8 PCCP101 103 ROOF CURB cen testes EE SEERNE AE ERS 9 101 103 DOWNFEOW PLENUM ce coat toe torte tnter tior den tenter tote 9 PCEF101 103 ELBOW AND FLASHING KIT nennen nenne nnne nnn inn nnne nina nnne nini nenne nnns 10 PCET101 103 ECONOMIZER KENEEN E ANERON NEENA AAAA KERNIE ONANAN ARENAN ANARE ARRAREN 10 PCMD101 103 DOWNFLOW MANUAL DAMPER 11 GPHMD101 103 HORIZONTAL MOTORIZED DAMPER WITH DUCT FLANGE eene enn 11 SQRPC SQUARE TO ROUND CONVERTER 12 SQRPCH SQUARE ROUND CONVERT
39. TY DAMAGE PERSONAL INJURY OR DEATH Checking EBTDR High Voltage Contacts 1 With power off remove wires from terminals NC COM and NO 2 Usinga VOM check for resistance from NO to COM Should read open Next check for resistance from NC to COM Should read closed 3 Ifnotas above replace EBTDR Checking EBTDR Contact Operation With power on LINE VOLTAGE NOW PRESENT 1 Setthe thermostat to the fan on position 2 Checkfor 24 volts atthe C and G terminals ofthe EBTDR 3 Ifno voltage present check fan circuit from thermostat If 24 volts present proceed to step 4 4 Using a VOM check for line voltage from the purple wire at the transformer terminal 3 on 240 volt units terminal 2 on 208 volt units to terminal NO on the EBTDR Should read line voltage If no voltage present check line voltage wiring in unit If line voltage present proceed to step 5 5 Using a VOM check for line voltage from the purple wire at the transformer terminal 3 on 240 volt units terminal 2 on 208 volt units to the COM terminal on the EBTDR Should read line voltage If not as above replace EBTDR 2 Thru 4 Ton Units AB Revision The 2 thru 4 ton AB revision model coolers and heat pumps have an isolation relay with a 240 volt holding coil in addition to the EBTDR DISCONNECT POWER SUPPLY BEFORE SERVICING Turn power off Testing relay holding coil 1 Remove the leads from the holding coil terminals 1 and 3
40. air duct The minimum filter area should not be less than those sizes listed in the Specification Section Under no circumstances should the unit be operated without return air filters 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 restrictor orifices These models use the FasTest Access Fitting System with a saddle that is either soldered to the suction and liquid lines or is fastened with a locking nut to the access fitting box core and then screwed into the saddle Do not remove the core from the saddle until the refrigerant charge has been removed Failure to do so could result in property dam age or personal injury The single phase units use permanent split capacitors PSC design compressors Starting components are therefore not required run capacitor assists the compressor to start and remains in the circuit during operation PRODUCT DESIGN The outdoor fan motor and the indoor blower motor are single phase capacitor type motors Air for condensing cooling is drawn through the outdoor coil by a propeller fan and is discharged vertically out the top of the unit The outdoor coil is designed for 0 static No addi tional restriction ductwork shall be applied Conditioned air is drawn through the filter s field installed
41. ameplate 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 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 2 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 unpainted tube on the compressor Do not use a low voltage output instrument such as a volt ohmmeter 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 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 S 17D OPERATION TEST Ifthe voltage capacitor overload and motor winding test fail to show the cause
42. codes or ordinances 48 MIN gt ho GPC GPH13 24 60 H21 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 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 14 Roof Curb and Platform GPC GPH13 24 60 H21 GPC GPH Package Units are designed for outdoor installa tions 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 Platform Roof Curb PCCP101 103 and Downflow Plenum PCP101 103 is recommended for horizon tal models only A return air filter must be installed behind the return air grille s or provision must be made for a filter in an accessible location within the return
43. compressor contactor If they are burned or pitted replace the contactor 7 Usinga halide or electronic leak detector check all piping and etc for refrigerant leaks 8 Checkthe combustion chamber Heat Exchanger for soot scale etc Inspect all burners for lint and proper position ing 9 Start the system using the proper instrumentation check gas inlet and manifold pressures burner flame and microamp signal Adjust if necessary 10 Start the system and run both a Cooling amp Heating Perfor mance Test If the results of the test are not satisfactory see the Service Problem Analysis Chart of the possible cause TEST EQUIPMENT Proper test equipment for accurate diagnosis is as essential as regular hand tools The following is a must for every service technician and service shop 1 Thermocouple type temperature meter measure dry bulb temperature 2 Sling psychrometer measure relative humidity and wet bulb temperature 3 Amprobe measure amperage and voltage 4 Volt Ohm Meter testing continuity capacitors and motor windings 5 Accurate Leak Detector testing for refrigerant leaks High Vacuum Pump evacuation Electric Vacuum Gauge Manifold Gauges and high vacuum hoses to measure and obtain proper vacuum 8 Accurate Electronic Scale measure proper refrigerant charge 9 Inclined Manometer measure static pressure and pres sure drop across coils Other recording type instruments
44. d 4 fthe 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 5 Evacuate the system to at least 29 inches gauge before opening valve to thermocouple vacuum gauge 34 6 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 7 If thermocouple vacuum gauge continues to rise and levels off at about 5000 microns moisture and non condensables are still present If gauge continues to rise a leak is present Repair and re evacuate 8 Close valve to thermocouple vacuum gauge and vacuum pump Shut off pump and prepare to charge 103 CHARGING Charge the system with the exact amount of refrigerant Refer to the specification section or check the unit nameplates for the correct refrigerant charge After completing airflow measurements and adjustments the unit s refrigerant charge must be checked The unit comes factory charged but this charge is based on 400 CFM per ton at minimum ESP per ARI test conditions generally between 15 25 ESP When air quantity or ESP is different than above charge must be adjusted to the proper amount All package units are charged to the superhea
45. d electric heat kit installed for heating If auxiliary electric heaters should be used they may be controlled by outdoor thermostats OT 18 60A or OT EHR18 60A GPC 2 thru 4 ton units A Revision Models With the thermostat set to the heat position and a call for heat R to W will be energized This will energize the electric heat sequencers When the normally open contacts of the heat sequencers close this will energize the electric resis tance heat and also the indoor blower motor through the nor mally closed contacts of the EBTDR GPC 2 thru 4 ton units AB Revision Models With the thermostat set to the heat position and a call for heat R to W will be energized This will energize the electric heat sequencers When the normally open contacts of the heat sequencers close this will energize the electric resis tance heat and also the 240 volt coil on the isolation relay in the control panel The normally open contacts of the isola tion relay will close energizing the indoor blower motor through the normally closed contacts of the EBTDR 17 SYSTEM OPERATION GPC 5 ton units A and AA Revision Models With the thermostat set to the heat position and a call for heat R to W will be energized This will energize the electric heat sequencers and the blower relay The electric heat will be energized through the normally open contacts of the elec tric heat sequencers The indoor blower will be energized through the normally open
46. e nsectCoi Cean 3 5 o K S 200 S 200 S 113 Blow er Speed Duct Static Press Filter Reduce Blow er Speed Recover Part of Charge Inspect Coil Clean Recover Charge Evacuate Recharge Remove Obstruction to Air Flow S 114 Check Blow er Speed Duct Static Press Filter Reduce Blow er Speed Recover Part of Charge Inspect Coil Clean Recover Charge Evacuate Recharge Remove Obstruction to Air Flow LI LI Lle jeje 1 4 1 Check Window s Doors Vent Fans Etc LI pet 1 Relocate Thermostat _ el lel _ Readjust Air Volume Dampers LLLI Refigure Cooingtoad Replace Compressor 6 L L 1 58 115 LI i Li 9 Test Compressor Efficiency 8 104 LI Lj pe fel ele Test Compressor Efficiency 58 104 eee eee e L ef fReplace Vale or Solenoid 521 122 LI e LI Lll Test Control 824 11 1 1 Test Defrost Thermostat 925 Check Flow rator amp Seat or Replace Flow rator 111 __ __ 14144 j j jeje Check Flow rator amp Seat or Replace Flow rator Cooling or Heating Cycle Heat Pump e Heating Cycle Only Heat Pump 2 Co SERVICING S 1 CHECKING VOLTAGE AQ WARNING HIGH VOLTAGE DISCONNECT ALL POWER BEF
47. e 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 A 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 ONCE A MONTH 1 Inspect the return filters of the evaporator unit and clean change if necessary NOTE Depending on operation conditions it may be necessary to clean the filters more often If permanent type filters are used they should be washed with warm water dried and sprayed with an adhesive according to manufacturers recommendations 2 When operating on the cooling cycle inspect the conden sate line piping from the evaporator coil Make sure the piping is clear for proper condensate flow ONCE A YEAR Qualified Service Personnel Only 1 Clean the indoor and outdoor coils 2 Clean the casing of the outdoor unit inside and out 3 Motors are permanently lubricated and do not require oil ing TO AVOID 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 connections are tight Inspect wire insulation to be certain that it is good 22 6 Check the contacts of the
48. erfor mance data in the Technical Manual for the specific unit 3 Take motor amperage draw to determine that the motor is not overloaded during adjustments 70777 mE lt lt 2 X So 2 RETURN E25 Checking Temperature Rise 39 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 YELLOW M ORANGE 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 qo od nd Ig J O ORANGE SEE NOTE 2 lt a a gt lt 2 o c ul lt lt ta gt c ul Q c a o 2 lt x z o a o E 25 lt i N E E 4 oc Za T Ex wo mo x o oz amp o a lt T OF oz HIGH VOLTAGE W WHITE BR BROWN BL BLUE OUTDOOR THERMOSTAT CLOSE ON TEMPERATURE FALL
49. esos 85 9 12 15 18 85 10 13 17 20 110 115 21 26 6 117125 30 33 37 Superheat aturated suction Suction Pressure Temperature R 22 35 SERVICING S 109 CHECKING SUBCOOLING Refrigerant liquid is considered subcooled whenever its tem perature is lower than the saturation temperature correspond ing to its pressure The degree of subcooling equals the de grees of temperature decrease below the saturation tempera ture at the existing pressure 1 Attach an accurate thermometer or preferably a thermo couple type temperature tester to the liquid line as it leaves the condensing unit 2 Installa high side pressure gauge on the high side service valve Record the gauge pressure and the temperature of the line 4 Convert the discharge pressure gauge reading to tempera ture by finding the gauge reading in Temperature Pres sure Chart and reading to the left find the temperature in the F Column 5 The difference between the thermometer reading and pres sure to temperature conversion is the amount of subcool ing EXAMPLE a Discharge Pressure 260 b Corresponding Temp F 120 c Thermometer on Liquid line 109 F To obtain the amount of subcooling subtract 109 F from 120 F The difference is 11 subcooling The normal subcooling range is 10 15 INDOOR LIQUID SUCTION E TEMP F PRESSURE PRESSURE t
50. for failure WARNING HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH 1 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 Ifthe compressor starts and continues to run the cause for failure is somewhere else in the system B Ifthe compressor fails to start replace 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
51. frost timing periods of 30 60 or 90 minutes may be selected by connecting the circuit board jumper to 30 60 or 90 respectively Accumulation of time for the timing period selected starts when the sensor closes approximately 31 F and when the room thermostat calls for heat At the end of the timing period the unit s defrost cycle will be initiated provided the sensor remains closed When the sensor opens approximately 75 F the defrost cycle is terminated and the timing period is reset If the de frost cycle is not terminated due to the sensor temperature aten minute override interrupts the unit s defrost period SYSTEM OPERATION FAN OPERATION Continuous Fan Mode A AB Revision 2 4 Ton and A AA Revision 5 Ton If the thermostat calls for continuous fan the indoor blower will be energized from the normally open contacts of the EBTDR after a 7 second delay on 2 thru 4 ton units or from the G terminal of the thermostat to the X13 blower motor on 5 ton units Anytime there is a call for continuous fan the indoor blower will be energized through the normally open contacts of the EBTDR on 2 thru 4 ton units and from the G terminal of the thermostat to the GE X13 motor on 5 ton units regardless of a call for heat or cool GPC GPH13 24 60 H21 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 a 65 second delay on
52. he 5 ton units 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 fan off delay GPC GPH13 24 60 H21 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 Heat Pump Models Any time the room thermostat is switched to cool the O terminal is energized This energizes the 24 volt coil on the reversing valve and switches it to the cooling position When the contacts of the room thermostat close this closes the circuit from R to Y and R to G in the unit This energizes the compressor contactor and will energize the indoor blower following the EBTDR 7 second fan on delay on 2 thru 4 ton units and instantly on 5 ton units with the GE X13 motor When the thermostat is satisfied it opens its contacts break ing the low voltage circuit causing the compressor contactor to open and indoor fan to stop after the EBTDR 65 second delay on 2 thru 4 ton units and after the programmed 60 second off delay on 5 ton units with the GE X13 motor 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 HEATING CYCLE Cooling Only Units NOTE The following only applies if the cooling only unit has an approve
53. he 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 bimetal element helping the thermostat call for the next cooling cycle This prevents the room temperature from rising too high before the system is restarted A properly sized anticipator should 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 25 SERVICING S 4 CHECKING TRANSFORMER AND CONTROL CIRCUIT
54. he 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 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 Your unit comes with a 180 second anti short cycle to prevent the compressor from starting and running backwards MODELS EQUIPPED WITH A HARD START DEVICE A start capacitor is wired in parallel with the run capacitor to increase the starting torque The start capacitor is of the 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 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
55. here replace C Open no reading replace Start capacitor would read resistor resistance 5 15 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 4 15 AMP FUSE AMMETER TESTING CAPACITANCE S 16 CHECKING MOTORS 16 CHECKING FAN AND BLOWER MOTOR WINDINGS PSC MOTORS The auto reset fan motor overload is designed to protect the motor against high temperature and high amperage conditions by breaking the common circuit within the motor similar to the compressor internal overload However heat generated within the motor is faster to dissipate than the compressor allow at least 45 minutes for the overload to reset then retest DISCONNECT POWER SUPPLY BEFORE SERVICING 1 Remove the motor leads from its respective connection points and capacitor if applicable 2 Checkthe continuity between each of the motor leads 3 Touch one probe of the ohmmeter to an unpainted end of the motor frame ground and the other probe in turn to each lead If the windings do not test continuous or a reading is obtained from any lead to ground replace the motor S 16D CHECKING GE X13 MOTORS The GE X13 Motor is a one piece fully encapsulated 3 phase brushless DC single phase
56. in the system NOTE Never use the system compressor as a vacuum pump or run when under a high vacuum Motor damage could occur 33 SERVICING 4 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 IN A DAMAGED OR FAILED COMPRESSOR R 22 f MANIFOLD 2 HIGH SIDE GAUGE ANDVALVE 7 LOW SIDE GAUGE AND VALVE 800 PSI RATED HOSES CHARGING CYLINDER AND SCALE VACUUM PUMP TO ADAPTER UNIT SERVICE VALVE PORTS VACUUM PUMP AU 1 Connectthe vacuum pump vacuum tight manifold set with high vacuum hoses thermocouple vacuum gauge and charg ing cylinder as shown 2 Ifthe service dill valves are to be used for evacuation it is recommended that a core remover be used to lift the core for greater efficiency 3 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 contaminate
57. inuous replace the relay or con tactor 26 S 8 CHECKING CONTACTOR CONTACTS DISCONNECT POWER SUPPLY BEFORE SERVICING SINGLE PHASE 1 Disconnect the wire leads from the terminal T side of the contactor 2 With power ON energize the contactor LINE VOLTAGE NOW PRESENT VOLT OHM UR for testing coil Voltmeter for 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 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 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 the same as in A replace contactor SERVICING Ohmmeter for testing holding coil Voltmeter for testing contacts TESTING COMPRESSOR CONTACTOR Three phase S 9 CHECKING FAN RELAY CONTACTS 2 Thru 4 Ton Units The Electronic Blower Time Delay Relay is used on the 2 thru 4 ton units 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 PROPER
58. m the bearing surfaces causing premature bearing failure Compliant Scroll compressors use white oil which is com patible with 3GS 3GS oil may be used if additional oil is required Compliant scroll compressors perform quiet shutdowns that allow the compressor to restart immediately without the need for a time delay This compressor will restart even if the system has not equalized NOTE Operating pressures and amp draws may differ from standard reciprocating compressors This information can be found in the unit s Technical Information Manual INDOOR BLOWER MOTOR Some GPC GPH model package units use a GE X13 blower motor while others use the standard PSC type blower motor The GE X13 motor is a 3 Phase brushless DC single phase AC input ball bearing construction motor with an integral con trol 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 statin the cooling and heat pump mode and the blower relay in the electric heat mode GE X13 Motor ELECTRICAL WIRING The units are designed for operation at the voltages and hertz as shown on the rating plate All internal wiring is complete Ensure the power supply to the compressor contactor is brought to the unit as shown on the supplied unit wiring diagram The 24V wiring must be connected between the unit control panel and the room thermostat
59. on 2 thru 4 ton units and after the pro grammed 60 second off delay on 5 ton units with the GE X13 motor When auxiliary electric heaters are used a two stage heat ing single 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 OT 18 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 18 GPC GPH13 24 60 H21 GPC 2 thru 4 ton units A Revision Models 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 When the normally open contacts of the heat sequencers close this will ener gize the electric resistance heat and also the indoor blower motor through the normally closed contacts of the EBTDR GPH 2 thru 4 ton units AB Revision Models 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 When the normally open contacts of
60. r is connected for 230V operation If the unit is to operate on 208V reconnect the transformer primary lead as shown on the unit wiring diagram If it is necessary for the installer to supply additional line 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 SYSTEM OPERATION COOLING The refrigerant used in the system is R 22 Itis clear color less non toxic non irritating and non explosive liquid The chemical formula is CHCLF The boiling point at atmospheric pressure is 41 4 F A few of the important principles that make the refrigeration cycle possible are heat always flows from a warmer to a cooler body under lower pressure a refrigerant will absorb heat and vaporize at a low temperature the vapors may be drawn off and condensed ata higher pressure and tempera ture to be used again The indoor evaporator coil functions to cool and dehumidify the air conditioned spaces through the evaporative process taking place within the coil tubes NOTE Actual temperatures and pressures are to be obtained from the expanded ratings in the Technical Information Manual High temperature high pressure vapor leaves the compres sor through the discharge line and enters the condenser coil Air drawn through the condenser coil by the condenser fan cau
61. s 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 5 114 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 Evacuate and recharge S 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 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
62. s 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 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 the leads from the compressor terminals 4 amp WARNING SEE WARNINGS 17 BEFORE REMOVING COMPRES SOR TERMINAL COVER 2 Using an ohmmeter test continuity between terminals S and C S on single phase units or terminals T1 T2 and T3 on 3 phase units SERVICING 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 S 17B GROUND TEST If fuse circuit breaker ground fault protective device etc has tripped this is a strong indication that an electrical problem exists and must be found and corrected The circuit protective device rating must be checked and its maximum rating should coincide with that marked on the equipment n
63. ses the refrigerant to condense into a liquid by removing heat from the refrigerant As the refrigerant is cooled below its condensing temperature it becomes subcooled The subcooled high pressure liquid refrigerant now leaves the condenser coil via the liquid line until it reaches the indoor expansion device As the refrigerant passes through the expansion device and into the evaporator coil a pressure drop is experienced caus ing the refrigerant to become a low pressure liquid Low pres sure saturated refrigerant enters the evaporator coil where heat is absorbed from the warm air drawn across the coil by the evaporator blower As the refrigerant passes through the last tubes of the evaporator coil it becomes superheated that is it absorbs more heat than is necessary for the refrig erant to vaporize Maintaining proper superheat assures that liquid refrigerant is not returning to the compressor which can lead to early compressor failure Low pressure superheated vapor leaves the evaporator coil and returns through the suction line to the compressor where the cycle begins again COOLING CYCLE Cooling Only Models When the contacts of the room thermostat close making terminals R to Y and R to G the low voltage circuit to the contactor is completed starting the compressor and outdoor fan motor This also energizes the indoor blower through the normally open contacts of the EBTDR on 2 thru 4 ton units and through the blower relay on t
64. ses this con stitutes a poorly designed system To determine proper air movement proceed as follows 1 Using a draft gauge inclined manometer measure the static pressure of the return duct atthe inlet of the unit Negative Pressure e g A EN 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 so the less air CFM being delivered the greater the rise The temperature rise should be adjusted in accordance to a given unit specifications and its external static pressure 1 Take entering and leaving air temperatures 2 Select the proper speed tap from the unit s blower p
65. stub If the oil is not acidic either a burnout has not occurred or the burnout is so mild that a complete cleanup is not necessary If acid level is unacceptable the system must be cleaned by using the drier cleanup method 37 SERVICING d CAUTION DO NOT ALLOW THE SLUDGE OR OIL TO CONTACT THE SKIN SEVERE BURNS MAY RESULT Suction Line Drier Clean up Method Discard at least twelve 12 inches of the suction line immedi ately out of the compressor stub due to burned residue and contaminates 1 Remove compressor discharge line strainer liquid line strainer and or drier and capillary tubes from indoor and outdoor coils 2 Units with an expansion valve coil remove the 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 liner drier Install suction line drier Braze all joints leak test evacuate and recharge system Start up the unit and record the pressure drop across the cleanup drier 8 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 8 PSIG 9 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 8 PSIG the drier must be adequate and is trapping the contaminants and it is permissible to leave it in
66. t method at the compressor suction line these are fixed orifice devices For charging in the warmer months 10 F superheat at the com pressor is required at conditions 95 F outdoor ambient dry bulb temperature 80 F dry bulb 67 F wet bulb indoor ambi ent approximately 50 humidity This superheat varies when conditions vary from the conditions described A superheat charge chart is available for other operating condi tions Use itto provide the correct superheat at the conditions the unit is being charged at After superheat is adjusted it is recommended to check unit sub cooling at the condenser coil liquid line out In most oper ating conditions 10 15 F of sub cooling is adequate An inaccurately charged system will cause future problems 1 Using a charging scale allow liquid refrigerant 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 DO NOT charge in a liquid form 4 With the system still running close the valve on the charg ing manifold At this time you may still have some liquid refrigerant in the charging manifold and will definitely have liquid in the liquid hose Reseatthe liquid line core Slowly open the high side manifold valve and transfer the liquid refrigerant from the liquid line hose and charging manifold into the suction ser
67. the local power company in regards to either low or high voltage Unit Supply Voltage Voltage 460 208 230 Three phase units require balanced 3 phase power supply to operate If the percentage of voltage imbalance 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 SERVICING 2 CHECKING WIRING 4 WARNING HIGH VOLTAGE DISCONNECT ALL POWER BE
68. 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 SERVICING S 15A RESISTANCE CHECK 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 2 Set an ohmmeter on its highest ohm scale and connect the leads to the capacitor A Good Condition indicator swings to zero and slowly returns to infinity Start capacitor will bleed resistor will not return to infinity It will still read the resistance of the resistor B Shorted indicator swings to zero and stops t
69. to the low side through the fixed orifice restriction device Check equalization time as follows 1 Attach a gauge manifold to the suction and liquid line dill valves 2 Start the system and allow the pressures to stabilize 3 Stop the system and check the time it takes for the high and low pressure gauge readings to equalize If it takes more than seven 7 minutes to equalize the restric tion device is inoperative Replace install a liquid line 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 restriction 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 Evaporator coils with a fixed orifice metering device could allow refrigerant to return to the compressor under extreme overcharge conditions If high head pressure is not indicated an overcharge or a sys tem containing non condensable
70. utside the U S call 1 713 861 2500 Not a technical assistance line for dealers Your telephone company will bill you for the call IMPORTANT INFORMATION SAFE REFRIGERANT HANDLING While these items will not cover every conceivable situation they should serve as a useful guide 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 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 TECHNICIAN MUST PERFORM THE INSTALLATION AND SERVICE OF THIS PRODUCT SHOULD QUESTIONS ARISE CONTACT YOUR LOCAL EPA OFFICE VIOLATIONS O
71. vice valve port CAREFUL Watch so that liquid refrigerant does not enter the compressor 5 With the system still running reseat the suction valve core remove hose and reinstall both valve core caps 6 Check system for leaks Units having flow control restrictors can be checked against the Desired Superheat vs Outdoor Temperature Chart in this section SERVICING 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 Start the system and run a Cooling Performance Test If the test shows Below normal high side pressure Above normal low side pressure Low temperature difference across coil Lowamp draw at compressor and the charge is correct The compressor is faulty replace the compressor 108 SUPERHEAT CHECKING SUPERHEAT Refrigerant gas is considered superheated whenever its tem perature is higher than the saturation temperature correspond ing to its pressure The degree of superheat equals the de grees of temperature increase above the saturation tempera ture at existing pressure See Temperature Pressure Chart 1 Attach an accurate thermometer or preferably a thermo

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