Home

servicing - eComfort

1. A L2 INDUCER Li ODF O LOW HIGH LOW HIGH PARK SO N K K6 FS Q3 KEY RS RE 8 C9 K7 188 Ut po 227 un T s LAI D 7X rad IN V jJ U6 5 La 4 4 U7 MN 3 2 U4 VE ES E La id 05 Ki FAS y DN V y a a 1802 A _ _ 2 SPEED UP 150 NONE Fi Maa A eme s O 150 ff tomin 1 S FAULT BLOWER STAGE ECON RECALL OFF DELAY DELAY C W1W2G Y1 Y2 22 SYSTEM OPERATION Pin Voltage Function 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 ose Pressure Switch Output 2 Pressure Switch Input e unused Main Valve Low Table 2 Circuit Definitions and Voltage Ratings for the 9 Circuit Connector Circuits DI Low or Inducer Low Table 3 High Voltage Terminals 23 SYSTEM OPERATION 2 Seconds within Flame Stabiliza
2. 50 Ah 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 7 or death 1 Remove the wires from the auxiliary limit control termi nals 2 Using an ohmmeter test for continuity across the two terminals No reading indicates the control is open Pushthe red resetbutton test again if stillopen replace the control VOLT OHM METER COLOR IDENTIFYING TAB TESTING AUXILIARY LIMIT CONTROL S 302 CHECKING FLAME ROLLOUT SWITCH APD GPD 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 Thecontrolis designed to open shoulda flame roll out occur An over firing condition or flame impingement on the heat shield can also cause the control to open If the rollout control has opened the circuit between the ignition control and gas valve will be interrupted and the ignition control module will go into lockout The servicer should reset the ignition control by opening and closing the thermostat circuit The servicer should look for the ignitor glowing which indicates there is power to the ignition control The servicer should measure the voltage between each side of the rollout control and ground while the ignition control is t
3. 12 1 4 14 3 4 22 3 4 16 0 22 1 4 160 y o o 16 12 1 4 14 3 4 A y 22 3 4 189 22 1 4 180 N A Y ma LA e SQUARE TO ROUND CONVERTER HORIZONTAL APPLICATIONS s Measurements are in inches 11 ACCESSORIES GPGHFR101 103 EXTERNAL HORIZONTAL FILTER RACK PRODUCT DESIGN Locations and Clearances NOTE To ensure proper condensate drainage unit must be installed in a level position In installations where the 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 Z223 1 12 MIN 36 MIN FOR SERVICE _ 36 MIN FOR SERVICE NOTE Roof overhang should be no more than 36 Minimum clearances are required to avoid air recirculation and keep the unit operating at peak efficiency A minimum 12 inch clearance is required to the condenser coil NOTE The flue outlet hood is packaged separately inside the unit and must be installed prior to operation 4 WARNING
4. U3 K2 U5 NL 180 gt Epa SPEED UP 150 F1 MGM aig EUN Aa 1120 25 MIN KU Ku swt O 1 7 FAULT BLOWER STAGE ECON RECALL OFF DELAY DELAY C W1W2G PCBAG127 DSI Control Board Testing Direct Spark Ignition DSI Systems PCBAG127 Board 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 Novoltage check3 amp automotive type fuse on control board A blown fuse could indicate a short in the 24 volt circuit thermostat or limit circuit b Voltage Present check limit and rollout S 301 and S 302 If limit and rollout are closed then check for 24 at the gas valve terminals C No24 at gas valve check 9 pin connector and wires from ignition controlto gas valve If wires and connections at 9 pin connector check good replace ignition control d Voltage present at gas valve replace gas valve SERVICING Testing High Stage Heat Operation with Low Stage Heat Operating 1 Board set for 2 stage thermostat Checkfor24 Vo
5. improper Air Flow or Datrbuton Locking out on Main tit Delayed Flashback Orifice Size Gas Pressure Cracked Heat Exchanger 30 PTT TTT TTT TT TTT TT LLL 9 j e ee gt oo oo 999 Test Method Remedy Press k Flu Test Control Nega ing sformer Test ure Sw itch Chec e Draw dow n Pressure Test tive Pressure See Service Procedure Reference S 1 S 4 5 2 5 3 5 4 5 3 5 4 5 313 5 3 5 300 5 301 5 302 5 314 5 313 5 304 5 303 5 314 5 314 5 304 5 3 5 313 5 304 5 301 5 300 5 308 5 309 5 306 5 307 5 302 5 304 5 310 5 310 5 302 5 310 SERVICING S 1 5 3 S 3A S 3B S 3C S 4 S 7 S 8 S 12 S 13 S 15 S 15A S 15B S 16A 5 16 5 160 5 17 S 17A S 17B S 17D 5 18 5 21 S 24 S 25 S 100 5 101 5 102 S 103 Table of Contents Checking Voltage Checking Wiring eese Checking Thermostat Wiring amp Anticipator 33 Thermostat amp Wiring suus Cooling Anticipato Heating Checking Transformer amp Control Circuit Checking Contactor and or Relays Checking Contactor Contacts Checking Fan Relay Contact
6. Checking High Pressure Control Checking Low Pressure Control Checking Resistance Capacitance Checking Fan amp Blower Motor Windings PSC Motors Checking ECM Motor Windings Checking EEM Motors Checking Compressor Windings Resistance Gund TOS Operation Test Testing Crankcase Heater optional item Checking Reversing Valve amp Solenoid Testing Defrost Control Testing Defrost Thermostat Refrigeration Repair Practice Leak Testing visitas ni n E Ah WARNING HIGH VOLTAGE 40 S 104 Checking Compressor Efficiency 42 S 105B Thermostatic Expansion Valve 42 9 106 QOverfeeding eee 44 S 107 Underfeeding 44 108 Superheat 44 S 109 Checking Subcooling 46 S 110 Checking Expansion Valve Operation 46 S 111 Fixed Orifice Restriction Devices 46 S 11
7. 4 Disconnect manifold set Installation is complete S 109 CHECKING SUBCOOLING Refrigerant liquid is considered subcooled when its tem perature is lower than the saturation temperature corre sponding to its pressure The degree of subcooling equals the degrees of temperature decrease below the saturation temperature at the existing pressure 1 Attach an accurate thermometer or preferably a thermo couple type temperature tester to the liquid line close to the pressure switch 2 Install a high side pressure gauge on the high side liquid service valve at the front of the unit 3 Record the gauge pressure and the temperature of the line 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 right to the column under the design subcooling value Where the two intersect is the required liquid line temperature Alternately you can convert the liquid line pressure gauge reading to temperature by finding the gauge reading in Temperature Pressure Chart and reading to the left find the temperature in the F Column 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 Co
8. TURN OFF Gas TOAPPLIANCE POUR COUPER L ADMISSIO 1 Set the thermostat to lowest setting 2 Turn off all electric power to the appliance if service is to be performed 3 Push the gas control lever to OFF Position Do not force 4 Replace control access panel DE GAZ DE L APPAREIL 1 R gler le thermostat la temp rature la plus bass 2 Couper l alimentation lectrique de l appareil s il faut proc der des operations d entretien 3 Pousse le levier du contr le du gaz OFF ARRET position Ne pas forcer 4 Remettre en place le panneau d acc s 0140F00000P REV D ACCESSORIES PGMDD101 102 Manual 25 Fresh Air Damper Downflow Application Medium Chassis PGMDH103 Manual 25 Fresh Air Damper Horizontal Application Large Chassis PGMDMH102 Motorized 25 Fresh Air Damper Horizontal Application Medium Chassis SQRPG103 Square to Round Adapter w 18 Round Downflow Application Large Chassis SQRPGH101 102 Square to Round Adapter w 16 Round Horizontal Application Medium Chassis SQRPGH103 Square to Round Adapter w 18 Round Horizontal Application Large Chassis PGFR101 102 103 01 102 103 Internal Filter Rack All Internal Filter Rack All Chassis Flush Flush Mount Concentrie Duct Kit Duct Kit CDK4872530 Step Down Concentric Duct Kit CDK4872535 Step Down Concentric Duct Kit w Filter NOTE Complete lineup of thermostats can be found in the Thermostat Specification Sheets ACC
9. 139 432 0 122 534 0 139 434 0 123 536 0 139 436 0 123 598 0 140 438 0 123 540 0 140 440 0 124 544 0 141 442 0 124 548 0 141 4440 124 552 0 142 446 0 125 556 0 142 448 0 125 560 0 143 450 0 126 564 0 143 4520 126 568 0 144 4540 126 572 0 145 456 0 127 576 0 145 458 0 127 580 0 146 460 0 127 584 0 146 0 8 0 8 0 8 0 8 0 8 0 8 8 8 8 9 9 9 PSIG F 522 0 137 524 0 137 1 1 N oA ojoj jii 99 ji SEC ii 2 w N 49 1 410 Mo 156 0 54 258 0 360 0 109 462 0 128 588 0 147 158 0 55 260 0 362 0 109 464 0 128 160 0 56 262 0 364 0 110 466 0 128 o 592 0 147 596 0 148 600 0 149 604 0 149 608 0 150 1 612 0 150 616 0 151 620 0 151 624 0 152 628 0 152 632 0 153 636 0 153 640 0 154 644 0 155 648 0 155 652 0 156 656 0 156 660 0 157 664 0 157 668 0 158 672 0 158 676 0 159 680 0 159 684 0 160 688 0 160 692 0 161 696 0 161 o N P 162 0 57 264 0 366 0 110 468 0 129 I N 166 0 58 268 0 370 0 11 472 0 129 o 168 0 59 270 0 372 0 111 474 0 130 o i i 7 7 7 7 7 7 7 7 7 7 476 0 130 478 0 130 480 0 131 9 9 9 9 9 9 9 9 9 9 EN M M o 1 1 482 0 131 484 0 131 486 0 132
10. a Suction Pressure 143 b Corresponding Temp 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 fallin the range of allowable superheat SUPERHEAT AND SUBCOOLING ADJUSTMENT ON TXV APPLICATIONS 1 Run system at least 10 minutes to allow pressure to stabilize 2 Temporarily install thermometer on liquid small line near 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 superheat are 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 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 at light load conditions 55 to 60 F under such conditions only the subcooling can be evaluated This is because suction pressure is dependent on the indoor coil match indoor airflow and wet bulb temperature NOTE Do NOT adjust charge based on suction pressure unless there is a gross undercharge 46
11. 13 PRODUCT DESIGN A 3 4 14 NPT drain connector is provided for removal of condensate water from the indoor coil In order to provide proper condensate flow do not reduce the drain line size NOTE Tighten drain to a maximum torque of 10 in Ibs Refrigerant flow control is achieved by use of a flowrator The single phase models use permanent split capacitors PSC design compressors Starting components are there fore not required A low MFD run capacitor assists the compressor to start and remains in the circuit during opera tion A GPD Package Units are designed for outdoor installations only in either residential or light commercial applications and are available in 2 2 5 3 3 5 amp 4 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 or provision must be made fora filter in an accessible location within the return air duct 3 phase models have an internal downflow filter rack The minimum filter area should not be less than those sizes listed in the Specification Section Under nocircumstances should the unitbe operated without return air filters PD model units use EEM type indoor blower motors EEM motors are constant torque motors with very low power con
12. 488 0 132 490 0 132 4920 132 494 0 133 496 0 133 4980 133 o 194 0 67 296 0 398 0 116 500 0 134 196 0 68 298 0 400 0 117 502 0 134 198 0 68 300 0 402 0 117 504 0 134 200 0 69 302 0 404 0 117 506 0 135 202 0 70 304 0 406 0 118 1 508 0 135 al N 9 510 0 135 512 0 136 514 0 136 9 9 9 N 210 0 72 312 0 4140 119 516 0 136 212 0 73 314 0 416 0 119 518 0 137 214 0 73 8 316 0 418 0 120 3 520 0 137 3 Based on ALLIED SIGNAL Data 4 4 5 6 6 7 7 8 8 9 0 0 1 1 2 2 3 3 4 4 5 5 6 6 7 470 0 129 8 8 9 9 0 0 1 T 2 2 3 3 4 4 5 5 6 6 7 8 8 8 9 9 SERVICING 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 5 1058 THERMOSTATIC EXPANSION V
13. TO PREVENT POSSIBLE DAMAGE THE UNIT SHOULD REMAIN IN AN UPRIGHT POSITION DURING ALL RIGGING AND MOVING OPERATIONS TO FACILITATE LIFTING AND MOVING IF A CRANE IS USED PLACE THE UNIT IN AN ADEQUATE CABLE SLIDE IMPORTANT NOTE If using bottom discharge with roof curb ductwork should be attached to the curb prior to installing the unit Refer to Roof curb Installation Instructions for proper curb installation Curbing must be installed in compliance with the National Roofing Contractors Association Manual Lower unit carefully onto roof mounting curb While rigging unit center of gravity will cause condenser end to be lower than supply air end NOTE A roof curb can be used to utilize bottom discharge PD14 Package Units are designedfor outdoor installations only in either residential or light commercial applications NOTE To ensure proper condensate drainage unit must be installed in a level position The connecting ductwork Supply and Return can be con nected for either horizontal or down discharge airflow In the down discharge applications a matching Roof Curb is recom mended A return air filter must be installed behind the return air grille s or provision must be made for a filter in an accessible location within the return air duct The minimum filter area should not be less than those sizes listed in the Specification Section Under no circumstances should the unit be oper ated without return air filters
14. WARNING Do not front seat the service valve s with the compressor open with the suction line of the comprssor closed or severely restricted 1 Connect the vacuum pump vacuum tight manifold set with high vacuum hoses thermocouple vacuum gauge and charging cylinder as shown 2 Startthe vacuum pump and open the shut off valve to the high vacuum gauge manifold only After the compound gauge low side has dropped to approximately 29 inches of vacuum open the valve to the vacuum thermocouple gauge See that the vacuum pump will blank off to a maximum of 25 microns A high vacuum pump can only produce a good vacuum if its oil is non contaminated 41 SERVICING R 410A MANIFOLD LOW SIDE HIGH SIDE GAUGE GAUGE AND VALVE AND VALVE 27 800 PSI RATED 71 HOSES 7 Y an CHARGING CYLINDER AND SCALE VACUUM PUMP TO ADAPTER UNIT SERVICE VALVE PORTS VACUUM PUMP 2 2 EVACUATION 3 Ifthe vacuum pumpis working properly close the valve to the vacuum thermocouple gauge and open the high and low side valvestothe high vacuum manifold set With the valve onthe charging cylinder closed open the manifold valveto the cylinder 4 Evacuate the system to at least 29 inches gauge before opening valve to thermocouple vacuum gauge 5 Continue to evacuate to a maximum of 250 microns Close valve to vacuum pump and watch rate of rise If vacuum does notri
15. When the contacts of the room thermostat close this closes the circuit from R to Y and R to G in the unit This energizes the compressor contactor and will energize the EEM indoor blower motor after a 6 second delay When the thermostat is satisfied it opens its contacts breaking the low voltage circuit causing the compressor contactor to open and indoor fan to stop after the programmed 60 second off delay on the EEM motor Ifthe room thermostat fan selector switch should be setto the on position then the indoor blower would run continuous rather than cycling with the compressor HEATING GAS amp L P 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 compact tubular construction provides excellent heat transfer for maximum operating efficiency Inshottype gas burners with integral cross lighters are used eliminating the need for adjustable air shutters The same burner is designed for use on either natural or propane gas fuels SYSTEM OPERATION 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 I D blower to detect a blocked flue condition Blower operationis controlled by the ignition control module The module allows for field adjustment of the blower delay at the end of the h
16. that serves your comfort equipment 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 damage which may result Ah WARNING HIGH VOLTAGE Disconnect ALL power before servicing or installing this unit Multiple power sources may be present Failure to do so may cause property damage personal injury or death To locate an authorized servicer please consult your telephone book or the dealer from whom you purchased this product For further assistance please contact GOODMAN BRAND PRODUCTS AMANA BRAND PRODUCTS TOLL FREE TOLL FREE 1 877 254 4729 U S only 1 877 254 4729 U S only email us at customerservice goodmanmfg com email us at customerservice goodmanmfg com fax us at 713 856 1821 fax us at 713 856 1821 Not a technical assistance line for dealers Not a technical assistance line for dealers Outside the U S call 1 713 861 2500 Not a technical assistance line for dealers Your telephone company will bill you for the call IMPORTANT INFORMATION SAFE REFRIGERANT HANDLING While these items will not cover every conceivable situation they should serve as a useful guide WARNING Refrigerants are heavier than air They can push out the oxygen in your lungs or in any enclosed space T
17. 30 30 000 BTUH 36 36 000 BTUH 42 42 000 BTUH 48 48 000 BTUH Amana is a registered trademark of Maytag Corporation or its related companies and is used under license All rights reserved These units have 410 refrigerant PRODUCT IDENTIFICATION Single Phase Dual Fuel Package Units 14 24 42 Brand Goodman Brand Package Dual Fuel units up to 14 Seer with R410A Initial release of the multi position single phase gas electric models Amana Brand Goodman Brand Package Dual Fuel units up to 14 Seer A GPD14 24 48 M41BA with R410A Initial release of the multi position single phase gas electric models Broad Ocean Digi Motor Amana Brand Goodman Brand Package Dual Fuel units up to 14 Seer A GPD14 24 48 M41CA with R410A Multi position single phase gas electric models Broad Ocean Digi Motor Aluminum evaporator coils Amana Brand Goodman Brand Package Dual Fuel units up to 14 Seer MATAN with R410A Initial release of the 3 ton increased efficiency models N DANGER sm CARBON MONOXIDE POISONING HAZARD Special warning for installation of furnaces or air handling units in enclosed area such as garages utility rooms or parking areas Carbon monoxide producing devices such as automobile space heater gas water heater etc Should not be operated in enclosed areas such as unventilated garages or utility rooms because of the danger of ca
18. T2 and T3 on 3 phase units TESTING COMPRESSOR WINDINGS SERVICING If either winding does not test continuous replace the compressor NOTE open compressoris 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 reset the circuit breaker ONE TIME ONLY to see if it was just a nuisance opening If it opens again DO NOT continue to reset mz WARNING TOU Disconnect ALL power before servicing Disconnect all power to unit making sure that all power 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 TE
19. 239 368 200 418 788 1 617 2 423 30 27 61 114 192 296 161 336 632 1 299 1 946 40 23 52 97 164 253 137 284 541 1 111 1 665 50 20 46 86 146 224 122 255 480 985 1 476 60 19 42 78 132 203 110 231 436 892 1 337 80 16 36 67 113 174 94 198 372 764 1 144 100 14 32 59 100 154 84 175 330 677 1 014 125 12 28 52 89 137 74 155 292 600 899 150 11 26 48 80 124 67 141 265 544 815 200 10 22 41 69 106 58 120 227 465 697 250 9 19 36 61 94 51 107 201 412 618 300 8 18 33 55 85 46 97 182 374 560 350 7 16 30 51 78 43 89 167 344 515 400 7 15 28 47 73 40 83 156 320 479 DATA IN ACCORDANCE WITH NFPA PAMPHLET NO 54 COOLING The refrigerant used in the system is R 410A It is a clear colorless non toxic and non irritating liquid R 410A is a 50 50 blend of R 32 and R 125 The boiling point at atmo spheric pressure is 62 9 F A few of the important principles that make the refrigeration cycle possible are heat always flows from a warmer to a cooler body Under lower pressure arefrigerant will absorb heat and vaporize at a low temperature The vapors may be drawn off andcondensed ata higher pressure and tempera ture to be used again 18 The indoor evaporator coil functions to cool and dehumidify the air conditioned spaces through the evaporative process taking place within the coil tubes NOTE Actual temperatures and pressures are to be obtained fromthe expanded ratings inthe Technical Information Manual High
20. Fuse Inspect Fuse Size amp Type Loose Connection Inspect Connection Tighten Shorted or Broken Wires Open Overload Test Circuits With Ohmmeter Test Continuity of Overload Faulty Thermostat Test continuity of Thermostat amp Wiring Faulty Transformer Check control circuit with voltmeter Shorted or Open Capacitor Shorted or Grounded Compressor Test Capacitor Motor Windings Compressor Stuck Test Cord Faulty Compressor Contactor continuity of Coil amp Contacts Faulty Ignition Control Ignition Control Open Control Circuit Control Circuit with Voltmeter Test Voltage Low Voltage Faulty Evap Fan Motor Shorted or Grounded Fan Motor Repair or Replace Test Motor Windings Improper Cooling Anti d pator Check resistance of Anticipator Shortage of Refrigerant Test For Leaks Add Refrigerant Restricted Liquid Line Replace Restricted Part Dirty Air Filter Dirty Indoor Coil Not enough air across Indoor Coil Inspect Filter Clean or Replace Inspect Coil Clean Speed Blower Check Duct Static Press much air across Indoor Coil Reduce Blower Speed Overcharge of Refrigerant Recover Part of Charge Dirty Outdoor Coil Noncondensibles Inspect Coil Clean Recover Charge Evacuate Recharge Recirculation of Condensing Air Remove Obstruction to Air Flow Infiltration of Outdoor Air Check Windo
21. 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 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 WARNING 2 2 Disconnect ALL power before servicing 1 Remove control panel cover or etc to gain access to transformer With power ON 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 fline voltage available at primary voltage side of trans former and wiring and splices good transformer is inop erative Replace S 7 CHECKING CONTACTOR AND OR RELAYS WARNING HIGH VOLTAGE Disconnect ALL power before servicing or installing this unit Multiple power sources may be present Failure to do so may cause property damage personal m or death The compressor contactor and other relay holding coils are wired into the low or line voltage circuits When the control circuit is energized the coil pulls in the normally open contacts or opens the normally closed co
22. Improper orifice size check orifice for obstruction WARNING S 310 CHECKING PRESSURE CONTROL cid A pressure control device is used to measure negative pressure at the induced draft blower motor inlet to detect a partial or blocked flue With Power ON 4 Energizefurnace 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 Pressure Switch Operation DSI Direct Spark System combustion The pressure switch is ignored unlessthereisacallforheat 5 Remove and check the two electrical wires and using When the control receives call for heat the control checks the VOM check from Common to NO Normally Open to see that the pressure switch is open If the control sees it should read closed with I D motor running If notas that the pressure switch is closed before the induced draft above replace pressure control 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 6 Reconnect allwires to the control and place in heating cycle 7 Astheunitfires on high stage the inclined manometer If the pressure switch opens before the ignition period the negative pressure will drop to 1 0 0 3 W C induced draft blower will remain on and the control will stay in pre purge until the pressure switch is closed for an entire 8 If
23. 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 pointof restriction Insevere cases frostwillform atthe restriction and extend down the line inthe direction ofthe 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 S 113 OVERCHARGE OF REFRIGERANT An overcharge of refrigerant is normally indicated by an excessively high head pressure An evaporator coil using an expansion valve metering device will basically modulate and control a flooded evaporator and prevent liquid return to the compressor An evaporator coil using a fixed orifice restrictor device flowrator metering device could allow refrigerantto return to the compressor under extreme overcharge conditions Also with a fixed orifice restrictor device flowrator metering device extreme cases of insufficient indoor air can cause icingofthe indoor coil and liquid return tothe 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 s
24. a Heating Performance Test and apply the results to the Service Problem Analysis Guide Toconducta heating performance test the BTU inputtothe package gas unit must be calculated After the heating cycle has been in operation for at least fifteen minutes and with all other gas appliances turned off the gas meter should be clocked To find the BTU input multiply the number of cubic feet of gas consumed per hour by the heating value of the gas being used The calorific value of the gas being used is found by contacting your local utility SCHEDULED MAINTENANCE 1 Million 100 Thousand 10 Thousand 1 Thousand CUBIC O FEET GAS RATE CUBIC FEET PER HOUR Size of Test Dial Seconds for me 1 4 1 2 1 2 5 Revolution cut cu ft cu ft Seconds for One 1 4 cu ft Revolution cu ft Size of Test Dial 1 2 cu ft n 287 28 EA paja 750 50 18 144 360 667 53 17 4 136 340 563 58 124 310 529 60 15 EE a 120 300 27 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 acrossto the one 1 cubicfootdial 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 uti
25. 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 m or death 1 Remove electrical power to unit Some units may have more than one source of power 2 Remove the wires from the limit control terminals 3 Using an ohmmeter test for continuity across the two terminals 4 If limit test open allow unit to cool and retest 5 Ifstill open replace the control S 301 TESTING AUXILIARY LIMIT The auxiliary limit control is a preset nonadjustable control mounted in the blower compartment area It is connected in series with the rollout switch wiring to the gas valve Ifits temperature should be exceeded it will open interrupting the voltage to the gas valve causing it to open An additional limit primary limit control is required for safety control of high temperature within the furnace or ductwork AUX LIMIT
26. 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 Q 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 SYSTEM OPERATION IGNITION CONTROL SEQUENCE OF OPERATION CONT B Cooling Operation High stage cool Thermostat type is set to two stage Thermostat Y 1 Y2 or Y 1 Y2 and inputs initiate high stage cooling IDT ODT Pressure Loss of Charge Switch circuits are checked for closed condition Cooling operation can proceed only if these circuits are closed 1 Lowandhigh stage compressor outputs are energized 2 Condenser fan motor is energized at high speed 3 Air circulating blower is energized at high cool speed after cool ON delay expires Cool ON delay timer begins when thermostat inputs are detected Control monitors thermostat gas valve flame and IDT ODT Pressure Loss of Charge Switches during high stage cooling
27. operation Thermostat Y1 and Y2 or Y1 Y2 and QG inputs are removed Low and high stage compressor outputs are de ener gized High speed condenser fan motor is de energized 4 Aircirculatingblower 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 nextthermostat request A Continuous Fan Operation 1 Thermostat G input initiates Continuous Fan opera tion 2 Aircirculation 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 3 Thermostat input is removed 4 Aircirculation blower is immediately de energized 5 Control returns to Standby and awaits nextthermostat request A GPD14 DEFROST CYCLE NOTE The defrost board is equipped with a jumper for SmartShift M defrost technology operation This operation turns the compressor off for 30 seconds at defrost initiation andtermination Theunitis factory shipped for SmartShift defrosttechnology operation To operate unitat rated efficien cies move the jumper on the defrost board from DLY to NORM During operation the power to the circuit board is controlled by atemperature sensor which is clamped to a feeder tube entering the outdoor coil Defrost timing periods of 30 60 and 90 minutes may be selected by se
28. supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department 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 hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion D Do not use this appliance if any part has been underwater Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been underwater 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 OFF Position Do not force 6 Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you PD14 M1AA ERE LIRE AVANT DE METTRE EN MARCHELIRE AVERTISSEMENT Quiconque ne respecte pas la lettre les instructions dans le pres nt manuel risque de d clencher un incendie ou une explosion entrainant des dommages mat riels des lesions corporelles ou la perte de vies humaines appareil ne comporte pas de veilleuse Il est muni d un dispo
29. switch has closed Trial for ignition period begins after pre purge period expires Low and high stage gas valves are energized along with the igniter for trial for ignition period Igniter is de energized when flame is detected Flame is achieved and detected during trial for ignition period Flame stabilization period begins when flame is detected De energize high stage gas valve and switch induced draft blower to low speed within five seconds of flame detection Air circulating blower is energized at low heat speed after heat ON delay time expires Heat ON delay timer begins when flame is detected Control monitors thermostat flame limit and pres sure switch inputs 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 20 Thermostat type is set to two stage Thermostat W1 and W2 inputs initiate high stage heating Induced draft blower is energized at high speed forthe pre purge period Pre purgetimer begins after control recognizes pressure switch has closed Trial for ignition period begins after pre purge period expires Low and high stage ga
30. 2 Checking Restricted Liquid Line 47 S 113 RefrigerantOvercharge 47 5 114 Non condensables 47 S 115 Compressor Burnout 48 S 122 Reversing Valve Replacement 48 S 200 Checking External Static Pressure 48 S 201 Checking Temperature Rise 49 S 300 Testing Primary 49 S 301 Testing Auxiliary 50 S 302 Checking Flame Rollout Switch 50 S 303 Testing Inducer 51 5 304 Testing Gas 52 S 305 Checking Main Burners 52 S 306 Checking 53 S 307 Checking Gas Pressure 53 S 308 Checking For Delayed Ignition 54 S 309 Checking for 54 S 310 Checking Pressure Control 55 S 311 High Altitude Application 55 S 313 Testing Ignition Control Module 56 S 314 Checking Flame 59 Disconnect ALL power before servicing or installing this unit Multiple power sourc
31. 7000 8000 U S BURNER ORIFICE HAO2 CANADA BURNER ORIFICE 45 55 47 55 45 55 E 47 56 47 56 48 57 48 58 49 58 48 57 HIGH ALTITUDE INPUT BURNER KIT 22 500 BTUH NAT 20 000 BTUH L P ELEV 2000 3000 ATION ABOVE SEA LEVEL FEET 4000 4500 5000 6000 7000 8000 U S BURNER ORIFICE HAO2 CANADA BURNER ORIFICE 44 55 44 55 44 55 45 56 45 56 46 57 47 58 47 58 4757 HIGH ALTITUDE INPUT BURNER KIT 25 000 BTUH NAT 20 000 BTUH L P ELEV 2000 3000 ABOVE SEA LEVEL FEET 4000 4500 5000 6000 7000 8000 U S BURNER ORIFICE CANADA BURNER ORIFICE HA02 43 55 53 55 4355 44 56 44 56 44 56 45 57 45 57 S 313 TESTING IGNITION CONTROL MODULE NOTE Failure to earth ground the unit or a high resistance connection in the ground may cause the control to lockout due to failure to flame sense servicing 56 AA WARNING To avoid personal injury or death due to electric shock wiring to the unit must be properly grounded Disconnect power before installing or 12 INDUCER LOW HIGH LOW HIGH K4 Q3 FS 72 K3 T2 c9 K7 Ut rU P2 o U7 U4
32. ALVE The expansion valve is designed to control the rate of liquid refrigerant flow into an evaporator coil in exact proportion to the rate of evaporation of the refrigerant in the coil The amount of refrigerant entering the coil is regulated since the valve responds to temperature of the refrigerant gas leaving the coil feeler bulb contact and the pressure ofthe refriger ant in the coil This regulation of the flow prevents the return of liquid refrigerant to the compressor The three forces which govern the operation of the valve are 1 the pressure created in the power assembly by the feeler bulb 2 evaporator pressure and 3 the equivalent pressure of the superheat spring in the valve 0 bleed type expansion valves are used onthe 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 44 UCT OPERATI
33. ERSONAL INJURY OR DEATH PROPANE TANK SIZING MINIMUM TANK SIZE REQUIRED IF LOWEST OUTDOOR MAXIMUM GAS TEMPERATURE AVG FOR 24 HOURS REACHES NEEDED TO VAPORIZE 125K BTU HR 50 CFH 250K BTU HR 100 CFH 375K BTU HR 150 CFH 500K BTU HR 200 CFH 750K BTU HR 300 CFH AVERAGE RATE HOUR WITHDRAWL IN 8 HOUR PERIOD 17 PRODUCT DESIGN PROPANE GAS PIPING CHARTS Sizing Between First and Second Stage Regulator Maximum Propane Capacities listed are based on 1 PSIG Pressure Drop at 10 PSIG Setting Capacities in 1 000 BTU HR PIPE OR TUBING LENGTH NOMINAL PIPE SIZE SCHEDULE 40 TUBING SIZE O D TYPE L 1 394 1 297 2 146 1 996 1 084 1 217 1 873 1 017 1 149 1 769 961 923 1 421 772 790 660 700 585 634 530 584 488 543 454 To convert to Capacities at 15 PSIG Settings Multiply by 1 130 To convert to Capacities at 5 PSIG Settings Multiply by 0 879 1 165 2 437 2 267 2 127 2 009 1 613 Sizing Between Single or Second Stage Regulator and Appliance Maximum Propane Capacities Listed are Based on 1 2 W C Pressure Drop at 11 W C Setting Capacities in 1 000 BTU HR TUBING TUBINGSIZE O D TYPE L NOMINAL PIPE SIZE LENGTH FEET 58 58 34 12 3 4 1 1 1 4 1 127 10 49 110 206 348 539 291 608 1 146 2 353 3 525 20 34 76 141
34. ESSORIES ROOF CURBS 22 m d ke 15 8 1 a e 0 RETURN SUPPLY DOWNFLOW FILTER RACK PGFR101 102 103 2 ide 2 BE 3 2 EP a a 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 PDED101 102 PDED103 LB A B 16 1 4 16 X 20 2 FILTER 16 20 MIST ELIMINATOR ECONOMIZER HORIZONTAL APPLICATIONS Measurement in inches ACCESSORIES MOTORIZED MANUAL FRESH AIR DAMPERS HORIZONTAL APPLICATIONS _ B A A 7 5 8 5 3 4 A 41 7 8 227 1 MANUAL MOTORIZED TES MOTORIZED MANUAL FRESH AIR DAMPERS DOWNFLOW APPLICATIONS A ESA 2 BOTTOM VIEW 1 178 x 4 PGMDD103 BOTTOM VIEW TU 7 8 gt 32 9 B MANUAL A LE MOTORIZED a 10 ACCESSORIES SQUARE TO ROUND CONVERTER DOWNFLOW APPLICATIONS ao gt
35. HE METER TANK 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 specific gravity ofthe gas and length oftherun 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 2 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 Usepipe jointcompound on male threads only Pipe joint compound mustbe resistantto the action of the fuel used 3 Use ground joint unions 4 Installadripleg to trap dirt and 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 shutoff valve should be conveniently located within six 6 feet ofthe 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 metallic pipe and fittings b Semi rigid metallic tubing and meta
36. ON DO NOT USE SUBSTITUTES 5 106 OVERFEEDING Overfeeding by the expansion valve results in high suction pressure cold suction line and possible liquid slugging of the compressor If these symptoms are observed 1 Checkforanovercharged unit by referring to the cooling performance charts in the servicing section 2 Checkthe operation ofthe power elementinthe 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 these symptoms are observed 1 Checkforarestricted liquid line ordrier A restriction will be indicated by a temperature drop across the drier 2 Checkthe operation ofthe power element ofthe valve as described in S 110 Checking Expansion Valve Opera 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 arethe most common causes for evaporator malfunction CHECKING SUPERHEAT Refrigerant gas is considered superheated when its tem perature is higher than the saturation temperature corre sponding to its pressure The degree of superheat equals the degrees of temperature increase abov
37. OVANNVN NVINQOO9 AVI AL TOYLNOD Ad IVHLN3 2 NMOHS SV TIVLSNI NOILISOd IVNOI LdO H3 13AIOLLN3 LOd 801 166 NVIA3 1OO LVISOWYSHL 1108201 uossaudWoo AVIS AL SLOVLNOD ML MOTI3A LNA IVAIQO3 HO 021 061 OIND 19151 39VLS LETOIN Wiring is subject to change Always refer to the wiring diagram on the unit for the most up to date wiring 60 ACCESSORIES WIRING DIAGRAMS ECONOMIZER HIGH VOLTAGE WARNING DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH PS E gt Ele E ase 7 JUMPER OCCUPIED 620 RESISTOR 8 3 glas E z 5 TH lt c o E 8 2 5256 lt i 5 8 9200 vo z x 5 a0 a 58 86 8 3 2 3 2 583 ee Gg 999 SE ES 82 2 8 g A ge LoS E I E E PDEH FOR A GPD14 M4 Wiring is subject to change Always refer to the wiring diagram on the unit for the most up to date wiring 61
38. REFRIGERATION REPAIR PRACTICE DANGER Always remove the refrigerant charge in a proper manner before applying heat to the system When repairing the refrigeration system WARNING 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 Remove all burrs and clean the brazing surfaces of the tubing with sand cloth or paper Brazing materials do not flow well on oxidized or oily surfaces 4 Cleanthe inside of all newtubing to remove oils and pipe chips 5 When brazing sweep the tubing with dry nitrogen to preventthe formation of oxides on the inside surfaces 6 Complete any repair by replacingthe liquid line drier in the System evacuate and charge BRAZING MATERIALS Copper to Copper Joints Sil Fos used without flux alloy of 15 silver 8096 copper and 5 phosphorous Recom mended heat 1400 F Copper to Steel Joints Silver Solder used without a flux alloy of 30 silver 3896 copper 32 zinc Recommended heat 1200 F 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 m
39. ROGERS MODEL 36G 1 STAGE GAS VALVE Pressure Regulator under cap screw Open to Fc Atmosphere INLET b SOF Honeywell Hi OUTLET GN ON i 29 Outlet Inlet 5 Pressure Pressure Gas Valve On Off Selector Switch Manifold Inlet Pressure Pressure HONEYWELL MODEL VR8215 1 STAGE GAS VALVE MEASURING INLET AND MANIFOLD GAS PRESSURE With Power ON T WARNING Y Line Voltage now present 3 Put furnace into heating cycle and turn on all other gas consuming appliances For NATURAL GAS a Inlet pressure should a nominal 7 w c b 2stage heat models only Manifold pressure on low stage should be 2 0 w c 3 w c c Manifold pressure for 1 stage heat models and high stage for 2 stage heat models should be 3 5 3 W C 54 For PROPANE GAS a Inlet pressure should be a nominal 11 w c b 2 stage heat models only Manifold pressure on low stage should be 6 w c c Manifold pressure for 1 stage heat models and high stage for 2 stage heat models should be 10 W C Manifold Gas Pressure Natural Gas 10 0 Single Stage Manifold Gas Pressure Range Nominal Low Stage 1 6 2 2 w c ss High Stage 3 2 3 8 w c 5 7 6 3 W C High Stage 9 7 10 3 w c Two Stage If operating pressures differ from above make necessary pressure regulator adjustments check pipin
40. ST If a ground is indicated then carefully remove the compressorterminal protective cover and inspect for loose leads or insulation breaks in the lead wires 4 Ifnovisual problems indicated carefully remove the leads at the compressor terminals WARNING Damage can occur to the glass embedded terminals if the leads are not properly removed This can result in terminal and hot oil discharging Carefully retestfor grouna directly between compressor terminals and ground 5 lf ground is indicated replace the compressor 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 m or death 1 Removeunit wiring from disconnect switch and wire atest cord to the disconnect switch NOTE The wire size of the test cord must equal the line wire size and the fuse must be of the proper size and type 2 Withthe protective terminal cover in place use the three leads to the compressor terminals that were discon nected at the nearest point to the compressor and connectthe common start and run clipstothe 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 WARNING Y L
41. Service Instructions PD14 Dual Fuel Package Units with R 410A Refrigerant amp Accessories This Forced Air Central Unit Design Complies With Requirements Embodied in The American National TA Standard National Standard of Canada Shown Intertek Below ANSI Z21 47 CSA 2 3 Central Furnaces 0 LISTE This manual is to be used by qualified professionally trained HVAC technicians only Goodman does not assume any responsibility for property damage or personal injury due to improper service procedures or services performed by an unqualified person is a registered trademark of Maytag Corporation or its related companies RS6313000r3 and is used under license All rights reserved September 201 4 Copyright O 2011 2013 2014 GoodmanCompany L P TABLE OF CONTENTS IMPORTANT INFORMATION 2 3 SYSTEM OPERATION 19 25 PRODUCTION IDENTIFICATION 4 5 SCHEDULED MAINTENANCE 26 27 LIGHTING INSTRUCTIONS 6 TROUBLESHOOTING CHARTS 29 30 cu 7 12 SERVICING TABLE OF CONTENTS 31 PRODUCT DESIGN usine 13 18 SERVICING 32 59 ACCESSORIES WIRING DIAGRAMS 60 IMPORTANT INFORMATION Pride and workmanship go into every product to provide our customers with quality products Itis possible however that durin
42. adas como estacionamientos cuartos de servicio Los equipos aparatos que producen mon xido de carbono tal como autom vil calentador de gas calentador de agua por medio de gas etc no deben ser operados en reas cerradas debido al riesgo de envenenamiento por mon xido de carbono CO que resulta de las emisiones de gases de combusti n Si el equipo aparato se opera en dichas reas debe existir una adecuada ventilac n directa al exterior Las emisiones de mon xido de carbono pueden circular a trav s del aparato cuando se opera en cualquier modo El mon xido de carbono puede causar enfermedades severas como dafio cerebral permanente muerte 0140M00020 D These units have R410A refrigerant LIGHTING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING If you do not follow these instructions explosion may result causing property VARNI NG exactly a fire or damage personal injury or loss of life A This appliance does not have a pilot It is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand B BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas
43. alve 3 Purge all remaining components with dry nitrogen or carbon dioxide until clean Install new components including liquid line drier 5 Braze all joints leak test evacuate and recharge sys tem 48 6 Startup the unit and record the pressure drop across the drier 7 Continue to run the system for a minimum of twelve 12 hours and recheck the pressure drop across the drier Pressure drop should not exceed 6 PSIG 8 Continue to run the system for several days repeatedly checking pressure drop across the suction line drier If the pressure drop never exceeds the 6 PSIG the drier has trapped the contaminants Remove the suction line drier from the system 9 If the pressure drop becomes greater then it must be replaced and steps 5 through 9 repeated until it does not exceed 6 PSIG NOTICE Regardless the cause for burnout must be deter mined and corrected before the new compressor is started S 122 REVERSING VALVE REPLACEMENT Remove the refrigerant charge from the system When brazing a reversing valve into the system it is of extreme importance that the temperature of the valve does not exceed 250 F at any time Wrap the reversing valve with a large rag saturated with water Re wet the rag and thoroughly cool the valve after each brazing operation of the four joints involved The wet rag aroundthe reversing valve will eliminate conduction of heatto the valve body when brazing the line connection T
44. alve on the high side of the charging manifold 3 Startthe system and charge the balance ofthe refriger ant 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 thatfitinto the system charging hose set to accomplish this DO NOT charge liquid R410A into the compressor 4 With the system still running close the valve on the charging cylinder 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 Dueto their design Scroll compressors are inherently more tolerant of liquid refrigerant NOTE Even though the compressor section of a Scroll compressor is more tolerant of liquid refrigerant continued floodback or flooded start conditions may wash oil from the bearing surfaces causing premature bearing failure SERVICING Pressure vs Temperature Chart R 410A F 420 0 120 422 0 121 4240 121 526 0 138 426 0 121 528 0 138 428 0 1221 530 0 138 430 0 122 532 0
45. curing the ECM power head and separate it from the motor 3 Disconnect the 3 pin motor connector from the power head and lay it aside 4 Using an ohmmeter check the motor windings for con tinuity to ground pins to motor shell If the ohmmeter indicates continuity to ground the motoris defective and must be replaced 5 Using an ohmmeter check the windings for continuity pin to pin If no continuity is indicated the thermal limit 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 EEM MOTORS The EEM motor is a one piece fully encapsulated 3 phase brushless DC single phase AC input motor with ball bearing construction Unlike the ECM 2 3 2 5 motors the EEM features an integral control module Note The GE TECMate will not currently operate the EEM motor 1 Using a voltmeter check for 230 volts to the motor connections L and N If 230 volts is present proceed to step 2 If 230 volts is not present check the line voltage circuit to the motor 2 Using a voltmeter check for 24 volts from terminal C to either terminal 1 2 3 4 or 5 depending on which tap is being used at the motor If voltage present proceed to Step 3 If no voltage check 24 volt circuit to motor 3 If voltage was present in steps 1 and 2 the motor has failed and will need to be replaced Note When replacing motor ensure the belly band is betwee
46. d e Pressure Switch Stuck Open High Temperature Lint Flame Present Outside the Flame Detect Mode 6 Compressor Short Cycle Delay Active Same Call for Heat Indoor Thermostat Outdoor Thermostat Pressure Switch Loss of Charge Switch CA IA Steady ON Red LED Fault Codes 57 SERVICING LED 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 NORMAL SEQUENCE OFOPERATION DSI Direct Spark Ignition System PCBAG123 Board 1 Thermostat calls for heat by energizing W The control checks the pressure switch for open condition If the pressure switch is closed the control will flash code 3 and wait for the pressure switch to open 2 The induced draft motor is energized and the control flashes code 2 and waits for the pressure switch to close Once the pressure switch is closed the LED stops flashing andthe control begins timing the 15 second pre purge speed up 14144 12112111 UNUSED onsouBeiq Transformer DSI Control Board 3 Thecontrol energizes the spark igniter and gas valve for 7 seconds If flame is established the control goes into a 30 second h
47. d to the compressor motor through terminal conductors which pass through the compressor housing wall These terminals are sealedin a dielectric material which insulates them from the housing and maintains the pressure tight integrity of the hermetic compressor The terminals and their dielectric embedment are strongly constructed but are vulnerable to careless compressor installation or maintenance proce dures and equally vulnerable to internal electrical short circuits caused by excessive system contaminants WARNING To avoid possible explosion Never apply flame or steam to a refrigerant cylinder If you must heat a cylinder for faster charging partially immerse it in warm water Never fill a cylinder more than 80 full of liquid refrigerant Never add anything other than R 22 to an R 22 cylinder or R 410A to an R 410A cylinder The service equipment used must be listed or certified for the type of refrigerant used Store cylinders in a cool dry place Never use a cylinder as a platform or a roller AA WARNING To avoid possible explosion use only returnable not disposable service cylinders when removing refrig erant from a system Ensure the cylinder is free of damage which could lead to a leak or explosion Ensure the hydrostatic test date does not exceed 5 years Ensure the pressure rating meets or exceeds 400 Ibs When in doubt do not use cylinder In either
48. d 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 of the conditioned space The anticipator is a part of the thermostat and if it should fail for any reason the thermostat must be replaced See the following for recommended heater anticipator setting To determine the proper setting use an ammeter to measure the current on the W wire going to the thermostat Use an amprobe as shown below Wrap 10 turns of thermo stat wire aroundthe stationary jaw of the amprobe and divide the reading by 10 10 TURNS OF THERMOSTAT WIRE From W on thermostat 17 STATIONARY JAW OF AMPROBE READS 4 AMPS CURRENT DRAW WOULD BE 4 AMPS Checking Heat Anticipator Amp Draw 33 SERVICING S 4 CHECKING TRANSFORMER AND CON TROL CIRCUIT WARNING
49. e control should reset at 420 PSIG 25 PSIG S 13 CHECKING LOW PRESSURE CONTROL Thelow pressure control senses the pressure inthe suction line and will openits contacts on adrop in pressure Thelow pressure control will automatically reset itself with a rise in pressure The low pressure control is designed to cut out open at approximately 7 PSIG 3 PSIG It will automatically cut in close at approximately 25 PSIG 5 PSIG Testfor continuity using a VOM andif notas above replace the control i S 15 CHECKING CAPACITOR CAPACITOR RUN A run capacitor is wired across the auxiliary and main windings of a single phase permanent split capacitor motor The capacitors primary function is to reduce the line current while greatly improving the torque characteristics of a motor This is accomplished by using the 90 phase relationship between the capacitor current and voltage in conjunction with the motor windings so that the motor will give two phase operation when connected to a single phase circuit The capacitor also reduces the line current to the motor by improving the power factor 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 t
50. e 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 compartment All line voltage splices must be made inside the unit control box GAS SUPPLY AND PIPING Ah 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 Shownin the table above The minimum supply pressure must not be varied downward becausethis could lead tounreliable 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 15 PRODUCT DESIGN GAS PIPING Ah CAUTION TO AVOID POSSIBLE UNSATISFACTORY OPERATION OR EQUIPMENT DAMAGE DUE TO UNDERFIRING OF EQUIPMENT DO NOT UNDERSIZE THE NATURAL GAS PROPANE PIPING FROM T
51. e 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 willbe so the less air CFM being delivered the greater the rise The temperature rise should be adjusted in accordance to a given unit specifications and its external static pressure 1 Check BTUH input to unit do not exceed input rating stamped on rating plate 2 Takeentering and leaving air temperatures 3 Select the proper speed tap or dip switch setting for direct drive units 4 Take motor amperage draw to determine that the motoris not overloaded during adjustments RO SUPPLY RETURN RISE SUPPLY TRETURN Checking Temperature Rise S 300 TESTING PRIMARY LIMIT CONTROL APD GPD 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 sectionto determine the proper limit cutout temperature for the model being serviced 49 SERVICING In all instances the limit control is wired in series with the ignition
52. e size with orifice sizing drills If resizing is required a new orifice of the same physical size and angle with proper drill size opening should be installed S 307 CHECKING GAS PRESSURE Gas inlet and manifold pressures should be checked and adjusted in accordance to the type of fuel being consumed WARNING Disconnect gas and electrical power supply 1 Connect a water manometer or adequate gauge to the inlet pressure fitting of the gas valve 2 Removethe pressure tap fitting at the manifold if provided orcheckatthe gas valve outletfitting and connect another manometer or gauge Gas Valve Manometer On Off ae Hose Switch nh Low Pressure tmosphere Adjust Ja e lt Outlet lt q P Inlet High Pressure JH Adjust v Open to 4 Atmosphere Outlet Pressure Manometer Tap Hose Manometer WHITE ROGERS MODEL 36G 2 STAGE GAS VALVE 53 SERVICING Pressure Regulator Adjustment Open to Under Cap Screw Atmosphere Manifold Pressure Outlet Pressure Open to Tap Atmosphere se D OUTLET FLE Y Gas Valve Inlet Pressure On Off Tap Selector Switch Inlet Pressure WHITE
53. e the saturation temperature at existing pressure See Temperature Pressure Charton following page 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 58 60 62 64 66 68 70 72 7 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 122 124 126 128 REQUIRED SUBCOOLING TEMPERATURE F L Bg n de 100 102 100 104 102 100 106 104 102 100 108 106 104 102 110 108 106 104 112 110 108 106 114 112 110 108 116 114 112 110 118 116 114 112 120 118 116 114 122 120 118 116 124 122 120 118 126 124 122 120 45 SERVICING 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 Refertothe superheattable providedfor proper system superheat Add charge to lower superheat or recover charge to raise superheat Superheat Formula Suct Line Temp Sat Suct Temp EXAMPLE
54. eat on delay 4 The indoor blower is energized at the heat speed after a 30 second on delay 58 5 Thecontrol monitors the safety circuit inputs flame and thermostat during operation 6 When the thermostat is satisfied the gas valve is de energized and the induced draft blower remains on fora 29 second post purge The indoor blower remains on for the selected heat blower off delay 90 120 or 150 seconds Indoor blower off timing begins when thermo stat call for heat ends Testing Direct Spark Ignition DSI systems Thermostat calling for heat 15 second prepurge time and 7 second trial for ignition 1 Check for 230 VAC from L1 terminal of control module to L2 No voltage check wire connections continuity etc 2 Check for 24 VAC at R to C thermostat terminals Novoltage check3 amp automotive type fuse on control board A blown fuse would indicate a short in the 24 VAC circuit thermostat or limit circuit b Voltage Present check limit auxiliary limit and rollout S 300 S 301 and S 302 If limit auxiliary limit and rollout are closed then check for 24 VAC at the gas valve terminals No 24 VAC at gas valve replace Control board B1809918 Ignition Board Fault Codes Status Light Equipment Status On NormalOperaion No Power or Internal Control Fault Check Input Power Check Fuse on Control Replace Control Check Gas Flow Check Gas Pressure Check Gas Valve Check Flame Sens
55. eating cycle 6 As soon as flame 15 established a microamp reading should be evident once proof of flame microamp reading is established the hot surface ignitor will be de ener gized 7 The nominal microamp reading is 4 microamps 8 If the microamp current is less than 0 5 microamp the control will lockout and flash a code of 1 flash after attempting to reestablish flame sense 9 Ifthe microamp reading is less than the minimum fied check for high resistance wiring connections the distance 3 16 between the sensor and burner flame sensor connections dirty flame sensor or poor ground ing 10 If no reading check for continuity on all components and if good replace ignition control module NOTE Contaminated fuel or combustion air can create a nearly invisible coating on the flame sensor This coating works as an insulator causing a loss in the flame sense signal If this situation occurs the flame sensor must be cleaned with steel wool Do not use sand paper the silicone in sand paper will further contaminate the sensor 59 ECONOMIZER DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH HIGH VOLTAGE UNIT MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO ACCESSORIES WIRING DIAGRAMS warnine LN31VAIQO3 HO 021 061 1V1S 1 ADVLS ILINW GN3WINOO3H 3 LON INVHOVIG ONIHIM H3ZINONOO ONIENL
56. eating 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 APD GPD units are equipped with a direct spark ignition system Ignition is provided by 22 000 volt electronic spark A flame sensor then monitors for the presence of flame and closes the gas valve if flame is lost HEATING CYCLE On a call for first stage heat the contacts of the room thermostat close This energizes terminals R to Y and R to G the low voltage circuit to the contactor is completed starting the compressor and outdoor fan motor This also energizes the EEM motor after approximately 6 seconds When the thermostat is satisfied breaking the circuit be tween R to Y and R to G the compressor and outdoor fan motor will stop The indoor blower will stop after a pro grammed 60 second off delay NOTE Should the second stage heating contacts in the room thermostat close a W1 signal will be sent to the ignition control and the Y signal would be removed A normal gas heating sequence would then follow 19 SYSTEM OPERATION IGNITION CONTROL SEQUENCE OF OPERATION A Heating Operation Low stage heat 10 11 12 13 Thermostat type is set to two stage Thermostat W1 input initiates low stage heating Induced draftbloweris energized athigh speedforthe pre purge period Pre purge timer begins after control recognizes pressure
57. erty damage personal m or death Disconnectthe motor wire leads from its connection point atintegrated ignition control module Using and ohmmeter testfor continuity between each of the motor leads Touch one probe of the ohmmeter to the motor frame ground and the other probe in turn to each lead Ifthe windings do nottest continuous or a reading is obtained to ground replace the motor 4 After completing check and or replacement of induced draft blower motor 5 Turnonelectrical power and verify proper unit operation 51 S 304 TESTING GAS VALVE Direct Spark Ignition DSI Systems A combination redundant operator type gas valve which provides all manual and automatic control functions required for gas fired heating equipment is used on 13 SEER models Atwo stage combination redundant operatortype gas valve which provides all manual and automatic control functions requiredfor gas fired heating equipmentis used on 15 SEER models The valve provides control of main burner gas flow pressure regulation and 100 percent safety shut off 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 Ensure gas valve and main gas supply are on 2 Using a voltmeter check from the purple and blue wires on 1 stage gas valves and from C and M on 2 stage gas valves for 24 volt
58. es may be present Failure to do so may cause property damage personal injury or death 31 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 m or death 1 Remove doors control panel cover etc from unit being tested With power ON A WARNING Line Voltage now present 2 Using avoltmeter measure the voltage across terminals 11 and L2 ofthe contactor for 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 unit starting and operating and determine the unit Locked Rotor Voltage Locked Rotor Voltage 15 the actual voltage available at the compressor during starting locked rotor or a stalled condition Measured voltage should be above minimum listed in chart below To measure Locked Rotor Voltage attach a voltmeter to therun R and common C terminals ofthe compressor ortothe T and T 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 withi
59. eversing valve slides back to its normal heat position 21 SYSTEM OPERATION PCBAG127 CONTROL BOARD The following tables list the functions for the connectors DESCRIPTION and terminals the timings and the fault codes for the PCBAG127 control board 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 4 is a direct spark ignition system that uses a 22 000 volt spark HIGH VOLTAGE to ignite the burners A flame sensor is used to monitor the Disconnect ALL power before servicing flame or installing this unit Multiple power may cause property damage personal injury The board has the option of using a single or two stage ther sources may be present Failure to do so 27 or death 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
60. g its lifetime a product may require service Products should be serviced only by a qualified service technician whois familiar with the safety procedures required in the repair and who is equipped with the proper tools parts testing instruments and the appropriate service manual REVIEW ALL SERVICE INFORMATION IN THE APPROPRIATE SERVICE MANUAL BEFORE BEGINNING REPAIRS IMPORTANT NOTICES FOR CONSUMERS AND SERVICERS RECOGNIZE SAFETY SYMBOLS WORDS AND LABELS WARNING This unit should not be connected to or used in conjunction with any devices that are not design certified for use with this unit or have not been tested and approved by Goodman Serious property damage or personal injury reduced unit performance and or hazardous conditions may result from the use of devices that have not been approved or certified by Goodman A warnine ONLY INDIVIDUALS MEETING AT A MINIMUM THE REQUIREMENTS OF AN ENTRY LEVEL TECHNICIAN AS SPECIFIED BY THE AIR CONDITIONING HEATING AND REFRIGERATION INSTITUTE AHRI MAY USE THIS INFORMATION ATTEMPTING TO INSTALL OR REPAIR THIS UNIT WITHOUT SUCH BACKGROUND MAY RESULT IN PRODUCT DAMAGE PERSONAL INJURY OR DEATH WARNING Do not store combustible materials or use gasoline or other flammable liquids or vapors in the vicinity of this appliance as property damage or personal injury could occur Have your contractor point out and identify the various cut off devices switches etc
61. g of burners BECKETT BURNER SERVICING WARNING Disconnect gas and electrical power supply In checking main burners look for 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 A The length of Dimension A determines the angle of Gas Stream Defraction B A dent or burr will cause severe deflection of gas stream No resizing should be attempted until all factors are taken into consideration such as inlet manifold gas pressure alignment and positioning specific gravity and BTU content of the gas being consumed Theonly time resizingis required is when a reductionin firing rate is required for an increase in altitude Orifices should be treated with care in order to prevent damage They should be removed and installed with a box end wrench in order to prevent distortion In no instance should an orifice be peened over and redrilled This will change the angle or deflection of the vacuum effect or entraining of primary air which will make it difficult to adjust theflame properly Thissame problem can occur if an orifice spud of a different length is substituted A WARNING Disconnect gas and electrical power supply 1 Check orifice visually for distortion and or burrs 2 Check orific
62. g size etc and or consult with local utility 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 adjustto proper pressure See S 307 2 Improperburnerpositioning burners should be inlocat ing slots level front to rear and left to right 3 Carry over lighter tube or cross lighter obstructed clean 4 Main burner orifice s deformed or out of alignment to burner replace S 309 CHECKING FOR FLASHBACK Flashback will also cause burning in the burner venturi but is caused by the burning speed being greater than the gas air flow velocity coming from a burner port Flashback may occur at the 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 bethe same burning in the burner venturi a definite attempt should be made to determine which has occurred SERVICING If flashback should occur check for the following Reconnect wires to the Common and NO terminals 1 Improper gas pressure adjust to proper pressure See S 307 2 Checkburner for proper alignment and or replace burner 33
63. h the start capacitor and the relay holding coil is wired parallel with the start winding As the motor starts and comes up to speed the increase in voltage across the start winding will energize the start relay holding coil and open the contacts to the start capacitor Two quick ways to test a capacitor are a resistance and a capacitance check S 15A RESISTANCE CHECK d WARNING HIGH VOLTAGE Disconnect ALL power before servicing or installing this unit Multiple power sources may be present Failure to do so may cause property damage personal injury or death 1 Discharge capacitor and remove wire leads WARNING Discharge capacitor through a 20 to 30 OHM resistor before handling 36 CAPACITOR TESTING CAPACITOR RESISTANCE 2 Setan ohmmeter on its highest ohm scale and connect the leads to the capacitor a Good Condition indicator swings to zero and slowly returns to infinity Start capacitor with bleed resistor will not return to infinity It will still read the resistance of the resistor b Shorted indicator swings to zero and stops there replace c Open no reading replace Start capacitor would read resistor resistance S 15B CAPACITANCE CHECK Using a hookup as shown below take the amperage and voltage readings and use them in the formula Volt Ohm Meter 1415 FUSE TESTING CAPACITANCE SERVICING WARNING Discharge capacitor through a 20
64. he 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 35 SERVICING Yourunit comes with a 180 second anti short cycle to prevent the compressor from starting and running backwards MODELS EQUIPPED WITH A HARD START DEVICE A start capacitor is wired in parallel with the run capacitor to increase the starting torque The start capacitor is of the electrolytic type rather than metallized polypropylene as used in the run capacitor switching device must be wired in series with the capacitor to remove it from the electrical circuit after the compressor starts to run Not removing the start capacitor will overheat the capacitor and burn out the compressor windings These capacitors have a 15 000 ohm 2 watt resistor wired across its terminals The object of the resistor is to discharge the capacitor under certain operating conditions rather than having it discharge across the closing of the contacts within the switching device such as the Start Relay and 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 wit
65. he use of a wet rag sometimes can be a nuisance There are commercial grades of heat absorbing paste that may be substituted After the valve has been installed leak test evacuate and recharge 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 SERVICING INCLINED MANOMETER N RETURN Total External Static 2 Measurethe static pressure ofthe supply duct Positive Pressure 3 Add the two readings together NOTE Both readings may be taken simultaneously and read directly on the manometer if so desired 4 Consult proper table for quantity of air If the external static pressure exceeds the minimum or maximum allowable statics check for closed dampers dirty filters undersized or poorly laid out ductwork S 201 CHECKING TEMPERATURE RISE Temperature ris
66. hecks closed proceed 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 replace con trol b Voltage present replace contactor Testing High Stage Cooling Operation with Low Stage Cooling Operating 1 Board set for 2 stage thermostat a Check for 24 volts at thermostat terminals C and Y2 on control board No voltage check thermostat and thermostat wiring Voltage present check pressure switch circuit If pressure switch circuit checks closed proceed to next step Check for 24 volts to compressor unloader sole noid If no voltage present check 6 pin connector and wires from compressor unloader solenoid to 6 pin connector on board If connector and wires check good replace control 2 Board set for 1 stage thermostat a LED Flashes Status Off Wait the selected delay time either 5 or 10 minutes depending on jumper setting Check for 24 volts at compressor unloader sole noid No voltage check 6 pin connector and wires from compressor unloader solenoid to 6 pin connector on board If connector and wires check good replace control System Condition Internal Control Fault Micro Controller Detected Hardware Failure or Gas Valve Detected Energized When it Should be De energized Due to Excessive nes Pressure Switch Stuck Close
67. hen the problem would lie within the equipment Check for current leakage shorted motors etc 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 injury or death 1 Checkwiring visually for signs of overheating damaged insulation and loose connections 2 Use an ohmmeter to check continuity of any suspected open wires Ifany wires must be replaced replace with comparable gauge and insulation thickness S 3 CHECKING THERMOSTAT WIRING AND ANTICIPATOR THERMOSTAT WIRE SIZING CHART LENGTH OF RUN MIN COPPER WIRE GAUGE AWG 25 feet S 3A THERMOSTAT AND WIRING fu WARNING A Line Voltage now present With power ON thermostat calling for cooling 1 Use a voltmeterto 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 Checkthe continuity ofthe thermostat and wiring Repair or replace as necessary Indoor Blower Motor With power ON m WARNING Line Voltage now present 1 Set fan selector switch at thermostat to ON position 2 With voltmeter check for 24 volts at wires and G No voltage indicates the trouble 15 in the thermostat or wiring 4 Checkthe continuity ofthe thermostat an
68. ine Voltage now present A If the compressor starts and continues to run the cause for failure is somewhere else in the system B If the compressor fails to start replace 39 SERVICING S 18 TESTING CRANKCASE HEATER OPTIONAL ITEM The crankcase heater must be energized a minimum of four 4 hours before the condensing unit is operated Crankcase heaters are used to prevent migration accumu lation of refrigerant in the compressor crankcase during the off cycles and prevents liquid slugging oroil pumping on start up Acrankcase heater will not prevent compressor damage due to a floodback or over charge condition WARNING m Disconnect ALL power before servicing 1 Disconnect the heater lead in wires 2 Usinganohmmeter check heater continuity should test continuous If not replace S 21 CHECKING REVERSING VALVE AND SO LENOID Occasionally the reversing valve may stick in the heating or cooling position or in the mid position When stuck in the mid position part of the discharge gas from the compressor is directed back to the suction side resulting in excessively high suction pressure An increase inthe suction line temperature through the reversing valve can also be measured Check operation of the valve by starting the system and switching the operation from COOLING to HEATING cycle If the valve fails to change its position test the voltage 24V at the valve coil terminals while the syste
69. l 4 Cet appareil menager etant dote d un systeme d allumage automatique ne pas essayer allumer le br leur manuellement 5 Pousse le levier du contr le du gaz OFF ARRET position 6 Attendre cinq 5 minutes pour laisser echapper tout le gaz Renifler tout autour de l appareil y compris pr s du plancher pour d celer une odeur de gaz Si c est le cas then smell gas STOP Follow B in the safety information above on this label if you don t smell ROBINETAGAZ ARR TEZ Passer l etape B des instructions de securite MANUEL EN POS sur la portion superieure de cette etiquette ON MARCHE gas go to next step GAS 7 Push gas control lever INLET to ON 6 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 MANUAL GAS LEVER SHOWN IN ON POS S il n y a pas d odeur de gaz passer suivante 7 Pousse le levier du contr le du gaz ON MARCHE position 8 Remettre en place le panneau d acc s 9 Mettre l appareil sous tension 10 R gler le thermostat la temp rature d sir e 11 Si l appareil ne se met pas en marche suivre les instructions intitul es Comment couper l admission de gaz de l appareil et appeler un technicien qualifi ou le fournisseur de gaz
70. lity has stated thatthe calorific value of the gas is 1025 BTU per cubic foot Multiplying the ninety 90 cubic feet by 1025 BTU fP gives us an input of 92 250 BTU hr Checking the BTU input on the rating plate of the unit being tested EXAMPLE PD1436090M41 INPUT 92 000 BTU HR OUTPUTCAP 72 900BTU HR Shouldthefigure 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 4 CAUTION ALWAYS CONNECT A MANOMETER TO THE 1 8 PIPE TAP AT THE GAS VALVE BEFORE ADJUSTING THE PRESSURE REGULATOR IN NO CASE SHOULD THE FINAL MANIFOLD PRESSURE VARY MORE THAN PLUS OR MINUS 3 INCHES WATER COLUMN FROM 3 5 INCHES WATER COLUMN FOR NATURAL GAS OR 10 INCHES WATER COLUMN FOR PROPANE GAS 28 adjustthe pressure regulator on 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 1 1 water column with a
71. ll 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 SERVICING Complaint POSSIBLE CAUSE DOTS IN ANALYSIS GUIDE INDICATE POSSIBLE CAUSE SYMPTOM System will not start Power Failure Compressor will not start fan runs No Cooling 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 overl oad System runs continuously little cooling Unsatisfactory Cooling Too cool and then too warm Not cool enough on warm days Certain areas too cool others too warm Low suction pressure Compressor is noisy Low head pressure System Operating Pressures High suction pressure High head pressure COOLING ANALYSIS CHART Test Method Remedy See Service Procedure Ref Test Voltage Blown
72. llic fittings Aluminum alloy tubing shall notbe used in exterior locations 16 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 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 pRIP LEG GROUND JOINT UNION INSTALLED AHEAD OF GAS VALVE 4 GROMMET NOTE The unit gas supply entrance is factory sealed with plugs Keep plugs in place until gas supply is ready to be installed Once ready replace the plugs with the supplied grommets and install gas supply line CHECKING THE GAS PIPING 4 CAUTION TO AVOID THE POSSIBILITY OF PROPERTY DAMAGE PERSONAL INJURY OR FIRE THE FOLLOWING INSTRUCTIONS MUST BE PERFORMED REGARDING GAS CONNECTIONS AND PRESSURE TESTING Theunit and its gas connections must be leak tested before placing in operation Because of the dange
73. ls DFT and R R DFT on PCBDM133 and PCBDM160 at defrost control board 2 Connect jumper across test pins on defrost control board 3 Setthermostatto callforheating System should go into defrost within 21 seconds Immediately remove jumper from test pins 5 Using VOM check for voltage across terminals C amp O O RV on PCBDM133 and PCBDM 1 60 Meter should read 24 volts 6 Using VOM checkfor voltage across fan terminals DF1 and DF2onthe board You should read line voltage 208 230 VAC indicating the relay is open in the defrost mode 7 Using VOM check for voltage across W2 W on PCBDM133 and PCBDM160 amp C terminals on the board You should read 24 volts 8 If notas above replace control board 9 Set thermostat to off position and disconnect power before removing any jumpers or wires NOTE Remove jumper across defrost thermostat before returning system to service S 25 TESTING DEFROST THERMOSTAT 1 Installathermocouple type temperature test lead onthe tube adjacent to the defrost control Insulate the lead point of contact 2 Check the temperature at which the control closes its contacts by lowering the temperature of the control The defrost control should close at 34 F 5 F 3 Check the temperature at which the control opens its contacts by raising the temperature of the control The defrost control should open at 60 F 5 F 4 Ifnotas above replace control SERVICING S 100
74. lts atthermostatterminals W2 and on the control board b voltage check thermostat and thermostat wiring c Voltage present check for 24 volts at gas valve terminals C and HI d Novoltagepresentat valve check9 pin connector and wires from ignition controlto gas valve If wires and connections at 9 pin connector check good replace ignition control e Voltage presentat gas valve replace gas valve 2 Board set for 1 stage thermostat a Wait the selected delay time either 5 or 10 minutes depending on jumper setting b Checkfor 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 d Voltage present at gas valve terminals C and HI replace valve Cooling Mode Indoor thermostat calling for cool 1 Check for 230 volts from L1 terminal of control module to L2 No voltage check wire connections continuity etc Check for 24 volts at R and C thermostat terminals on ignition control a Novoltage check3 amp automotive type fuse on control board A blown fuse could indicate a short in the 24 volt circuit b Voltage present proceed to step 3 Check for 24 volts at thermostat terminals C and Y1 Novoltage check thermostat wiring and thermo stat b Voltage present check pressure switch circuit If pressure switch circuit c
75. ly grounded in accordance with the local codes or intheir absence with the latest edition of the National Electrical Code ANSI NFPA No 70 orin Canada Canadian Electrical Code C22 1 Part1 Afuseddisconnected mustbe provided and sized in accordance with the unit minimum circuit ampacity The best protection for the wiring is the smallest fuse or breaker which will hold the equipment on line during normal operation without nuisance trips Such adevice will provide maximum circuit protection PRODUCT DESIGN 48 WARNING DO NOT EXCEED THE MAXIMUM OVERCURRENT DEVICE SIZE SHOWN ON THE UNIT DATA PLATE All line voltage connections must be made through weather proof fittings All exterior power supply and ground wiring must be in approved weather proof conduit Low voltage wiring from the unit control paneltothe 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 unittransformer is connected for 230V operation If the unitisto operate on 208V reconnectthe transformer primary lead and the induced draft blower leads as shown on the unit wiring diagram A WARNING TO AVOID THE RISK OF PROPERTY DAMAGE PERSONAL INJURY OR FIRE USE ONLY COPPER CONDUCTORS If it is necessary for th
76. m is on the COOLING cycle If no voltage is registered at the coil terminals check the operation ofthe thermostat andthe continuity ofthe connect ing wiring from the O terminal of the thermostat to the unit If voltage is registered at the coil tap the valve body lightly while switchingthe system from HEATING to COOLING etc If this fails to cause the valve to switch positions remove the coil connector cap and test the continuity of the reversing valve solenoid coil If the coil does not test continuous replace it If the coil test continuous and 24 volts is present at the coil terminals the valve is inoperative replace it S 24 TESTING DEFROST CONTROL NOTE PCBDM133 and PCBDM160 defrostcontrols have a three 3 minute compressor off cycle delay 40 NOTE The PCBDM133 and PCBDM160 defrost controls are shipped from the factory with the compressor delay option selected This will de energize the compressor contactor for 30 seconds on defrost initiation and defrost termination If the jumper is setto Normal the compressor will continue to run during defrost initiation and defrost termination The control will also ignore the low pressure switch connected to R PS1 and PS2 for 5 minutes upon defrost initiation and 5 minutes after defrost termination Tocheckthe defrost control for proper sequencing proceed as follows With power ON unit not running 1 Jumper defrost thermostat by placing a jumper wire across the termina
77. n the vents on the motor andthe wiring has the proper drip loop to prevent condensate from entering the motor 37 SERVICING High Voltage Connections 3 16 Low Voltage Connections EEM MOTOR CONNECTIONS S 17 CHECKING COMPRESSOR WARNING Hermetic compressor electrical terminal venting can be dangerous When insulating material which supports a hermetic compressor or electrical terminal suddenly disintegrates due to physical abuse or as a result of an electrical short between the terminal and the compressor housing the terminal may be expelled venting the vapor and liquid contents of the compressor housing and system Ifthe compressor terminal PROTECTIVE COVER and gasket if required are not properly in place and secured there is a remote possibility if a terminal vents that the vaporous and liquid discharge can be ignited spouting flames several feet causing potentially severe orfatal injury to anyone in its path This discharge can be ignited external to the compressor if the terminal cover is not properly in place and ifthe discharge impinges on a sufficient heat source 38 Ignition of the discharge can also occur at the venting terminal or inside the compressor if there is sufficient contaminant air present in the system and an electrical arc occurs as the terminal vents Ignition cannot occur at the venting terminal without the presence of contaminant air and cannot occur exte
78. n the voltage tabulation as shown If the voltage falls below the minimum voltage check the line wire size Long runs of undersized wire can cause low voltage If wire size is adequate notify the local power company in regards to either low or high voltage Unit Supply Voltage Voltage Three phase units require a balanced 3 phase power supply to operate If the percentage of voltage imbalance exceeds 3 the unit must not be operated until the voltage condition is corrected 32 Max Voltage Deviation From Average Voltage X 100 Average Voltage 96 Voltage Imbalance Tofindthe percentage of imbalance measure the incoming power supply 11 12 240 L1 L3 232V Avg V 710 236 7 L2 L3 238V 3 Total 710V 240 236 7 43 3 232 236 7 4 7 238 236 7 41 3 To find Max deviation Max deviation was 4 7V 96 Voltage Imbalance 4 7 1 99 236 7 If the percentage of imbalance had exceeded 3 it must be determined the imbalance is in the incoming power supply orthe equipment To do this rotate the legs of the incoming power and retest voltage as shown below L1 L2 240V 11 13 227 L2 L3 238V Rotate all 3 incoming legs as shown 11 12 227 L1 L3 238V L2 L3 240V By the voltage readings we see thatthe imbalance rotated or traveled with the switching ofthe incoming legs Therefore the imbalance lies within the incoming power supply Ifthe imbalance had not changed t
79. not the same as in A replace contactor VOLT OHM Ohmmeter for testing holding coil Voltmeter for testing contacts TESTING COMPRESSOR CONTACTOR Three Phase 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 injury 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 removed If not continuous the contacts are open 3 Attach a gauge to the dill valve port on the base valve With power ON T WARNING A Line Voltage now present 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 itis operating normally See causes for high head pressure in Service Problem Analysis Guide If it cuts out below this pressure range replace the control Th
80. not as listed replace control 15second pre purge period The LED will flasha code of 3 Note the pressure switch must be mounted with the to indicate open pressure switch diaphragm in a vertical position If the pressure switch opens after the gas valve has been energized the control will de energizethe gas valveandrun S 311 HIGH ALTITUDE APPLICATION the indoor blower through the heat off delay The inducer staysonuntilthe pressure switch re closes Thenthe control makes another ignition attempt High Altitude Derate U S Installations Only 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 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 1 Remove wires from the electrical terminals 2 Using a VOM check from Common to NO No
81. ntacts When the coil is de energized springs return the contacts to their normal position 34 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 SINGLEPHASE 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 Disconnectthe wireleads fromthe terminal T side ofthe contactor 2 With power ON energize the contactor 4 WARNING LINE VOLTAGE NOW PRESENT VOLT OHM METER Ohmmeter for testing holding coil Voltmeter for testing contacts TESTING COMPRESSOR CONTACTOR Single Phase 3 Using a voltmeter test across terminals A L1 L2 Novoltage Check breaker or fuses on main power supply B L2 T1 No voltage indicates CC1 contacts open If a no voltage reading is obtained replace the contactor SERVICING THREE PHASE Using a voltmeter test across terminals A 11 12 11 13 and 12 13 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
82. o 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 suspected thoroughly ventilate the area before beginning work Liquid refrigerant can be very cold To avoid possible frostbite or blindness avoid contact with refrigerant and wear gloves and goggles If liquid refrigerant does contact your skin or eyes seek medical help immediately Always follow EPA regulations Never burn refrig erant as poisonous gas will be produced WARNING To avoid possible injury explosion or death practice safe handling of refrigerants WARNING The compressor POE oil for R 410A units is extremely susceptible to moisture absorption and could cause compressor failure Do not leave system open to atmosphere any longer than necessary for installation WARNING System contaminants improper service procedure and or physical abuse affecting hermetic compressor electrical terminals may cause dangerous system venting The successful developmentof hermetically sealed refrigera tion compressors has completely sealed the compressor s moving parts and electric motor inside a common housing minimizing refrigerant leaks and the hazards sometimes associated with moving belts pulleys or couplings Fundamental to the design of hermetic compressors is a method whereby electrical current is transmitte
83. of these instances an electrical short between the terminal and the compressor housing may result in the loss of integrity between the terminal and its dielectric embed ment This loss may cause the terminals to be expelled thereby venting the vaporous and liquid contents of the 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 number is used for positive identification of component parts used in manufacturing Please use this number when requesting service or parts information MINOR REVISION PRODUCT SERIES SEER Pating HEATING INPUT 070 69 000 BTUH 090 92 000 BTUH 115 115 000 BTUH MAJOR REVISION VOLTAGE 1 208 230V 1ph 60Hz CONFIGURATION PRODUCT M Multi Position FAMILY D Dual Fuel NOMINAL CAPACITY 24 24 000 BTUH
84. onnect 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 ONCE A MONTH 1 Inspectthe return filters of the evaporator unit and clean or change if necessary NOTE Depending on operation conditions it may be necessary to clean or replace the filters more often If permanenttype filters are used they should be washed with warm water and dried 2 When operating on the cooling cycle inspect the con densate line piping from the evaporator coil Make sure the piping is clear for proper condensate flow ONCE A YEAR QUALIFIED SERVICE PERSONNEL ONLY 1 Clean the indoor and outdoor coils 2 Clean the cabinet inside and out 3 Motors are permanently lubricated and do not require oiling TOAVOID PREMATURE MOTORFAILURE DO NOTOIL 4 Manually rotate the outdoor fan and indoor blower to be sure they run freely 5 Inspect the control panel wiring compressor connec tions and all other component wiring to be sure all connections are tight Inspect wire insulation to be certain that it is good 6 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 6001 scale etc Inspect all burners for lint and proper positioning 9 S
85. or Check Flame Rollout Check Aux Limit Ignition Failure Open Rollout Switch or Open Aux Limit Switch 2 Blinks Pressure Switch Open Check Pressure Switch 3 Blinks Check Pressure Switch Closed 4 Blinks Open Limit Main Limit Switch Open Switch 5 Blinks False Flame Sensed Sticking Gas Valve 6 Blinks Compressor Output Compressor Delay Anti Cycle Timer NOTE The flash rate is 0 25 seconds on 0 25 seconds off with a 2 second pause between codes SERVICING S 314 CHECKING FLAME SENSOR Aflame sensing device is used in conjunction with the ignition control module to prove combustion If a microamp signal is 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 1 Disconnectthe flame sensor wire from terminal FS ofthe ignition control module _ Flame Sensor Flame Sensor 2 Connect a microamp meter in series with this wire and terminal FS 3 Besure the negative side of the meter is to the wire and the positive of the meter is to terminal FS 4 Turnon Power WARNING A Line Voltage now present 5 With Power ON Place the unit into a h
86. r and obtain an oil sample from the suction stub If the oil is not acidic either a burnout has not occurred or the burnout is so mild that a complete clean up is not necessary If acid level is unacceptable the system mustbe 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 aburnout the POE oils will remove any burnout residue left in the system If not captured by the refrigerant filter they will collect in the compressor or other system components causing a failure of the replacement compressor and or spread contaminants throughout 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 asrequired NOTE At least twelve 12 inches of the suction line immediately out of the compressor stub must be discarded due to burned residue and contaminates 1 Remove compressor discharge line strainer 2 Remove the liquid line drier and expansion v
87. r of explosion or fire never use a match or open flame to test for leaks Never exceed specified pressure fortesting 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 closingits individual 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 PRODUCT DESIGN TANKS AND PIPING PROPANE UNITS AQ WARNING PERSONAL INJURY HAZARD 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 CAUSE SERIOUS PERSONAL INJURY OR DEATH All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters See NBFU Manual 58 or Natural Standards of Canada B149 2 Installation Code for Propane Gas Burning Appliances and Equipment For satisfactory operation propane gas pressure 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 of the container or containers 2 Proper pressure regulation Two stage regulation is recommended from the standpoint of both cost and efficiency 3 Pressure dropin lines between
88. rbon monoxide CO poisoning resulting from the exhaust emissions If a furnace or air handler is installed in an enclosed area and a carbon monoxide producing device is operated therein there must be adequate direct outside ventilation Carbon monoxide emissions can be re circulated throughout the structure if the furnace or air handler is operating in any mode CO can cause serious illness including permanent brain damage or death N DANGER RISQUE D EMPOISONNEMENT AU MONOXYDE DE CARBONE Avertissement special au sujet de l installation d appareils de chauffage ou de traitement d air dans des endroits clos tets les garages les locaux d entretien et les stationnements Evitez de mettre en marche les appareils produisant du monoxyde de carbone tels que les automobile les appareils de chauffage autonome etc dans des endroits non ventil s tels que les d empoisonnement au monoxyde de carbone Si vous devez faire fonctionner ces appareils dans un endroit clos assures vous qu il y ait une ventilation directe provenant de l exterie Les missions de monoxyde de carbone peuvent etre recircules dans les endroits clos si l appareil de chauffage ou de traitement d air sont en marche Le monoxyde de carbone peut causer des maladies graves telles que des dommages permanents au cerveau et meme la mort N PELIGRO RIESGO DE INTOXICACI N POR MON XIDO DE CARBONO Advertencia especial para la instalaci n de calentadores maneja oras de aire en reas cerr
89. regulators and between second stage regulator and the appliance Pipe size required will depend on length of pipe run and total load of all appliances Complete information regarding tank sizing for vaporization recommended regulator settings and pipe sizing is available from mostregulator manufacturers and propane gas suppli ers Propaneis an excellent solvent and special pipe dope must be used when assembling piping forthis gas as it will quickly dissolve white lead or most standard commercial com pounds Shellac base compounds resistant to the actions of liquefied petroleum gases such as Gasolac Stalactic Clyde s or John Crane are satisfactory TYPICAL PROPANE PIPING 5 to 15 PSIG First Stage 20 PSIG Max Regulator Continuous 11 W C 200 PSIG Second Stage Maximum Regulato WARE A WARNING IF YOUR PROPANE GAS APPLIANCE IS INSTALLED IN AN EXCAVATED AREA OR A CONFINED SPACE WE STRONGLY RECOMMENDED THAT YOU CONTACT YOUR PROPANE SUPPLIER ABOUT INSTALLING A GAS DETECTING WARNING DEVICE THAT WOULD ALERT YOU TO A GAS LEAK PROPANE GAS IS HEAVIER THAN AIR AND ANY LEAKING GAS CAN SETTLE IN ANY LOW AREAS OR CONFINED SPACES PROPANE GAS ODORANT MAY FADE MAKING THE GAS UNDETECTABLE EXCEPT WITHA WARNING DEVICE AN UNDETECTED GAS LEAK WILL CREATE A DANGER OF EXPLOSION OR FIRE IF YOU SUSPECT THE PRESENCE OF GAS FOLLOW THE INSTRUCT IONS ON PAGES 9 11 FAILURE TO DO SO COULD RESULT IN SERIOUS P
90. rmally 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 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 Tosite 4 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 kitis used for both Natural and LP gas at high altitudes Use LPM 05 2 stage heat models or LPT 03 1 stage heat models propane conversion kitfor propane conversions at altitudes below 2000 feet Natural gas installations below PRESSURE SWITCH INCLINED MANOMETER 2000 feet do not require a kit 55 SERVICING LPT 00A may be used on models with AA revisions LPT 03 is compatible with both the White Rodgers and the Honeywellgas valves For propane conversions above 2000 feet high altitude kit HA 02 15 required in addition to the propane conversion kit Natural gas and LP gas installations at altitudes gt 2000 ft HIGH ALTITUDE INPUT BURNER KIT 20 000 BTUH NAT 20 000 BTUH L P ELEVATION ABOVE SEA LEVEL FEET 2000 3000 4000 4500 5000 6000
91. rnally fromthe venting terminal withoutthe presence of an external ignition source Therefore proper evacuation of a hermetic system is essen tial atthe 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 The line break internal overload senses both motor amperage and winding temperature High motor temperature 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 circuitbreaker 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 injury or death 1 Removethe leads fromthe compressorterminals WARNING See warnings S 17 before removing compressor terminal cover 2 Using an ohmmeter testcontinuity between terminals S C R and 5 on single phase units or terminals T1
92. rocating compressors This information may befoundinthe Cooling Performance Data section A scroll is an involute spiral which when matched with a mating scroll form as shown generates a series of crescent shaped gas pockets between the two members During compression one scroll remains stationary fixed scroll while the other form orbiting scroll is allowed to orbit but not rotate around the first form As this motion occurs the pockets between the two forms are slowly pushed to the center of the two scrolls while simultaneously being reduced in volume When the pocket reaches the center of the scroll form the gas which is now at a high pressure is discharged out of a port located at the center During compression several pockets are being compressed simultaneously resulting in a very smooth process Both the suction process outer portion of the scroll members and the discharge process inner portion are continuous ELECTRICAL WIRING The units are designed for operation on 60 hertz currentand 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 unit as shown on the supplied unit wiring diagram The 24V wiring must be connected between the unit control panel and the room thermostat LINE VOLTAGE WIRING Power supply to the unit must be N E C Class 1 and must comply with all applicable codes The unit must be electri cal
93. rresponding Temp F 120 c Thermometer on Liquid line 109 F To obtain the amount of subcooling subtract 109 F from 120 The difference is 11 subcooling See the specification sheet or technical information manual for the design subcooling range for your unit S 110 CHECKING EXPANSION VALVE OPERA TION 1 Remove the remote bulb ofthe expansion valve from the suction line 2 Start the system and cool the bulb in a container of ice water closing the valve As you cool the bulb the suction pressure should fall and the suction temperature will rise SERVICING 3 Next warm the bulb in your hand As you warm the bulb the suction pressure should rise and the suction tempera ture will fall 4 temperature or pressure change is noticed the expansion valve is operating If no change is noticed the valve is restricted the power element is faulty or the equalizer tube is plugged 5 Capture the charge replace the valve and drier and evacuate S 111 FIXED ORIFICE RESTRICTOR DEVICES The fixed orifice restrictor device flowrator used in conjunc tion with the indoor coil is a predetermined bore 1 D Itis designed to control the rate of liquid refrigerant flow into an evaporator coil The amount of refrigerant that flows through the fixed orifice restrictor device is regulated by the pressure difference between the high and low sides of the system In the cooling cycle when the outdoor air tempera
94. ry to power the gas valve SERVICING VOLT OHM METER COLOR IDENTIFYING 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 15 de energized Power to the thermostat R is removed while the limit switch is open When the limit switch re closes the induced draft motor runs through its post purge and the indoor blower goes through the heat off delay If a call for heat exists when the limit switch re closes the control goes through a pre purge period and then makes an ignition attempt The indoor blower remains on for the delay off time during the re ignition attempt 1 If no voltage is measured on either side of control it indicates ignition control or wiring to control problem If voltage is measured on one side of the control and not the other it indicates the control is open 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 Check to see if any damage was done to the f
95. s to gas valve 3 1124 volts are present and no gas flows through the valve replace valve Gas Valve On Off Switch Inlet Pressure 8 2 J 7 QOOF TI X Outlet Pressure Tap W R 36G54 238 WHITE ROGERS MODEL 36G 2 STAGE GAS VALVE 52 Pressure Regulator Outlet Pressure _ r Adjustment Under Cap Screw M NE INLET gt D OUTLET 4 jo 2 Gas Valve On Off Selector Switch Inlet Pressure Tap W R 36G22 202 WHITE ROGERS MODEL 36G 1 STAGE GAS VALVE Pressure Regulator Inlet under cap screw Pressure Outlet Tap Pressure OUTLET Gas Valve On Off Selector Switch HONEYWELL MODEL VR8215 1 STAGE GAS VALVE S 305 CHECKING MAIN BURNERS The main burners are used to provide complete combustion of various fuels in a limited space and transfer this heat of the burning process to the heat exchanger Proper ignition combustion and extinction are primarily due to burner design orifice sizing gas pressure primary and secondary air vent and proper seatin
96. s valves are energized along with the igniter for trial for ignition period Igniter is de energized when flame is detected Flame is achieved and detected during trial for ignition period Flame stabilization period begins when flame is detected 10 11 12 13 A GPD14 Gas valve and induced draft blower remain at high stage and high speed Air circulating blower is energized at high heat speed after heat ON delay time expires Heat ON delay timer begins when flame is detected Control monitors thermostat flame limit and pres sure switch inputs during high stage heating Thermostat W1 and W2 inputs are removed High and low stage gas valves are de energized Induced 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 returnsto Standby and awaits nextthermostat request A Cooling Operation Low stage cool 10 14 Thermostat type is set to two stage Thermostat Y1 or thermostat Y1 and 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
97. se above 1500 microns in three to five minutes system can be considered properly evacuated 6 If thermocouple vacuum gauge continues to rise and levels off at about 5000 microns moisture and non condensables are still present If gauge continuesto rise aleakis present Repair and re evacuate 7 Closevalvetothermocouple vacuum gauge and vacuum pump Shut off pump and prepare to charge 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 42 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 standards CAUTION Operating the compressor with the suction valve closed will void the warranty and cause serious compressor damage Charge the system with the exact amount of refrigerant Refer to the specification section or check the unit name plates forthe correct refrigerant charge An inaccurately charged system will cause future prob lems 1 Using a quality set of charging scales weigh the proper amountof refrigerantforthe system Allow liquid refriger ant only to enter the high side 2 After the system will take all it will take close the v
98. sitif d allumage qui allume automatiquement le br leur Ne pas tenter d allumer le br leur manuellement B 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 AUNE ODEUR DE GAZ Ne pas tenter d allumer d appareils o Ne toucher aucun interrupteur ne pas vous servir des t l phones dans le b timent o Appelez imm diatement votre fournisseur de gaz depuis un voisin Suivez les instructions du fournisseur de gaz o Sivous ne pouvez rejoindre le fournisseur de gaz appelez le service des incendies C Ne pousser ou tourner la manette d admission du gaz 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 D Ne pas se servir de cet appareil s il a t plong dans 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 c mmande qui ont t plong es dans l eau 1 ARRETEZ Lisez les instructions de s curit dans la section sup rieure de cette tiquette 2 R gler le thermostat la temp rature la plus basse 3 Couper l alimentation lectrique de l apparei
99. sumption and are energized by a 24V signal from the ignition control board The EEM motors feature an integrated control module Air for condensing cooling cycle is drawn through the outdoor coil by apropellerfan 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 PD series package units use the Compliant Scroll compres sor there are a number of design characteristics which are different from the traditional reciprocating compressor Due to their design Scroll compressors are inherently more tolerantofliquid refrigerant NOTE Eventhough 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 which is NOT compatible with mineral oil based lubri cants like 3GS POE oil must be used if additional oil is required Compliantscroll compressors perform quiet shutdowns that allow the compressor to restartimmediately without the need for a time delay This compressor will restart even if the system has not equalized 14 Operating pressures and amp draws may differ from standard recip
100. tartthe system using the proper instrumentation check gas inlet and manifold pressures burner flame and microamp signal Adjust if necessary 26 10 Startthe system and run a Heating Performance Test If the results of the test are not satisfactory see the Service Problem Analysis Guide for the possible cause TEST EQUIPMENT Proper test equipment for accurate diagnosis is as essen tial as regular hand tools The following is a must for every service technician and service shop 1 Thermocouple type temperature meter measure dry bulb temperature 2 Slingpsychrometer measurerelative humidity and wet bulb temperature 3 Amprobe measure current 4 Volt Ohm Meter testing continuity capacitors motor windings and voltage 5 Accurate Leak Detector testing for refrigerant leaks 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
101. temperature high pressure vapor leaves the compres sor through the discharge line and enters the condenser coil Air drawn through the condenser coil by the condenser fan causes the refrigerant to condense into a liquid by removing heat the refrigerant As the refrigerant is cooled below its condensing temperature it becomes subcooled The subcooled high pressure liquid refrigerant now leaves the condenser coil via the liquid line until it reaches the indoor expansion device As the refrigerant passes through the expansion device and into the evaporator coil a pressure drop is experienced causing the refrigerant to become alow pressure liquid Low pressure saturated refrigerant enters the evaporator coil where heat is absorbed from the warm air drawn across the coil by the evaporator blower As the refrigerant passes through the last tubes of the evaporator coil it becomes superheated that is it absorbs more heat than is necessary for the refrigerant to vaporize Maintaining proper superheat assures that liquid refrigerant is not returning to the compres sor which can lead to early compressor failure Low pressure superheated vapor leaves the evaporator coil and returns through the suction line to the compressor where the cycle begins again Heat Pump Models Any time the room thermostat is switched to cool the O terminal is energized This energizes the 24 volt coil on the reversing valve and switches it to the cooling position
102. tion Period Flame Failure Response Time TEST 2 Seconds or Per ANSI Z21 20 Outside of Flame Stabilization Period Low to High Stage Delay Selectable 5 minutes or 10 minutes Default 10 minutes Heat ON Delay 30 Seconds S Table 4 Control Timings Function Len rlashesistatus Normal Intrnal Gas Valve Fault Lockout Pressure Switch Stuck Closed Pressure Switch Stuck Open Open High Temperature Limit Flame Detected with Gas Valve De Energized Compressor Short Cycle Delay Active Limit Opened 5 Times in Same Call For Heat Indoor Thermostat Outdoor 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 SYSTEM OPERATION Typical Dual Fuel System in Cooling Accumulator Accumulator Reversing Valve Energized Reversing Valve De Energized 25 SCHEDULED MAINTENANCE Package gas units require regularly scheduled maintenance to preserve high performance standards prolongthe service life of the equipment and lessen the chances of costly failure In many 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 Disc
103. 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 injury or death 1 Remove the motor leads from its respective connection points and capacitor if applicable 2 Checkthe continuity between each of the motor leads 3 Touch one probe of the ohmmeter to the motor frame ground and the other probe in turn to each lead Ifthe windings do nottest continuous ora reading is obtained from lead to ground replace the motor S 16C CHECKING ECM MOTOR WINDINGS WARNING HIGH VOLTAGE Disconnect ALL power before servicing or installing this unit Multiple power sources may be present Failure to do so may cause property damage personal injury or death 1 Disconnectthe 5 pin and the 16 pin connectors from the ECM power head 2 Removethe2 screws se
104. tting the circuit board jumper to 30 60 and 90 respectively Accumulation of time for the timing period selected starts when the sensor closes approximately 34 F and when the wall thermostat calls for heat Atthe end of the timing period the unit s defrost cycle will be initiated provided the sensor remains closed Upon a call for defrost the blower will continue to run andthe defrost board will send a W1 signal to the ignition control At the same time the compressor will stop for 30 seconds ifthe SmartShift defrost technology delay feature is selected on the defrost board Atthis time the reversing valve shifts from heat to cool position and condenser fans shut off The inducer motor will immediatly energize for a 15 second prepurge A7 second trial for ignition begins by energizing the low and high stages of the gas valve along with this spark ignition Main burners light and control detects presence of flame The compressor after its 30 OFF second delay restarts in cooling mode to defrost the condensor coil When the sensor opens approximately 60 F the defrost cycle is terminated and the timing period is reset If the defrost cycle is not terminated due to the sensor tempera ture a twelve minute override interrupts the unit s defrost period At this time the W1 signal is removed from the ignition control board the compressor will stop for a 30 second SmartShift defrost technology delay if selected and the r
105. ture rises the high side condensing pressure rises Atthe same time the cooling load onthe indoor coil increases causing the low side pressure to rise but at a slower rate Since the high side pressure rises faster when the tempera ture increases more refrigerant flows to the evaporator increasing the cooling capacity of the system When the outdoor temperature falls the reverse takes place The condensing pressure falls and the cooling loads on the indoor coil decreases causing less refrigerant flow Astrainer is placed on the entering side of the tube to prevent any foreign material from becoming lodged inside the fixed orifice restriction device If a restriction should become evident proceed as follows 1 Recoverrefrigerantcharge 2 Remove the orifice or tube strainer assembly and replace 3 Replace liquid line drier evacuate and recharge CHECKING EQUALIZATION TIME During the OFF cycle the high side pressure bleeds to the low side through the fixed orifice restriction device Check equalization time as follows 1 Attach a gauge manifold to the suction and liquid line dill valves 2 Start the system and allow the pressures to stabilize 3 Stop the system and check the time it takes for the high and low pressure gauge readings to equalize If it takes more than seven 7 minutes to equalize the restrictor device is inoperative Replace install a liquid line drier evacuate and recharge S 112 CHECKING
106. urnace especially the wiring Confirm that heat exchanger is not obstructed by feeling for discharge air from the flue hood when the combustion blower is running but the unit is not firing If the above steps do not suggest the reason the control has tripped the furnace should be fired Flame rollout could occur Keep face and hands a safe distance from burner area Remove the heating compartment door Turn of the power or open the thermostat circuit Resetthe rollout control Turn power on and put the unit into a call for heating 4 CAUTION Lookunder the heatshield as the unitis running Flames should be drawn into firing tubes a Ifonlyoneburners flame is not drawn into the tube that tube is restricted b f without the air circulation blower running all flames are not drawn into the tubes either the collector box combustion blower or flue outlet is obstructed If the combustion blower or flue outlet is obstructed the pressure switch should have opened preventing the unit from firing also inspect the unit pressure switch and wiring c burner flame is not drawn into the tube only when the air circulation blower is running then a cracked heat exchanger tube is present S 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 prop
107. ust be set to open at no more than 150 psig Pressure testthe system using dry nitrogen and soapy water to locate leaks If you wish to use a leak detector charge the system to 10 psi using the appropriate refrigerant then use nitrogen to finish charging the system to working pressure then apply the detector to suspect areas If leaks are found repairthem After repair repeat the pressure test If no leaks exist proceed to system evacuation S 102 EVACUATION WARNING REFRIGERANT UNDER PRESSURE Failure to follow proper procedures may cause property damage personal injury or death This is the mostimportant part of the entire service procedure The and efficiency of the equipmentis dependent uponthe thoroughness exercised by the serviceman when evacuating air non condensables and moisture from the system Air in a system causes high condensing temperature and pressure resulting in increased power input and reduced performance Moisture chemically reacts with the refrigerant oil to form corrosive acids These acids attack motor windings and parts causing breakdown The equipment required to thoroughly evacuate the system is 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 Neverusethe system compressoras a vacuum pump orrunwhen under a high vacuum Motor damage could occur
108. ws Doors Vent Fans Etc Improperly Located Thermostat Air Flow Unbalanced Relocate Thermostat Readjust Air Volume Dampers System Undersized Refigure Cooling Load Broken Internal Parts Replace Compressor Inefficient Compressor High Pressure Control Open Test Compressor Efficiency Reset And Test Control Unbalanced Power 3PH Test Voltage Wrong Type Expansion Valve Expansion Device Restricted Expansion Valve Bulb Loose Replace Valve Remove restriction or replace expansion device EE Tighten Bulb Bracket Inoperative Expansion Valve Loose Hold down Bolts Faulty Reversing Valve Faulty Defrost Control Faulty Defrost Thermostat Flowrator Not Seating Properly Check Valve Operation 54110 LOT 29 SERVICING GAS HEATING ANALYSIS CHART Complaint No Heat Unsatisfactory Heat POSSIBLE CAUSE DOTS IN ANALYSIS GUIDE INDICATE amp POSSIBLE CAUSE 5 2 2 SYMPTOM 2 Pow er Failure Blow n Fuse oose Connection ry Shorted or Broken Wires proper at Amp Sting 7 1 improper Thermostat Location _ Limit or Rol Out Switch Flame Sensor Gas Valve or Gas Supp Shut FauyWducedDrfBbwer Dirty Flame Sensor Low uk _ Flame Sensor notin Flame Low FautyGasVave No Figh Stage Heat Stage Ony
109. ystem is observed 1 Start the system 2 Remove and capture small quantities of refrigerant as from the suction line access fitting until the head pressure is reduced to normal 3 Observethe system while running a cooling performance test If a shortage of refrigerant is indicated then the system contains non condensables S 114 NON CONDENSABLES If non condensables are suspected shut down the system and allow the pressures to equalize Wait at least 15 minutes Compare the pressure to the temperature of the coldest coil since this is where most of the refrigerant will be Ifthe pressure indicates a higher temperature than that of the coil temperature non condensables are present Non condensables are removed from the system by first removing the refrigerant charge replacing and or installing liquid line drier evacuating and recharging 47 SERVICING 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 hosetothe liquid line dill valve and properly remove and dispose ofthe refrigerant NOTICE Violation of EPA regulations may result in fines or other penalties Now determine if a burn out has actually occurred Confirm by analyzing an oil sample using a Sporlan Acid TestKit AK 3 or its equivalent Remove the compresso

servicing - eComfort

Contents

Download Pdf Manuals

Related Search

Related Contents