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APG15 Service Man

1. a 15 8 lt 1 3 8 mos a s c RETURN su DOWNFLOW FILTER RACK PGFR101 102 103 E i s f i a p i 3 2 Bs 1 ls 26 1 2 Filter Size 14 x 25 x 2 Measurement in inches NOTE PGFR cannot be used with downflow economizers ACCESSORIES PGED103 DOWNFLOW ECONOMIZER PGED103 A B 16 18 14 X 25 FILTER ATTACHMENT 16 X 20 x 2 FILTER 16 X 20 MIST ELIMINATOR ECONOMIZER HORIZONTAL APPLICATIONS Measurement in inches ACCESSORIES MOTORIZED MANUAL FRESH AIR DAMPERS DOWNFLOW APPLICATIONS _ B 4 7 5 8 Y 5 3 4 41 7 8 wont Jr MOTORIZED MANUAL FRESH AIR DAMPERS HORIZONTAL APPLICATIONS BOTTOM VIEW 5 3 4 CUM 7 8 B BOTTOM VIEW ET C41 7 8 gt 5 oe Cmos LA LE ACCESSORIES SQUARE TO ROUND CONVERTER DOWNFLOW APPLICATIONS be 12 1 4 gt A 143 4 c C gt A qp E 4 E Bi c S ID z2m4 19 22 1 4 TM VA F No p A R Y LA E E 7 a 12 1 4 d e 14 3 4 dl Y j PO d FUN N a B 22 3 4 180 22 1 4 180 Y 4 E
2. Ifthe vacuum pumpis 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 valveonthe charging cylinder closed openthe manifold valve to the cylinder Evacuate the system to atleast 29 inches gauge before opening valve to thermocouple vacuum gauge Continue to evacuate to a maximum of 250 microns Close valve to vacuum pump and watch rate of rise If vacuum does not rise above 1500 microns in three to five minutes system can be considered properly evacuated If thermocouple vacuum gauge continues to rise and levels off at about 5000 microns moisture and non condensables are still present If gauge continuesto rise aleakis present Repair and re evacuate Closevalvetothermocouple vacuum gauge and vacuum pump Shut off pump and prepare to charge SERVICING S 103 CHARGING 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 CAUTION Use refrigerant certified to ARI standards Used refrigerant may cause compressor damage and will void the warranty Most portable machines cannot clean used refrigerant to meet ARI standards CAUTION Operating the compressor with the suction valve closed will void the warranty an
3. Voltmeter for testing contacts TESTING COMPRESSOR CONTACTOR Single Phase 3 Using a voltmeter test across terminals A L1 L2 Novoltage Check breaker orfuses on main power supply B L2 T1 No voltage indicates CC1 contacts open If a no voltage reading is obtained replace the contactor 33 SERVICING THREE PHASE Using a voltmeter test across terminals A L1 L2 L1 L3 and L2 L3 If voltage is present proceedtoB If voltage is not present check breaker or fuses on main power supply B T1 T2 T1 T3 and T2 T3 If voltage readings are not the same as in A replace contactor Ohmmeter for testing holding coil Voltmeter for testing contacts TESTING COMPRESSOR CONTACTOR ThreePhase S 9 CHECKING FAN RELAY CONTACTS The fan relays are incorporated into the control board See section S 313 for checking control board S 12 CHECKING HIGH PRESSURE CONTROL WARNING HIGH VOLTAGE Disconnect ALL power before servicing or installing this unit Multiple power sources may be present Failure to do so may cause property damage personal m or death The high pressure control senses the pressure in the liquid line If abnormally high condensing pressures develop the contacts of the control open breaking the control circuit before the compressor motor overloads This control is automatically reset 1 Using an ohmmeter check across terminals of high pressure control with wire remo
4. 15 PRODUCT DESIGN NOTE In b and c the connector or tubing must be installed so as to be protected against physical and thermal damage Aluminum alloy tubing and connectors must be coated to protect against external corrosion where they are in contact with masonry plaster or insulation or are subject to repeated wettings by such liquids as water except rain water detergents or sewage MANUAL SHUT OFF VALVE N DRIP LEG _ GROUND JOINT UNION INSTALLED AHEAD OF GAS VALVE Pd GROMMET NOTE The unit gas supply entrance is factory sealed with plugs Keep plugs in place until gas supply is ready to be installed Once ready replace the plugs with the supplied grommets and install gas supply line CHECKING THE GAS PIPING 4h CAUTION TO AVOID THE POSSIBILITY OF PROPERTY DAMAGE PERSONAL INJURY OR FIRE THE FOLLOWING INSTRUCTIONS MUST BE PERFORMED REGARDING GAS CONNECTIONS AND PRESSURE TESTING The unit and its gas connections must be leak tested before placing in operation Because of the danger of explosion or fire never use a match or open flame to test for leaks Never exceed specified pressure for testing Higher pressure may damage the gas valve and cause overfiring which may result in heat exchanger failure This unit must be isolated from the gas supply system by closing its individual
5. 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 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 imbalance lies within the incoming power supply Ifthe imbalance had not changed then the problem would lie within the equipment Check for current leakage shorted motors etc 31 SERVICING S 2 CHECKING WIRING WARNING HIGH VOLTAGE Disconnect ALL power before servicing or installing this unit Multiple power sources may be present Failure to do so may cause property damage personal m or death 1 Check wiring visually for signs of overheating damaged insulation and loose connections 2 Use an ohmmeter to check continuity of any suspected open wires 3 Ifany wires must be replaced replace with comparable gauge and insulation thickness S 3 CHECKING THERMOSTAT WIRING AND ANTICIPATOR THERMOSTAT WIRE SIZING CHART MIN COPPER WIRE LENGTH OF RUN GAUGE AWG 25 eat S 3A THERMOSTAT AND WIRING Eu WARNING DT Line Voltage now present With power ON thermostat calling for cooling 1 Usea voltmeter to
6. Cracked Heat Exchanger Stuck Gas Valve Check Burner Flames Replace Gas Valve Furnace Undersized Replace with Proper Size Furnace Faulty Pressure Switch Test Pressure Switch Blocked or Restricted Flue Check Flue Drawdown Pressure Open Roll Out Switch Bouncing On Pressure Switch Test Control S 302 Test Negative Pressure S 310 29 SERVICING S 1 S 2 S 3 S 3A S 3B S 3C S4 S 7 S 8 S 9 S 12 S 13 S 15 S 15A S 15B S 16A S 16D S 17 S 17A S 17B S 17C S 17D S 18 S 100 S 101 S 102 S 103 30 Table of Contents Checking Voltage 2m eicere 31 Checking Wiring eene 32 Checking Thermostat Wiring amp Anticipator 32 Thermostat amp Wiring 32 Cooling Anticipator sseeseees 32 Heating Anticipator 32 Checking Transformer amp Control Circuit 33 Checking Contactor and or Relays 33 Checking Contactor Contacts 33 Checking Fan Relay Contact 34 Checking High Pressure Control 34 Checking Low Pressure Control 34 Checking Capacitor ssssesssss 34 Resistance Check 35 Capacitance Check 35 Checking Fan amp Blower Motor Windings PSC Motors 36 Chec
7. Induced draftbloweris energized athigh speed for the pre purge period Pre purge timer begins after control recognizes pressure switch has closed Trial for ignition period begins after pre purge period expires Low and high stage gas valves are energized along with the igniter for trial for ignition period Igniter is de energized when flame is detected Flameis achieved and detected during trial for ignition period Flame stabilization period begins when flame is detected Gas valve and induced draft blower remain at high stage and high speed Air circulating blower is energized at high heat speed after heat ON delay time expires Heat ON delay timer begins when flame is detected 10 11 12 13 Control monitors thermostat flame limit and pres sure switch inputs during high stage heating Thermostat W1 and W2 inputs are removed High and low stage gas valves are de energized Induced draft blower switches from high speed to low speed and remains energized for post purge period Air circulating blower remains energized at high heat speed for High Stage Heat OFF Delay period then Switches to low heat speed for the remainder of the selected heat OFF delay Heat OFF delay begins when W1 and W2 inputs are removed Control returns to Standby and awaits next thermostat request 19 SYSTEM OPERATION A Cooling Operation Low stage cool 10 11 Thermostat type is set to two stage Thermos
8. 200 10 22 41 69 106 58 120 227 465 697 PROPANE TANK SIZING MINIMUM 250 o 1 s o o st 107 201 412 618 ZE REQUIRED IF LOWEST OUTDOOR 300 8 18 33 55 85 46 97 182 374 560 MAXIMUM GAS TEMPERATURE AVG FOR 24 HOURS REACHES 350 7 16 30 91 78 48 89 167 344 515 NEEDED TO 400 7 15 28 47 73 40 83 156 320 479 VAPORIZE DATA IN ACCORDANCE WITH NFPA PAMPHLET NO 54 125K BTU HR 50 CFH 250K BTU HR COOLING 100 CFH 375K BTU HR The refrigerant used in the system is R 410A It is a clear 150 CFH colorless non toxic and non irritating liquid R 410A is a 500K BTU HR 50 50 blend of R 32 and R 125 The boiling point at atmo 200 CFH spheric pressure is 62 9 F 750K BTU HR 300 CFH A few of the important principles that make the refrigeration AVERAGE RATE HOUR WITHDRAWL IN 8 HOUR PERIOD cycle possible are heat always flows from a warmer to a cooler body Under lower pressure a refrigerant will absorb heat and vaporize at alow 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 17 SYSTEM OPERATION NOTE The pressures and temperatures shown in the refrigerant cycle illustrations on the following pages are for demonstration purposes only Actual temperatures and pres sures are to be obtained
9. 6 6 6 6 6 158 0 260 0 362 0 109 464 0 128 592 0 160 0 262 0 364 0 110 466 0 128 596 0 162 0 264 0 366 0 110 468 0 129 600 0 268 0 608 0 270 0 612 0 272 0 616 0 274 0 620 0 276 0 624 0 278 0 628 0 280 0 632 0 282 0 l 636 0 284 0 640 0 286 0 644 0 288 0 648 0 290 0 652 0 292 0 656 0 204 0 660 0 296 0 664 0 298 0 668 0 300 0 l 672 0 302 0 676 0 304 0 680 0 306 0 684 0 308 0 688 0 310 0 692 0 312 0 696 0 314 0 316 0 Based on ALLIED SIGNAL Data 2 4 6 2 4 156 0 4 258 0 360 0 109 462 0 128 588 0 6 2 4 6 2 2 F 37 38 39 0 1 l 3 3 5 7 7 8 9 50 51 51 52 53 l 54 54 55 56 57 l 266 0 604 0 58 i 59 l 59 0 1 1 3 3 l 5 5 7 7 68 E 68 69 l 70 f 70 71 72 l 72 73 3 42 SERVICING S 106 OVERFEEDING Overfeeding by the expansion valve results in high suction pressure cold suction line and possible liquid slugging of the compressor If these symptoms are observed 1 Check for an overcharged unit by referring to the cooling performance charts in the servicing section 2 Checkthe operation of the power elementin the valve as explained in S 110 Checking Expansion Valve Opera tion 3 Check for restricted or plugged equalizer tube S 107 UNDERFEEDING Underfeeding by the expansion valve results in low system capacity and low suction pressures If the
10. housing and maintains the pressure tight integrity of the hermetic compressor The terminals and their dielectric embedmentare strongly constructed but are vulnerable to careless compressor installation or maintenance proce dures and equally vulnerable to internal electrical short circuits caused by excessive system contaminants Ah WARNING To avoid possible explosion Never apply flame or steam to a refrigerant cylinder If you must heat a cylinder for faster charging partially immerse it in warm water Never fill a cylinder more than 80 full of liquid refrigerant Never add anything other than R 22 to an R 22 cylinder or R 410A to an R 410A cylinder The service equipment used must be listed or certified for the type of refrigerant used Store cylinders in a cool dry place Never use a cylinder as a platform or a roller A WARNING To avoid possible explosion use only returnable not disposable service cylinders when removing refrig erant from a system Ensure the cylinder is free of damage which could lead to a leak or explosion Ensure the hydrostatic test date does not exceed 5 years Ensure the pressure rating meets or exceeds 400 Ibs When in doubt do not use cylinder In either of these instances an electrical short between the terminal and the compressor housing may result in the loss of integrity between the terminal and its dielectric embed ment This lo
11. l eau m me partiellement Faire inspecter l appareil par un technicien qualifi et remplacer toutr partie du Syst me de contr le et toute commande qui ont t plong es dans l eau BN OPERATING INSTRUCTIONS 1 STOP Read the safety information above on this label 2 Set the thermostat to lowest setting 3 Turn off all electric power to the appliance 4 This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand 5 Push the gas control lever to grp Position Do not force 6 Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you then smell gas STOP Follow B in the safety information above on this label if you don t smell gas go to next step 7 Push gas control lever INET to ON 8 Replace access panel 9 Turn on all electric ARRIVEE power to the appliance DU GAZ 10 Set thermostat to desired setting 11 If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas company IN ON MANUAL GAS LEVER SHOWN EEE c CCE NN 1 v ROBINET A GAZ MANUEL ON MARCHE EN POS R gler le thermostat la temp rature la plus basse Couper l alimentation lectrique de l appareil Cet appareil menager etant dote d un systeme pousse le levier du contr le du g
12. specific gravity ofthe gas and length ofthe run The gas line installation must comply with local codes or in the absence of local codes with the latest edition of the National Fuel Gas Code ANSI 2223 1 NATURAL GAS CAPACITY OF PIPE IN CUBIC FEET OF GAS PER HOUR CFH LENGTH OF NOMINAL BLACK PIPE SIZE PIPE IN FEET wan sa 1 aaa 1 112 CFH BTUH FURNACE INPUT CALORIFIC VALUE OF GAS CONNECTING THE GAS PIPING NATURAL GAS 1 Use black iron or steel pipe and fittings for the building piping 2 Usepipejointcompound on male threads only Pipe joint compound must be resistant to the action ofthe fuel used Use ground joint unions Kw Install a drip leg to trap dirtand moisture before it can enter the gas valve The drip leg must be a minimum of three inches long 5 Use two pipe wrenches when making connection to the gas valve to keep it from turning 6 Install a manual shut off valve This shut off valve should be conveniently located within six 6 feet of the unit and between the meter and unit 7 Tighten all joints securely 8 Connect the unit to the building piping by one of the following methods a Rigid metallic pipe and fittings b Semi rigid metallic tubing and metallic fittings Aluminum alloy tubing shall notbe used in exterior locations C Listed gas appliance connectors used in accor dance with the terms of their listing that are completely in the same room as the equipment
13. 000 volt spark to ignite the burners A flame sensor is used to monitor the flame The board has the option of using a single or two stage ther mostat The board also controls the indoor blower and has an adjustable heat fan off delay There is also a fault recall button for recalling the last 5 fault codes To recall the fault codes depress the fault recall but ton for at least 2 seconds but not more than 4 seconds To clear the fault code memory depress the fault recall button for at least 5 seconds The following tables list the functions for the connectors and terminals the timings and the fault codes for the PCBAG100 control board WARNING HIGH VOLTAGE Disconnect ALL power before servicing or installing this unit Multiple power sources may be present Failure to do so may cause property damage personal m or death Hu INDUCER L1 ODF 3 O A D LOW HIGH a Low HIGH PARK Ko FS K3 K5 T2 x c9 ET No DA y J O Ut po Y2 P E NA y Ad gt LAN A NO Nec A U6 5 le Lan 4 U7 AN 3 LO EN U4 2 s A 1 A K2 U5 a K1 PN J ts ESTES Nae SA y JO dd go C SPEED UP 150 NONE F1 NAN CANIN AN CNN CB 120 7 5 MIN KUZK J Ku TA Ku RU RU KT sm O 90 10MIN AN SEANS EAEAN EASE c FAULT BLOWER STAGE ECON RECALL OFF DE
14. Instructions for proper curb installation Curbing mustbe installed in compliance with the National Roofing Contractors Association Manual Lower unit carefully onto roof mounting curb While rigging unit center of gravity will cause condenser end to be lower than supply air end NOTE A roof curb can be used to utilize bottom discharge APG GPG Package Units are designed for outdoor installa tions only in either residential or light commercial applica tions PRODUCT DESIGN A 3 4 14 NPT drain connector is provided for removal of condensate water from the indoor coil In order to provide proper condensate flow do not reduce the drain line size Refrigerant flow control is achieved by use of thermostatic expansion valves TXV 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 PG15 Package Gas Units are designed for outdoor installa tions only in either residential or light commercial applica tions and are available in 2 3 4 amp 5 ton sizes They are designed for 208 230 volt single phase applications The connecting ductwork Supply and Return can be con nected for either horizontal or vertical airflow In the vertical application a matching Roof Curb is recommended Areturn air filter must be installed behind the return air grille s
15. ON delay expires Cool ON delay timer begins when thermostat inputs are detected Control monitors thermostat gas valve flame and IDT ODT Pressure Loss of Charge Switches during high stage cooling operation Thermostat Y 1 and Y2 or Y1 Y2 and G inputs areremoved Low and high stage compressor outputs are de energized High speed condenser fan motor is de energized Air circulating blower switches to low cool speed for the cool OFF delay Cool OFF delay timer begins when thermostat input is removed Control returns to Standby and awaits next thermostat request A Continuous Fan Operation 1 Thermostat G input initiates Continuous Fan opera tion Air circulation blower shall be immediately energized at the continuous fan speed For purposes of this specification the continuous fan speed shall be the low heat speed Thermostat G input is removed Air circulation blower is immediately de energized Control returnsto Standby and awaits next thermostat request SYSTEM OPERATION Typical Package Cooling or Package Gas Indoor Coil Outdoor Coil Thermostatic Expansion Valve 21 SYSTEM OPERATION PCBAG100 CONTROL BOARD DESCRIPTION The ignition control is designed for use in gas heating electric cooling package equipment rooftop applications and oper ates with a two stage heat and two stage cooling system It is adirect spark ignition system that uses a 22
16. a restriction should become evident proceed as follows 1 Recoverrefrigerant charge 2 Remove the orifice or tube strainer assembly and re place 3 Replace liquid line drier evacuate and recharge CHECKING EQUALIZATION TIME During the OFF cycle the high side pressure bleeds to the low side through the fixed orifice restriction device Check equalization time as follows 1 Attach a gauge manifold to the suction and liquid line dill valves 2 Start the system and allow the pressures to stabilize 3 Stop the system and check the time it takes for the high and low pressure gauge readings to equalize If it takes more than seven 7 minutes to equalize the restrictor device is inoperative Replace install a liquid line drier evacuate and recharge 45 SERVICING S 112 CHECKING RESTRICTED LIQUID LINE When the system is operating the liquid line is warm to the touch If the liquid line is restricted a definite temperature drop will be noticed atthe point of restriction In severe cases frost will form atthe restriction and extend down the line inthe direction of the flow Discharge and suction pressures will be low giving the appearance of an undercharged unit However the unit will have normal to high subcooling Locate the restriction replace the restricted part replace drier evacuate and recharge S 113 OVERCHARGE OF REFRIGERANT An overcharge of refrigerant is normally indicated by an excessively hi
17. 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 43 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 44 L 8 Jj 45D ee 16 fe e 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 REQUIRED SUBCOOLING TEMPERATURE F 100 102 104 106 108 110 112 114 116 118 120 122 124 126 100 102 104 106 108 110 112 114 116 118 120 122 124 100 102 104 106 108 110 112 114 116 118 120 122 100 102 104 106 108 110 112 114 116 118 120 SERVICING S 109 CHECKING SUBCOOLING Refrigerantliquid is considered subcooled when its tempera ture is lowerthanthe saturation temperature corresponding toits pressure The degree ofsubcooling equals the degrees oftemperature decrease below the saturation temperature at the existing pressure 1 Attachanaccurate thermometer or preferably a thermo couple type temperature tester to the liquid line close to the pressure switch 2 Installahighside pressure gauge onthe high side liquid Service valve atthe front of the unit 3 Record the gauge pressure and the t
18. atintegrated ignition control module 2 Usingand ohmmeter testfor continuity between each of the motor leads 3 Touch one probe of the ohmmeter to the motor frame ground and the other probe in turn to each lead Ifthe windings do nottest continuous ora reading is obtained to ground replace the motor 4 After completing check and or replacement of induced draft blower motor 5 Turnonelectrical power and verify proper unit operation S 304 TESTING GAS VALVE Direct Spark Ignition DSI Systems A two stage combination redundant operator type gas valve which provides all manual and automatic control functions required for gas fired heating equipment is used The valve provides control of main burner gas flow pressure regulation and 100 percent safety shut off WARNING HIGH VOLTAGE Disconnect ALL power before servicing or installing this unit Multiple power sources may be present Failure to do so may cause property damage personal m or death 1 Ensure gas valve and main gas supply are on 2 Usingavoltmeter check from C and M on gas valve for 24 volts to gas valve 3 If24 volts are presentand no gas flows through the valve replace valve 50 Gas Valve On Off Switch Inlet Pressure Outlet Pressure Tap WIR 36G54 238 WHITE ROGERS MODELS 36F amp 36G GAS VALVES S 305 CHECKING MAIN BURNERS The main burners are used to provide complete
19. avoid personal injury or death due to electric shock wiring to the unit must be properly grounded Disconnect power before installing or servicing 2 INDUCER i ODF m O apri lt 7 LOW HIGH Low HIGH PARK we Bu Le MN 1 Je Lo KEY jJ v FS Il Ro Ke T2 A ca No A F po LD y ut po U J mE CK 25 PNL NC AE Bla AO 180 a zx SPEED UP 150 NONE F1 NAN AN EN ANNE AN aaa E eyes ESPESSO mlO a o MIN o 5 ARR RIRE RE RU Ny FAULT BLOWER STAGE ECON R C W1W2 G Y1Y2 RECALL OFF DELAY DELAY DSI Control Board 53 SERVICING Testing Direct Spark Ignition DSI Systems Heating Mode Indoor thermostat calling for heat 15 second prepurge time and 7 second trial for ignition 1 Check for 230 volts from L1 terminal of control module to L2 No voltage check wire connections continuity etc 2 Check for 24 volts at R to C thermostat terminals a d No voltage check 3 amp automotive type fuse on control board A blown fuse could indicate a short in the 24 volt circuit thermostat or limit circuit Voltage Present check limit and rollout S 301 and S 302 If limit and rollout are closed then check for 24 VAC at the gas valve terminals No 24 VAC at gas valve check 9 pin connector and wires from ignition contro
20. check for 24 volts at thermostat wires C and Y in the condensing unit control panel 2 No voltage indicates trouble in the thermostat wiring or external transformer source 3 Check the continuity of the thermostat and wiring Repair or replace as necessary Indoor Blower Motor With power ON Hm WARNING DD Line Voltage now present 1 Setfan selector switch at thermostat to ON position 32 2 With voltmeter check for 24 volts at wires C and G 3 No voltage indicates the trouble is in the thermostat or wiring 4 Checkthe continuity ofthe thermostat and wiring Repair or replace as necessary S 3B COOLING ANTICIPATOR The cooling anticipator is a small heater resistor in the thermostat During the off cycle it heats the bimetal element helping the thermostat call for the next cooling cycle This prevents the room temperature from rising too high before the system is restarted A properly sized anticipator should maintain room temperature within 1 1 2 to 2 degree range The anticipator is supplied in the thermostat and is notto be replaced If the anticipator should fail for any reason the thermostat must be changed S 3C HEATING ANTICIPATOR The heating anticipator is a wire wound adjustable heater which is energized during the ON cycle to help prevent overheating ofthe conditioned space The anticipator is a part of the thermostat and if it should fail for any reason the thermostat must be replaced
21. in the system If not captured by the refrigerant filter they will collect in the compressor or other system components causing a failure of the replacement compressor and or spread contaminants throughout the system damaging additional components Use part number RF000127 suction line filter drier kit This drier should be installed as close to the compressor suction fitting as possible The filter must be accessible and be rechecked for a pressure drop after the system has operated for a time It may be necessary to use new tubing and form as required NOTE At least twelve 12 inches of the suction line immediately out of the compressor stub must be discarded due to burned residue and contaminates 1 Remove compressor discharge line strainer 2 Removethe liquid line drier and expansion valve 3 Purge all remaining components with dry nitrogen or carbon dioxide until clean 4 Install new components including liquid line drier 5 Braze all joints leak test evacuate and recharge sys tem SERVICING 6 Startup the unit and record the pressure drop across the drier 7 Continue to run the system for a minimum of twelve 12 hours and recheck the pressure drop across the drier Pressure drop should not exceed 6 PSIG 8 Continue to run the system for several days repeatedly checking pressure drop across the suction line drier If the pressure drop never exceeds the 6 PSIG the drierhas trapped the contaminants Remov
22. manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 psig 3 48 kPa 16 TANKS AND PIPING PROPANE UNITS 4h WARNING PERSONAL INJURY HAZARD IRON OXIDE RUST CAN REDUCE THE LEVEL OF ODORANT IN PROPANE GAS A GAS DETECTING DEVICE IS THE ONLY RELIABLE METHOD TO DETECT A PROPANE GAS LEAK CONTACT YOUR LOCAL PROPANE SUPPLIER ABOUT INSTALLING A GAS DETECTING WARNING DEVICE TO ALERT YOU IN THE EVENT THAT A GAS LEAK SHOULD DEVELOP FAILURE TO DETECT A PROPANE GAS LEAK COULD RESULT IN AN EXPLOSION OR FIRE WHICH COULD CAUSE SERIOUS PERSONAL INJURY OR DEATH All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters See NBFU Manual 58 or Natural Standards of Canada B149 2 Installation Code for Propane Gas Burning Appliances and Equipment Forsatisfactory operation propane gas pressure mustbe 10 inch W C at the unit manifold with all gas appliances in operation Maintaining proper gas pressure depends on three main factors 1 Vaporization rate which depends on a temperature of the liquid and b wetted surface area ofthe container or containers 2 Proper pressure regulation Two stage regulation is recommended from the standpoint of both cost and efficiency 3 Pressure drop in lines between regulators and between second stage regulator and the appliance Pipe size required will depend on length
23. or provision must be made for a filter in an accessible location within the return air duct The minimum filter area should not be less than those sizes listed in the Specification Section Under nocircumstances should the unitbe operated without return air filters The PG15 41AA models are equipped with X13 indoor blower motors X 13 motors are constanttorque motors with very low power consumption and are energized by a 24V signal from the ignition control board The X 13 features an integrated control module Air for condensing cooling cycle is drawn through the outdoor coil by a propellerfan andis discharged vertically out the top of the unit The outdoor coil is designed for 0 static No additional restriction ductwork shall be applied Conditioned air is drawn through the filter s field installed across the coil and back into the conditioned space by the indoor blower The PG15 series package units use the Compliant Scroll compressor there are a number of design characteristics which are differentfrom the traditional reciprocating compres sor Due to their design Scroll compressors are inherently more tolerant of liquid refrigerant NOTE Even though the compressor section of a Scroll compressor is more tolerant of liquid refrigerant continued flood back or flooded start conditions may wash oil from the bearing surfaces causing premature bearing failure These Scroll compressors use POE or polyolester oil w
24. pressure should rise and the suction tem perature will fall 4 f a temperature or pressure change is noticed the expansion valve is operating If no changeis noticed the valve is restricted the power element is faulty or the equalizer tube is plugged 5 Capture the charge replace the valve and drier and evacuate S 111 FIXED ORIFICE RESTRICTOR DEVICES The fixedorifice restrictor device flowrator used in conjunc tion with the indoor coil is a predetermined bore I D Itis designed to control the rate of liquid refrigerant flow into anevaporator coil The amountof refrigerant that flows through the fixed orifice restrictor device is regulated by the pressure difference between the high and low sides of the system Inthe cooling cycle when the outdoor air temperature rises the high side condensing pressure rises Atthe same time the cooling load on the indoor coil increases causing the low side pressure to rise but at a slower rate Since the high side pressure rises faster when the tempera ture increases more refrigerant flows to the evaporator increasing the cooling capacity of the system When the outdoor temperature falls the reverse takes place The condensing pressure falls and the cooling loads on the indoor coil decreases causing less refrigerant flow Astraineris placed on the entering side of the tube to prevent any foreign material from becoming lodged inside the fixed orifice restriction device If
25. 10 11 12 13 Thermostat type is set to two stage Thermostat W1 input initiates low stage heating Induced draft blower is energized at high speed for the pre purge period Pre purge timer begins after control recognizes pressure switch has closed Trial for ignition period begins after pre purge period expires Low and high stage gas valves are energized along with the igniter for trial for ignition period Igniter is de energized when flame is detected Flameis achieved and detected during trial for ignition period Flame stabilization period begins when flame is detected De energize high stage gas valve and switch induced draft blower to low speed within five seconds of flame detection Air circulating blower is energized at low heat speed after heat ON delay time expires Heat ON delay timer begins when flame is detected Control monitors thermostat flame limit and pres sure switch inputs during low stage heating Thermostat W1 input is removed Low stage gas valve is de energized Induced draft blower remains energized at low speed for post purge period Air circulating blower remains energized at low heat speed for heat OFF delay Heat OFF delay begins when W1 input is removed Control returns to Standby and awaits next thermostat request B Heating Operation High stage heat Thermostat type is set to two stage Thermostat W1 and W2 inputs initiate high stage heating
26. ICES FOR CONSUMERS AND SERVICERS RECOGNIZE SAFETY SYMBOLS WORDS AND LABELS WARNING This unit should not be connected to or used in conjunction with any devices that are not design certified for use with this unit or have not been tested and approved by Goodman Serious property damage or personal injury reduced unit performance and or hazardous conditions may result from the use of devices that have not been approved or certified by Goodman WARNING Installation and repair of this unit should be performed ONLY by individuals meeting the requirements of an Entry Level Technician as specified by the Air Conditioning and Refrigeration Institute ARI Attempting to install or repair this unit without such background may result in product damage personal injury or death WARNING Goodman will not be responsible for any injury or property damage arising from improper service or service procedures If you perform service on your own product you assume responsibility for any personal injury or property WARNING Do not store combustible materials or use gasoline or other flammable liquids or vapors in the vicinity of this appliance as property damage or personal injury could occur Have your contractor point out and identify the various cut off devices switches etc that serves your comfort equipment damage which may result WARNING HIGH VOLTAGE Disconnect ALL power b
27. IFYING TAB CHECKING FLAME ROLLOUT SWITCH Limit Switch Operation Applies to Primary Auxiliary and Roll Out Limits DSI systems Ifa limit switch opens the indoor blower is energized on heat speed and the induced draft blower is energized The LED on the control flashes 4 to indicate an open limit switch The blower and inducer remain on while the limit switch is open The gas valve is de energized Power to the thermo stat R is removed while the limit switch is open Whenthe limitswitch re closes the induced draft motor runs through its post purge and the indoor blower goes through the heat off delay If a call for heat exists when the limit switch re closes the control goes through a pre purge period and then makes an ignition attempt Theindoorblowerremains on forthe delay off time during the re ignition attempt 1 Ifno voltage is measured on either side of control it indicates ignition control or wiring to control problem 2 If voltage is measured on one side of the control and not the other it indicates the control is open 3 If voltage is measured on both sides of the control the wiring to gas valve or valve is at fault Servicing procedure with furnace not firing 1 Confirm that the outer door was in place and all screws tightened No leaks under the door 2 Check to see if any damage was done to the furnace especially the wiring 3 Confirm that heat exchanger is not obstructed by feeling for dis
28. INPUT 24V AC DC OUTPUT 24VDC RECTIFIER INSIDE Molded Plug Unloader Test Procedure Ifit 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 should go up or down atleast 25 percent Ifstep one does not give the expected results shut unit off Apply 18 to 28 volt ac to the unloader molded plug leads and listen for a click as the solenoid pulls in Remove power and listen for another click as the unloader returns to its original position 3 If clicks can t be heard shut off power and remove the control circuit molded plug from the compressor and measure the unloader coil resistance The resistance should be 32 to 60 ohms depending on compressor temperature 4 Next check the molded plug SERVICING 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 endofone molded plug lead to either ofthe two female connectors in the plug One ofthe connec tors should read closeto 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 ohmmet
29. Inspect Filter Clean or Replace Dirty Indoor Coil Inspect Coil Clean Not enough air across Indoor Coil Speed Blower Check Duct Static Press Too much air across Indoor Coil Reduce Blower Speed Overcharge of Refrigerant Recover Part of Charge Dirty Outdoor Coil Inspect Coil Clean Noncondensibles Recover Charge Evacuate Recharge Recirculation of Condensing Air Remove Obstruction to Air Flow Infiltration of Outdoor Air Check Windows Doors Vent Fans Etc Improperly Located Thermostat Relocate Thermostat Air Flow Unbalanced Readjust Air Volume Dampers System Undersized Refigure Cooling Load Broken Internal Parts Replace Compressor Inefficient Compressor Test Compressor Efficiency High Pressure Control Open Reset And Test Control Unbalanced Power 3PH Test Voltage Wrong Type Expansion Valve Replace Valve Expansion Device Restricted Remove restriction or replace expansion device Expansion Valve Bulb Loose Tighten Bulb Bracket Inoperative Expansion Valve Check Valve Operation Loose Hold down Bolts Tighten Bolts 28 SERVICING GAS HEATING ANALYSIS CHART Complaint No Heat Unsatisfactory Heat POSSIBLE CAUSE DOTS IN ANALYSIS GUIDE INDICATE POSSIBLE CAUSE SYMPTOM System Will Not Start Burner Won t Ignite Burner Ignites Locks Out Burner Shuts Off prior to T Stat being Sa
30. LAY DELAY R C W1W2G Y1Y2 22 SYSTEM OPERATION Pim Voltage union 24VAC Indoor Outdoor Thermostat IDT ODT Output 24VAC High Stage Compressor Output 24VAC Pressure Switch Loss of Charge Switch Input 24VAC Indoor Outdoor Thermostat IDT ODT Input 24VAC Pressure Switch Loss of Charge Switch Output 6 24VAC Low Stage Compressor Output Table 1 Circuit Definitions and Voltage Ratings for the 6 Circuit Connector Circuits Pim Voltage Fonction 6 AAC Pressure Switch Output 8 VA Pressure Switch input e unused Main Valve Low Output Table 2 Circuit Definitions and Voltage Ratings for the 9 Circuit Connector Circuits DI Low or Inducer Low Table 3 High Voltage Terminals 23 SYSTEM OPERATION Tral fr ignition TFI 2 Seconds within Flame Stabilization Period Flame Failure Response Time 2 Seconds or Per ANSI Z21 20 Outside of Flame Stabilization Period Low to High Stage Delay Selectable 5 minutes or 10 minutes Default 10 minutes Heat ON Delay 30 Seconds Selectable 90 120 150 or 180 Seconds Aaron RAAY Default 150 Seconds Table 4 Control Timings LED Flashes Status Normal Intrnal Gas Valve Fault Lockout Pressure Switch Stuck Closed Pressure Switch Stuck Open Open High Temperature Limit Flame Detected with Gas Valve De Energized Compressor Short Cycle Delay Active Limit Opened 5 Times in Same Call For Heat Indoor Thermostat Out
31. LE CAUSE SYMPTOM System will not start See Service Procedure Ref Compressor will not start fan runs Comp and Cond Fan will not start Evaporator fan will not start Condenser fan will not start Compressor runs goes off on overload Compressor cycles on overload System runs continuously little cooling Too cool and then too warm Not cool enough on warm days Certain areas too cool others too warm Compressor is noisy Low suction pressure Low head pressure High suction pressure High head pressure Power Failure Test Voltage Blown Fuse Inspect Fuse Size amp Type Loose Connection Inspect Connection Tighten Shorted or Broken Wires Test Circuits With Ohmmeter Open Overload Test Continuity of Overload ty Thermostat Test continuity of Thermostat amp Wiring ty Transformer Check control circuit with voltmeter rted or Open Capacitor Test Capacitor rted or Grounded Compressor Test Motor Windings Compressor Stuck Use Test Cord Faulty Compressor Contactor Test continuity of Coil amp Contacts Unloader Solenoid Not Energized Test Unloader Solenoid ty Ignition Control Test Ignition Control Open Control Circuit Test Control Circuit with Voltmeter Voltage Test Voltage ty Evap Fan Motor Repair or Replace Shorted or Grounded Fan Motor Test Motor Windings Improper Cooling Anticipator Check resistance of Anticipator Shortage of Refrigerant Test For Leaks Add Refrigerant Restricted Liquid Line Replace Restricted Part
32. LL 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 Remove the wires from the auxiliary limit control termi nals Using an ohmmeter test for continuity across the two terminals Noreading indicates the controlis open Push the red reset button test again if still open replace the control SERVICING VOLT OHM METER a COLOR IDENTIFYING TAB TESTING AUXILIARY LIMIT CONTROL 302 CHECKING FLAME ROLLOUT SWITCH APG GPG units are equipped with a temperature activated manual reset control This control is mounted to the manifold assembly and is wired in series with the auxiliary limit and gas valve The control is designed to open should a flame roll out occur An over firing condition or flame impingement on the heat shield can also cause the control to open If the rollout control has opened the circuit between the ignition control and gas valve will be interrupted and the ignition control module will go into lockout The servicer should reset the ignition control by opening and closing the thermostat circuit The servicer should look for the ignitor glowing which indicates there is powerto the ignition control The servicer should measure the voltage between each side of the rollout control and ground while the ignition control is try to power the gas valve VOLT OHM METER ee COLOR IDENT
33. R DEATH o o z m l o z o o 9 gt Lu o Lu LL Lu a Lu a l l lt M o Lu z z o o o a HIGH VOLTAGE ACCESSORIES WIRING DIAGRAMS warnine LNITVAINDA YO 0ZL 06 LHO JOWS IVLS L 39V1S LLININ GNSAWWOOSY ILON INVHOVIO DNISIM YAZINONODS ZOL LOL H daIDd TICON 09 ONINNLOVANNVW NVINdOO9 AVIS AL JOH INOO Ad WHLNA LNITVAINDA YO 0Z1 06LHO HINO 1VIS L 3OVLS ILINN NMOHS SV TIVLSNI NOILISOd YIANVO INCIWINIIA IWNOLLdO YSLAWOILNALOd S01 L 6 QV NVIW3T1OO H38HNva lVISOWMN3HI 100201 HOSSIAANOO AVIS AL SIOVINOO AVIS AL MOTNJA N3349 9 Wiring is subject to change Always refer to the wiring diagram on the unit for the most up to date wiring 56
34. SOO EE en en an e e soon zs om aw use e fu SQUARE TO ROUND CONVERTER HORIZONTAL APPLICATIONS mo alelo Measurements are in inches 10 ACCESSORIES GPGHFR101 103 EXTERNAL HORIZONTAL FILTER RACK PRODUCT DESIGN In installations where the unitis installed above ground level and not serviceable from the ground Example Roof Top installations the installer must provide a service platform for the service person with rails or guards in accordance with local codes or ordinances or in their absence with the latest edition of the National Fuel Gas Code ANSI 2223 1 36 MIN FOR SERVICE NOTE Roof overhang should be no more than 36 Minimum clearances are required to avoid air recirculation and keep the unit operating at peak efficiency Aminimum 12 inch clearance is required to the condenser coil NOTE The flue outlet hood is packaged separately inside the unit and must be installed prior to operation 4h WARNING TO PREVENT POSSIBLE DAMAGE THE UNIT SHOULD REMAIN IN AN UPRIGHT POSITION DURING ALL RIGGING AND MOVING OPERATIONS TO FACILITATE LIFTING AND MOVING IF A CRANE IS USED PLACE THE UNIT IN AN ADEQUATE CABLE SLIDE IMPORTANT NOTE If using bottom discharge with roof curb ductwork should be attached to the curb prior to installing the unit Refer to Roof curb Installation
35. See the following for recommended heater anticipator setting Todetermine the propersetting use an ammeterto measure the current on the W wire going to the thermostat Use an amprobe as shown below Wrap 10 turns of thermo stat wire around the stationary jaw ofthe amprobe and divide the reading by 10 10 TURNS OF THERMOSTAT WIRE From W on thermostat J STATIONARY JAW OF AMPROBE READS 4 AMPS CURRENT DRAW WOULD BE 4 AMPS Checking Heat Anticipator Amp Draw SERVICING S 4 CHECKING TRANSFORMER AND CONTROL CIRCUIT WARNING HIGH VOLTAGE Disconnect ALL power before servicing or installing this unit Multiple power sources may be present Failure to do so may cause property damage personal injury or death q A step down transformer 208 240 volt primary to 24 volt sec ondary is provided with each indoor unit This allows ample capacity for use with resistance heaters The outdoor sec tions do not contain a transformer Ex WARNING Disconnect ALL power before servicing 1 Remove control panel cover or etc to gain access to transformer With power ON A WARNING A Line Voltage now present 2 Using a voltmeter check voltage across secondary voltage side of transformer R to C 3 Novoltage indicates faulty transformer bad wiring or bad splices 4 Check transformer primary voltage at incoming line voltage connections and or splices 5 Ifline voltage av
36. Service mene Instructions v APG GPG15 Gas Electric Package Units with R 410A Refrigerant amp Accessories US Liste This manual is to be used by qualified professionally trained HVAC technicians only Goodman RS6300007 Rev 2 does not assume any responsibility for property damage or personal injury due to improper October 2007 service procedures or services performed by an unqualified person Copyright O 2007 Goodman Manufacturing Company L P TABLE OF CONTENTS IMPORTANT INFORMATION 2 3 SCHEDULED MAINTENANCE 25 27 PRODUCTION IDENTIFICATION saisis 4 TROUBLESHOOTING CHARTS 28 29 ACCESSORIES ie puis hastas 5 11 SERVICING TABLE OF CONTENTS 30 PRODUCT DESIGN ss 12 17 SERVICING sesion 31 55 SYSTEM OPERATION ista cubanas 18 24 ACCESSORIES WIRING DIAGRAMS 56 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 THE APPROPRIATE SERVICE MANUAL BEFORE BEGINNING REPAIRS IMPORTANT NOT
37. ailable at primary voltage side of trans former and wiring and splices good transformer is inop erative Replace S 7 CHECKING CONTACTOR AND OR RELAYS WARNING HIGH VOLTAGE Disconnect ALL power before servicing or installing this unit Multiple power sources may be present Failure to do so may cause property damage personal injury or death q The compressor contactor and other relay holding coils are wired into the low or line voltage circuits When the control circuit is energized the coil pulls in the normally open contacts or opens the normally closed contacts When the coil is de energized springs return the contacts to their normal position NOTE Most single phase contactors break only one side of the line L1 leaving 115 volts to ground present at most internal components 1 Remove the leads from the holding coil 2 Using an ohmmeter test across the coil terminals If the coil does not test continuous replace the relay or contactor S 8 CHECKING CONTACTOR CONTACTS SINGLE PHASE WARNING HIGH VOLTAGE Disconnect ALL power before servicing or installing this unit Multiple power sources may be present Failure to do so may cause property damage personal m Y or death 1 Disconnectthe wire leads from the terminal T side of the contactor 2 With power ON energize the contactor LINE VOLTAGE NOW PRESENT VOLT OHM METER Ohmmeter for testing holding coil
38. aters are used to prevent migration or accumu lation of refrigerantin the compressor crankcase during the offcycles and prevents liquid slugging or oil pumping on start up A crankcase heater will not prevent compressor damage due to a floodback or over charge condition Ex WARNING ae Disconnect ALL power before servicing 1 Disconnect the heater lead in wires 2 Using an ohmmeter check heater continuity should test continuous If not replace S 100 REFRIGERATION REPAIR PRACTICE DANGER Always remove the refrigerant charge in a proper manner before applying heat to the system When repairing the refrigeration system E WARNING one Disconnect ALL power before servicing 1 Never open a system that is under vacuum Air and moisture will be drawn in 2 Plug or cap all openings 3 Remove all burrs and clean the brazing surfaces of the tubing with sand cloth or paper Brazing materials do not flow well on oxidized or oily surfaces 4 Clean the inside ofall new tubing to remove oils and pipe chips 5 When brazing sweep the tubing with dry nitrogen to prevent the formation of oxides on the inside surfaces 6 Complete any repair by replacing the liquid line drier in the system evacuate and charge BRAZING MATERIALS Copper to Copper Joints Sil Fos used without flux alloy of 15 silver 80 copper and 5 phosphorous Recom mended heat 1400 F Copper to Steel Joints Silver Solder used wi
39. az a Attendre cinq 5 minutes pour laisser echapper tout le Pousse le levier du contr le du gaz Remettre en place le panneau d acc s Mettre l appareil sous tension R gler le thermostat la temp rature d sir e Si l appareil ne se met pas en marche suivre les ARRETEZ Lisez les instructions de s curit dans la section sup rieure de cette tiquette d allumage automatique ne pas essayer allumer le br leur manuellement OFF ARRET position gaz Renifler tout autour de l appareil y compris pr s du plancher pour d celer une odeur de gaz i c est le cas ARR TEZ Passer l etape B des instructions de securite sur la portion superieure de cette etiquette S il n y a pas d odeur de gaz passer l et pe suivante ON MARCHE position instructions intitul es Comment couper l admission de gaz de l appareil et appeler un technicien qualifi ou le fournisseur de gaz E TO TURN OFF GAS TO APPLIANCE ITE RECS POUR COUPER L ADMISSION DE GAZ DE L APPAREIL 1 Set the thermostat to lowest setting 1 R gler le thermostat la temp rature la plus bass 2 Turn off all electric power to the appliance 2 Sea Cee d ERN s il j ice i u i jen 3 e Ge A A a 3 S le levier du contr le du gaz OFF ARRET position Do not force Ne pas forcer 4 Replace control access panel 4 Remettre en place le panneau d acc s 0140F00000P ACCESSORIES ROOF CURBS
40. ce Moisture chemically reacts with the refrigerant oil to form corrosive acids These acids attack motor windings and parts causing breakdown The equipment required to thoroughly evacuate the systemis ahigh vacuum pump capable of producing a vacuum equiva lent to 25 microns absolute and a thermocouple vacuum gauge to give a true reading of the vacuum in the system NOTE Never use the system compressor as a vacuum pump orrun when under ahigh vacuum Motor damage could occur WARNING Do not front seat the service valve s with the compressor open with the suction line of the comprssor closed or severely restricted 40 Connect the vacuum pump vacuum tight manifold set with high vacuum hoses thermocouple vacuum gauge and charging cylinder as shown Startthe vacuum pump and openthe shut off valvetothe high vacuum gauge manifold only After the compound gauge lowside has dropped to approximately 29 inches of vacuum open the valve to the vacuum thermocouple gauge See that the vacuum pump will blank off to a maximum of 25 microns A high vacuum pump can only produce a good vacuum if its oil is non contaminated R 410A MANIFOLD N LOW SIDE HIGH SIDE ee GAUGE GAUGE p pcc AND VALVE ANDVALVE 7 800 PSI 1 RATED a idis 4 Y Y A CHARGING CYLINDER AND SCALE VACUUM PUMP TO ADAPTER UNIT SERVICE VALVE PORTS L El ZZ EVACUATION
41. charge air from the flue hood when the combustion blower is running but the unit is not firing Ifthe above steps do not suggest the reason the control has tripped the furnace should be fired 1 Remove the heating compartment door 2 Turn of the power or open the thermostat circuit 3 Resetthe rollout control 4 Turn power on and put the unit into a call for heating AX CAUTION Flame rollout could occur Keep face and hands a safe distance from burner area 5 Look under the heat shield as the unit is running Flames should be drawn into firing tubes a Ifonly one burners flame is notdrawn into the tube that tube is restricted b f without the air circulation blower running all flames are not drawn into the tubes either the collector box combustion blower or flue outlet is obstructed Ifthe combustion blowerorflue outlet is obstructed the pressure switch should have opened preventing the unitfromfiring also inspect the unit pressure switch and wiring 49 SERVICING c Ifthe burner flame is not drawn into the tube only when the air circulation blower is running then a cracked heat exchanger tube is present 303 TESTING INDUCER MOTOR WARNING HIGH VOLTAGE Disconnect ALL power before servicing or installing this unit Multiple power sources may be present Failure to do so may cause property damage personal m or death 1 Disconnectthe motor wire leads from its connection point
42. combustion of various fuels in a limited space and transfer this heat of the burning process to the heat exchanger Proper ignition combustion and extinction are primarily due to burner design orifice sizing gas pressure primary and secondary air vent and proper seating of burners BECKETT BURNER WARNING Disconnect gas and electrical power supply In checking main burners lookfor signs of rust oversized and undersized carry over ports restricted with foreign material etc S 306 CHECKING ORIFICES A predetermined fixed gas orifice is used in all of these furnaces That is an orifice which has a fixed bore and position SERVICING A 1 1 1 GAS STREAM P DENT OR The length of Dimension A determines the angle of Gas Stream Defraction B A dent or burr will cause severe deflection of gas stream Noresizing should be attempted until allfactors are taken into consideration such as inlet manifold gas pressure align ment and positioning specific gravity and BTU contentofthe gas being consumed The only time resizing is required is when a reduction in firing rate is required for an increase in altitude Orifices should be treated with care in order to prevent damage They should be removed and installed with a box end wrench in order to prevent distortion In no instance should an orifice be peened over and redrilled This will change the angle or deflection of the vacuum effect o
43. coming from a burner port Flashback may occur atthe moment of ignition after a burner heats up or when the burner turns off The latter is known as extinction pop Since the end results of flashback and delayed ignition can be the same burning in the burner venturi a definite attempt should be made to determine which has occurred If flashback should occur check for the following 1 Improper gas pressure adjust to proper pressure See S 307 2 Check burner for proper alignment and or replace burner 33 Improper orifice size check orifice for obstruction S 310 CHECKING PRESSURE CONTROL A pressure control device is used to measure negative pressure at the induced draft blower motor inlet to detect a partial or blocked flue Pressure Switch Operation DSI Direct Spark System The pressure switch is ignored unless there is a call for heat When the control receives a call for heat the control checks to see that the pressure switch is open If the control sees that the pressure switch is closed before the induced draft blower is energized the LED will flash a code of 2 to indicate the pressure switch is stuck closed and the inducer will remain off until the pressure switch opens If the pressure switch opens before the ignition period the induced draft blower will remain on and the control will stay in pre purge until the pressure switch is closed for an entire 15 second pre purge period The LED will flash a code
44. croamp meter in series with this wire and terminal FS 3 Be sure the negative side of the meter is to the wire and the positive of the meter is to terminal FS 4 Turnon Power ER WARNING Line Voltage now present With Power ON Place the unit into a heating cycle 6 As soon as flame is established a microamp reading should be evidentonce proof offlame microamp reading is established the hot surface ignitor will be de ener gized 7 The nominal microamp reading is 4 microamps 8 If the microamp current is less than 0 5 microamp the control will lockout and flash a code of 1 flash after attempting to reestablish flame sense 9 Ifthe microamp reading is less than the minimum speci fied check for high resistance wiring connections the distance 3 16 between the sensor and burner flame sensor connections dirty flame sensor or poor ground ing 10 If no reading check for continuity on all components and if good replace ignition control module NOTE Contaminated fuel or combustion air can create a nearly invisible coating on the flame sensor This coating works as an insulator causing a loss in the flame sense signal If this situation occurs the flame sensor must be cleaned with steel wool Do not use sand paper the silicone in sand paper will further contaminate the sensor 99 ECONOMIZER UNIT MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY O
45. croll compressors are inherently more tolerant of liquid refrigerant NOTE Even though the compressor section of a Scroll compressor is more tolerant of liquid refrigerant continued floodback or flooded start conditions may wash oil from the bearing surfaces causing premature bearing failure S 104 CHECKING COMPRESSOR EFFICIENCY The reason for compressor inefficiency is broken or damaged scroll flanks on Scroll compressors reducing the ability of the compressor to pump refrigerant vapor The condition of the scroll flanks is checked in the following manner 1 Attach gauges to the high and low side of the system 2 Start the system and run a Cooling Performance Test If the test shows a Below normal high side pressure b Above normal low side pressure c Low temperature difference across coil d Low amp draw at compressor And the charge is correct The compressor is faulty replace the compressor S 105B THERMOSTATIC EXPANSION VALVE The expansion valve is designed to control the rate of liquid refrigerantflow into an evaporator coil in exact proportion to the rate of evaporation of the refrigerant in the coil The amount of refrigerant entering the coil is regulated since the valve responds to temperature ofthe refrigerant gas leaving the coil feeler bulb contact and the pressure ofthe refriger ant in the coil This regulation of the flow prevents the return of liquid refrigerantto the compressor Thethreef
46. d cause serious compressor damage Charge the system with the exact amount of refrigerant Refer to the specification section or check the unit name plates for the correct refrigerant charge An inaccurately charged system will cause future prob lems 1 Using a quality set of charging scales weigh the proper amount of refrigerantforthe system Allow liquid refriger ant only to enter the high side 2 Afterthe system will take all it will take close the valve on the high side of the charging manifold 3 Startthe system and charge the balance ofthe refrigerant through the low side NOTE R410A should be drawn out of the storage container or drum in liquid form due to its fractionation properties but should be Flashed to its gas state before entering the system There are commercially available restriction devices that fitinto the system charging hose setto accomplish this DO NOT charge liquid R410A into the compressor 4 With the system still running close the valve on the charging cylinder Atthis time you may still have some liquid refrigerant in the charging cylinder hose and will definitely have liquid in the liquid hose Reseatthe liquid line core Slowly open the high side manifold valve and transferthe liquid refrigerantfrom the liquid line hose and charging cylinder hose into the suction service valve port CAREFUL Watch so that liquid refrigerant does not enter the compressor Due to their design S
47. d indicate a short in the 24 volt circuit b Voltage present proceed to step 3 Check for 24 volts at thermostat terminals C and Y 1 a No voltage check thermostat wiring and ther mostat b Voltage present check pressure switch circuit If pressure switch circuit checks closed pro ceed to step 4 Check for 24 volts at contactor coil a No voltage check 6 pin connector and wires from contactor coil to 6 pin connector on control board If wires and connector check good re place control b Voltage present replace contactor Testing High Stage Cooling Operation with Low Stage Cooling Operating 1 2 Board set for 2 stage thermostat a Checkfor24 volts atthermostatterminals C and Y2 on control board b No voltage check thermostat and thermostat wiring c Voltage present check pressure switch circuit If pressure switch circuit checks closed pro ceed to next step d Check for 24 volts to compressor unloader solenoid If no voltage present check 6 pin connector and wires from compressor unloader solenoid to 6 pin connector on board If connec tor and wires check good replace control Board set for 1 stage thermostat a Wait the selected delay time either 5 or 10 minutes depending on jumper setting b Check for 24 volts at compressor unloader solenoid c No voltage check 6 pin connector and wires from compressor unloader solenoid to 6 pin connector on board If connector an
48. d wires check good replace control SERVICING System Condition LED Flashes Status O Internal Control Fault Micro Controller Detected Hardware Failure or Gas Valve Detected Energized When it Should be De energized 3 Pressure Switch Stuck Open 4 open High Temperature Limit Flame Present Outside the Flame Detect Mode e Compressor Short Cycle Delay Active Same Call for Heat Indoor Thermostat Outdoor Thermostat ICI C AME Pressure Switch Loss of Charge Switch BR CE Steady ON Red LED Fault Codes LED qu Flashes Status Flame Condition 2 Flame Present Outside the Flame Detect Mode Low Flame Signal Current Steady ON Normal Flame No Flame Present Amber LED Flame Status Codes NOTE The flash rate is 0 25 seconds on 0 25 seconds off with a 2 second pause between codes S 314 CHECKING FLAME SENSOR Aflame sensing device is used in conjunction with the ignition control module to prove combustion If a microamp signalis not present the control will de energize the gas valve and retry for ignition or lockout DSI Direct Spark Ignition Systems WARNING HIGH VOLTAGE Disconnect ALL power before servicing or installing this unit Multiple power sources may be present Failure to do so may cause property damage personal injury or death q 1 Disconnectthe flame sensor wire from terminal FS ofthe ignition control module Flame Sensor 2 Connect a mi
49. dance 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 4h WARNING DO NOT EXCEED THE MAXIMUM OVERCURRENT DEVICE SIZE SHOWN ON THE UNIT DATA PLATE 14 All line voltage connections must be made through weather proof fittings All exterior power supply and ground wiring must be in approved weather proof conduit Low voltage wiring from the unit control panel to the thermostat requires coded cable See the following figures for ground level and rooftop wiring Note Junction box location shown is optional and is for illustration purposes only JUNCTION BOX Electrical Power Directly To Junction Box Electrical Power Routed Through Bottom of Unit The unit transformer is connected for 230V operation Ifthe unitis to operate on 208V reconnect the transformer primary lead and the induced draft blower leads as shown on the unit wiring diagram PRODUCT DESIGN 4h WARNING TO AVOID THE RISK OF PROPERTY DAMAGE PERSONAL INJURY OR FIRE USE ONLY COPPER CONDUCTORS If itis necessary for the installer to supply additional line voltage wiring to the inside of the package unit the wiring must comply with all local codes This wiring must have a minimum temperature rating of 105 C and must be routed away from the burner compartm
50. door Thermostat is Open Pressure Switch Loss of Charge Switch is Open O 5 Normal Flame ff No Flame Present Low Flame Current Flame Detected with Gas Valve De energized Table 5 LED Status Codes and Corresponding System Condition Off 24 SCHEDULED MAINTENANCE Package gas units require regularly scheduled maintenance 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 contract which places all maintenance in the hands of a trained serviceman should be pointed out to the owner WARNING HIGH VOLTAGE Disconnect ALL power before servicing or installing this unit Multiple power sources may be present Failure to do so may cause property damage personal injury or death q piada A MONTH Inspectthe return filters of the evaporator unit and clean orchangeifnecessary NOTE Depending on operation conditions it may be necessary to clean or replace the filters more often If permanenttype filters are used they should be washed with warm water and dried 2 When operating on the cooling cycle inspect the con densate line piping from the evaporator coil Make sure the piping is clear for proper condensate flow ONCE A YEAR QUALIFIED SERVICE PERSONNEL ONLY 1 Clean the indoor and outdoor coils 2 Clean the cabin
51. e coil temperature non condensables are present Non condensables are removed from the system by first removing the refrigerant charge replacing and or installing liquid line drier evacuating and recharging 46 S 115 COMPRESSOR BURNOUT When a compressor burns out high temperature develops causing the refrigerant oil and motor insulation to decom pose forming acids and sludge If a compressor is suspected of being burned out attach a refrigerant hose to the liquid line dill valve and properly remove and dispose ofthe refrigerant Ah NOTICE Violation of EPA regulations may result in fines or other penalties Now determine if a burn out has actually occurred Confirm by analyzing an oil sample using a Sporlan Acid Test Kit AK 3 or its equivalent Remove the compressor and obtain an oil sample from the suction stub Ifthe oil is not acidic either a burnout has not occurred or the burnout is so mild that a complete clean up is not necessary If acid level is unacceptable the system must be cleaned by using the clean up drier method CAUTION Do not allow the sludge or oil to contact the skin Severe burns may result NOTE The Flushing Method using R 11 refrigerant is no longer approved by Amana Brand Heating Cooling Suction Line Drier Clean Up Method The POE oils used with R410A refrigerant is an excellent solvent Inthe case of a burnout the POE oils will remove any burnout residue left
52. e scroll remains stationary fixed scroll while the other form orbiting scroll is allowed to orbit but not rotate around the first form 13 PRODUCT DESIGN As this motion occurs the pockets between the two forms are slowly pushed to the center of the two scrolls while simultaneously being reduced in volume When the pocket reaches the center of the scroll form the gas which is now at a high pressure is discharged out of a port located at the center During compression several pockets are being compressed simultaneously resulting in a very smooth process Both the suction process outer portion of the scroll members and the discharge process inner portion are continuous ELECTRICAL WIRING The units are designed for operation on 60 hertz current and at voltages as shown on the rating plate All internal wiring is complete Ensure the power supply to the compressor contactor is brought to the unitas shown on the supplied unit wiring diagram The 24V wiring must be connected between the unit control panel and the room thermostat LINE VOLTAGE WIRING Power supply to the unit must be N E C Class 1 and must comply with all applicable codes The unit must be electri cally grounded in accordance with the local codes or in their absence with the latest edition of the National Electrical Code ANSI NFPA No 70 or in Canada Canadian Electri cal Code C22 1 Part 1 A fused disconnected must be provided and sized in accor
53. e the suction line drier from the system 9 If the pressure drop becomes greater then it must be replaced and steps 5 through 9 repeated until it does not exceed 6 PSIG NOTICE Regardless the cause for burnout must be deter mined and corrected before the new compressor is started S 200 CHECKING EXTERNAL STATIC PRESSURE The minimum and maximum allowable duct static pressure is found in the Technical Information Manual Too great of an external static pressure will result in insuffi cient air that can cause icing of the coil whereas too much air can cause poor humidity control and condensate to be pulled off the evaporator coil causing condensate leakage Too much air can cause motor overloading and in many cases this constitutes a poorly designed system To determine proper air movement proceed as follows 1 Using a draft gauge inclined manometer measure the static pressure of the return duct at the inlet of the unit Negative Pressure INCLINED MANOMETER RETURN Total External Static 2 Measure the static pressure of the supply duct Positive Pressure 3 Add the two readings together NOTE Bothreadings may be taken simultaneously and read directly on the manometer if so desired 4 Consult proper table for quantity of air If the external static pressure exceeds the minimum or maximum allowable statics check for closed dampers dirty filters undersized
54. e the unit Locked Rotor Voltage Locked Rotor Voltage is the actual voltage available at the compressor during starting locked rotor ora stalled condition Measured voltage should be above minimum listed in chart below To measure Locked Rotor Voltage attach a voltmeter to therun R and common C terminals ofthe compressor ortotheT andT terminals of the contactor Start the unit and allow the compressor to run for several seconds then shut down the unit Immediately attempt to restart the unit while measuring the Locked Rotor Voltage 6 Voltmeter should read within the voltage tabulation as shown If the voltage falls below the minimum voltage check the line wire size Long runs of undersized wire can cause low voltage If wire size is adequate notify the local power company in regards to either low or high voltage Unit Supply Voltage 2081230 Three phase units require a balanced 3 phase power supply to operate Ifthe 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 X 100 Imbalance Average Voltage To find the percentage of imbalance measure the incoming power supply L1 L2 240V L1 L3 232V Avg V 710 236 7 L2 L3 238V 3 Total 710V 240 236 7 3 3 232 236 7 4 7 238 236 7 1 3 To find Max deviation Max deviation was 4 7 V Voltage Imbalance 4 7 1 99
55. efore 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 CONSUMERINFORMATION LINE CONSUMERINFORMATION LINE GOODMAN BRAND PRODUCTS AMANA BRAND PRODUCTS TOLL FREE 1 877 254 4729 U S only TOLL FREE 1 877 254 4729 U S only email us at hac consumer affairs goodmanmfg com email us at hac consumer affairs amanahvac com fax us at 713 856 1821 fax us at 931 438 4362 Not a technical assistance line for dealers Not a technical assistance line for dealers Outside the U S call 1 713 861 2500 Outside the U S call 1 931 433 6101 Not a technical assistance line for dealers Not a technical assistance line for dealers Your telephone company will bill you for the call Your telephone company will bill you for the call IMPORTANT INFORMATION SAFE REFRIGERANT HANDLING While these items will not cover every conceivable situation they should serve as a useful guide WARNING Refrigerants are heavier than air They can push out the oxygen in your lungs or in any enclosed space To avoid possible difficulty in breathing or death Never purge refrigerant into an enclosed room or space By law all refrigerants must be reclaimed If an indoor leak is sus
56. emperature of the line 4 Compare the hi pressure reading to the Required Liquid Line Temperature chart on the following page Find the hi pressure value on the left column Follow thatline right tothe column under the design subcooling value Where the two intersect is the required liquid line temperature Alternately you can convert the liquid line pressure gauge reading to temperature by finding the gauge reading in Temperature Pressure Chart and reading to the left find the temperature in the F Column 5 The difference between the thermometer reading and pressure to temperature conversion is the amount of subcooling Add charge to raise subcooling Recover charge to lower subcooling Subcooling Formula Sat Liquid Temp Liquid Line Temp EXAMPLE a Liquid Line Pressure 417 b Corresponding Temp F 120 c Thermometer on Liquid line 109 F To obtain the amount of subcooling subtract 109 F from 120 F The differenceis 11 subcooling See the specification sheet or technical information manual for the design subcooling range for your unit S 110 CHECKING EXPANSION VALVE OPERATION 1 Removethe remote bulb ofthe expansion valve from the suction line 2 Startthe system and cool the bulb in a container of ice water closing the valve As you cool the bulb the suction pressure shouldfall andthe suction temperature will rise 3 Nextwarmthe bulb in your hand As you warm the bulb the suction
57. ent All line voltage splices must be made inside the unit control box GAS SUPPLY AND PIPING 4h CAUTION THIS PACKAGE GAS UNIT IS FACTORY SET TO OPERATE ON NATURAL GAS AT THE ALTITUDES SHOWN ON THE RATING PLATE IF OPERATION ON PROPANE IS REQUIRED OBTAIN AND INSTALL THE PROPER CONVERSION KIT S BEFORE OPERATING THIS UNIT FAILURE TO DO SO MAY RESULT IN UNSATISFACTORY OPERATION AND OR EQUIPMENT DAMAGE The rating plate is stamped with the model number type of gas and gas input rating Make sure the unit is equipped to operate on the type of gas available Inlet Gas Pressure Min 5 0 W C Max 10 0 W C Min 11 0 W C Max 13 0 W C Inlet Gas Pressure Must Not Exceed the Maximum Value Shown in the table above The minimum supply pressure must not be varied downward because this could lead to unreliable ignition In addition gas input to the burners must not exceed the rated input shown on the rating plate Overfiring of the unit could result in premature heat exchanger failure GAS PIPING 4h CAUTION TO AVOID POSSIBLE UNSATISFACTORY OPERATION OR EQUIPMENT DAMAGE DUE TO UNDERFIRING OF EQUIPMENT DO NOT UNDERSIZE THE NATURAL GAS PROPANE PIPING FROM THE METER TANK TO THE FURNACE WHEN SIZING A TRUNK LINE PER THE TABLES INCLUDE ALL APPLIANCES ON THAT LINE THAT COULD BE OPERATED SIMULTANEOUSLY The gas pipe supplying the unit mustbe properly sized based onthe cubic feet per hour of gas flow required
58. er leads and re peat Thefemale connector that read infinity previ ously should now read close to zero ohms C Replace plugifeitherofthese 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 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 ur 1 Removeunitwiring from disconnect switch and wire atest cord to the disconnect switch NOTE The wire size ofthe 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 discon nected at the nearest point to the compressor and connectthe common start and run clips to the respective leads 3 Connect good capacitors of the right MFD and voltage rating into the circuit as shown 4 With power ON close the switch T WARNING YI Line Voltage now present A lf the compressor starts and continues to run the cause for failure is somewhere else in the system B If the compressor fails to start replace S 18 TESTING CRANKCASE HEATER OPTIONAL ITEM The crankcase heater must be energized a minimum of four 4 hours before the condensing unit is operated Crankcase he
59. et inside and out 3 Motors are permanently lubricated and do not require oiling TO AVOID PREMATURE MOTOR FAILURE DO NOT OIL 4 Manually rotate the outdoor fan and indoor blower to be sure they run freely 5 Inspect the control panel wiring compressor connec tions and all other component wiring to be sure all connections are tight Inspect wire insulation to be certain that it is good 6 Check the contacts of the compressor contactor If they are burned or pitted replace the contactor 7 Using a halide or electronic leak detector check all piping and etc for refrigerant leaks 8 Check the combustion chamber Heat Exchanger for soot scale etc Inspect all burners for lint and proper positioning 9 Startthe system using the proper instrumentation check gas inlet and manifold pressures burner flame and microamp signal Adjust if necessary 10 Start the system and run a Heating Performance Test If the results of the test are not satisfactory see the Service Problem Analysis Guide for the possible cause TEST EQUIPMENT Proper test equipment for accurate diagnosis is as essen tial as regular hand tools The following is a must for every service technician and service shop 1 Thermocouple type temperature meter measure dry bulb temperature 2 Sling psychrometer measure relative humidity and wet bulb temperature 3 Amprobe measure current 4 Volt Ohm Meter testing continuity capacitor
60. from the Expanded Performance Chart Liquid refrigerant at condensing pressure and temperatures 270 psig and 122 F leaves the outdoor condensing coil through the drier and is metered into the indoor coil through the metering device As the cool low pressure saturated refrigerant enters the tubes of the indoor coil a portion of the liquid immediately vaporizes It continues to soak up heat and vaporizes as it proceeds through the coil cooling the indoor coil down to about 48 F Heatis continually being transferred to the cool fins and tubes of the indoor evaporator coil by the warm system air This warming process causes the refrigerant to boil The heat removed from the air is carried off by the vapor As the vapor passes through the last tubes of the coil it becomes superheated Thatis it absorbs more heat than is necessary to vaporize it This is assurance that only dry gas will reach the compressor Liquid reaching the compressor can weaken or break compressor valves The compressor increases the pressure of the gas thus adding more heat and discharges hot high pressure super heated gas into the outdoor condenser coil In the condenser coil the hot refrigerant gas being warmer than the outdoor air first loses its superheat by heat trans ferred from the gas through the tubes 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
61. gh head pressure Anevaporator coil using an expansion valve metering device will basically modulate and control a flooded evaporator and prevent liquid return to the compressor An evaporator coil using a fixed orifice restrictor device flowrator metering device could allow refrigerant to return to the compressor under extreme overcharge conditions Also with a fixed orifice restrictor device flowrator metering device extreme cases of insufficient indoor air can cause icing of the indoor coil and liquid return to the compressor but the head pressure would be lower There are other causes for high head pressure which may be found in the Service Problem Analysis Guide If other causes check out normal an overcharge or a system containing non condensables would be indicated If this system is observed 1 Start the system 2 Remove and capture small quantities of refrigerant as from the suction line access fitting until the head pressure is reduced to normal 3 Observe the system while running a cooling performance test If a shortage of refrigerant is indicated then the system contains non condensables S 114 NON CONDENSABLES If non condensables are suspected shut down the system and allow the pressures to equalize Wait at least 15 minutes Compare the pressure to the temperature of the coldest coil since this is where most of the refrigerant will be Ifthe pressure indicates a higher temperature than that of th
62. hich is NOT compatible with mineral oilbased lubri cants like 3GS POE oil must 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 Operating pressures and amp draws may differ from standard reciprocating compressors This information may be found in the Cooling Performance Data section Some other models of the PG15 series package units use a 2 stage scroll compressor The basic scroll design has been modified with the addition of an internal unloading mechanism that opens a by pass port in the first compres sion pocket effectively reducing the displacement of the scroll The opening and closing of the by pass port is controlled by an internal electrically operated solenoid Modulation Ring amp Bypass Seals Solenoid Coil Assembly The ZPS modulated scroll uses a single step of unloading to go from full capacity to approximately 67 capacity A single speed high efficiency motor continues to run while the scroll modulates between the two capacity steps Bypass Ports Closed 100 Capacity Bypass Ports Open 67 Capacity A scroll is an involute spiral which when matched with a mating scroll form as shown generates a series of crescent shaped gas pockets between the two members During compression on
63. ifold pressure on low stage should be 2 0 w c 3 w c c Manifold pressure on high stage should be 3 5 3 w c ForPROPANE GAS a Inlet pressure should be a nominal 11 w c b Manifold pressure on low stage should be 6 w c c Manifold pressureonhigh stage should be 10 w c Manifold Gas Pressure Gas Range Nominal Low Stage_ 1 6 2 2 w c EE High Stage 3 2 3 8 w c Low Stage 5 7 6 3 w c EE High Stage 9 7 10 3 w c If operating pressures differ from above make necessary pressure regulator adjustments check piping size etc and or consult with local utility 51 SERVICING S 308 CHECKING FOR DELAYED IGNITION Delayed ignition is a delay in lighting a combustible mixture of gas and air which has accumulated in the combustion chamber When the mixture does ignite it may explode and or rollout causing burning in the burner venturi If delayed ignition should occur the following should be checked 1 Improper gas pressure adjust to proper pressure See S 307 2 Improper burner positioning burners should be in locat ing slots level front to rear and left to right 3 Carry over lighter tube or cross lighter obstructed clean 4 Main burner orifice s deformed or out of alignment to burner replace 309 CHECKING FOR FLASHBACK Flashback will also cause burning in the burner venturi butis caused by the burning speed being greater than the gas air flow velocity
64. ion with the motor windings so that the motor will give two phase operation when connected to a single phase circuit The capacitor also reduces the line current to the motor by improving the powerfactor CAPACITOR START SCROLL COMPRESSOR MODELS Hard start components are not required on Scroll compres sor equipped units due to a non replaceable check valve located in the discharge line of the compressor However hard start kits are available and may improve low voltage starting characteristics This check valve closes off high side pressure to the com pressor after shut down allowing equalization through the scroll flanks Equalization requires only about one or two seconds during which time the compressor may turn back wards SERVICING Your unitcomes witha 180 second anti short cycle to prevent the compressor from starting and running backwards MODELS EQUIPPED WITH A HARD START DEVICE A start capacitor is wired in parallel with the run capacitor to increase the starting torque The start capacitor is of the electrolytic type rather than metallized polypropylene as used in the run capacitor Aswitching 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 re
65. ker ground fault protective device etc has not tripped WARNING HIGH VOLTAGE Disconnect ALL power before servicing or installing this unit Multiple power sources may be present Failure to do so may cause property damage personal m or death 1 Remove the leads from the compressor terminals WARNING See warnings S 17 before removing compressor terminal cover 2 Using an ohmmeter test continuity between terminals S R C R and C S on single phase units or terminals T1 T2 and T3 on 3 phase units OHMMETER TESTING COMPRESSOR WINDINGS 37 SERVICING If either winding does not test continuous replace the compressor NOTE If an open compressor is indicated allow ample time for the internal overload to reset before replacing compressor 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 cor rected 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 accept able to replace the fuse or resetthe circuit breaker ONE TIME ONLY to see if it was just a nuisance opening If it opens again DO NOT continue to reset E WARNING ae Disconnect ALL power before servicing Disconnect all power to unit making sure that all po
66. king GE X13 Motors 36 Checking Compressor Windings 37 Resistance Tests 37 Ground Test 38 Unloader Test tee 38 Operation Test 39 Testing Crankcase Heater optional item 39 Refrigeration Repair Practice 39 Leak Testing 40 EVACUATION sisi ont 40 Changing cic oer e etri reete 41 WARNING HIGH VOLTAGE S 104 Checking Compressor Efficiency 41 S 105B Thermostatic Expansion Valve 41 9 106 Overfeeding cette eene 43 9 107 Underfeeding nece 43 S 108 Superheat iii 43 S 109 Checking Subcooling ii 45 S 110 Checking Expansion Valve Operation 45 S 111 Fixed Orifice Restriction Devices 45 S 112 Checking Restricted Liquid Line 46 S 113 RefrigerantOvercharge iii 46 S 114 Non condensables 46 S 115 Compressor Burnout usususss 46 S 200 Checking Extedrnal Static Pressure 47 S 201 Checking Temperature Rise 47 S 300 Testing Primary Limit sess 48 S 301 Testing Auxiliary Limit 48 S 302 Checking Flame Rollout Switch 49 S 303 Testing Inducer Motor 50 S 304 Testing Gas Valve 50 S 305 Checking Main Bur
67. l to gas valve If wires and connections at 9 pin connector check good replace ignition control Voltage presentat gas valve replace gas valve Testing High Stage Heat Operation with Low Stage Heat Operating 1 Board set for 2 stage thermostat a e Checkfor 24 Volts atthermostatterminals W2 and C on the control board No voltage check thermostat and thermostat wiring Voltage present check for 24 volts at gas valve terminals C and HI No voltage present at valve check 9 pin connector and wires from ignition control to gas valve If wires and connections at 9 pin connector check good replace ignition control Voltage presentat gas valve replace gas valve 2 Board set for 1 stage thermostat a 54 Wait the selected delay time either 5 or 10 minutes depending on jumper setting Check for 24 volts at gas valve terminals C and HI No voltage present check 9 pin connector and wires from ignition control to gas valve If wires and connections at 9 pin connector check good re place ignition control Voltage presentat gas valve terminals C and HI replace valve Cooling Mode Indoor thermostat calling for cool 1 Check for 230 volts from L1 terminal of control module toL2 No voltage check wire connections continuity etc Check for 24 volts at R and C thermostat terminals on ignition control a No voltage check 3 amp automotive type fuse on control board A blown fuse coul
68. lace in heating cycle 7 As the unit fires on high stage the inclined manometer negative pressure will drop to 1 0 0 3 W C 8 If notas listed replace control Note the pressure switch must be mounted with the dia phragm in a vertical position SERVICING S 311 HIGH ALTITUDE APPLICATION High Altitude Derate U S Installations Only IMPORTANT NOTE The gas electric units naturally derate with altitude Do not attempt to increase the firing rate by changing orifices or increasing the manifold pressure This can cause poor combustion and equipment failure At all altitudes the manifold pressure must be within 0 3 inches W C of that listed on the nameplate for the fuel used At all altitudes and with either fuel the air temperature rise must be within the range listed on the unit nameplate Refer to the Installation Manual provided with the LP kit for conversion from natural gas to propane gas and for altitude adjustments When this package unit is installed at high altitude the appropriate High Altitude orifice kit must be installed As altitude increases there is a natural reduction in the density of both the gas fuel and combustion air This kit will provide the proper design certified input rate within the specified altitude range High altitude kits are not approved for use in Canada For installations above 2 000 feet use kit HA 02 The HA 02 kit is used for both Natural and LP gas at high altitudes Use LPM 05
69. 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 18 HEATING The heating cycle is accomplished by using a unique tubular design heat exchanger which provides efficient gas heating on either natural gas or propane gas fuels The heat exchangers compacttubular construction provides excellent heat transfer for maximum operating efficiency Inshot type gas burners with integral cross lighters are used eliminating the need for adjustable air shutters The same burner is designed for use on either natural or propane gas fuels The induced draft blower draws fuel and combustion air into the burners and heat exchanger for proper combustion A pressure switch is used in conjunction with the D blower to detect a blocked flue condition Blower operation is controlled by the ignition control module The module allows for field adjustment of the blower delay at the end of the heating cycle The range of adjustment is for 90 120 150 or 180 seconds The factory delay setting is 30 seconds delay on 150 seconds delay off Direct Spark Ignition DSI Systems APG GPG units are equipped with a direct spark ignition system Ignition is provided by 22 000 volt electronic spark Aflame sensorthen monitors for the presence of flame and closes the gas valve if flame is lost SYSTEM OPERATION SEQUENCE OF OPERATION A Heating Operation Low stage heat
70. m superheat Add charge to lower superheat or recover charge to raise superheat Superheat Formula Suct Line Temp Sat Suct Temp EXAMPLE a Suction Pressure 143 b Corresponding Temp F 50 c Thermometer on Suction Line 61 F To obtain the degrees temperature of superheat subtract 50 0 from 61 0 F The difference is 11 Superheat The 11 Superheat would fall in the range of allowable superheat SUPERHEAT AND SUBCOOLING ADJUSTMENT ON TXVAPPLICATIONS 1 Run system at least 10 minutes to allow pressure to stabilize 2 Temporarily install thermometer on liquid small line near pressure switches with adequate contact and insulate for best possible reading 3 Check subcooling and superheat Systems with TXV application should have a subcooling and superheat of 12 15 F a Ifsubcooling and superheatare low adjust TXV to 9 3 F then check subcooling b If subcooling is low and superheat is high add charge to raise subcooling to 10 F then check superheat c Ifsubcooling and superheatare high adjust TXV valve to 12 15 F then check subcooling d Ifsubcoolingis high and superheatis low adjust TXV valve to 12 15 F superheat and remove charge to lower the subcooling to 2 15 F The TXV should NOT be adjusted atlightload conditions 55 to 60 F under such conditions only the subcooling can be evaluated This is because suction pressure is dependentonthe indoor coil match indoor
71. ners 50 S 306 Checking OF ifices sssssssss 50 S 307 Checking Gas Pressure 51 S 308 Checking For Delayed Ignition 52 S 309 Checking for Flashback 52 S 310 Checking Pressure Control 52 S 311 High Altitude Application 53 S 313 Testing Ignition Control Module 53 S 314 Checking Flame Sensor 55 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 A SERVICING S 1 CHECKING VOLTAGE WARNING HIGH VOLTAGE Disconnect ALL power before servicing or installing this unit Multiple power sources may be present Failure to do so may cause property damage personal injury or death q 1 Remove doors control panel cover etc from unit being tested With power ON Ez WARNING Line Voltage now present 2 Usingavoltmeter measurethe voltage across terminals L1andL2 ofthe contactorfor single phase units and L3 for 3 phase units 3 Noreading indicates open wiring open fuse s no power or etc from unit to fused disconnect service Repair as needed 4 With ample voltage at line voltage connectors energize the unit 5 Measurethe voltage with the unitstarting and operating and determin
72. nverter HEC amp 36 CDK3 Concentric Converter PG 48 amp 60 GOODMAN BRAND THERMOSTATS CHSATG Nonprogrammable 1 Cool 1 Heat CH70TG Nonprogrammable Digital 1 Cool 1 Heat LIGHTING INSTRUCTIONS LIRE AVANT DE METTRE EN MARCHELIRE exact damage personal injury or loss of life WARNING If you do not follow these instructions y a fire or explosion may result causing property with an ignition device which automatically lights the burner Do not try to light the burner by hand B BEFORE OPERATING area for gas Be sure to smell next to the f because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS o Do not try to light any appliance o Do not touch any electric switch do not use any phone in your building 00r phone Follow the gas supplier s instructions o If you cannot reach your gas supplier call the fire department hand don t try to repair it call a qualified service or explosion the appliance and to replace any part of the control System and any gas control which has been underwater AVERTISSEMENT Quiconque ne respecte pas la risque de d clencher un incendie ou une explosion entrainant des dommages mat riels des lesions A This appliance does not have a pilot It is equipped corporelles ou la perte de vies humaines lettre les instructions dans le pres nt manuel smell all around the dome o Immediately call your gas s
73. of 3 to indicate open pressure switch 52 If the pressure switch opens after the gas valve has been energized the control will de energize the gas valve and run the indoor blower through the heat off delay The inducer stays on until the pressure switch re closes Then the control makes another ignition attempt WARNING HIGH VOLTAGE Disconnect ALL power before servicing or installing this unit Multiple power sources may be present Failure to do so may cause property damage personal injury or death 1 Remove wires from the electrical terminals 2 Using a VOM check from Common to NO Normally Open should read open If switch reads as noted proceed to Step 3 otherwise replace control 3 Remove the pressure control hose from the control and interconnect with an inclined manometer as shown HOSE TO J TUBE N xi PRESSURE SWITCH INCLINED MANOMETER Reconnect wires to the Common and NO terminals With Power ON Ez WARNING Y Line Voltage now present 4 Energize furnace for heating cycle The induced draft blower motor will begin to run The inclined manometer should read approximately 1 2 0 3 W C with no combustion 5 Remove and checkthe two electrical wires and using the VOM check from Common to NO Normally Open it should read closed with I D motor running If not as above replace pressure control 6 Reconnect all wires to the control and p
74. of pipe run and total load of all appliances Complete information regarding tank sizing for vaporization recommended regulator settings and pipe sizing is avail able from most regulator manufacturers and propane gas suppliers Propane is an excellent solvent and special pipe dope must be used when assembling piping for this gas as it will quickly dissolve white lead or most standard commercial com pounds Shellac base compounds resistant to the actions of liquefied petroleum gases such as Gasolac Stalactic Clyde s or John Crane are satisfactory PRODUCT DESIGN PROPANE GAS PIPING CHARTS Sizing Between First and Second Stage Regulator 5 to 15 PSIG Maximum Propane Capacities listed are based on 1 PSIG Pressure Drop at 10 First Stage PSIG Setting Capacities in 1 000 BTU HR 20 PSIG Max Regulator Continuous PEOR 11 W C TUBING TUBING SIZE O D TYPE L Mere a LENGTH n FEET f 5 8 3 4 718 1 2 3 4 200 PSIG Second Stage 1 303 2 205 3 394 1 843 3 854 Maximum Regulato f 1415 1887 2904 1 577 3 298 f 988 1 672 2 574 1 398 2 923 f 896 1 515 2 332 1 267 2 649 f 824 1 394 2 146 1 165 2 437 4 767 1 297 1 996 1 084 2 267 719 1 217 1 873 1 017 2 127 679 1 149 1 769 961 2 009 546 923 1 421 772 1 613 467 790 1 216 660 1 381 414 700 1 078 585 1 224 A WARN NG 378 634 976 530 1 109 345 584 898 488 1 020 IF YOUR PROPANE GAS APPLIANCE IS INSTALLED IN jj Oe LE To convert
75. or poorly laid out ductwork S 201 CHECKING TEMPERATURE RISE Temperature rise is related to the BTUH output of the unit and the amount of air CFM circulated over the heat exchanger 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 Check BTUH input to unit do not exceed input rating stamped on rating plate 2 Takeentering and leaving airtemperatures 3 Selectthe properspeed tap or dip switch setting for direct driveunits 4 Take motoramperage drawto determine that the motoris not overloaded during adjustments SUPPLY RISE SUPPLY RETURN Checking Temperature Rise 47 SERVICING S 300 TESTING PRIMARY LIMIT CONTROL APG GPG units use a snap disk type primary limit device Sometimes referred to as stat on a stick The limit setting is fixed and must not be readjusted in the field COLOR IDENTIFYING Volt Ohm SLEEVES Meter TESTING PRIMARY LIMIT CONTROL Refertothe specification section to determine the proper limit cutout temperature for the model being serviced In all instances the limit cont
76. orces which govern the operation ofthe valve are 1 the pressure created in the power assembly by the feeler bulb 2 evaporator pressure and 3 the equivalent pressure ofthe superheat spring in the valve 096 bleed type expansion valves are used on the indoor coils The 0 valve will not allow the system pressures High and Low side to equalize during the shut down period The valve will shut off completely at approximately 100 PSIG Pressure Good thermal contact between the feeler bulb and the suction line is essential to satisfactory valve control and performance The bulb must be securely fastened to a clean straight section of the suction line Application of the bulb to a horizontal run of line is preferred If a vertical installation cannot be avoided the bulb should be mounted so that the capillary tubing comes out at the top THE VALVES PROVIDED ARE DESIGNED TO MEET THE SPECIFICATION REQUIREMENTS FOR OPTIMUM PROD UCT OPERATION DONOT USE SUBSTITUTES 41 SERVICING Pressure vs Temperature Chart R 410A PSIG F PSIG F PSIG 216 0 743 522 0 2180 749 524 0 220 0 755 526 0 2220 76 1 528 0 224 0 76 7 530 0 226 0 772 532 0 2280 778 534 0 2300 78 4 536 0 2320 789 538 0 234 0 795 540 0 236 0 80 0 544 0 238 0 80 6 548 0 2400 81 1 552 0 2420 81 6 556 0 2440 822 560 0 2460 827 564 0 248 0 833 568 0 250 0 83 8 572 0 2520 843 576 0 2540 848 580 0 256 0 584 0 6 6 6 6 6 6 6
77. pected thoroughly ventilate the area before beginning work Liquid refrigerant can be very cold To avoid possible frostbite or blindness avoid contact with refrigerant and wear gloves and goggles If liquid refrigerant does contact your skin or eyes seek medical help immediately Always follow EPA regulations Never burn refrig erant as poisonous gas will be produced WARNING To avoid possible injury explosion or death practice safe handling of refrigerants WARNING The compressor POE oil for R 410A units is extremely susceptible to moisture absorption and could cause compressor failure Do not leave system open to atmosphere any longer than necessary for installation WARNING System contaminants improper service procedure and or physical abuse affecting hermetic compressor electrical terminals may cause dangerous system venting The successful development of hermetically sealed refrigera tion compressors has completely sealed the compressor s moving parts and electric motor inside a common housing minimizing refrigerant leaks and the hazards sometimes associated with moving belts pulleys or couplings Fundamental to the design of hermetic compressors is a method whereby electrical current is transmitted to the compressor motor through terminal conductors which pass through the compressor housing wall These terminals are sealed ina dielectric material which insulates them from the
78. pressure regulatoron the gas valve turn down clockwise to increase pressure and input and out counter clockwise to decrease pressure and input Since propane gas is not normally installed with a gas meter clocking will be virtually impossible The gas orifices used with propane are calculated for 2500 BTU gas per cubic foot and with proper inlet pressures and correct piping size full capacity will be obtained With propane gas no unit gas valve regulator is used however the second stage supply line pressure regulator should be adjusted to give 11 water column with all other gas consuming appliances running The dissipation ofthe heattransferredto the heat exchanger is now controlled by the amount of air circulated over its surface The flow rate CFM of air circulated is governed by the external static pressure in inches of water column of duct work cooling coil registers and etc applied externally to the unit versus the motor speed tap A properly operating unit must have the BTU input and flow rate CFM of air within the limits shown to prevent short cycling of the equipment As the external static pressure goes up the temperature rise will also increase Consultthe proper tables for temperature rise limitation 27 SERVICING COOLING ANALYSIS CHART System Operating Pressures Unsatisfactory Complaint No Cooling Cooling POSSIBLE CAUSE Test Method Remedy DOTS IN ANALYSIS GUIDE INDICATE POSSIB
79. propane conversion kit for propane conversions at altitudes below 2000 feet Natural gas installations below 2000 feet do not require a kit For propane conversions above 2000 feet high altitude kit HA 02 is required in addtion to LPM 05 propane conversion kit Natural gas and LP gas installations at altitudes gt 2000 ft 20 000 BTUH NAT 20 000 BTUHIL P HIGH ALTITUDE INPUT BURNER KIT ELEVATION ABOVE SEA LEVEL FEET 2000 3000 4000 4500 5000 6000 7000 8000 U S BURNER ORIFICE 45 55 47 55 47 56 47 56 48 57 48 58 49 58 HA02 CANADA BURNER ORIFICE 45 55 48 57 22 500 BTUH NAT 20 000 BTUHIL P ELEVATION ABOVE SEA LEVEL FEET 2000 3000 4000 4500 5000 6000 7000 8000 U S BURNER ORIFICE 44 55 44 55 45 56 45 56 46 57 47 58 47 58 HA02 CANADA BURNER ORIFICE 44 55 47 57 HIGH ALTITUDE INPUT BURNER KIT 25 000 BTUH NAT 20 000 BTUHIL P ELEVATION ABOVE SEA LEVEL FEET 2000 3000 4000 4500 5000 6000 7000 8000 U S BURNER ORIFICE 43 55 53 55 44 56 44 56 44 56 45 57 45 57 HA02 s7 CANADA BURNER ORIFICE 43 55 HIGH ALTITUDE INPUT BURNER KIT S 313 TESTING IGNITION CONTROL MODULE NOTE Failure to earth ground the unit ora high resistance connection in the ground may cause the control to lockout due to failure to flame sense Ah WARNING To
80. r entraining of primary air which will make it difficult to adjust the flame properly This same problem can occurifan orifice spud of a different length is substituted WARNING Disconnect gas and electrical power supply 1 Checkorifice visually for distortion and or burrs 2 Check orifice size with orifice sizing drills 3 Ifresizing is required a new orifice of the same physical size and angle with proper drill size opening should be installed 307 CHECKING GAS PRESSURE Gas inlet and manifold pressures should be checked and adjusted in accordance to the type of fuel being consumed WARNING Disconnect gas and electrical power supply 1 Connect a water manometer or adequate gauge to the inlet pressure fitting of the gas valve 2 Removethe pressure tap fitting at the manifold if provided orcheckatthe gas valve outletfitting and connectanother manometer or gauge Gas Valve Manometer On Off _ Inlet Pressure Hose Switch ap Open to Low Pressure Atmosphere Adjust TER a 9 gJ Outlet lt q X MX Inlet High Pressure 7 a Adjust v Open to zr Atmosphere Outlet Pressure o Manometer Tap Hose Manometer MEASURING INLET AND MANIFOLD GAS PRESSURE With Power ON Ez WARNING A Line Voltage now present 3 Put furnace into heating cycle and turn on all other gas consuming appliances ForNATURALGAS a Inlet pressure should be a nominal 7 w c b Man
81. rame ground and the other probe in turn to each lead Ifthe windings do nottest continuous ora reading is obtained from lead to ground replace the motor S 16C CHECKING ECM MOTOR WINDINGS WARNING HIGH VOLTAGE Disconnect ALL power before servicing or installing this unit Multiple power sources may be present Failure to do so may cause property damage personal m or death 1 Disconnectthe 5 pin and the 16 pin connectors from the ECM power head 2 Removethe2 screws securing the ECM power head and separate it from the motor 3 Disconnect the 3 pin motor connector from the power head and lay it aside 36 4 Using an ohmmeter check the motor windings for conti nuity to ground pins to motor shell If the ohmmeter indicates continuity to ground the motor is defective and must be replaced 5 Usinganohmmeter 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 Motor OK when R 100k ohm 3 pin WINDING TEST S 16D CHECKING GE X13 MOTORS Applies to PG15 41A The GE X13 Motor is a one piece fully encapsulated 3 phase brushless DC single phase AC input motor with ball bearing construction Unlike the ECM 2 3 2 5 motors the GE 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
82. returns to infinity Start capacitor with bleed resistor will not return to infinity It will still read the resistance of the resistor b Shorted indicator swings to zero and stops there replace c Open no reading replace Start capacitor would read resistor resistance S 15B CAPACITANCE CHECK Using a hookup as shown below take the amperage and voltage readings and use them in the formula VOLTMETER CAPACITOR TESTING CAPACITANCE 35 SERVICING WARNING Discharge capacitor through a 20 to 30 OHM resistor before handling Capacitance MFD 2650 X Amperage Voltage S 16A CHECKING FAN AND BLOWER MOTOR WINDINGS PSC MOTORS The auto reset fan motor overload is designed to protect the motor against high temperature and high amperage condi tions by breaking the common circuit within the motor similar to the compressor internal overload However heat gener ated within the motoris faster to dissipate than the compres sor allow at least 45 minutes for the overload to reset then retest WARNING HIGH VOLTAGE Disconnect ALL power before servicing or installing this unit Multiple power sources may be present Failure to do so may cause property damage personal m or death 1 Remove the motor leads from its respective connection points and capacitor if applicable 2 Checkthe continuity between each of the motor leads 3 Touch one probe of the ohmmeter to the motor f
83. rol is wired in series with the ignition control If the temperature within the furnace should exceed this setting the control will open de energizing the ignition control which in turn will open the electrical circuitto the gas valve The control will automatically reset when the temperature within the combustion chamber is sufficiently lowered WARNING HIGH VOLTAGE Disconnect ALL power before servicing or installing this unit Multiple power sources may be present Failure to do so may cause property damage personal injury or death 1 Remove electrical power to unit Some units may have more than one source of power Remove the wires from the limit control terminals 3 Using an ohmmeter test for continuity across the two terminals If limit test open allow unit to cool and retest 5 If still open replace the control 48 301 TESTING AUXILIARY LIMIT The auxiliary limit control is a preset nonadjustable control mounted in the blower compartment area It is connected in series with the rollout switch wiring to the gas valve Ifits temperature should be exceeded it will open interrupting the voltage to the gas valve causing it to open An additional limit primary limit control is required for safety control of high temperature within the furnace or ductwork AUX LIMIT WARNING HIGH VOLTAGE Disconnect A
84. s motor windings and voltage 5 Accurate Leak Detector testing for refrigerant leaks 6 High Vacuum Pump evacuation 7 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 pressure drop across coils Other recording type instruments 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 HEATING PERFORMANCE TEST Before attempting to diagnose an operating fault run a Heating Performance Test and apply the results to the Service Problem Analysis Guide To conducta heating performance test the BTU inputto the package gas unit must be calculated After the heating cycle has been in operation for at least fifteen minutes and with all other gas appliances turned off the gas meter should be clocked To find the BTU input multiply the number of cubic feet of gas consumed per hour by the heating value of the gas being used The calorific value of the gas being used is found by contacting your local utility 25 SCHEDULED MAINTENANCE 1 Million 100 Thousand 10 Thousand 1 Thousand CUBIC O FEET GAS RATE CUBIC FEET PER HOUR Size of Test Dial Size of Test Dial Second
85. s 1 4 1 2 1 2 Seconds 1 4 1 2 1 2 for One cu ft cu ft cu ft cu ft for One cu ft cu ft cu ft cu ft Revolution Revolution 26 SCHEDULED MAINTENANCE Example It takes forty 40 seconds on the gas meter for the hand on the cubic foot dial to make one complete revolution with all appliances off except the unit Using the gas rate chart observe the forty 40 seconds locate and read across to the one 1 cubicfoot dial column There you will find the number 90 which shows that ninety 90 cubic feet of gas will be consumed in one 1 hour Let s assume the local gas utility has stated that the calorific value of the gas is 1025 BTU per cubic foot Multiplying the ninety 90 cubic feet by 1025 BTU ft gives us an input of 92 250 BTU hr Checking the BTU input on the rating plate of the unit being tested EXAMPLE GPG153609041 INPUT 92 000 BTU HR OUTPUT CAP 72 900BTU HR Should the figure you calculated notfall within five 5 percent of the nameplate rating of the unit adjust the gas valve pressure regulator or resize orifices In no case should the input exceed that shown on the rating plate 4h CAUTION ALWAYS CONNECT A MANOMETER TO THE 1 8 PIPE TAP AT THE GAS VALVE BEFORE ADJUSTING THE PRESSURE REGULATOR IN NO CASE SHOULD THE FINAL MANIFOLD PRESSURE VARY MORE THAN PLUS OR MINUS 3 INCHES WATER COLUMN FROM 3 5 INCHES WATER COLUMN FOR NATURAL GAS OR 10 INCHES WATER COLUMN FOR PROPANE GAS Toadjustthe
86. se symptoms are observed 1 Check fora 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 Opera tion S 108 SUPERHEAT The expansion valves are factory adjusted to maintain 12 to 15 degrees superheat of the suction gas Before checking the superheat or replacing the valve perform all the proce dures outlined under Air Flow Refrigerant Charge Expan sion Valve Overfeeding Underfeeding These 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 toits pressure The degree of superheat equals the degrees of temperature increase above the saturation temperature at existing pressure See Temperature Pressure Chart on following page CAUTION To prevent personal injury carefully connect and disconnect manifold gauge hoses Escaping liquid refrigerant can cause burns Do not vent refrigerant to atmosphere Recover during system repair or final unit disposal 1 Run system at least 10 minutes to allow pressure to stabilize 2 Temporarily install thermometer on suction large line near compressor with adequate contact and insulate for best possible reading 3 Refer to the superheat table provided for proper syste
87. sing potentially severe or fatal injury to anyone in its path This discharge can be ignited external to the compressor if theterminal coveris not properly in place and ifthe discharge impinges on a sufficient heat source Ignition ofthe discharge can also occuratthe venting terminal orinside the compressor ifthere is sufficient contaminantair present in the system and an electrical arc occurs as the terminal vents Ignition cannot occur at the venting terminal without the presence of contaminant air and cannot occur externally from the venting terminal without the presence of an external ignition source Therefore proper evacuation of a hermetic system is essen tial 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 extin guished or turned off prior to servicing a system S 17A RESISTANCE TEST Each compressor is equipped with an internal overload Theline breakinternal overload senses both motor amperage and winding temperature High motortemperature or amper age heats the disc causing itto open breaking the common circuit within the compressor on single phase units Heat generated within the compressor shell usually due to recycling of the motor high amperage or insufficient gas to cool the motor is slow to dissipate Allow at least three to four hours for it to cool and reset then retest Fuse circuit brea
88. sistor is to discharge the capacitor under certain operating conditions rather than having it discharge across the closing of the contacts within the switching device such as the Start Relay and to reduce the chance of shock to the servicer See the Servicing Section for specific information concerning capacitors RELAY START A potential or voltage type relay is used to take the start capacitor out of the circuit once the motor comes up to speed This type of relay is position sensitive The normally closed contacts are wired in series with the start capacitor and the relay holding coil is wired parallel with the start winding As the motor starts and comes up to speed the increase in voltage across the start winding will energize the start relay holding coil and open the contacts to the start capacitor Two quick ways to test a capacitor are a resistance and a capacitance check S 15A RESISTANCE CHECK 4h 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 WARNING Discharge capacitor through a 20 to 30 OHM resistor before handling CAPACITOR TESTING CAPACITOR RESISTANCE 2 Setanohmmeter on its highest ohm scale and connect the leads to the capacitor a Good Condition indicator swings to zero and slowly
89. ss may cause the terminals to be expelled thereby venting the vaporous and liquid contents of the compressor housing and system Aventing 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 ina stream of spray which may be dangerous to anyone in the vicinity Death or serious bodily injury could occur Under no circumstances is a hermetic compressor to be electrically energized and or operated without having the terminal protective cover properly in place See Service Section S 17 for proper servicing PRODUCT IDENTIFICATION The model numberis used for positive identification of component parts used in manufacturing Please use this number when requesting service or parts information Minor Revision A Initial Revision Product Brand A Amana Brand G Goodman Brand Major Revision A Initial Revision Product Type Single Package Cooling Heating Product Family G Gas Electric Voltage Product Series 1 208 230V 60Hz 1ph SEER Rating Refrigerant Nominal Capacity 4 R 410A 24 24 000 BTUH 36 36 000 BTUH 48 48 000 BTUH Heating Inp
90. tasfi Short Cycles Long Cycles Soot and or Fumes To Much Heat Not Enough Heat Test Method Remedy See Service Procedure Reference Test Voltage Test Voltage Loose Connection Check Wiring Shorted or Broken Wires Check Wiring Check Transformer Faulty Thermostat Check Thermostat Faulty Transformer Check Transformer Poor or High Resistance Ground Improper Heat Anticipator Setting Measure Ground Resistance Adjust Heat Anticipator Setting S 3 Improper Thermostat Location Relocate Thermostat Faulty Limit or Roll Out Switch Test Control S 300 S 301 S 30 2 Faulty Flame Sensor Faulty Ignition Control Test Flame Sensor S 314 Test Control S 313 Gas Valve or Gas Supply Shut Off Turn Valves to On Position S 304 Faulty Induced Draft Blower Test Blower S 303 Dirty Flame Sensor Low uA Clean Flame Sensor S 314 Flame Sensor not in Flame Low uA Test Adjust Position of Flame Sensor S 314 Faulty Gas Valve Replace Gas Valve S 304 No High Stage Heat Open Auxillary Limit Check Thermostat Control Gas Valve S 3 S 313 S 304 Reset Control Improper Air Flow or Distribution Check Duct Static Locking out on Main Limit Check Controls Gas Press amp Temp Rise Delayed Ignition Flashback Test for Delayed Ignition Test for Flashback Orifice Size Check Orifices Gas Pressure Check Gas Pressure
91. tat Y1 or thermostat Y1 and G input initiates low stage cooling IDT ODT Pressure Loss of Charge Switch circuits are checked for closed condition Cooling operation can proceed only if these circuits are closed Low stage compressor output is energized Condenser fan motor is energized at low speed Air circulating blower is energized at low cool speed after cool ON delay expires Cool ON delay timer begins when thermostat inputs are detected Control monitors thermostat gas valve flame and IDT ODT Pressure Loss of Charge Switches during low stage cooling Thermostat Y 1 or Y 1 and G inputs are removed Low stage compressor output is de energized Low speed condenser fan motor is de energized Air circulating blower remains energized at low cool speed for the cool OFF delay Cool OFF delay timer begins when thermostat input is removed Control returnsto Standby and awaits nextthermostat request B Cooling Operation High stage cool Thermostat type is set to two stage Thermostat Y 1 and Y2 or Y1 Y2 and G inputs initiate high stage cooling IDT ODT Pressure Loss of Charge Switch circuits are checked for closed condition Cooling operation can proceed only if these circuits are closed 20 Low and high stage compressor outputs are ener gized Condenser fan motor is energized at high speed Air circulating blower is energized at high cool speed after cool
92. thout a flux alloy of 30 silver 38 copper 32 zinc Recommended heat 1200 F 39 SERVICING S 101 LEAK TESTING NITROGEN OR NITROGEN TRACED WARNING To avoid the risk of fire or explosion never use oxygen high pressure air or flammable gases for leak testing of a refrigeration system WARNING To avoid possible explosion the line from the nitrogen cylinder must include a pressure regulator and a pressure relief valve The pressure relief valve must be set to open at no more than 150 psig Pressure testthe system using dry nitrogen and soapy water tolocate 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 repeatthe pressure test If no leaks exist proceed to system evacuation S 102 EVACUATION WARNING REFRIGERANT UNDER 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 equipmentis dependent upon the thoroughness exercised by the serviceman when evacuating air non condensables and moisture from the system Air in a system causes high condensing temperature and pressure resulting in increased power input and reduced performan
93. to Capacities at 15 PSIG Settings Multiply by 1 130 AN EXCAVATED AREA OR A CONFINED SPACE WE To convert to Capacities at 5 PSIG Settings Multiply by 0 879 STRONGLY RECOMMENDED THAT YOU CONTACT YOUR PROPANE SUPPLIER ABOUT INSTALLING A GAS DETECTING WARNING DEVICE THAT WOULD ALERT YOU TO A GAS LEAK Sizing Between Single or Second Stage Regulator and Appliance PROPANE GAS IS HEAVIER THAN AIR AND ANY eo eee LEAKING GAS CAN SETTLE IN ANY LOW AREAS on OR CONFINED SPACES TUBING TUBING SIZE O D TYPE L NOMINAL PIPE SIZE PROPANE GAS ODORANT MAY FADE MAKING LENGTH ee 3 8 1 2 5 8 3 4 7 8 1 2 3 4 1 1 1 4 1 1 2 THE GAS UNDETECTABLE EXCEPT WITH A 10 49 110 206 348 539 291 608 1 146 2 353 3 525 WARNING DEVICE 20 34 76 141 239 368 200 418 788 1 617 2 423 AN UNDETECTED GAS LEAK WILL CREATE A 30 27 61 114 192 296 161 336 632 1 299 1 946 DANGER OF EXPLOSION OR FIRE IF YOU SUSPECT 40 23 52 97 164 253 137 284 541 1 111 1 665 THE PRESENCE OF GAS FOLLOW THE INSTRUCT 50 20 46 86 146 224 122 255 480 985 1 476 IONS ON PAGE 7 FAILURE TO DO SO COULD iuc 19 42 e 182 209 440 294 498 0602 1897 RESULT IN SERIOUS PERSONAL INJURY OR DEATH do EE Cc po E CA 100 14 32 59 100 154 84 175 330 677 1 014 125 12 28 52 89 137 74 155 292 600 899 150 14 26 48 80 124 67 141 265 544 815
94. upplier from a neighbor s C Use only your hand to push in or turn the gas control lever Never use tools If the lever will not push in or turn by technician Force or attempted repair may result in a fire D Do not use this appliance if any part has been underwater Immediately call a qualified service technician to inspect A B Ne pousser ou tourner la manette d admission du gaz Ne pas se servir de cet appareil s il a t plong dans Cet appareil ne comporte pas de veilleuse Il est muni d un dispositif d allumage qui allune automatiquement le br leur Ne pas tenter d allumer le br leur manuellement AVANT DE LE FAIRE FONCTIONNER renifler tout autour de l appariel pour dec ler une odeur de gaz Renifler pr s du plancher car certains gaz sont plus lourds que l air et peuvent s accumuler au niveau du sol QUE FAIRE S IL Y A UNE ODEUR DE GAZ o Ne pas tenter d allumer d appareils o Ne toucher aucun interrupteur ne pas vous servir des t l phones dans le b timent o Appelez imm diatement votre fournisseur de gaz depuis un voisin Suivez les instructions du fournisseur de gaz o Si vous ne pouvez rejoindre le fournisseur de gaz appelez le service des incendies qu la main Ne jamais emploer d outil cette fin Si la manette reste coinc e ne tenter pas de la r parer appelez un technicien qualifi Quiconque tente de forcer la manette ou de la r parer peut provoquer une explosion ou un incendie
95. ut 60 60 000 BTUH 070 69 000 090 92 000 115 115 000 140 138 000 Amana Goodman Package Gas 15 Seer R410a gas electric units Initial A GPG1524 60 1AA release Amana Goodman Package Gas 15 Seer R410a gas electric units Sound AIGPG1536 60 1AB improvements Change condenser motor and blade These units have R410A refrigerant ACCESSORIES ACCESSORIES Part Number Fits Models LPM 05 Propane Conversion Kit HA 02 High Altitude Kit PGC101 102 103 Roof Curb PGED102 Downflow Economizer PG 24 amp 36 AI PGED103 Downflow Economizer PG 48 amp 60 PGEH102 Horizontal Economizer PG 24 amp 36 AI PGEH103 Horizontal Economizer PG 48 amp 60 PGMDD102 Downflow Manual 25 Fresh Air Damper PG 24 amp 36 PGMDD102 Downflow Manual 25 Fresh Air Damper PG 48 amp 60 PGMDH102 Horizontal Manual 25 Fresh Air Damper PG 24 amp 36 PGMDH103 Horizontal Manual 2596 Fresh Air Damper PG 48 amp 60 PGMDMD 102 Downflow Motorized 25 Fresh Air Damper PG 24 amp 36 PGMDMD 103 Downflow Motorized 25 Fresh Air Damper PG 48 amp 60 PGMDMH102 Horizontal Motorized 25 Fresh Air Damper PG 24 amp 36 PGMDMH103 Horizontal Motorized 25 Fresh Air Damper PG 48 amp 60 SQRPG102 Square to Round Adapter 16 Round PG 24 amp 36 SQRPG103 Square to Round Adapter 18 Round PG 48 amp 60 PGFR101 102 103 Internal Filter Rack II MN NON PGEHFR101 103 103 External Filter Rack Filter Rack CDK1 2 Concentric Co
96. ved If not continuous the contacts are open 3 Attach a gauge to the dill valve port on the base valve With power ON E WARNING A Line Voltage now present 34 4 Startthe system and place a piece of cardboard in front ofthe condenser coil raising the condensing pressure 5 Checkpressure atwhich the high pressure control cuts out If it cuts out at610 PSIG 10 PSIG it is operating normally See causes for high head pressure in Service Problem Analysis Guide If it cuts out below this pressure range replace the control The control should reset at 420 PSIG 25 PSIG S 13 CHECKING LOW PRESSURE CONTROL The low pressure control senses the pressure in the suction line and will open its contacts on a drop in pressure The low pressure control will automatically reset itself with a rise in pressure The low pressure control is designed to cut out open at approximately 7 PSIG 3 PSIG It will automatically cut in close at approximately 25 PSIG x 5 PSIG Test for continuity using a VOM and if notas above replace the control S 15 CHECKING CAPACITOR CAPACITOR RUN A run capacitor is wired across the auxiliary and main windings of a single phase permanent split capacitor motor The capacitors primary function is to reduce the line current while greatly improving the torque characteristics of a motor This is accomplished by using the 90 phase relationship betweenthe capacitor current and voltage in conjunct
97. volts to the motor connections L and N If 230 volts is present proceed to step 2 If 230 volts is not present check the line voltage circuit to the motor 2 Using a voltmeter check for 24 volts from terminal C to either terminal 1 2 3 4 or 5 depending on which tap is being used at the motor If voltage present proceed to step 3 If no voltage check 24 volt circuit to motor 3 Ifvoltage was presentin 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 SERVICING High Voltage Connections 1 3 16 Low Voltage Connections GE X13 MOTOR CONNECTIONS S 17 CHECKING COMPRESSOR WARNING Hermetic compressor electrical terminal venting can be dangerous When insulating material which supports a hermetic compressor or electrical terminal suddenly disintegrates due to physical abuse or as a result of an electrical short between the terminal and the compressor housing the terminal may be expelled venting the vapor and liquid contents of the compressor housing and system Ifthe compressorterminal PROTECTIVE COVER and gasket if required are not properly in place and secured there is a remote possibility if a terminal vents that the vaporous and liquid discharge can be ignited spouting flames several feet cau
98. wer legs are open 1 DONOT remove protective terminal cover Discon nect the three leads going to the compressor termi nals at the nearest point to the compressor 2 Identify the leads and using a Megger Hi Potential Ground Tester or other suitable instrument which puts outa voltage between 300 and 1500 volts check for a ground separately between each of the three leads and ground such as an unpainted tube on the compressor Do not use a low voltage output instrument such as a volt ohmmeter COMPRESSOR GROUND TEST 3 If a ground is indicated then carefully remove the compressor terminal protective cover and inspect for loose leads or insulation breaks in the lead wires 4 lfno visual problems indicated carefully remove the leads at the compressor terminals 38 WARNING Damage can occur to the glass embedded terminals if the leads are not properly removed This can result in terminal and hot oil discharging Carefully retest for ground directly between compressor terminals and ground 5 If ground is indicated replace the compressor S 17C UNLOADER TEST PROCEDURE A nominal 24 volt direct current coil activates the internal unloader solenoid The input control circuit voltage must be 18 to 28 volt ac The coil power requirement is 20 VA The external electrical connection is made with a molded plug assembly This plug contains a full wave rectifier to supply direct current to the unloader coil

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