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1. 45 624 22 OP a T 46 1 648 1 E 47 WIRING DIAGRAMS sce 48 18 60 OUTDOOR THERMOSTAT neni nnn as nanan nannan 48 OT18 60A OUTDOOR THERMOSTAD 2 2 22 Quim ee ade uude 49 SINGLEPHASEHKHR P HEAT KITS 50 51 SPK SINGLE POINT WIRING siae 52 IMPORTANT INFORMATION Pride and workmanship go into every product to provide our customers with quality products Itis possible however that during its lifetime a product may require service Products should be serviced only by a qualified service technician who is familiar with the safety procedures required in the repair and who is equipped with the proper tools parts testing instruments and the appropriate service manual REVIEW ALL SERVICE INFORMATION IN THE APPROPRIATE SERVICE MANUAL BEFORE BEGINNING REPAIRS IMPORTANT NOTICES FOR CONSUMERS AND SERVICERS RECOGNIZE SAFETY SYMBOLS WORDS AND LABELS THs UNIT SHOULD NOT BE CONNECTED TO OR USED IN CONJUNCTION WITH ANY DEVICES THAT ARE NOT DESIGN CERTIFIED
2. 28 S 16D CHECKING EEM MOTORS 28 S 17 CHECKING COMPRESSOR WINDINGS 29 5 17 RESISTANCE TEST eL 29 cavri icueldaii 29 S 1 7D Operation 30 S 18 TESTING CRANKCASE HEATER at nr etn kann mannm nano onm u ua nar nca nanc usn imu aatem D kun cran asma 30 S 18A CHECKING CRANKCASE HEATER THERMOSTAT hann th 30 5 21 CHECKING REVERSING VALVE AND 30 5 24 TESTING DEFROST CONTROL 31 S 25 TESTING DEFROST THERMOSTAT penecnetedscecveetetdiesncteesvstceceesuasresdduecreseteeddcesersenstce 31 5 50 CHECKING HEATER LIMIT CONTROL S 31 5 52 CHECKINGIHEATER cic tert end iae eoe 31 S 100 REFRIGERATION REPAIR 32 521011 c 32 5 102 55 04 02 01150821 nc ILLU 32 5 103 2 25 22 T 33 S 104 CHECKING COMPRESSOR E
3. NN NN 4 RS6334002 January 2015 410 X 2 x M 244 Service Instructions 16 PACKAGE HEAT PUMPS PC 15 PACKAGE COOLING HORIZONTAL MODELS WITHR 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 2015 Goodman Manufacturing Company L P IMPORTANT INFORMATION siisiccaisiscnsuscicdscusersdesiduedenntinainnniansuiiedswaieiseanaasscunsiislscunndasenabscenntinanswelaus 4 5 PRODUCT IDENTIFICATION 15 15 6 PRODUCT DIMENSIONS T 7 8 101 103 ROOF c 9 PCP101 103 DOWNFLOW PLENUM 9 PCEF101 103 ELBOW AND FLASHING KIT 10 2 2
4. HO TVNOSH3d ALH3dOHd AVIN OS OG OL 1N3Sa3ud AVIN S39unos LINN SNINHVM SIHL HO SNIOIAH3S 340438 H3MOd 11 LOANNOOSIG PCE ECONOMIZER FOR PC PH H41 Wiring is subject to change Always refer to the wiring diagram on the unit for the most up to date wiring 55 20 0 10 LNIOd 845 LINDYIO HOSSdHdlNOO HOO 99 000 SLAM HM OVI OA 1 ONIYIM 4 V HLIAA SHIM NAAOHG MOVIE 3AVH SH3MV3H8 NAAYD ADVLIOA 09 ANY OS SHIM d IdHfld V HAVH MOV Tel lt lt ONIYIM AHOLO VJ SH3MV3H8 06 9 46 Or 72 40109 SNIHIA L1 4 21 V SLINN HOS 1 9 11 OdD 8 DdV YOJA SALON uo 21910919 OL NM 81 SILON 33S pP av 09 L 8006 945 xog IOHINOO OL WIRING DIAGRAMS HO TVNOSH3d ALH3dOHd ASNVO OS OG 1N3Sa3ud AVIN 64 06 H3MOd LINN SNINHVM SIHL HO SNIOIAH3S 3HOH38 H3MOd 11 LO3N
5. a EEES 10 PCMD101 103 DOWNFLOW MANUAL DAMPER 11 GPHMD101 103 HORIZONTAL MOTORIZED DAMPER WITH DUCT FLANGE ecce nnne 11 SQRPCSQUARE TO ROUND CONVERTER irren incu uota eine eiua une 12 SQRPCH SQUARE TO ROUND CONVERTER 12 101 103 EXTERNALFIETER aE aeaa 13 PRODUCT DESIGN mer 14 c 15 LINE VOLTAGE WIRING cece 16 SYSTEM cb 17 PC15 PH16 H41 jeselcmE Y 17 COOLING mE 17 HEATING E 17 DEFROST e iell 18 FAN OPERATION 18 SCHEDULED MAINT ENANGE 21 ONCE MONTH 21 ONCE 21 TIES TIEQUIPMEN p e 21 SERVICING ere mere M M 22 COOLING HEAT PUMP SERVICE
6. 2 lt a gt 2 zZ lt 2 lt lt a gt LE lt o lt o o a o Sx 25 dz lt i o E oc od 20 gt lt n 50 D mo o u oz a ut oz a5 HIGH VOLTAGE SEENOTE3 708240 WARNING GPH16 24 42 H41 SEE NOTE 8 SEE NOTE 3 COMPONENT LEGEND CCR COMPRESSOR CONTACTOR RELAY CH CRACKCASE HEATER CHS CRACKCASE HEATER SWITCH CM CONDENSER MOTOR COMP COMPRESSOR DC DEFROST CONTROL DFT DEFROST THERMOSTAT EM EVAPORATOR MOTOR GND EQUIPMENT GROUND HVDR HIGH VOLTAGE DEFROST RELAY LPS LOW PRESSURE SWITCH LVDR LOW VOLTAGE DEFROST RELAY LVJB LOW VOLTAGE JUNCTION BOX PLF FEMALE PLUG CONNECTOR RVC REVERSING VALVE COIL RCCF RUN CAPACITOR FOR COMPRESSOR AND FAN SA START ASSIST TR TRANSFORMER HPS HIGH PRESSURE SWITCH JUNCTION TERMINAL INTERNAL TO INTEGRATED CONTROL PLUG CONNECTION IGNITER SWITCH PRESS OVERCURRENT E3 PROT DEVICE NOTES SEE NOTE 7 lt SS 2 SEE NOTE 6 SEE NOTE 6 FACTORY WIRING a INE VOLTAGE LOW VOLTAGE OPTIONAL HIGH VOLTAGE FIELD WIRING en HIGH VOLTAGE LOW VOLTAGE WIRE CODE BLACK BLUE BROWN GREEN ORANGE PURPLE R
7. lt n 50 Dc 5 20 o u oz ut 9 oz a5 HIGH VOLTAGE 7 SEE NOTE 3 WARNING THERMOSTAT TE YL SEE NOTE 3 4 77 um 099 5 ndi COMPONENT LEGEND CONTACTOR COMPRESSOR CONTACTOR RELAY CRACKCASE HEATER CRACKCASE HEATER SWITCH CONDENSER MOTOR COMPRESSOR DEFROST CONTROL DEFROST THERMOSTAT EVAPORATOR MOTOR EQUIPMENT GROUND HIGH VOLTAGE DEFROST RELAY LOW PRESSURE SWITCH LOW VOLTAGE DEFROST RELAY LOW VOLTAGE JUNCTION BOX FEMALE PLUG CONNECTOR REVERSING VALVE COIL RUN CAPACITOR FOR COMPRESSOR AND FAN START ASSIST TRANSFORMER HIGH PRESSURE SWITCH COMPRESSOR SOLENOID RELAY HI STAGE SOLENOID JUNCTION TERMINAL INTERNAL TO INTEGRATED CONTROL PLUG CONNECTION IGNITER 7707 SWITCH PRESS a OVERCURRENT PROT DEVICE NOTES GPH1648H41 SEE OTE 8 FA NOTE 7 GND 5 6 SEE NOTE 6 FACTORY WIRING emmm LINE VOLTAGE LOW VOLTAGE OPTIONAL HIGH VOLTAGE FIELD WIRING m HIGH VOLTAGE LOW VOLTAGE WIRE CODE BLACK BLUE BROWN GREEN ORANGE PURPLE RED WHITE YELLOW ise SDVOOWD FoOcaAA lt EQUIPMENT GROUND FIELD GROUND FIELD SPLICE 17 SWITCH TEMP REPLACEMENT WIRE MUST BE SAME SIZE AND TYPE INSULATION AS ORIGINAL AT LEAST 105 C USE COPPER CONDUCTOR ONLY TO CHANGE EVAP
8. 20 KW SINGLE PHASE HKR P HEAT KIT Wiring is subject to change Always refer to the wiring diagram on the unit for the most up to date wiring 54 PC15 PH16H41 WIRING DIAGRAMS MS7105K2046 B HONEYWELL ACTUATOR COLOR CODES FOR PLUG 1 G WIRE LENGTHS FOR PLUG 1 ORANGE 1 X 78 GROUND 1 X 50 COLOR CODES FOR PLUG 2 D Y YELLOW BL BLUE R RED WIRE LENGTHS FOR PLUG 2 PURPLE 2X 77 YELLOW 2X 77 BLUE 1 X 77 GREEN 1X 77 6 COMMON O 0 8 2 O Y1 CONTACTOR WIRE DIAGRAM EN MOLEX 3597706 GROUND LUG 50048926 002 MOLEX 3597706 500 48926 002 mat L1 LI C mat occ EJ L1 Ll 71 E GND oat 1 C 5 5 1 0 O E 5 HONEYWELL W7220 E i IAQ COM y2 0 n L O 24v 71 L1 0 5 240 LI act com c L LI 24 MOLEX 3597706 MOLEX 3597706 50048926 002 50048926 002 MOLEX 3597702 50048926 001 CONNECT TO C7400S 1000 ILI ENTHALPY CONTROL 8 OO MOLEX 3597702 50048926 001 9 7250 1001 MIXED AIR SENSOR REVI ALVE ENERGIZED IN COOLING MODE
9. In the cooling cycle when the outdoor air temperature rises the high side condensing pressure rises At the same time the cooling load on the indoor coil increases causing the low side pressure to rise but at a slower rate Since the high side pressure rises faster when the tempera ture increases more refrigerant flows to the evaporator increas ing the cooling capacity of the system When the outdoor temperature falls the reverse takes place The condensing pressure falls and the cooling loads on the indoor coil decreases causing less refrigerant flow If a restriction should become evident proceed as follows 1 Recover refrigerant charge 2 Remove the orifice assembly and clean or replace 3 Replace liquid line drier evacuate and recharge CHECKING EQUALIZATION TIME During the OFF cycle the high side pressure bleeds 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 ittakes more than seven 7 minutes to equalize the restric tion device is inoperative Replace install a liquid line drier evacuate and recharge S 112 CHECKING RESTRICTED LIQUID LINE When the system is operating the liquid line is warm to the touch If th
10. 516 0 136 518 0 137 520 0 137 3 Based on ALLIED SIGNAL Data minii I 164 0 57 266 0 87 368 0 110 470 0 129 604 0 149 5 38 SERVICING REQUIRED LIQUID LINE TEMPERATURE LIQUID PRESSURE 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 78 100 102 104 106 108 110 112 114 116 118 120 122 124 126 128 REQUIRED SUBCOOLING TEMPERATURE F ATACCESSFITTING PSIG 8 10 12 14 16 18 84 82 80 78 86 84 82 80 88 86 84 82 90 88 86 84 100 102 100 104 102 100 106 104 102 100 108 106 104 102 110 108 106 104 112 110 108 106 114 112 110 108 116 114 112 110 118 116 114 112 120 118 116 114 122 120 118 116 124 122 120 118 126 124 122 120 39 on BURNOUT When acompressor burns out high temperature develops caus ing the refrigerant oil and motor insulation to decompose form ing acids and sludge If a compressor is suspected of being burned out attach a refrigerant hose to the liquid line dill valve and properly remove and dispose of the refrigerant NOTICE VIOLATION OF EPA REGULATIONS MAY RESULT IN FINES OR OTHER PENALTIES Now determine if a burn out has actually occurred Confirm by analyzing an oil sample using a Sporlan Acid Test Kit AK 3 or its equivalent
11. 1872 D Plus 1 872 B Minus 1323 Minus 1323 B f Normal 1491 B Normal 1491 B Plus 1 642 Plus 1 642 0 1 0 9 ESP Denotes factory settings for APCI56041 42 AIRFLOW pies sid ELECTRI APC1524 APH1624 APC1530 APH1630 APC1536 APH1636 APC1524 5 5 APC1548 APH1648 APC1560 oro B D B oD B D Apu B 162 D OOA B D B P Factory Setting Factory Setting DIP Switch Settings Adjustments Through DIP Switch Combinations for Single amp Two Stage Thermostats M MODEL pir aa APH1624 On 95 1530 B On of 97 1630 D On 103 po 1536 B On Of 107 APH 1636 D On On 123 A Of Of 122 1542 B On Of 19 1642 On On j 135 or APC1548 B on Of 149 APH1648 D On On 108 A of P of 150 1560 On Of 1600 D o 180 43 WIRING DIAGRAMS 44 o o z o z 2 5 gt tc tc a 5 lt LE 2 2 o o a HIGH VOLTAGE WARNING 3 ag
12. PC15 PH16 H41 When the contacts of the room thermostat close this closes the circuit from R to Y and R to G in the unit This energizes the compressor contactor and will energize the indoor blower instantly on models equipped with EEM blower motor When the thermostat is satisfied it opens its contacts break ing the low voltage circuit causing the compressor contactor to open and indoor fan to stop after the programmed 60 sec ond off delay on models equipped with EEM blower motors If the room thermostat fan selector switch should be set to the on position then the indoor blower would run continu ous rather than cycling with the compressor HEATING CYCLE COOLING ONLY UNITS NOTE The following only applies if the cooling only unit has an approved electric heat kit installed for heating If auxiliary electric heaters should be used they may be controlled by outdoor thermostats OT18 60A or OT EHR18 60A PC MODELS EQUIPPED WITH EEM BLOWER TORS With the thermostat set to the heat position and a call for heat R to W will be energized This will energize the electric heat sequencers and the EEM motor The electric heat will be energized through the normally open contacts of the elec tric heat sequencers The indoor blower will be energized through W from the thermostat When the thermostat is satisfied this breaks the circuit from R to W This will turn off the electric heaters and the indoor blower after the
13. S 15 CHECKING CAPACITOR CAPACITOR RUN A run capacitor is wired across the auxiliary and main wind ings of a single phase permanent split capacitor motor The capacitors primary function is to reduce the line current while greatly improving the torque characteristics of a motor This is accomplished by using the 90 phase relationship between the capacitor current and voltage in conjunction with the motor windings so that the motor will give two phase operation when connected to a single phase circuit The capacitor also re duces the line current to the motor by improving the power factor CAPACITOR START SCROLL COMPRESSOR MODELS Hard start components are not required on Scroll compressor equipped units due to a non replaceable check valve located in the discharge line of the compressor However hard start kits are available and may improve low voltage starting characteris tics This check valve closes off high side pressure to the compres sor after shut down allowing equalization through the scroll flanks Equalization requires only about one or two seconds during which time the compressor may turn backwards Your unit comes with a 180 second anti short cycle to prevent the compressor from starting and running backwards MODELS EQUIPPED WITH A HARD START DEVICE A start capacitor is wired in parallel with the run capacitor to increase the starting torque The start capacitor is of the elec trolytic type rather than metall
14. bon dioxide until clean 3 Install new components including liquid line drier 40 4 Braze all joints leak test evacuate and recharge system 5 Start up the unit and record the pressure drop across the drier 6 Continue to run the system for a minimum of twelve 12 hours and recheck the pressure drop across the drier Pres sure drop should not exceed 6 PSIG 7 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 8 If the pressure drop becomes greater then it must be re placed 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 ex treme importance that the temperature of the valve does not exceed 250 F at any time Wrap the reversing valve with a large rag saturated with water Re wet the rag and thoroughly cool the valve after each braz ing operation of the four joints involved The wet rag around the reversing valve will eliminate conduction of heat to the valve body when brazing the line connection The use of a wet rag sometimes can be a nuisance There
15. CLASS 2 WIRE SEE UNIT RATING PLATE FOR TYPE AND SIZE OF OVER CURRENT PROTECTION 208 240 1 60 0140G00871 C WIRING DIAGRAMS SEE NOTE 2 lt a gt 2 5 l lt 2 lt lt a gt x o 2 lt o lt o 25 dz lt i o E zo oc od Ox 20 gt lt n 50 D 5 20 c o u oz ut oz a5 HIGH VOLTAGE WARNING SUPPLY VOLTAGE 208 230 1 60 208 230 NOTE 3 COMPONENT LEGEND CONTACTOR CONDENSER MOTOR COMPRESSOR EVAPORATOR MOTOR EQUIPMENT GROUND LOW VOLTAGE JUNCTION BOX FEMALE PLUG CONNECTOR RUN CAPACITOR FOR COMPRESSOR AND FAN START ASSIST TRANSFORMER HIGH PRESSURE SWITCH GPC1560H41 2 OwWN WON o E CONTROL BOX FACTORY WIRING VOLTAGE LOW VOLTAGE OPTIONAL HIGH VOLTAGE FIELD WIRING gt HIGH VOLTAGE LOW VOLTAGE WIRE CODE BK BLACK BL BLUE BR BROWN GR GREEN OR ORANGE PU PURPLE RD RED COMPRESSOR SOLENOID RELAY WH WHITE HI STAGE SOLENOID JUNCTION TERMINAL INTERNAL TO INTEGRATED CONTROL PLUG CONNECTION SWITCH PRESS OVERCURRENT PROT DEVICE NOTES YL YELLOW EQUIPMENT GROUND rh FIELD GROUND FIELD SPLICE SWITCH TEMP IGNITER REPLACEMEN
16. If leaks are found repair them After repair repeat the pressure test If no leaks exist proceed to system evacuation For a system that contains a refrigerant charge and is sus pected of having a leak stop the operation and hold the explor ing tube of the detector as close to the tube as possible check all piping and fittings If a leak is detected do not attempt to apply more brazing to the joint Remove and capture the charge unbraze the joint clean and rebraze 33 SERVICING For asystem that has been newly repaired and does not con tain acharge connect a cylinder of refrigerant through a gauge manifold to the liquid and suction line dill valves and or liquid line dill valve and compressor process tube NOTE Refrigerant hoses must be equipped with dill valve de pressors or special adaptor used Open the valve on the cylin der and manifold and allow the pressure to build up within the system Check for and handle leaks as described above After the test has been completed remove and capture the leak test refrigerant S 102 EVACUATION WARNING REFRIGERANT UNDER PRESSURE FAILURE TO FOLLOW PROPER PROCEDURES MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH This is the most important part of the entire service procedure The life and efficiency of the equipment is dependent upon the thoroughness exercised by the serviceman when evacuating air non condensable and moisture from the system Air in
17. 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 Volt Ohm Meter TESTING CAPACITOR RESISTANCE 28 2 Set an ohmmeter on its highest ohm scale and connect the leads to the capacitor A Good Condition indicator swings to zero and slowly returns to infinity Start capacitor will bleed resistor will not return to infinity It will still read the resistance of the resistor B Shorted indicator swings to zero and stops there replace C Open no reading replace Start capacitor would read resistor resistance S 15B CAPACITANCE CHECK WARNING DISCHARGE CAPACITOR THROUGH A 20 TO 30 OHM RESISTOR BEFORE HANDLING Using a hookup as shown below take the amperage and volt age readings and use them in the formula Capacitance MFD 2650 X Amperage Voltage VOLTMETER CAPACITOR TESTING CAPACITANCE SERVICING S 16 CHECKING MOTORS S 16A CHECKING FAN AND BLOWER MOTOR WINDINGS PSC MOTORS Applies only to units with PSC Motors The auto reset fan motor overload is designed to protect the motor against high temperature and high amperage conditions by breaking the common circuit within the motor similar to the compressor internal overload However heat generated within the motor is faster to dissipate than the compressor a
18. Static 2 Measure the static pressure of the supply duct Positive Pressure 3 Add the two readings together NOTE Both readings may be taken simultaneously and read directly on the manometer as shown in the illustration above if so desired 4 Consult proper table for quantity of air If the external static pressure exceeds the minimum or maxi mum allowable statics check for closed dampers dirty filters undersized or poorly laid out ductwork S 201 CHECKING TEMPERATURE RISE Temperature rise is related to the BTUH output of the unit and the amount of air CFM circulated over the indoor coil All units are designed for a given range of temperature increase This is the temperature of the air leaving the unit minus the temperature of the air entering the unit The more air CFM being delivered through a given unit the less the rise will be so the less air CFM being delivered the greater the rise The temperature rise should be adjusted in accordance to a given unit specifications and its external static pressure 1 Take entering and leaving air temperatures 2 Select the proper speed tap from the unit s blower perfor mance data in the Technical Manual for the specific unit 3 Take motor amperage draw to determine that the motor is not overloaded during adjustments A 2 2 141 22272 22222 22 22222 227 RISE S
19. a system causes high condensing temperature and pres Sure resulting in increased power input and reduced perfor mance Moisture chemically reacts with the refrigerant and oil to form corrosive hydrofluoric and hydrochloric acids These attack motor windings and parts causing breakdown The equipment required to thoroughly evacuate the system is a high vacuum pump capable of producing a vacuum equiva lentto 25 microns absolute and a thermocouple vacuum gauge to give a true reading of the vacuum in the system NOTE Never use the system compressor as a vacuum pump or run when under a high vacuum Motor damage could occur 4 WARNING SCROLL COMPRESSORS DO NOT FRONT SEAT THE SERVICE VALVE S WITH THE COMPRESSOR OPERATING IN AN ATTEMPT TO SAVE REFRIGERANT WITH THE SUCTION LINE OF THE COMPRESSOR CLOSED OR SEVERLY RESTRICT ED THE SCROLL COMPRESSOR WILL DRAW A DEEP VACUUM VERY QUICKLY THIS VACUUM CAN CAUSE INTERNAL ARCING OF THE FUSITE RESULTING IN A DAMAGED OR FAILED COMPRESSOR 34 R 410A MANIFOLD LOW SIDE HIGH SIDE GAUGE GAUGE AND VALVE 5 77 AND VALVE rn 800 PSI RATED if HOSES 7 4 ae CHARGING CYLINDER AND SCALE VACUUM PUMP TO ADAPTER UNIT SERVICE VALVE PORTS T VACUUM PUMP MMMM Connect the vacuum pump vacuum tight manifold set with high vacuum hoses thermocouple vacuum gauge and charg ing cylinder as shown Start the vacuum
20. age Should read within the voltage tabulation as shown 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 24 S 2 CHECKING WIRING 4 WARNING HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH 1 Check wiring visually for signs of overheating damaged insulation and loose connections 2 Use an ohmmeter to check continuity of any suspected open wires 3 If any wires must be replaced replace with comparable gauge and insulation thickness S 3 CHECKING THERMOSTAT WIRING AND ANTICIPATOR S 3A THERMOSTAT AND WIRING 4 WARNING LINE VOLTAGE NOW PRESENT With power ON and thermostat calling for cooling 1 Use a voltmeter to verify 24 volts present at thermostat wires C and R 2 If no voltage present check transformer and transformer wiring If 24 volts present proceed to step 3 3 Use a voltmeter to check for 24 volts at thermostat wires C and Y 4 No voltage indicates trouble in the thermostat wiring or external transformer source 5 Checkthe continuity of the thermostat and wiring Repair or replace as necessary INDOOR BLOWER MOTOR With p
21. are commercial grades of heat absorbing paste that may be sub stituted After the valve has been installed leak test evacuate and re charge S 105 THERMOSTATIC EXPANSION VALVE The expansion valve is designed to control the rateof liquid refrigerant flow into an evaporator coil in exact proportion to the rate of evaporation of the refrigerant in the coil The amount of refrigerant entering the coil is regulated since the valve responds to temperature of the refrigerant gas leaving the coil feeler bulb contact and the pressure of the refrigerant in the coil This regulation of the flow prevents the return of liquid refrigerant to the compressor The illustration below shows typical heatpump TSV check valve operation in the heating and cooling modes CI COOLING HEATING TXV VALVES Some TXV valves contain an internal check valve thus eliminat ing the need for an external check valve and bypass loop The three forces which govern the operation of the valve are 1 the pressure created in the power assembly by the feeler bulb 2 SERVICING evaporator pressure and 3 the equivalent pressure ofthe su perheat spring in the valve 0 bleed type expansion valves are used on indoor and out door coils The 096 bleed valve will not allow the system pres sures high and Low side to equalize during the shut down period The valve will shut of completely at approximately 100 PSIG 30
22. as neces sary S 100 REFRIGERATION REPAIR PRACTICE 4 amp DANGER ALWAYS REMOVE THE REFRIGERANT CHARGE IN A PROPER MANNER BEFORE APPLYING HEAT TO THE SYSTEM These models use the FasTest Access Fitting System with a saddle that is either soldered to the suction and liquid lines or is fastened with a locking nut to the access fitting box core and then screwed into the saddle Do not remove the core from the saddle until the refrigerant charge has been removed Failure to do so could result in property dam age or personal injury When installing a new core or reinstalling the core after re moval itis very important to note that before inserting the core into the saddle the core and saddle must be free of debris and the O Ring must have a thin coating of refrigerant oil applied to it The oil is to prevent the O Ring from being deformed when the core is tightened completely The core should be torqued to 8 ft Ib When repairing the refrigeration system 4 amp WARNING DISCONNECT ELECTRICAL POWER SUPPLY 1 Never open a system that is under vacuum Air and mois ture will be drawn in 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 Clean the inside of all new tubing to remove oils and pipe chips 5 When brazing sweep the tubing with dry nitrogen to pre
23. be connected between the unit control panel and the room thermostat WARNING TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK WIRING TO THE UNIT MUST BE PROPERLY POLARIZED AND GROUNDED A WARNING HIGH VOLTAGE DISCONNECT ALL POWER BEFORE CHANGING ANY ELECTRICAL WIRING MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH WARNING TO AVOID THE RISK OF PROPERTY DAMAGE PERSONAL INJURY OR FIRE USE ONLY COPPER CONDUCTORS LINE VOLTAGE WIRING Power supply to the unit must be N E C Class 1 and must comply with all applicable codes The unit must be electrically grounded in accordance with the local codes or in their ab sence with the latest edition of the National Electrical Code ANSI NFPA No 70 or in Canada Canadian Electrical Code C22 1 Part 1 A fused disconnected must be provided and sized in accordance with the unit minimum circuit ampacity The best protection for the wiring is the smallest fuse or breaker which will hold the equipment on line during normal operation 15 PRODUCT DESIGN without nuisance trips Such a device will provide maximum circuit protection 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 voltag
24. most up to date wiring 53 WIRING DIAGRAMS PC15 PH16H41 FL 0 1 Ti PLM BK 1 2 3 BK ERN R M10 4 M20 5 6 BK BK ee 4 8 ou 2 0 TOA 2 4 Fut v gro 5 3 L1 L2 T lt i 2 ONE 1 ELEMENT ROWS L1 L2 TWO 2 ELEMENT ROWS 22 595 oe 5 KW 10 KW zaf tc nsa uos tc ul 5 HE mot 528 zug PLM ii o BK 1 lt 9 R Y E Y BK PU 2 lt 28 EP ed BL B 3 M2 2 T 4 BL a R1 R2 R OM8T gt o BK BK R 2 BR 5 BK 27 58 r 6 7 lt 8 BK R 8 2 n Tem L1 L2 L1 L2 THREE 3 ELEMENT ROWS FOUR 4 ELEMENT ROWS 11121112 15
25. motor 3 Ifvoltage was present in steps 1 and 2 the motor has failed and will need to be replaced Note When replacing motor ensure the belly band is between the vents on the motor and the wiring has the proper drip loop to prevent condensate from entering the motor High Voltage Connections 3 16 Low Voltage Connections EEM MOTOR CONNECTIONS S 17 CHECKING COMPRESSOR WINDINGS WARNING HERMETIC COMPRESSOR ELECTRICAL TERMINAL VENTING CAN BE DANGEROUS WHEN INSULATING MATERIAL WHICH SUPPORTS A HERMETIC COM PRESSOR OR ELECTRICAL TERMINAL SUDDENLY DISINTEGRATES DUE TO PHYSICAL ABUSE OR ASA RESULT OF AN ELECTRICAL SHORT BETWEEN THE TERMINAL AND THE COMPRESSOR HOUSING THE TERMINAL MAY BE EXPELLED VENTING THE VAPOR AND LIQUID CONTENTS OF THE COMPRES SOR HOUSING AND SYSTEM If the compressor terminal PROTECTIVE COVER and gasket if required is not properly in place and secured there is a remote possibility if a terminal vents that the vaporous and liquid discharge can be ignited spouting flames several feet causing potentially severe or fatal injury to anyone in its path This discharge can be ignited external to the compressor if the terminal cover is not properly in place and if the discharge impinges on a sufficient heat source 29 SERVICING 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 a
26. not vent refrigerant to atmosphere Recover during system repair or final unit disposal 1 Run system at least 10 minutes to allow pressure to sta bilize 2 Temporarily install thermometer on suction large line near compressor with adequate contact and insulate for best possible reading 36 3 Referto the superheat table provided for proper system superheat Add charge to lower superheat or recover charge to raise superheat Superheat Formula Suct Line Temp Sat Suct Temp Ambient Condenser Inlet Temp F Drybulb LM Retur Temp F Drybulb 65 n Air EXAMPLE a Suction Pressure 143 b Corresponding Temp F 50 c Thermometer on Suction Line 59 F To obtain the degrees temperature of superheat subtract 50 0 from 59 0 F The difference is 9 Superheat The 9 Superheat would fall in the range of allowable superheat S 109 CHECKING SUBCOOLING Refrigerant liquid is considered subcooled when its tempera ture is lower than the saturation temperature corresponding to its pressure The degree of subcooling equals the degrees of temperature decrease below the saturation temperature at the existing pressure 1 Attach an accurate thermometer or preferably a thermo couple type temperature tester to the liquid line close to the pressure switch 2 Install a high side pressure gauge on the liquid access fitting Record the gauge pressure and the temperature of the line 4 Com
27. pump and open the shut off valve to the high vacuum gauge manifold only After the compound gauge low side has dropped to approximately 29 inches of vacuum open the valve to the vacuum thermocouple gauge See that the vacuum pump will blank off to a maxi mum of 25 microns A high vacuum pump can only pro duce a good vacuum if its oil is non contaminated Ifthe vacuum pump is working properly close the valve to the vacuum thermocouple gauge and open the high and low side valves to the high vacuum manifold set With the valve on the charging cylinder closed open the manifold valve to the cylinder Evacuate the system to at least 29 inches gauge before opening valve to thermocouple vacuum gauge Continue to evacuate to a minimum of 250 microns Close valve to vacuum pump and watch rate of rise If vacuum does not rise above 1500 microns in three to five minutes system can be considered properly evacuated If thermocouple vacuum gauge continues to rise and levels off at about 5000 microns moisture and non condensables are still present If gauge continues to rise a leak is present Repair and re evacuate Close valve to thermocouple vacuum gauge and vacuum pump Shut off pump and prepare to charge SERVICING S 103 CHARGING 4 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 CA
28. 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 These scroll compressors use POE or polyolester oil which is NOT compatiable with mineral oil based lubricants like 3GS POE oil must be used if additional oil is required Compliant scroll compressors perform quiet shutdowns that allow the compressor to restart immediately without the need for a time delay This compressor will restart even if the system has not equalized NOTE Operating pressures and amp draws may differ from standard reciprocating compressors This information can be found in the unit s Technical Information Manual INDOOR BLOWER MOTOR All PC15 PH16 model package units use a EEM blower mo tor The EEM motor is a 3 Phase brushless DC single phase AC input ball bearing construction motor with an integral con trol module with an internal FCC B EMI filter The EEM motor is continuously powered with line voltage The switched 24 volt control signal is controlled by the thermostat in the cooling and heat pump mode ELECTRICAL WIRING The units are designed for operation at the voltages and hertz as shown on the rating plate All internal wiring is complete Ensure the power supply to the compressor contactor is brought to the unit as shown on the supplied unit wiring diagram The 24V wiring must
29. vent the formation of oxides on the inside surfaces 6 Complete any repair by replacing the liquid line drier in the system evacuate and charge At any time the system has been open for repair the factory installed liquid line filter drier must be replaced BRAZING MATERIALS Copper to Copper Joints Sil Fos used without flux alloy of 15 silver 80 copper and 5 phosphorous Recommended heat 1400 F Copper to Steel Joints Silver Solder used without a flux alloy of 30 silver 38 copper 32 zinc Recommended heat 1200 F Aluminum to Aluminum and Copper to Aluminum Joints ZA 1 Brazing Rods use Flux System Cesium Based Poly mer System alloy of 78 Zinc and 22 Aluminum Melting point 826 F Flow point 905 F S 101 LEAK TESTING NITROGEN OR NITROGEN TRACED 4 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 4 WARNING TO AVOID POSSIBLE EXPLOSION THE LINE FROM THE NITROGEN CYLINDER MUST INCLUDE A PRESSURE REGULATOR AND PRESSURE RELIEF VALVE THE PRESSURE RELIEF VALVE MUST BE SET TO OPEN AT NO MORE THAN 150 psig Pressure test the system using dry nitrogen and soapy water to locate leaks If you wish to use a leak detector charge the system to 10 psi using the appropriate refrigerant then use nitrogen to finish charging the system to working pressure then apply the detector to suspect areas
30. 1 103 DOWNFLOW PLENUM Use with PCCP Roof Curb 1 Flange 28 3 4 ACCESSORIES PC15 PH14641 PCEF101 103 ELBOW AND FLASHING KIT PCE 101 103 ECONOMIZER DOWNFLOW APPLICATIONS 20 3 8 5 gt j i Used With PCEC101 103 HORIZONTAL 20 x 17 1 2 PCEH101 103 HORIZONTAL HP Filter Must be used with PCP101 103 ACCESSORIES PC15 PH16H41 PCMD101 103 DOWNFLOW MANUAL DAMPER PCMDM101 103 DOWNFLOW MOTORIZED DAMPER USED WITH PCP101 103 DOWNFLOW PLENUM 29 3 4 MODEL DESCRIPTION PCMDH101 103 Manual Damper PCMDM101 103 Motorzied Damper GPHMD101 103 HORIZONTAL MANUAL DAMPER WITH DUCT FLANGE ACCESSORIES PC15 PH16H41 SQRPC SQUARE TO ROUND CONVERTER DOWNFLOW APPLICATIONS 1 FLANGES 1 1 2 SQUARE TO ROUND DUCT CONVERTER PANEL OUTER FLANGE _ STARTER FLANGE n B DL r r p 9 45 19 15 15 D 221 2 24 1 2 24 1 2 24 1 2 24 1 2 SUPPLY RETURN ACCESSORIES PCFR101 103 EXTERNAL FILTER KIT HORIZONTAL APPLICATIONS PC15 PH16H41 PRODUCT DESIGN LOCATION amp CLEARANCES NOTE To ensure proper condensate drainage unit must be in stalled in a level position In installations where the unit is installed above ground level and not serviceable from the ground Example Roof Top installations the i
31. 23 2 Ro te 20 sa n lt Se u 2 dE zo 5a8 PU RD zad SUPPLY VOLTAGE 208 240 1 60 208 240 THERMOSTAT GPC15 24 48 H41 NOTE 3 n ORAN o ArPAWOZAMIA CONTROL BOX COMPONENT LEGEND FACTORY WIRING emm LINE VOLTAGE BLOWER INTERLOCK RELAY LOW VOLTAGE CONTACTOR OPTIONAL HIGH CRACKCASE HEATER VOLTAGE CONDENSER MOTOR COMPRESSOR FIELD WIRING ELECTRONIC BLOWER TIME DELAY RELAY em HIGH VOLTAGE EVAPORATOR MOTOR LOW VOLTAGE FAN CAPACITOR EQUIPMENT GROUND WIRE CODE LOW VOLTAGE JUNCTION BOX BK BLACK FEMALE PLUG CONNECTOR BL BLUE RUN CAPACITOR FOR BR BROWN COMPRESSOR AND FAN GR GREEN START ASSIST OR ORANGE TRANSFORMER PU PURPLE HIGH PRESSURE SWITCH RD RED WH WHITE YL YELLOW JUNCTION TERMINAL EQUIPMENT GROUND rh INTERNAL TO FIELD GROUND INTEGRATED CONTROL PLUG CONNECTION FIELD SPLICE SWITCH PRESS SWITCH TEMP OVERCURRENT IGNITER PROT DEVICE NOTES REPLACEMENT WIRE MUST BE SAME SIZE AND TYPE INSULATION AS ORIGINAL AT LEAST 105 C USE COPPER CONDUCTOR ONLY TO CHANGE EVAPORATOR MOTOR SPEED REPLACE LEAD ON EBTDR COM WITH LEAD ON EBTDR M1 OR M2 FOR 208 VOLT TRANSFORMER OPERATION MOVE PURPLE WIRES FROM TERMINAL 3 TERMINAL 2 ON TRANSFORMER START ASSIST FACTOR EQUIPED WHEN REQUIRED USE COPPER CONDUCTORS ONLY USE N E C
32. 8 60A OUTDOOR THERMOSTAT Wiring is subject to change Always refer to the wiring diagram on the unit for the most up to date wiring WIRING DIAGRAMS PACKAGE SYSTEM WIRING DIAGRAM HEAT PUMPS ONLY TWO STAGE ELECTRIC HEAT ABOVE 10 kW TYPICAL H P ROOM THERMOSTAT 18 GAUGE 8 WIRE 9 PACKAGE HEAT PUMP NE 1 1 H 1 IO OFIN n RE L k R 1 0 1 4 4 gt ein s i ee a Y 4 b Y 1 1 1 1 1 1 1 1 i IF USED SEE NOTE 1 1 rb s OUTDOOR THERMOSTAT 42 G O OUTDOOR THERMOSTAT 1 LOW VOLTAGE CLOSE ON TEMPERATURE FALL JUNCTION BOX For outdoor temperatures below 0 with 50 or higher relative humidity set outdoor thermostat at 0 F NOTE 1 OT18 2 CAN BE CONNECTED BETWEEN W2 OF THERMOSTAT AND BROWN WIRE IF DESIRED UNIT MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH o rI o z 2 5 gt tc o a 5 o n lt 2 2 o o o a i lt H o gt COLOR CODES RED Y YELLOW BL BLUE BR BROWN O ORANGE W WHITE G GREEN d WARNING OT18 60A OUTDOOR THERMOSTAT Wiring is subject to change Always refer to the wiring diagram on the unit for the
33. ANALYSIS 22 5 1 CHECKING VOLTAGE es RR 23 5 2 CHECKING WIRING 23 5 3 CHECKING THERMOSTAT WIRING AND ANTICIPATOR 23 S 3A Thermostat and cepa Re Di 23 5 3 24 5 3 Heating Anticipator iaaa rarasaan 24 5 4 CHECKING TRANSFORMER AND CONTROL CIRCUIT 24 5 7 CHECKING CONTACTOR AND OR 24 5 8 CHECKING CONTACTOR 25 5 11 CHECKING LOSS OF CHARGE 26 5 15 CAPACITOR mI M 26 5 15 55 M 26 5 15 CAPACITANCE 555 5 2 2 2222 21 22222 2222 t 27 S 16 CHECKING 5 28 S 16A CHECKING FAN AND BLOWER MOTOR WINDINGS PSC MOTORS
34. ATING cycle If the valve fails to change its position test the voltage 24V at the valve coil terminals while the system is on the COOLING cycle If no voltage is registered at the coil terminals check the op eration of the thermostat and the continuity of the connecting wiring from the O terminal of the thermostat to the unit If voltage is registered at the coil tap the valve body lightly while switching the system from HEATING to COOLING etc If this fails to cause the valve to switch positions remove the coil connector cap and test the continuity of the reversing valve solenoid coil If the coil does not test continuous replace it If the coil test continuous and 24 volts is present at the coil terminals the valve is inoperative replace it S 24 TESTING DEFROST CONTROL NOTE PCBDM133 defrost controls havea three 3 minute compressor off cycle delay NOTE The PCBDM133 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 set to 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 To check the defrost control for proper sequencing proceed as follows With powe
35. E POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH ONCE A MONTH 1 Inspect the return filters of the evaporator unit and clean or change if necessary NOTE Depending on operation conditions it may be necessary to clean the filters more often If permanent type filters are used they should be washed with warm water dried and sprayed with an adhesive according to manufacturers recommendations 2 When operating on the cooling cycle inspect the conden sate line piping from the evaporator coil Make sure the piping is clear for proper condensate flow ONCE A YEAR Qualified Service Personnel Only 1 Clean the indoor and outdoor coils 2 Clean the casing of the outdoor unit inside and 3 Motors are permanently lubricated and do not require oil ing TO AVOID PREMATURE MOTOR FAILURE DO NOT OIL 4 Manually rotate the outdoor fan and indoor blower to be sure they run freely 5 Inspectthe control panel wiring compressor connections and all other component wiring to be sure all connections are tight Inspect wire insulation to be certain that it is good 22 6 Check the contacts of the 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 Checkthe combustion chamber Heat Exchanger for soot scale etc Inspect all burners for lint and pro
36. EATH 1 Remove the leads from the compressor terminals WARNING SEE WARNINGS S 17 BEFORE REMOVING COMPRES SOR TERMINAL COVER 2 Using an ohmmeter test continuity between terminals S R C R and C S on single phase units or terminals T1 T2 and T3 on 3 phase units 30 TESTING COMPRESSOR WINDINGS If either winding does not test continuous replace the com pressor NOTE If an open compressor is indicated allow ample time for the internal overload to reset before replacing compressor S 17B GROUND TEST If fuse circuit breaker ground fault protective device etc has tripped this is a strong indication that an electrical problem exists and must be found and corrected The circuit protective device rating must be checked and its maximum rating should coincide with that marked on the equipment nameplate With the terminal protective cover in place it is acceptable to replace the fuse or reset the circuit breaker ONE TIME ONLY to see if it was just a nuisance opening If it opens again DO NOT continue to reset Disconnect all power to unit making sure that all power legs are open 1 DONOT remove protective terminal cover Disconnect the three leads going to the compressor terminals at the near est point to the compressor 4 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 COMPRESSOR G
37. ED WHITE YELLOW EQUIPMENT GROUND FIELD GROUND FIELD SPLICE SWITCH TEMP REPLACEMENT WIRE MUST BE SAME SIZE AND TYPE INSULATION AS ORIGINAL AT LEAST 105 C USE COPPER CONDUCTOR ONLY TO CHANGE EVAPORATOR MOTOR SPEED MOVE WHITE AND YELLOW LEADS FROM 2 AND TO 4 AND 5 IF BOTH LEADS ARE ENERGIZED THE HIGHER SPEED SETTING IS USED FOR 208 VOLT TRANSFORMER OPERATION MOVE PURPLE WIRES FROM TERMINAL 3 TO TERMINAL 2 ON TRANSFORMER START ASSIST FACTORY EQUIPPED WHEN REQUIRED USE COPPER CONDUCTORS ONLY USE N E C CLASS 2 WIRE CRANKCASE HEATER AND CRANKCASE HEATER SWITCH FACTORY EQUIPPED WHEN REQUIRED DOUBLE POLE CONTACTOR SHOWN SINGLE POLE CONTACTOR COULD BE FACTORY EQUIPPED AS AN ALTERNATE CONFIGURATION COMMON SIDE OF CONTACTOR BE GROUNDED OR CONNECTED TO ANY OTHER COMMON 24 SEE UNIT RATING PLATE FOR TYPE AND SIZE OF OVER CURRENT PROTECTION 0140G01640 C Wiring is subject to change Always refer to the wiring diagram on the unit for the most up to date wiring 48 WIRING DIAGRAMS LPS 44 YL PK CONTROL BOX SEE NOTE 2 SUPPLY VOLTAGE 208 230 1 60 CHS SEE NOTE 2 a gt 2 2 2 l lt 2 lt lt a gt 144 o 2 lt o lt o Sn 25 dz lt i o E oc od Ox 2 gt
38. F 4 f notas above replace control S 50 CHECKING HEATER LIMIT CONTROL S OPTIONAL ELECTRIC HEATERS Each individual heater element is protected with an automatic rest limit control connected in series with each element to prevent overheating of components in case of low airflow This limit control will open its circuit at approximately 150 F to 160 F and close at approximately 110 F WARNING DISCONNECT ELECTRICAL POWER SUPPLY 1 Remove the wiring from the control terminals 2 Using an ohmmeter test for continuity across the normally closed contacts No reading indicates the control is open replace if necessary Make sure the limits are cool before testing IF FOUND OPEN REPLACE DO NOT WIRE AROUND S 52 CHECKING HEATER ELEMENTS Optional electric heaters may be added in the quantities shown in the spec sheet for each model unit to provide electric resis tance heating Under no condition shall more heaters than the quantity shown be installed SERVICING 4 WARNING HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH Disassemble and remove the heating element s 2 Visually inspect the heater assembly for any breaks in the wire or broken insulators 3 Using an ohmmeter test the element for continuity no reading indicates the element is open Replace
39. FFICIENCY 34 55 108 SUPERHEAT 2 34 S 109 CHECKING SUBCOOLING 2 ucc ciet iore un cea occu amu anuncio ganar aaau drann Kaa ENa aiani sirais 35 S 111 FIXED ORIFICE RESTRICTION DEVICES 35 S 112 CHECKING RESTRICTED LIQUID LINE 36 m tun kane manu casu 36 5 4 36 5 115 COMPRESSOR BURNOUT 39 5 122 REVERSING 39 S 105 THERMOSTATIC EXPANSION 39 5 200 CHECKING EXTERNAL STATIC PRESSURE aaa nna sanas ansa tn nas 40 S 201 CHECKING TEMPERATURE RISE 40 Mee Rc Hee 41 2PEHT60 24542 44 1648 1
40. FOR COMPRESSOR AND FAN START ASSIST TRANSFORMER JUNCTION TERMINAL EQUIPMENT GROUND INTERNAL TO FIELD GROUND INTEGRATED CONTROL PLUG CONNECTION SWITCH PRESS 9 NOTES 1 IGNITER OVERCURRENT PROT DEVICE SEE UNIT RATING PLATE FOR TYPE AND SIZE OF OVER CURRENT PROTECTION 208 230 1 60 FIELD SPLICE SWITCH TEMP CONTROL BOX FACTORY WIRING LINE VOLTAGE LOW VOLTAGE OPTIONAL HIGH VOLTAGE FIELD WIRING HIGH VOLTAGE LOW VOLTAGE WIRE CODE BK BL BR GR BLACK BLUE BROWN GREEN ORANGE PURPLE RED WHITE YELLOW V NA REPLACEMENT WIRE MUST BE SAME SIZE AND TYPE INSULATION AS ORIGINAL AT LEAST 105 C USE COPPER CONDUCTOR ONLY FOR 208 VOLT TRANSFORMER OPERATION MOVE PURPLE WIRES FROM TERMINAL 3 TO TERMINAL 2 ON TRANSFORMER START ASSIST FACTOR EQUIPED WHEN REQUIRED USE COPPER CONDUCTORS ONLY USE N E C CLASS 2 WIRE F 0140G03703 A WIRING DIAGRAMS lt a gt 2 2 l lt 2 a ui lt lt a gt 2 lt o lt o Sn 25 dz lt i o E zo oc od Ox 2 gt lt oz 50 D 5 mo o u oz ut 9 oz a5 HIGH VOLTAGE WARNING o PU RD 221 SA
41. FOR USE WITH THIS UNIT OR HAVE NOT BEEN TESTED AND APPROVED BY GOODMAN SERIOUS PROPERTY DAMAGE OR PERSONAL INJURY REDUCED UNIT PERFORMANCE AND OR HAZARDOUS CONDITIONS MAY RESULT FROM THE USE OF DEVICES THAT HAVE NOT BEEN APPROVED OR CERTIFED BY GOODMAN INSTALLATION AND REPAIR OF THIS UNIT SHOULD BE PERFORMED To PREVENT THE RISK OF PROPERTY DAMAGE PERSONAL INJURY OR DEATH ONLY BY INDIVIDUALS MEETING AT A MINIMUM THE REQUIREMENTS DO NOT STORE COMBUSTIBLE MATERIALS OR USE GASOLINE OR OTHER OF AN ENTRY LEVEL TECHNICIAN AS SPECIFIED BY THE FLAMMABLE LIQUIDS OR VAPORS IN THE VICINITY OF THIS APPLIANCE AIR CONDITIONING HEATING AND REFRIGERATION INSTITUTE AHRI ATTEMPTING TO INSTALL OR REPAIR THIS UNIT WITHOUT SUCH BACKGROUND MAY RESULT IN PRODUCT DAMAGE PERSONAL INJURY OR DEATH GOODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES IF YOU INSTALL OR PERFORM SERVICE ON THIS UNIT YOU ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMAGE WHICH MAY RESULT MANY JURISDICTIONS REQUIRE A LICENSE TO INSTALL OR SERVICE HEATING AND AIR CONDITIONING EQUIPMENT 4 WARNING HIGH VOLTAGE DiscoNNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH To locate an authorized servicer please consult your telephone book or the dealer from whom you purchased this produc
42. G PLATE FOR TYPE AND SIZE F OF OVER CURRENT PROTECTION 0140G03657 A Wiring is subject to change Always refer to the wiring diagram on the unit for the most up to date wiring 51 WIRING DIAGRAMS o lt TOA 23 4 2 553 z5 zzz 2 oro 2 2 uos LI mot zug H ac lt lt 589 LE OED ozo 5 HIGH VOLTAGE A WARNING 52 PACKAGE SYSTEM WIRING DIAGRAM 1 STAGE ELECTRIC HEAT TYPICAL HP SEE NOTE 1 ROOM THERMOSTAT 18 GAUGE 7 WIRE X 0009935 a aaa 2 1 OUTDOOR THERMOSTAT CLOSE ON TEMPERATURE FALL PACKAGE UNIT LOW VOLTAGE JUNCTION BOX RED __y YELLOw GREEN 1 7 40 ORANGE WHITE PACKAGE SYSTEM WIRING DIAGRAM 2 STAGE ELECTRIC HEAT ABOVE 10 KW TYPICAL HP SEE NOTE 1 ROOM THERMOSTAT 18 GAUGE 8 WIRE FOR HEAT PUMPS a 2 SEE NOTE 2 OUTDOOR THERMOSTAT CLOSE ON TEMPERATURE FALL PACKAGE UNIT LOW VOLTAGE JUNCTION BOX RED Ji y YELLOW I G GREEN JA O0 ORANGE WHITE BROWN _ BL BLUE NOTES Color Codes R Red Y Yellow 1 O and E used on heat pumps only BL Blue 2 Connect wire from terminal 1 on outdoor thermostat to the white BR Brown wire on package units if single stage indoor thermostat is used AE G Green OT1
43. IF USED SEE NOTE 3 SUPPLY VOLTAGE 208 230 1 60 IF USED 208 230 0000000 THERMOSTAT COMPONENT LEGEND CONTACTOR CONDENSER MOTOR COMPRESSOR EVAPORATOR MOTOR EQUIPMENT GROUND LOW VOLTAGE JUNCTION BOX FEMALE PLUG CONNECTOR RUN CAPACITOR FOR COMPRESSOR AND FAN START ASSIST TRANSFORMER HIGH PRESSURE SWITCH COMPRESSOR SOLENOID RELAY HI STAGE SOLENOID JUNCTION APC1560H41 CONTROL BOX FACTORY WIRING LINE VOLTAGE LOW VOLTAGE OPTIONAL HIGH VOLTAGE FIELD WIRING gt HIGH VOLTAGE LOW VOLTAGE WIRE CODE BLACK BLUE BROWN GREEN ORANGE PURPLE RED WHITE YELLOW TERMINAL EQUIPMENT GROUND INTERNAL TO FI INTEGRATED CONTROL PLUG CONNECTION ELD GROUND ELD SPLICE SWITCH TEMP SWITCH PRESS IGNITER OVERCURRENT PROT DEVICE NOTES REPLACEMENT WIRE MUST BE SAME SIZE AND TYPE INSULATION AS ORIGINAL AT LEAST 105 C USE COPPER CONDUCTOR ONLY FOR 208 VOLT TRANSFORMER OPERATION MOVE PURPLE WIRES FROM TERMINAL 3 TO TERMINAL 2 ON TRANSFORMER START ASSIST FACTOR EQUIPED WHEN REQUIRED USE COPPER CONDUCTORS ONLY USE N E C CLASS 2 WIRE SEE UNIT RATING PLATE FOR TYPE AND SIZE OF OVER CURRENT PROTECTION 1 17 208 230 1 60 0140603704 47 WIRING DIAGRAMS LPS YUPK YL CONTROL BOX SEE NOTE 2 SUPPLY VOLTAGE 208 240 1 60 2 POLE ONLY SEE NOTE 7 CHS
44. 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 22 TO AN R 22 CYLINDER OR R 410A AN R 410A CYLINDER THE SERVICE EQUIPMENT USED MUST BE LISTED OR CERTIFIED FOR THE TYPE OF REFRIGERANT USED STORE CYLINDERS IN A COOL DRY PLACE NEVER USE A CYLINDER AS A PLATFORM OR A ROLLER To AVOID POSSIBLE EXPLOSION USE ONLY RETURNABLE NOT DISPOSABLE SERVICE CYLINDERS WHEN REMOVING REFRIGERANT FROM A SYSTEM ENSURE THE CYLINDER IS FREE OF DAMAGE WHICH COULD LEAD TO A LEAK OR EXPLOSION ENSURE THE HYDROSTATIC TEST DATE DOES NOT EXCEED 5 YEARS ENSURE THE PRESSURE RATING MEETS OR EXCEEDS 400 LBS WHEN IN DOUBT DO NOT USE CYLINDER A warnine TO AVOID POSSIBLE INJURY EXPLOSION OR DEATH PRACTICE SAFE HANDLING OF REFRIGERANTS In either of these instances an electrical short between the terminal and the compressor housing may result in the loss of integrity between the terminal and its dielectric embed ment This loss may cause the terminals to be expelled thereby venting the vaporous and liquid contents of the com pressor housing and system A venting compressor terminal normally presents no danger to anyone providing the terminal protective cover is properly in place If however the terminal protective cover is not properly in place a venting terminal may discharge a combination o
45. ITCH FACTORY EQUIPPED WHEN REQUIRED DOUBLE POLE CONTACTOR SHOWN SINGLE POLE CONTACTOR COULD BE FACTORY EQUIPPED AS AN ALTERNATE CONFIGURATION COMMON SIDE OF CONTACTOR CAN NOT BE GROUNDED OR CONNECTED TO ANY OTHER COMMON 24V THERMOSTAT SEE UNIT RATING PLATE FOR TYPE AND SIZE OF OVER CURRENT PROTECTION 0140G03659 A Wiring is subject to change Always refer to the wiring diagram on the unit for the most up to date wiring 50 WIRING DIAGRAMS APH1648H41 SEE NOTE 2 lt gt CONTROL NOTE 7 NOTE BOX 1 RD CH mht 1 5 Kame P ame COMPONENT LEGEND FACTORY WIRING SUPPLY VOLTAGE CONTACTOR s VOLTAGE 208 230 160 CCR COMPRESSOR CONTACTOR RELAY LOW VOLTAGE CH CRANKCASE HEATER OPTIONAL HIGH SEE NOTE 7 CHS CRANKCASE HEATER SWITCH E d CONDENSER MOTOR VOLTAGE 5 MA COMP COMPRESSOR CSR COMPRESSOR SOLENOID RELAY FIELD WIRING DC DEFROST CONTROL NS DFT DEFROST THERMOSTAT HIGH VOLTAGE GND EQUIPMENT GROUND LOW VOLTAGE HPS HIGH PRESSURE SWITCH 2 POLE ONLY HVDR HIGH VOLTAGE DEFROST RELAY SEE NOTE 8 LPS LOW PRESSURE SWITCH LVDR LOW VOLTAGE DEFROST RELAY LVJB LOW VOLTAGE JUNCTION BOX PLF FEMALE PLUG CONNECTOR RVC REVERSING VALVE COIL RCCF RUN CAPACITOR FOR COMPRESSOR AND FAN SA START ASSIST SOL HI STAGE SOLENOID TR TRANSFORMER 208 230 VSM VARIABLE SPEED MOTOR SEE NOTE 2 VS
46. LLLI I estcenmetyoroverad I tej LI ll ll Test Motor Windinss Compressor Stuck Faulty Compressor Contactor Faulty Fan Control Open Control Circuit Low Voltage Faulty Evap Fan Motor Shorted or Grounded Fan Motor 111 fel L ILI ILLI Te improper Cooling Anticipator IL ILL ILLA 21111011 Shortage of Refrigerant 111 14 109191 Restricted Liquid Line Open Element or Limit Elec Heater ee ee ee ee Dirty Air Filter Dirty Indoor Coil Not enough air across Indoor Coil Too much air across Indoor Coil Overcharge of Refrigerant Dirty Outdoor Coil Noncondensibles Recirculation of Condensing Air infiltration of Outdoor Air improperly Located Thermostat 7911 1211 111011 Air Flow Unbalanced d 1 11 Je Ll ll System Undersized Broken Internal Parts EA EA EEE HHH Broken Valves inefficient Compressor leje Loose Hold dow n Bolts LL LL LL LLL eL Faulty Reversing Valve im _ Ll le e e elele Faulty Defrost Control L L I le ole e Cooling or Heating Cycle Heat Pump Faulty Defrost Thermostat Flow rator Not Seating Properly 4 Heating Cycle Only i 538 Fiter Gean or Remove Obstruction Ar Check Window s Doors Vent Fans Relocate Th
47. ND CAN LEAD TO THE IMPOSITION OF SUBSTANTIAL FINES THESE REGULATIONS MAY VARY BY JURISDICTION A CERTIFIED TECHNICIAN MUST PERFORM THE INSTALLATION AND SERVICE OF THIS PRODUCT SHOULD QUESTIONS ARISE CONTACT YOUR LOCAL EPA OFFICE VIOLATIONS OF EPA REGULATIONS MAY RESULT IN FINES OR PENALTIES A warnina SYSTEM CONTAMINANTS IMPROPER SERVICE PROCEDURE AND OR PHYSICAL ABUSE AFFECTING HERMETIC COMPRESSOR ELECTRICAL TERMINALS MAY CAUSE DANGEROUS SYSTEM VENTING The successful development of hermetically sealed refrig eration compressors has completely sealed the compressor s moving parts and electric motor inside a common housing minimizing refrigerant leaks and the hazards sometimes as sociated with moving belts pulleys or couplings Fundamental to the design of hermetic compressors is a method whereby electrical current is transmitted to the com pressor motor through terminal conductors which pass through the compressor housing wall These terminals are sealed in a dielectric material which insulates them from the housing and maintains the pressure tight integrity of the her metic compressor The terminals and their dielectric em bedment are strongly constructed but are vulnerable to care less compressor installation or maintenance procedures and equally vulnerable to internal electrical short circuits caused by excessive system contaminants To AVOID POSSIBLE EXPLOSION NEVER APPLY FLAME OR STEAM TO A REFRIGERANT CYLINDER
48. NOOSIG i39 VL 10A SPK SINGLE POINT WIRING KIT Wiring is subject to change Always refer to the wiring diagram on the unit for the most up to date wiring 56
49. ORATOR MOTOR SPEED MOVE YELLOW AND WHITE LEADS FROM 2 AND 3 TO 4 AND 5 IF BOTH LEADS ARE ENERGIZED THE HIGHER SPEED SETTING IS USED FOR 208 VOLT TRANSFORMER OPERATION MOVE PURPLE WIRES FROM TERMINAL 3 TO TERMINAL 2 ON TRANSFORMER START ASSIST FACTORY EQUIPPED WHEN REQUIRED USE COPPER CONDUCTORS ONLY USE N E C CLASS 2 WIRE CRANKCASE HEATER AND CRANKCASE HEATER SWITCH FACTORY EQUIPPED WHEN REQUIRED DOUBLE POLE CONTACTOR SHOWN SINGLE POLE CONTACTOR COULD BE FACTORY EQUIPPED AS AN ALTERNATE CONFIGURATION COMMON SIDE OF CONTACTOR CAN NOT BE GROUNDED OR CONNECTED TO ANY OTHER COMMON 24V SEE UNIT RATING PLATE FOR TYPE AND SIZE OF OVER CURRENT PROTECTION 0140G03658 A Wiring is subject to change Always refer to the wiring diagram on the unit for the most up to date wiring 49 WIRING DIAGRAMS APH16 24 42 H41 SEE NOTE 2 ArPANOSEAMIA coe o e COMPONENT LEGEND FACTORY WIRING SUPPLY VOLTAGE LINE VOLTAGE 208 230 1 60 CCR COMPRESSOR CONTACTOR RELAY LOW VOLTAGE CH CRANKCASE HEATER OPTIONAL HIGH SEE NOTE 7 CHS CRANKCASE HEATER SWITCH CHS VOLTAGE CM CONDENSER MOTOR COMP COMPRESSOR CSR COMPRESSOR SOLENOID RELAY FIELD WIRING DC DEFROST CONTROL DEFROST THERMOSTAT HIGH VOLTAGE GND EQUIPMENT GROUND LOW VOLTAGE HPS HIGH PRESSURE SWITCH 2 POLE ONLY HVDR HIGH VOLTAGE DEFROST RELAY SEE NOTE 8 LPS LOW PRES
50. ROUND TEST 2 Identify the leads and using a Megger Hi Potential Ground Tester or other suitable instrument which puts out a volt age between 300 and 1500 volts check for a ground sepa rately between each of the three leads and ground such as an unpainted tube on the compressor Do not use a low voltage output instrument such as a volt ohmmeter SERVICING Ifa ground is indicated then carefully remove the compres sor terminal protective cover and inspect for loose leads or insulation breaks in the lead wires 4 Ifno visual problems indicated carefully remove the leads at the compressor terminals Carefully retest for ground directly between compressor terminals and ground 5 lf ground is indicated replace the compressor S 17D OPERATION TEST If the voltage capacitor overload and motor winding test fail to show the cause for failure dh WARNING HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH 1 Remove unit wiring from disconnect switch and wire a test cord to the disconnect switch NOTE The wire size of the test cord must equal the line wire size and the fuse must be of the proper size and type 2 With the protective terminal cover in place use the three leads to the compressor terminals that were disconnected at the nearest point to the compressor and conn
51. Remove the compressor and obtain an oil sample from the suction stub If the oil is not acidic either a burnout has not occurred or the burnout is so mild that a complete clean up is not necessary If acid level is unacceptable the system must be cleaned by using the clean up drier method 4 CAUTION DO NOT ALLOW THE SLUDGE OR OIL TO CONTACT THE SKIN SEVERE BURNS MAY RESULT NOTE GOODMAN DOES NOT APPROVE THE FLUSHING METHOD USING R 11 REFRIGERANT SUCTION LINE DRIER CLEAN UP METHOD The POE oils used with R410A refrigerant is an excellent sol vent In the case of a burnout the POE oils will remove any burnout residue left in the system If not captured by the refrig erant filter they will collect in the compressor or other system components causing a failure of the replacement compressor and or spread contaminants throughout the system damag ing additional components Install a suction line filter drier This drier should be installed as close to the compressor suction fitting as possible The filter must be accessible and be rechecked for a pressure drop after the system has operated for a time It may be necessary to use new tubing and form as required NOTE At least twelve 12 inches of the suction line immedi ately out of the compressor stub must be discarded due to burned residue and contaminates 1 Remove the liquid line drier and expansion valve 2 Purge all remaining components with dry nitrogen or car
52. SURE SWITCH LVDR LOW VOLTAGE DEFROST RELAY LVJB LOW VOLTAGE JUNCTION BOX PLF FEMALE PLUG CONNECTOR RVC REVERSING VALVE COIL RCCF RUN CAPACITOR FOR COMPRESSOR AND FAN SA START ASSIST SOL HI STAGE SOLENOID TR TRANSFORMER 208 230 VSM VARIABLE SPEED MOTOR SEE NOTE 2 VSTB VARIABLE SPEED TERM BLOCK WIRE CODE BK BLACK BL BLUE BR BROWN GR GREEN OR ORANGE PU PURPLE RD RED WH WHITE YL YELLOW lt a gt 2 E lt z O o lt lt a gt o 2 lt o o o a 7 Sx 25 dz lt i o E oc od Ox 20 gt lt n 50 D mo c o u oz ut oz a5 HIGH VOLTAGE FIELD GROUND EQUIPMENT GROUND JUNCTION TERMINAL SWITCH TEMP o INTERNAL TO IGNITER uuu INTEGRATED CONTROL SWITCH PRESS PLUG CONNECTION OVERCURRENT E3 PROT DEVICE FIELD SPLICE WARNING NOTES REPLACEMENT WIRE MUST BE SAME SIZE AND TYPE INSULATION AS ORIGINAL AT LEAST 105 C USE COPPER CONDUCTOR ONLY FOR 208 VOLT TRANSFORMER OPERATION MOVE PURPLE AND RED WIRES FROM TERMINAL 3 TO TERMINAL 2 ON TRANSFORMER START ASSIST FACTOR EQUIPPED WHEN REQUIRED USE COPPER CONDUCTORS ONLY USE CLASS 2 WIRE SET DIP SWITCH 4 ON VSTB TO OFF POSITION REFER TO IO FOR FAN SPEED SETTINGS CRANKCASE HEATER AND CRANKCASE HEATER SW
53. T WIRE MUST BE SAME SIZE AND TYPE INSULATION AS ORIGINAL AT LEAST 105 USE COPPER CONDUCTOR ONLY TO CHANGE EVAPORATOR MOTOR SPEED MOVE YELLOW AND WHITE LEADS FROM EM 2 AND 3 TO 4 AND 5 IF BOTH THE HIGHER SPEED SETTING IS USED LEADS ARE ENERIZED FOR 208 VOLT TRANSFORMER OPERATION MOVE PURPLE WIRES FROM TERMINAL 3 TO TERMINAL 2 ON TRANSFORM START ASSIST FACTOR EQUIPED WHEN REQ USE COPPER CONDUCTORS ONLY USE N E C CLASS 2 WIRE ER UIRED SEE UNIT RATING PLATE FOR TYPE AND SIZE OF OVER CURRENT PROTECTION 208 230 1 60 0140G03702 A 45 WIRING DIAGRAMS 46 o o z o z 2 5 gt tc a 5 lt LE 2 2 o o a HIGH VOLTAGE WARNING 3 ag lt ao 20 n lt On 5 zo 5a8 IF USED SEE NOTE 3 SUPPLY VOLTAGE 208 230 1 60 208 230 NOTE 2 62 9 9 THERMOSTAT NOTE 2 APC15 24 48 H41 COMPONENT LEGEND BR CH CM COMP EBTD R EM FC BLOWER INTERLOCK RELAY CONTACTOR CRACKCASE HEATER CONDENSER MOTOR COMPRESSOR ELECTRONIC BLOWER TIME DELAY RELAY EVAPORATOR MOTOR FAN CAPACITOR EQUIPMENT GROUND LOW VOLTAGE JUNCTION BOX FEMALE PLUG CONNECTOR RUN CAPACITOR
54. TB VARIABLE SPEED TERM BLOCK WIRE CODE BK BLACK BL BLUE BR BROWN GR GREEN OR ORANGE PU PURPLE RD RED WH WHITE YL YELLOW lt a gt 2 gt lt 2 a ui lt lt a gt o 2 lt o lt o 25 dz lt i o E zo tc od Ox 20 gt lt n 50 Dc 5 20 c o u oz ay ut oz a5 HIGH VOLTAGE FIELD GROUND EQUIPMENT GROUND JUNCTION TERMINAL INTERNAL TO IGNITER INTEGRATED CONTROL SWITCH PRESS PLUG CONNECTION OVERCURRENT PROT DEVICE EJ FIELD SPLICE SWITCH TEMP WARNING NOTES REPLACEMENT WIRE MUST BE SAME SIZE AND TYPE INSULATION AS ORIGINAL AT LEAST 105 C USE COPPER CONDUCTOR ONLY FOR 208 VOLT TRANSFORMER OPERATION MOVE PURPLE AND RED WIRES FROM TERMINAL 3 TO TERMINAL 2 ON TRANSFORMER START ASSIST FACTOR EQUIPPED WHEN REQUIRED USE COPPER CONDUCTORS ONLY USE CLASS 2 WIRE SET DIP SWITCH 4 ON VSTB TO OFF POSITION REFER TO IO FOR FAN SPEED SETTINGS CRANKCASE HEATER AND CRANKCASE HEATER SWITCH FACTORY EQUIPPED WHEN REQUIRED DOUBLE POLE CONTACTOR SHOWN SINGLE POLE CONTACTOR COULD BE FACTORY EQUIPPED AS AN ALTERNATE CONFIGURATION COMMON SIDE OF CONTACTOR CAN NOT BE GROUNDED OR CONNECTED TO ANY OTHER COMMON 24V THERMOSTAT SEE UNIT RATIN
55. UPPLY Checking Temperature Rise 41 AIRFLOW ADJUSTING SPEED TAP FOR INDOOR BLOWER MOTOR Evaporator Blower Specifications with ECM Motors APH1624H41 APC1524H41 Cooling HP Adjust Electric Adjust D Minus 721 D Minus 721 D 909 D Normal 909 D Plus 953 D Plus 953 APH1630H41 APC1530H41 MEC E Speed Tap Tap Minus 969 D Minus 969 D Norma 985 D Normal 985 D Plus 1073 D Plus 1073 C C B B B Minus 834 B Minus 834 Normal 984 Normal 984 B Plus 1101 B Plus 1 101 847 847 9 0 1 0 9 ESP 0 1 0 9 ESP Cooling HP Adjust Electric Adjust Cooling HP Adjust Adjust Pee m OM TM D Minus 1135 D Minus 1135 D Minus 1289 D Minus 1 289 D Normal 1 270 D Normal 1270 D Normal 1392 D Normal 1 392 D Pus 1371 D Plus 1371 D Plus 1440 D Plus 1 40 B Minus 932 B Minus 932 8 Minus 1182 B Minus 1182 Normal 1065 B Normal 1065 Normal 1294 B Normal 1 294 B 1181 B 1 B Pls 113841 Plus 1384 823 1 080 1 080 0 1 0 9 ESP 0 1 0 9 ESP i Adjust Electric Adjust D Minus 1506 D Minus 1 506 D Normali 1699 D Normal 1 699 D Plus
56. USE PROPERTY DAMAGE PERSONAL INJURY OR DEATH CAUTION USE REFRIGERANT CERTIFIED TO AHRI STANDARDS USED REFRIGERANT MAY CAUSE COMPRESSOR DAMAGE AND WILL VOID THE WARRANTY MOST PORTABLE MACHINES CANNOT CLEAN USED REFRIGERANT TO MEET AHRI 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 nameplates for the correct refrigerant charge After completing airflow measurements and adjustments the unit s refrigerant charge must be checked The unit comes factory charged but this charge is based on 400 CFM per ton at minimum ESP per AHRI test conditions generally between 15 25 ESP When air quantity or ESP is different than above charge must be adjusted to the proper amount All package units are charged to the superheat method at the compressor suction line these are fixed orifice devices For charging in the warmer months 10 F superheat at the com pressor is required at conditions 95 F outdoor ambient dry bulb temperature 80 F dry bulb 67 F wet bulb indoor ambi ent approximately 50 humidity This superheat varies when conditions vary from the conditions described superheat charge chart is available for other operating condi tions Use it to provide the correct superheat at the conditions the unit is bei
57. al release of the 15 SEER H model cooling units to meet Ready 15 requirements Amana is a registered trademark of Maytag Corporation or its related entities and is used under license All rights reserved PRODUCT DIMENSIONS 14 000 66 542 We 4 5 Dimensions in inches 41450 14 000 6 500 14 000 0 RETURN BACK VIEW DUCT OPENINGS je 34 075 Chassis Model A B PH162441 22 000 29 932 Small PH163041 22 000 29 932 PH163641 24 000 34 932 Medium PH164241 24 000 34 932 PH164841 24 000 34 932 Dimensions in inches ACCESSORIES PC15 PH16 H41 ACCESSORIES PC PH H SERIES Outdoor Thermostat Required for heat pum ps with 0 outdoor ambient and 50 or higher relative humidity Heater Kit for all PC PH H Series Heater Kit for all PC PH H Series Heater kit for PC PH13 14 30 60 H Series Heater Kit for PC PH13 14 42 60 Series Downflow Economizer for H Series Package Units A C Be Used With PCP101 103 Square to Round Adapters 16 amp 14 Square to Round Adapter For Use With PCCP101 103 Curb 16 Rounds 1 Heat 1 Cool 2 Heat 2 Cool 7 Day Programming Digital ACCESSORIES PC15 PH16H41 PCCP101 103 ROOF CURB Roof Curb PCP10
58. bient Temperature 8 Design Superheat 95 F Outdoor Ambient Temperature Superheat Model F GPH1524H41 GPH1530H41 GPH1536H41 GPH1542H41 12 GPH1548H41 152 15 15 10 12 15 17 SYSTEM OPERATION COOLING The refrigerant used in the system is R 410A It is a clear colorless non toxic and non irritating liquid R 410A is a 50 50 blend of R 32 and R 125 The boiling point at atmospheric pressure is 62 9 F A few of the important principles that make the refrigeration cycle possible are heat always flows from a warmer to a cooler body Under lower pressure a refrigerant will absorb heat and vaporize at alow temperature The vapors may be drawn off and condensed at a higher pressure and tempera ture to be used again The indoor evaporator coil functions to cool and dehumidify the air conditioned spaces through the evaporative process taking place within the coil tubes Heat is continually being transferred to the cool fins and tubes of the indoor evaporator coil by the warm system air This warming process causes the refrigerant to boil The heat re moved from the air is carried off by the vapor As the vapor passes through the last tubes of the coil it becomes superheated That is it absorbs more heat than is necessary to vaporize it This is assurance that only dry gas will reach the compressor Liquid reaching the compressor can weaken or break compressor valves T
59. bleed valves used on some other models will continue to allow some equalization even though the valve has a shut off completely because of the bleed holes within the valve This type of valve should not be used as a replacement for a 096 bleed valve due to the resulting drop in performance The bulb must be securely fastened with two straps to a clean straight section of the suction line Application of the bulb to a horizontal run of line is preferred If a vertical installation cannot be avoided the bult must be mounted so that the capillary tubing comes out at the top THE VALVES PROVIDED ARE DESIGNED TO MEET THE SPECIFICATION REQUIRMENTS FOR OPTIMUM PRODUCT OPERATION DO NOT USE SUBSTITUTES 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 con stitutes a poorly designed system To determine proper air movement proceed as follows 1 Usinga draft gauge inclined manometer measure the static pressure of the return duct atthe inlet of the unit Negative Pressure Return GF 2 Total External
60. d the EEM motor The electric heat will be ener gized through the normally open contacts of the electric heat sequencers The indoor blower will be energized through W from the thermostat DEFROST CYCLE PACKAGE HEAT PUMPS The defrosting of the outdoor coil is jointly controlled by the defrost control board and the defrost thermostat SOLID STATE DEFROST CONTROL During operation the power to the circuit board is controlled by a temperature sensor which is clamped to a feeder tube entering the outdoor coil Defrost timing periods of 30 60 or 90 minutes may be selected by setting the circuit board jumper to 30 60 or 90 respectively Accumulation of time for the timing period selected starts when the sensor closes approximately 32 2 F and when the room thermostat ECM MOTOR SPEED ADJUSTMENT PC15 PH16 H41 calls for heat At the end of the timing period the unit s defrost cycle will be initiated provided the sensor remains closed When the sensor opens approximately 60 F the defrost cycle is terminated and the timing period is reset If the defrost cycle is not terminated due to the sensor tem perature a twelve minute override interrupts the unit s defrost period FAN OPERATION CONTINUOUS FAN MODE MODELS EQUIPPED WITH EEM BLOWER MOTORS If the thermostat calls for continuous fan the indoor blower will be energized from the G terminal of the thermostat to the EEM blower motor If a call for heat or cool
61. e wired into the low or line voltage circuits When the control circuit is energized the coil pulls in the normally open contacts or opens the normally closed contacts When the coil is de energized springs return the contacts to their normal position A WARNING DISCONNECT POWER SUPPLY BEFORE SERVICING 1 Remove the leads from the holding coil 2 Using an ohmmeter test across the coil terminals If the coil does not test continuous replace the relay or con tactor S 8 CHECKING CONTACTOR CONTACTS WARNING DISCONNECT POWER SUPPLY BEFORE SERVICING 25 SERVICING SINGLE PHASE 1 Disconnect the wire leads from the terminal T side of the contactor 2 With power ON energize the contactor WARNING LINE VOLTAGE NOW PRESENT VOLT OHM for testing Ee coil Voltmeter for testing contacts TESTING COMPRESSOR CONTACTOR Single Phase 3 Using a voltmeter test across terminals A L1toL2 No voltage Check breaker or fuses on main power supply If voltage present proceed to step B B T1to T2 Meter should read the same as L1 to L2 in step A If voltage readings are not the same as step A replace contactor 26 SERVICING S 11 CHECKING LOSS OF CHARGE PROTECTOR Heat Pump Models The loss of charge protector senses the pressure in the liquid line and will open its contacts on a drop in pressure The low pressure control will automatically reset itself wi
62. e liquid line is restricted a definite temperature drop will be noticed at the point of restriction In severe cases frost will form at the restriction and extend down the line in the direction of the flow Discharge and suction pressures will be low giving the ap pearance of an undercharged unit However the unit will have normal to high subcooling If a restriction is located replace the restricted part replace drier evacuate and recharge S 113 REFRIGERANT OVERCHARGE An overcharge of refrigerant is normally indicated by an exces sively 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 refrigerant to return to the compressor under extreme overcharge conditions Also with a fixed orifice restrictor device flowrator metering device extreme cases of insufficient indoor air can cause icing of the indoor coil and liquid return to the compressor but the head pressure would be lower There are other causes for high head pressure which may be found in the Service Problem Analysis Guide If other causes check out normal an overcharge or a system containing non condensables would be indicated If this system is observed 1 Start the system 2 Remove and capture small quantities of refri
63. e wiring from the unit control panel to the thermostat requires coded cable The unit transformer is connected for 230V operation If the unit is to operate on 208V reconnect the transformer primary lead as shown on the unit wiring diagram If it is necessary for the installer to supply additional line volt age wiring to the inside of the package unit the wiring must comply with all local codes This wiring must have a minimum temperature rating of 105 C All line voltage splices must be made inside the unit or heat kit control box EXPANSION VALVE TXV SYSTEM SINGLE SPEED APPLICATION APH1624 42 1 Purge gauge lines Connect service gauge manifold to access fittings Run system at least 10 minutes to allow pressure to stabilize 2 Temporarily install thermometer on liquid small line near liquid line access fitting with adequate contact and insu late for best possible reading 3 Check subcooling and superheat Systems with TXV ap plication should have a subcooling and superheat within the range listed on the chart a If subcooling and superheat are low adjust TXV then check subcooling 16 b If subcooling is low and superheat is high add charge to raise subcooling then check superheat c If subcooling and superheat are high adjust TXV valve then check subcooling d If subcooling is high and superheat is low adjust TXV valve superheat and remove charge to lower the subcooling The TXV should NOT be adj
64. ect the common start and run clips to the respective leads 3 Connect good capacitors of the right MFD and voltage rat ing into the circuit 4 With power ON close the switch WARNING LINE VOLTAGE NOW PRESENT A Ifthe compressor starts and continues to run the cause for failure is somewhere else in the system B Ifthe compressor fails to start replace 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 test the reversing valve if equipped heat pump models only See S 21 Ifthe reversing valves test good the compressor is faulty replace the compressor S 18 TESTING CRANKCASE HEATER OPTIONAL ITEM Note Not all compressors use crankcase heaters The crankcase heater must be energized a minimum of twenty four 24 hours before the compressor is operated Crankcase heaters are used to prevent migration or accumula tion of refrigerant in the compressor crankcase during the off cycles and prevents liquid slugging or oil pumping on start up On some models the crankcase heater is controlled by a crank case heater thermostat that is wired in series with the crank case hea
65. erature must be 60 F or higher Setthe room thermostat to COOL fan switch to AUTO and set the tem perature control well below room temperature After system has stabilized per start up instructions compare the operating pressures and outdoor unit amp draw to the num bers listed in the technical manual If pressures and amp draw are too low add charge If pressures and amp draw are too high remove charge Check subcooling and superheat as de tailed in the following section 5 With the system still running remove hose and reinstall both access fitting caps 6 Check system for leaks Due to their design Scroll compressors are inherently more tolerant of liquid refrigerant NOTE Even though the compressor section of a Scroll com pressor is more tolerant of liquid refrigerant continued flood back or flooded start conditions may wash oil from the bearing surfaces causing premature bearing failure S 104 CHECK ING COMPRESSOR EFFICIENCY The reason for compressor inefficiency is broken or damaged suction and or discharge valves or scroll flanks on Scroll com pressors reducing the ability of the compressor to pump re frigerant vapor 35 SERVICING The condition of the valves or scroll flanks is checked in the following manner 1 Attach gauges to the high and low side of the system 2 Start the system and run a Cooling Performance Test If the test shows gt Below normal high side pressure Above normal low s
66. ermostat 1 ReadustAr Volume Dampers Tighten Bots 1 Heat Pump 2 SERVICING S 1 CHECKING VOLTAGE WARNING HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH 1 Remove doors control panel cover etc from unit being tested With power ON 4 WARNING LINE VOLTAGE NOW PRESENT 2 Using a voltmeter measure the voltage across terminals L1 and L2 of the 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 Measure the voltage with the unit starting and operating and determine the unit Locked Rotor Voltage Locked Rotor Voltage is the actual voltage available at the compressor during starting locked rotor or a stalled condition Measured voltage should be above minimum listed in chart below To measure Locked Rotor Voltage attach a voltmeter to the run R and common C terminals of the compres sor or to the T and T terminals of the contactor Start the unit and allow the compressor to run for several sec onds then shut down the unit Immediately attempt to restart the unit while measuring the Locked Rotor Volt
67. etting use an amp meter to measure the amperage on the W wire going to the thermostat Use an amprobe as shown below Wrap 10 turns of thermostat wire around the stationary jaw of the amprobe and divide the reading by 10 10 TURNS OF THERMOSTAT WIRE From W on thermostat READS 4 AMPS CURRENT DRAW WOULD BE 4 AMPS Checking Heat Anticipator Amp Draw S 4 CHECKING TRANSFORMER AND CONTROL CIRCUIT A step down transformer 208 240 volt primary to 24 volt sec ondary is provided with each package unit This allows ample capacity for use with resistance heaters 4 WARNING HIGH VOLTAGE DISCONNECT ALL 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 control panel cover or etc to gain access to trans former With power ON WARNING LINE VOLTAGE NOW PRESENT 2 Using a voltmeter check voltage across secondary voltage side of transformer R to C 3 No voltage indicates faulty transformer bad wiring or bad splices 4 Checktransformer primary voltage at incoming line voltage connections and or splices 5 If line voltage is present at the primary voltage side of the transformer and 24 volts is not present on the secondary side then the transformer is inoperative Replace S 7 CHECKING CONTACTOR AND OR RELAYS The compressor contactor and other relay holding coils ar
68. f a hot lubricating oil and refrigerant 6 flammable mixture if system is contaminated with air in stream of spray which may be dangerous to anyone the vicinity Death or serious bodily injury could occur Under no circumstances is a hermetic compressor to be elec trically energized and or operated without having the terminal protective cover properly in place See Service Section S 17 for proper servicing PRODUCT IDENTIFICATION The model number is used for positive identification of component parts used in manufacturing Please use this number when requesting service or parts information G Goodman REVISION Brand or Distinctions H Horizontal A Amana PRODUCT SERIES MAJOR 15 15 SEER Rating REVISION 16 16 SEER Rating REFRIGERANT 4 R 410A TYPE Package VOLTAGE Cooling Heating 1 208 230V 1ph 60Hz 3 208 230v 3ph 60Hz 4 460v 3ph 60H 30 000 BTUH 36 000 BTUH 42 000 BTUH PRODUCT 48 000 BTUH FAMILY 48 000 BTUH C Cooling 60 000 BTUH H Heat Pump PRODUCT Amana Brand Goodman Brand or Distinctions Package Cooling PC1524 60H41AA 15 Seer 208 230 1 60 Single Phase Electric Cooling Unit with R 410A Initial release of the 15 SEER H model cooling units to meet Ready 15 requirements Amana Brand Goodman Brand or Distinctions Package Heat Pump PH1624 48H41AA 16 Seer 208 230 1 60 Single Phase Heat Pump with R 410A Initi
69. gerant as from the suction line access fitting until the head pressure is reduced to normal 3 Observe the system while running a cooling performance test If a shortage of refrigerant is indicated then the sys tem 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 If the pres sure indicates a higher temperature than that of the coil tem perature non condensables are present Non condensables are removed from the system by first re moving the refrigerant charge replacing and or installing liquid line drier evacuating and recharging 37 SERVICING Pressure vs Temperature Chart R 410A PSIG 420 0 120 422 0 121 424 0 121 426 0 121 N 428 0 122 430 0 122 432 0 122 434 0 123 436 0 123 438 0 123 440 0 124 442 0 124 444 0 124 446 0 125 448 0 125 450 0 126 452 0 126 454 0 126 456 0 127 458 0 127 460 0 127 462 0 128 464 0 128 466 0 128 468 0 129 534 0 139 i ii 472 0 129 4740 130 476 0 130 4780 130 480 0 131 482 0 4840 131 486 0 132 488 0 132 490 0 132 4920 132 4940 133 496 0 193 498 0 133 500 0 134 502 0 134 5040 134 506 0 135 508 0 135 510 0 155 5120 136 1 514 0 136
70. he compressor increases the pressure of the gas thus add ing more heat and discharges hot high pressure superheated gas into the outdoor condenser coil In the condenser coil the hot refrigerant gas being warmer than the outdoor air first loses its superheat by heat trans ferred from the gas through the tubes and fins of the coil The refrigerant now becomes saturated part liquid part vapor and then continues to give up heat until it condenses to a liquid alone Once the vapor is fully liquefied it continues to give up heat which subcools the liquid and it is ready to repeat the cycle COOLING CYCLE COOLING ONLY MODELS When the contacts of the room thermostat close making terminals R to Y and R to G the low voltage circuit to the contactor is completed starting the compressor and outdoor fan motor This also energizes the indoor blower through the 24V signal from the thermostat When the thermostat is satisfied breaking the circuit be tween R to Y and R to G the compressor and outdoor fan motor will stop The indoor blower will stop after the fan off delay If the room thermostat fan selector switch should be set to the on position then the indoor blower would run continu ous rather than cycling with the compressor HEAT PUMP MODELS Any time the room thermostat is switched to cool the O terminal is energized This energizes the 24 volt coil on the reversing valve and switches it to the cooling position 18
71. ide pressure Lowtemperature difference across coil Low amp draw at compressor and the charge is correct The compressor is faulty replace the compressor S 104 CHECKING COMPRESSOR EFFICIENCY The reason for compressor inefficiency is broken or damaged suction and or discharge valves or scroll flanks on Scroll com pressors reducing the ability of the compressor to pump re frigerant vapor 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 ac cess fittings 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 ittakes more than seven 7 minutes to equalize the restrictor device is inoperative Replace install a liquid line drier evacu ate and recharge S 108 SUPERHEAT CHECKING SUPERHEAT Refrigerant gas is considered superheated whenever its tem perature is higher than the saturation temperature correspond ing to its pressure The degree of superheat equals the de grees of temperature increase above the saturation tempera ture at existing pressure See Temperature Pressure Chart CAUTION To prevent personal injury carefully connect and disconnect manifold gauge hoses Escaping liquid refrigerant can cause burns Do
72. ill only affect both low stage and high stage cooling air flow by adjusting the Air flow to 8596 TWO STAGE HEATING When using staged electric heat cut jumper PJ4 on the control L o seem board PCT NA THERMOSTAT WIRING Use thermostat wiring diagrams provided with the thermostat when making these connections Indoor Thermostat Cooling amp Heat Pump CFM CFM Trim Adjust TABLE6 19 SYSTEM OPERATION TYPICAL PACKAGE COOLING Chatleff Orifice RESTRICTOR ORIFICE ASSEMBLY IN COOLING OPERATION In the cooling mode the orifice is pushed into its seat forcing refrigerant to flow through the metered hole in the center of the orifice 20 SYSTEM OPERATION TYPICAL HEAT PUMP SYSTEM IN COOLING Reversing Valve Energized Reversing Valve De Energized 21 SCHEDULED MAINTENANCE The owner should be made aware of the fact that as with any mechanical equipment the Package Cooling and Heat Pump units require regularly scheduled maintenance to preserve high performance standards prolong the service life of the equip ment and lessen the chances of costly failure In many instances the owner may be able to perform some of the maintenance however the advantage of a service con tract which places all maintenance in the hands of a trained serviceman should be pointed out to the owner A WARNING HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT MULTIPL
73. ized polypropylene as used in the run capacitor 27 SERVICING A switching device must be wired in series with the capacitor to remove it from the electrical circuit after the compressor starts to run Not removing the start capacitor will overheat the capacitor and burn out the compressor windings These capacitors have a 15 000 ohm 2 watt resistor wired across its terminals The object of the resistor is to discharge the capacitor under certain operating conditions rather than having it discharge across the closing of the contacts within the switching device such as the Start Relay and to reduce the chance of shock to the servicer See the Servicing Section for specific information concerning capacitors RELAY START A potential or voltage type relay is used to take the start ca pacitor out of the circuit once the motor comes up to speed This type of relay is position sensitive The normally closed contacts are wired in series with the start capacitor and the relay holding coil is wired parallel with the start winding As the motor starts and comes up to speed the increase in volt age across the start winding will energize the start relay hold ing coil and open the contacts to the start capacitor Two quick ways to test a capacitor are a resistance and a capacitance check S 15A RESISTANCE CHECK 4 WARNING HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT MULTIPLE POWER SOURCES MAY BE
74. llow 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 Check the continuity between each of the motor leads 3 Touch one probe of the ohmmeter to an unpainted end of the motor frame ground and the other probe in turn to each lead If the windings do not test continuous or a reading is obtained from any lead to ground replace the motor S 16D CHECKING EEM ENERGY EFFICIENT MOTOR MOTORS Applies only to units with 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 fea tures 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 connec tions L and 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
75. nd an electrical arc occurs as the ter minal vents Ignition cannot occur at the venting terminal without the pres ence of contaminant air and cannot occur externally from the venting terminal without the presence of an external ignition source Therefore proper evacuation of a hermetic system is essen tial at the time of manufacture and during servicing To reduce the possibility of external ignition all open flame electrical power and other heat sources should be extinguished or turned off prior to servicing a system If the following test indicates shorted grounded or open wind ings see procedure S 19 for the next steps to be taken S 17A RESISTANCE TEST Each compressor is equipped with an internal overload The line break internal overload senses both motor amperage and winding temperature High motor temperature or amper age heats the disc causing it to open breaking the common circuit within the compressor on single phase units The three phase internal overload will open all three legs Heat generated within the compressor shell usually due to recycling of the motor high amperage or insufficient gas to cool the motor is slow to dissipate allow at least three to four hours for it to cool and reset then retest 4 WARNING HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR D
76. ng charged at After superheat is adjusted it is recommended to check unit sub cooling at the condenser coil liquid line out In most oper ating conditions 12 4 F of sub cooling is adequate An inaccurately charged system will cause future problems 1 Using a quality set of charging scales weigh the proper amount of refrigerant for the system Allow liquid refrigerant only to enter the high side 2 After the system will take all it will take close the valve on the high side of the charging manifold 3 Start the system and charge the balance of the refrigerant through the low side NOTE R410A should be drawn out of the storage con tainer or drum in liquid form due to its fractionation proper ties but should be Flashed to its gas state before enter ing the system There are commercially available restric tion devices that fit into the system charging hose set to accomplish this DO NOT charge liquid R410A into the compressor 4 With the system still running close the valve on the charg ing cylinder At this time you may still have some liquid refrigerant in the charging cylinder hose and will definitely have liquid in the liquid hose Slowly open the high side manifold valve and transfer the liquid refrigerant from the liquid line hose and charging cylinder hose into the suction service valve port CAREFUL Watch so that liquid refrig erant does not enter the compressor Final Charge Adjustment The outdoor temp
77. nit The outdoor coil is designed for 0 static No addi tional restriction ductwork shall be applied Conditioned air is drawn through the filter s field installed across the evaporator coil and back into the conditioned space by the indoor blower COMPRESSORS Some H series package units use the Compliant Scroll com pressor instead of traditional reciprocating compressors Still other models use reciprocating compressors A scroll is an involute spiral which when matched with a mat ing scroll form as shown generates a series of crescent shaped gas pockets between the two members During compression one scroll remains stationary fixed scroll while the other form orbiting scroll is allowed to orbit but not rotate around the first form As this motion occurs the pockets between the two forms are slowly pushed to the center of the two scrolls while simulta neously being reduced in volume When the pocket reaches the center of the scroll form the gas which is now at a high pressure is discharged out of a port located at the center During compression several pockets are being compressed simultaneously resulting in a very smooth process Both the suction process outer portion of the scroll members and the discharge process inner portion are continuous Some design characteristics of the Compliant Scroll compres sor are Compliant Scroll compressors are more tolerant of liquid refrigerant NOTE Even
78. nsatisfactory System Complaint No Cooling Cooling Heating Operating Pressures POSSIBLE CAUSE little cooling htg fan runs DOTS IN ANALYSIS GUIDE INDICATE POSSIBLE CAUSE SYMPTOM goes off on overload blows cold air in heating Pow er Failure Blow n Fuse Unbalanced Pow er 3PH Loose Connection Shorted or Broken Wires Open Fan Overload Faulty Thermostat Faulty Transformer e e System will not start 111 1111 Compressor will not start 11111 Unit will not terminate defrost BERENI Unit will not defrost Low suction pressure FILET ET Low head pressure High suction pressure T High head pressure o 9 2 51 e 13 LJ o gt 5 is S o o 8 5 2 Lj L L Lj m Lj lee Comp and Cond Fan will not start ejeje e Evaporator fan will not start 24411 Condenser fan will not start deje l Compressor runs BEENDEN Compressor cycles on overload System runs continuously e Too cool and then too warm I I System runs Test Method Remedy 2 5 o 2 n 2 2 o o Test Circuits With Ohmmeter Test Continuity of Overload S 17A 52 53 Shorted Open Capacitor Internal Compressor Overload Open Shorted or Grounded Compressor e Jejejeje tT tT tT TestCapacitor ILI ISI
79. nstaller must provide a service platform for the service person with rails or guards in accordance with local codes or ordinances 48 MIN PC15 PH16 H41 NOTE Roof overhang should be no more than 36 and provisions made to deflect the warm discharge air out from the overhang Minimum clearances are required to avoid air recirculation and keep the unit operating at peak efficiency A WARNING TO PREVENT POSSIBLE DAMAGE THE UNIT SHOULD REMAIN IN AN UPRIGHT POSITION DURING ALL RIGGING AND MOVING OPERATIONS TO FACILITATE LIFTING AND MOVING IF A CRANE IS USED PLACE THE UNIT IN AN ADEQUATE CABLE SLIDE Refer to Roof curb Installation Instructions for proper curb in stallation Curbing must be installed in compliance with the National Roofing Contractors Association Manual Lower unit carefully onto roof mounting curb While rigging unit center of gravity will cause condenser end to be lower than supply air end 14 Roof Curb and Platform PC15 PH16 H41 PC15 PH16 Package Units are designed for outdoor installa tions only in either residential or light commercial applications NOTE To ensure proper condensate drainage unit must be in stalled in a level position The connecting ductwork Supply and Return can be connected for horizontal discharge airflow In the down discharge applica tions a matching Platform Roof Curb PCCP101 103 and Downflow Plenum PCP1 01 103 i
80. occurs during a continuous fan call the EEM motor will always recognize the call for the highest speed and ignore the lower speed call If the thermostat is not calling for heat or cool and the fan switch on the thermostat is returned to the automatic posi tion the fan will stop after the programmed 60 second off delay on units with the EEM motor Each ECM blower motor has been preprogrammed for operation at 4 distinct air flow levels when operating in Cooling Heat Pump mode or Electric Heat mode These 4 distinct levels may also be adjusted slightly lower or higher if desired The adjustment between levels and the trim adjustments are made by changing the dip switch s either to an OFF or ON position DIP SWITCH FUNCTIONS The ECM motor has an electronic control that contains eight 8 2 position dip switches The function of these dip switches is shown in Table 6 Airflow charts pages 42 and 43 For APC15 APH16 24 36 models dip switch 4 must be set to ON Dip switch 4 must be set to OFF for two stage compressor models APC15 APH16 48 60 Dip switch 4 ON energizes Y1 signal to the ECM motor anytime Y Y2 is energized The indoor motor will not operate properly if switch is not set correctly for the model THERMOSTAT FAN ONLY MODE During Fan Only Operations the CFM output is 5096 of the high stage cooling setting HUMIDITY CONTROL When using a Humidistat normally closed cut jumper PJ6 on the control board The Humidistat w
81. ower ON 4 WARNING LINE VOLTAGE NOW PRESENT 1 Use a voltmeter to verify 24 volts present at thermostat wires C and R 2 If no voltage present check transformer and transformer wiring If 24 volts present proceed to step 3 SERVICING 3 Set fan selector switch at thermostat to ON position 4 With voltmeter check for 24 volts at wires C and G 5 No voltage indicates the trouble is in the thermostat or wiring 6 Check the continuity of the thermostat and wiring Repair or replace as necessary S 3B COOLING ANTICIPATOR The cooling anticipator is a small heater resistor in the ther mostat During the off cycle it heats the bimetal element helping the thermostat call for the next cooling cycle This prevents the room temperature from rising too high before the system is restarted A properly sized anticipator should main tain room temperature within 1 1 2 to 2 degree range The anticipator is supplied in the thermostat and is not to be replaced If the anticipator should fail for any reason the ther mostat must be changed S 3C HEATING ANTICIPATOR The heating anticipator is a wire wound adjustable heater which is energized during the ON cycle to help prevent overheating of the conditioned space The anticipator is a part of the thermostat and if it should fail for any reason the thermostat must be replaced See the follow ing for recommended heater anticipator setting To determine the proper s
82. pare the hi pressure reading to the Required Liquid Line Temperature chart Find the hi pressure value on the left column Follow that line right to the column under the design subcooling value Where the two intersect is the required liquid line temperature Alternately you can convert the liquid line pressure gauge reading to temperature by finding the gauge reading in Tem perature Pressure Chart and reading to the left find the temperature in the F Column SERVICING 5 The difference between the thermometer reading and pres sure to temperature conversion is the amount of subcooling Subcooling Formula Sat Liquid Temp Liquid Line Temp EXAMPLE a Liquid Line Pressure 417 b Corresponding Temp F 120 Thermometer on Liquid line 109 F To obtain the amount of subcooling subtract 109 from 120 F The difference is 11 subcooling See the specification sheet or technical information manual for the design subcooling range for your unit See R410A Pressure vs Temperature chart S 111 FIXED ORIFICE RESTRICTION DEVICES The fixed orifice restriction device flowrator used in conjunc tion with the indoor coil is a predetermined bore I D Itis designed to control the rate of liquid refrigerant flow into an evaporator coil The amount of refrigerant that flows through the fixed orifice restriction device is regulated by the pressure difference be tween the high and low sides of the system
83. per position ing 9 Start the system using the proper instrumentation check gas inlet and manifold pressures burner flame and microamp signal Adjust if necessary 10 Start the system and run both a Cooling amp Heating Perfor mance Test If the results of the test are not satisfactory see the Service Problem Analysis Chart of the possible cause TEST EQUIPMENT Proper test equipment for accurate diagnosis is as essential as regular hand tools The following is a must for every service technician and service shop 1 Thermocouple type temperature meter measure dry bulb temperature 2 Sling psychrometer measure relative humidity and wet bulb temperature 3 Amprobe measure amperage and voltage 4 Volt Ohm Meter testing continuity capacitors and motor windings 5 Accurate Leak Detector testing for refrigerant leaks High Vacuum Pump evacuation Electric Vacuum Gauge Manifold Gauges and high vacuum hoses to measure and obtain proper vacuum 8 Accurate Electronic Scale measure proper refrigerant charge 9 Inclined Manometer measure static pressure and pres sure drop across coils Other recording type instruments can be essential in solving abnormal problems however in many instances they may be rented from local sources Proper equipment promotes faster more efficient service and accurate repairs with less call backs SERVICING COOLING HEAT PUMP SERVICE ANALYSIS GUIDE U
84. programmed 60 second off delay HEAT PUMP UNITS On a call for first stage heat the contacts of the room ther mostat close This energizes terminals R to Y and R to G the low voltage circuit to the contactor is completed starting the compressor and outdoor fan motor This also energizes the indoor blower instantly on models equipped with EEM blower motors 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 after the programmed 60 second off delay on models equipped with EEM blower motors When auxiliary electric heaters are used a two stage heat ing single stage cooling thermostat would be installed Should the second stage heating contacts in the room ther mostat close which would be wired to W1 at the unit low voltage connections this would energize the coil s of the electric heat relay s Contacts within the relay s will close bringing on the electric resistance heaters If auxiliary electric heaters should be used they may be con trolled by outdoor thermostats OT18 60A or 18 60 EMERGENCY HEAT MODE HEAT PUMPS NOTE The following only applies if the unit has an approved electric heat kit installed for auxiliary heating SYSTEM OPERATION PH MODELS EQUIPPED WITH EEM BLOWER TORS With the thermostat set to the emergency heat position R to W1 will be energized This will energize the electric heat se quencers an
85. r ON unit not running 1 Jumper defrost thermostat by placing a jumper wire across the terminals DFT and R R DFT on PCBDM133 at defrost control board 2 Connect jumper across test pins on defrost control board 3 Set thermostat to call for heating System should go into defrost within 21 seconds Immediately remove jumper from test pins Using VOM check for voltage across terminals C amp O O RV on PCBDM133 Meter should read 24 volts 6 Using VOM check for voltage across fan terminals DF1 and DF2 on the board You should read line voltage 208 230 VAC indicating the relay is open in the defrost mode 32 7 Using VOM check for voltage across W2 W on PCBDM133 amp C terminals on the board You should read 24 volts If not as above replace control board 9 Setthermostat to off position and disconnect power before removing any jumpers or wires NOTE Remove jumper across defrost thermostat before re turning system to service S 25 TESTING DEFROST THERMOSTAT 1 Install a thermocouple type temperature test lead on the tube adjacent to the defrost control Insulate the lead point of contact 2 Check the temperature at which the control closes its con tacts by lowering the temperature of the control It should close at approximately 32 F 2 3 Check the temperature at which the control opens its con tacts by raising the temperature of the control It should open at approximately 60
86. s recommended for horizon tal models only Areturn 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 operated without return air filters A3 4 14 drain connector is provided for removal of con densate water from the indoor coil In order to provide proper condensate flow do not reduce the drain line size Refrigerant flow control is achieved by use of restrictor orifices These models use the FasTest Access Fitting System witha saddle that is either soldered to the suction and liquid lines or is fastened with a locking nut to the access fitting box core and then screwed into the saddle Do not remove the core from the saddle until the refrigerant charge has been removed Failure to do so could result in property dam age or personal injury The single phase units use permanent split capacitors PSC design compressors Starting components are therefore not required Alow MFD run capacitor assists the compressor to start and remains in the circuit during operation PRODUCT DESIGN The outdoor fan motor is a single phase capacitor type motors Air for condensing cooling is drawn through the outdoor coil by a propeller fan and is discharged vertically out the top of the u
87. t For further assistance please contact CONSUMER INFORMATION LINE GOODMAN BRAND PRODUCTS TOLL FREE 1 877 254 4729 U S only email us at customerservice goodmanmfg com fax us at 713 856 1821 Not a technical assistance line for dealers Outside the U S call 1 713 861 2500 Not a technical assistance line for dealers Your telephone company will bill you for the call IMPORTANT INFORMATION SAFE REFRIGERANT HANDLING While these items will not cover every conceivable situation they should serve as a useful guide A warnine REFRIGERANTS ARE HEAVIER THAN AIR THEY CAN PUSH OUT THE OXYGEN IN YOUR LUNGS OR IN ANY ENCLOSED SPACE TO AVOID POSSIBLE DIFFICULTY IN BREATHING OR DEATH NEVER PURGE REFRIGERANT INTO AN ENCLOSED ROOM OR SPACE By LAW ALL REFRIGERANTS MUST BE RECLAIMED IF AN INDOOR LEAK IS SUSPECTED THOROUGHLY VENTILATE THE AREA BEFORE BEGINNING WORK LiQUID REFRIGERANT CAN BE VERY COLD TO AVOID POSSIBLE FROST BITE OR BLINDNESS AVOID CONTACT WITH REFRIGERANT AND WEAR GLOVES AND GOGGLES IF LIQUID REFRIGERANT DOES CONTACT YOUR SKIN OR EYES SEEK MEDICAL HELP IMMEDIATELY ALwavs FOLLOW EPA REGULATIONS NEVER BURN REFRIGERANT AS POISONOUS GAS WILL BE PRODUCED A warninc THE UNITED STATES ENVIRONMENTAL PROTECTION AGENCY EPA HAS ISSUED VARIOUS REGULATIONS REGARDING THE INTRODUCTION AND DISPOSAL OF REFRIGERANTS INTRODUCED INTO THIS UNIT FAILURE TO FOLLOW THESE REGULATIONS MAY HARM THE ENVIRONMENT A
88. ter A crankcase heater will not prevent compressor damage due to a floodback or over charge condition WARNING DISCONNECT POWER SUPPLY BEFORE SERVICING 1 Disconnectthe heater lead wires 2 Using an ohmmeter check heater continuity should test continuous if not replace S 18A CHECKING CRANKCASE HEATER THERMOSTAT Note Not all models with crankcase heaters will have a crankcase heater thermostat 1 Install a thermocouple type temperature test lead on the discharge line adjacent to the crankcase heater thermo stat 2 Checkthe temperature at which the control closes its con tacts by lowering the temperature of the control The crank case heater thermostat should close at 67 F 5 F 3 Checkthe temperature at which the control opens its con tacts by raising the temperature of the control The crank case heater thermostat should open at 85 F 5 F 4 f notas above replace control 31 SERVICING S 21 CHECKING REVERSING VALVE AND SOLENOID Occasionally the reversing valve may stick in the heating or cooling position or in the mid position When stuck in the mid position part of the discharge gas from the compressor is directed back to the suction side resulting in excessively high suction pressure An increase in the suc tion line temperature through the reversing valve can also be measured Check operation of the valve by starting the sys tem and switching the operation from COOLING to HE
89. th a rise in pressure The low pressure control is designed to cut out open at ap proximately 22 7 PSIG It will automatically cut in close at approximately 50 7 PSIG Test for continuity using a VOM and if not as above replace the control 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 discharge pressures develop the con tacts of the control open breaking the control circuit before the compressor motor overloads This control is automatically re set 1 Using ohmmeter check across terminals of high pres sure control with wire removed If not continuous the con tacts are open 2 Attach a gauge to the access fitting on the liquid line With power ON WARNING LINE VOLTAGE NOW PRESENT 3 Startthe system and place a piece of cardboard in front of the condenser coil raising the condensing pressure 4 Check pressure at which the high pressure control cuts out If it cuts out at 610 PSIG 10 PSIG it is operating normally See causes for high head pressure in Service Problem Analy sis Guide If it cuts out below this pressure range replace the control The control should reset at 420 PSIG 25 PSIG
90. usted at light load conditions 55 to 60 F under such conditions only the subcooling can be evaluated This is because suction pressure is dependent on indoor air flow and wet bulb temperature NOTE Do NOT adjust charge based on suction pressure unless there is a gross undercharge 4 Disconnect manifold set Installation is complete TWO SPEED APPLICATION APH1648 APC1560 Run the unit on low stage cooling for 10 minutes until refrigerant pressures stabilize Follow the guidelines and methods below to check unit operation and ensure that the refrigerant charge is within limits Charge the unit on low stage 1 Purge gauge lines Connect service gauge manifold to access fittings Run system at least 10 minutes to allow pressure to stabilize 2 Temporarily install thermometer on liquid small line near liquid line access fitting with adequate contact and insu late for best possible reading 3 Check subcooling and superheat Two stage systems run ning on low stage with TXV application should have a subcooling and superheat within the range listed on the chart PRODUCT DESIGN SATURATED SATURATED SUCTION PRESSURE LIQUID PRESSURE TEM PERATURE CHART TEM PERATURE CHART SATURATED SATURATED SUCTION SUCTION LIQUID LIQUID RESSU RE TEM PERATURE PRESSURE TEM PERATURE TABLE 6 Suction Pressure Liquid Pressure SUPERHEAT SUCTION LINE TEMP SAT SUCTION TEMP 15 Design Superheat 95 F Outdoor Am

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