Amana PHB**C Service manual

Service
Instructions
PHB**C, PHD**C PACKAGE HEAT PUMPS
PGA**C, PGB**C, PGD**C PACKAGE GAS
& PCC**C PACKAGE COOLERS
Models listed on
Page 6
This manual is to be used by qualified, professionally trained HVAC
technicians only. Goodman does not assume any responsibility for
property damage or personal injury due to improper service
procedures or services performed by an unqualified person.
is a trademark of Maytag Corporation and is used under license
to Goodman Company, L.P. All rights reserved.
RS6300003 Rev. 1
January 2007
®
Copyright © 1999-2007 Goodman Company, L.P.
INDEX
IMPORTANT INFORMATION ........................................................................................................ 4
PRODUCT IDENTIFICATION ........................................................................................................ 6
ACCESSORIES ............................................................................................................................. 9
LIGHTING INSTRUCTIONS ........................................................................................................ 13
PRODUCT DESIGN .................................................................................................................... 19
ELECTRICAL WIRING ................................................................................................................ 20
LINE VOLTAGE WIRING ............................................................................................................. 20
GAS SUPPLY AND PIPING ......................................................................................................... 21
SYSTEM OPERATION ................................................................................................................ 24
SCHEDULED MAINTENANCE ................................................................................................... 30
SERVICING ................................................................................................................................. 31
S-1
S-2
S-3
S-3A
S-3B
S-4
S-6
S-7
S-8
S-9
S-15
S-15A
S-15B
S-16
S-16B
S-16E
S-17
S-17A
S-17B
S-17D
S-18
S-21
S-22
S-24
S-25
S-50
S-52
S-53
S-100
S-101
S-102
S-103
S-104
S-105
2
CHECKING VOLTAGE .............................................................................................................. 35
CHECKING WIRING ................................................................................................................. 35
CHECKING THERMOSTAT, WIRING, AND ANTICIPATOR .................................................... 35
Thermostat and Wiring ............................................................................................................ 35
Cooling Anticipator................................................................................................................... 35
CHECKING TRANSFORMER AND CONTROL CIRCUIT ...................................................... 36
CHECKING TIME DELAY RELAY ............................................................................................ 37
CHECKING CONTACTOR AND/OR RELAYS ......................................................................... 37
CHECKING CONTACTOR CONTACTS .................................................................................. 37
CHECKING FAN RELAY CONTACTS ..................................................................................... 37
CHECKING CAPACITOR ......................................................................................................... 37
Resistance Check .................................................................................................................... 38
Capacitance Check .................................................................................................................. 38
CHECKING FAN AND BLOWER MOTOR ............................................................................... 38
ECM/ICM Motors ...................................................................................................................... 39
Testing Interface Board .......................................................................................................... 41
CHECKING COMPRESSOR WINDINGS ................................................................................ 45
Resistance Test ....................................................................................................................... 45
Ground Test .............................................................................................................................. 45
Operation Test ......................................................................................................................... 46
TESTING CRANKCASE HEATER ........................................................................................... 46
CHECKING REVERSING VALVE AND SOLENOID ................................................................ 47
REVERSING VALVE REPLACEMENT ..................................................................................... 47
TESTING DEFROST BOARD .................................................................................................. 47
TESTING DEFROST CONTROL (30°/60°) ............................................................................. 49
CHECKING HEATER LIMIT CONTROL(S) ............................................................................ 49
CHECKING HEATER ELEMENTS .......................................................................................... 49
OUTDOOR TEMPERATURE CONTROL ............................................................................... 50
REFRIGERATION REPAIR PRACTICE ................................................................................... 50
LEAK TESTING ........................................................................................................................ 50
EVACUATION ............................................................................................................................ 50
CHARGING ................................................................................................................................ 51
CHECKING COMPRESSOR EFFICIENCY ............................................................................. 52
THERMOSTATIC EXPANSION VALVE .................................................................................... 52
INDEX
S-106
S-107
S-108
S-109
S-110
S-111
S-112
S-113
S-114
S-115
S-200
S-301
S-302
S-304
S-306
S-307
S-308
S-309
S-310
S-311
S-313
S-314
S-315
OVERFEEDING ......................................................................................................................... 52
UNDERFEEDING ...................................................................................................................... 52
SUPERHEAT ............................................................................................................................. 53
CHECKING SUBCOOLING ..................................................................................................... 54
CHECKING EXPANSION VALVE OPERATION ....................................................................... 54
FIXED ORIFICE RESTRICTION DEVICES ............................................................................. 55
CHECKING RESTRICTED LIQUID LINE ................................................................................ 55
OVERCHARGE OF REFRIGERANT ........................................................................................ 55
NON-CONDENSABLES ........................................................................................................... 55
COMPRESSOR BURNOUT .................................................................................................... 55
CHECKING EXTERNAL STATIC PRESSURE ........................................................................ 56
TESTING AUXILIARY LIMIT ..................................................................................................... 57
CHECKING FLAME ROLLOUT SWITCH ................................................................................ 57
TESTING GAS VALVE ............................................................................................................... 58
CHECKING ORIFICES ............................................................................................................. 60
CHECKING GAS PRESSURE.................................................................................................. 60
CHECKING FOR DELAYED IGNITION ................................................................................... 61
CHECKING FOR FLASHBACK ................................................................................................ 61
CHECKING PRESSURE CONTROL ...................................................................................... 61
HIGH ALTITUDE APPLICATION ............................................................................................... 66
TESTING IGNITION CONTROL MODULE ............................................................................ 66
CHECKING FLAME SENSOR.................................................................................................. 68
CHECKING HOT SURFACE IGNITER .................................................................................... 70
WIRING DIAGRAMS .................................................................................................................... 71
3
IMPORTANT INFORMATION
Pride and workmanship go into every product to provide our customers with quality products. It is 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
WARNING
TO PREVENT THE RISK OF PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH,
DO NOT STORE COMBUSTIBLE MATERIALS OR USE GASOLINE OR OTHER
FLAMMABLE LIQUIDS OR VAPORS IN THE VICINITY OF THIS APPLIANCE.
W ARNING
G OODMAN W ILL NOT BE R ESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES.
I F YOU INSTALL OR PERFORM SERVICE ON THIS UNIT, YOU ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMA GE WHICH
MAY RESULT. M ANY JU RISDICTIONS REQU IRE A LICENSE TO INSTALL OR SERVICE HEATING AN D AIR CONDITIONING EQUIPMENT.
WARNING
HIGH VOLTAGE
DISCONNECT ALL POWER BEFORE SERVICING OR
INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY
BE PRESENT. F AILURE TO DO SO MAY CAUSE PROPERTY
DAMAGE, PERSONAL INJURY OR DEATH.
To locate an authorized servicer, please consult your telephone book or the dealer
from whom you purchased this product. For further assistance, please contact:
CONSUMER INFORMATION LINE - AMANA® BRAND PRODUCTS TOLL FREE
1-877-254-4729 (U.S. only)
email us at: hac.consumer.affairs@amanahvac.com
fax us at: (931) 438- 4362
(Not a technical assistance line for dealers.)
Outside the U.S., call 1-931-433-6101.
(Not a technical assistance line for dealers.)
Your telephone company will bill you for the call.
4
IMPORTANT INFORMATION
SAFE REFRIGERANT HANDLING
While these items will not cover every conceivable situation, they should serve as a useful guide.
WARNING
WARNING
TO AVOID POSSIBLE EXPLOSION:
• NEVER APPLY FLAME OR STEAM TO A REFRIGERANT CYLINDER. IF YOU
REFRIGERANTS ARE HEAVIER THAN AIR. THEY CAN "PUSH OUT" THE
TO AVOID
OXYGEN IN YOUR LUNGS OR IN ANY ENCLOSED SPACE.
MUST HEAT A CYLINDER FOR FASTER CHARGING, PARTIALLY IMMERSE
POSSIBLE DIFFICULTY IN BREATHING OR DEATH:
•NEVER PURGE REFRIGERANT INTO AN ENCLOSED ROOM OR SPACE.
BY
IT IN WARM WATER.
NEVER FILL A CYLINDER MORE THAN 80% FULL OF LIQUID REFRIGERANT.
• NEVER ADD ANYTHING OTHER THAN R-22 TO AN R-22 CYLINDER OR
R-410 A TO AN R-410A CYLINDER. THE SERVICE EQUIPMENT USED MUST
•
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.
BE LISTED OR CERTIFIED FOR THE TYPE OF REFRIGERANT USED.
TO AVOID POSSIBLE FROST•
BITE OR BLINDNESS, AVOID CONTACT WITH REFRIGERANT AND WEAR
STORE CYLINDERS IN A COOL, DRY PLACE. NEVER
USE A CYLINDER
AS A PLATFORM OR A ROLLER.
GLOVES AND GOGGLES. IF LIQUID REFRIGERANT DOES CONTACT YOUR
SKIN OR EYES, SEEK MEDICAL HELP IMMEDIATELY.
•ALWAYS FOLLOW
EPA REGULATIONS. NEVER BURN REFRIGERANT,
AS POISONOUS GAS WILL BE PRODUCED.
WARNING
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.
WARNING
TO
AVOID POSSIBLE INJURY, EXPLOSION OR DEATH, PRACTICE SAFE
HANDLING OF REFRIGERANTS.
WARNING
SYSTEM CONTAMINANTS, IMPROPER SERVICE PROCEDURE AND/OR PHYSICAL
ABUSE AFFECTING HERMETIC COMPRESSOR ELECTRICAL TERMINALS MAY
CAUSE DANGEROUS SYSTEM VENTING.
The successful development of hermetically sealed refrigeration compressors has completely sealed the compressor's
moving parts and electric motor inside a common housing,
minimizing refrigerant leaks and the hazards sometimes associated with moving belts, pulleys or couplings.
Fundamental to the design of hermetic compressors is a
method whereby electrical current is transmitted to the compressor motor through terminal conductors which pass
through the compressor housing wall. These terminals are
sealed in a dielectric material which insulates them from the
housing and maintains the pressure tight integrity of the hermetic compressor. The terminals and their dielectric embedment are strongly constructed, but are vulnerable to careless compressor installation or maintenance procedures and
equally vulnerable to internal electrical short circuits caused
by excessive system contaminants.
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 embedment. This loss may cause the terminals to be expelled,
thereby venting the vaporous and liquid contents of the compressor housing and system.
A venting compressor terminal normally presents no danger
to anyone, providing the terminal protective cover is properly
in place.
If, however, the terminal protective cover is not properly in
place, a venting terminal may discharge a combination of
(a) hot lubricating oil and refrigerant
(b) flammable mixture (if system is contaminated
with air)
in a stream of spray which may be dangerous to anyone in
the vicinity. Death or serious bodily injury could occur.
Under no circumstances is a hermetic compressor to be electrically energized and/or operated without having the terminal
protective cover properly in place.
See Service Section S-17 for proper servicing.
5
PRODUCT IDENTIFICATION
P
G
B
24
C
045
2
D
Product Type
Engineering Revision
Single Package
Cooling/Heating
Voltage
2: 230V/60Hz/1ph
Product Family
G - Gas/Electric
H - Heat Pump
C - Cooling
Heating Input
HEAT PUMPS
Product Series
0: No heat installed
C: 10 kw heat installed
A: 10 SEER Line
B: 11 SEER Line
C: 12 SEER Line
D: 13 SEER Line
PACKAGE GAS
Nominal Capacity
24: 24000 BTUH
30: 30000 BTUH
36: 36000 BTUH
42: 42000 BTUH
48: 48000 BTUH
60: 60000 BTUH
PGA60C0902*
PGA60C1152*
PGB24C0452*
PGB24C0702*
PGB24C0902*
PGB30C0702*
PGB30C0902*
PGB36C0702*
PGB36C0902*
PGB42C0902*
PGB42C1152*
PGB48C0902*
PGB48C1152*
PGB48C1402*
PGB60C0902*
PGB60C1152*
PGB60C1402*
6
PGD24C0452*
PGD24C0702*
PGD24C0902*
PGD30C0702*
PGD30C0902*
PGD36C0702*
PGD36C0902*
PGD42C0902*
PGD42C1152*
PGD48C0902*
PGD48C1152*
PGD48C1402*
PGD60C0902*
PGD60C1152*
PGD60C1402*
045:
070:
090:
115:
140:
45000 BTUH
70000 BTUH
90000 BTUH
115000 BTUH
140000 BTUH
Design Sequence
PHD36CC2*
PHB24C02*
PHB30C02*
PHB36C02*
PHB42C02*
PHB48C02*
PHB60C02*
PHD24C02*
PHD30C02*
PHD36C02*
PHD42C02*
PHD48C02*
PHD60C02*
PHB24CC2*
PHB30CC2*
PHB36CC2*
PHD24CC2*
PHD30CC2*
PCC24C02*
PCC30C02*
PCC36C02*
PCC42C02*
PCC48C02*
PCC60C02*
PRODUCT IDENTIFICATION
Gas Units
Package Gas Units
Model #
Manufacturing #
Description
Package Gas (A) 10 Seer gas/electric units. New chassis design with
PGA60C0902D
P1217301C-P1217302C smaller footprint. PGA models have stronger blower performance for down
PGA60C1152D
shot applications.
PGA60C0902D
PGA60C1152D
Package Gas (A) 10 Seer gas/electric units. Changed from 26" fan blade to
P1220301C-1220302C 22" fan blade to improve operating sound. PGA models have stronger blower
performance for down shot applications.
Package Gas (A) 10 Seer gas/electric units. Changed from Smart Valve
PGA60C0902E P1236201C-P1236202C
system to "DSI" direct spark ignition systems. PGA models have stronger
PGA60C1152E P1231901C-P1231902C
blower performance for down shot applications.
PGA**C***2F
Package Gas (A) 10 Seer gas/electric units. Revised features include
P1236309C-P1236313C alternate vendor for DSI ignition control, deletion of low voltage terminal
P1236408C-P1236411C board (pigtail low voltage wire connections), alternate ID blower, and
alternate condenser fan/motor.
PGB**C***2D
P1213601C-P1213608C Package Gas (B) 11 Seer gas/electric units. New chassis design with
P1217201C-P1217207C smaller footprint.
PGB**C***2D
P1220201C-P1220207C Package Gas (B) 11 Seer gas/electric units. Changed from 26" fan blade to
P1222201C-P1222208C 22" fan blade to improve operating sound.
PGB**C***2E
P1231701C-P1231708C Package Gas (B) 11 Seer gas/electric units. Changed from Smart Valve
P1231801C-P1231807C system to "DSI" direct spark ignition systems.
PGB**C***2E
P1236401C-P1236407C Package Gas (B) 11 Seer gas/electric units. Upgraded with burner bracket
P1236301C-P1236308C used on 90% gas furnaces.
PGD**C***2D
P1204301C-P1204308C
PGD**C***2D
P1222301C-P1222308C Package Gas (D) 13 Seer gas/electric units. Changed from 26" fan blade to
P1231402C-P1231407C 22" fan blade to improve operating sound.
PGD**C***2E
P1232001C-P1232008C
Package Gas (D) 13 Seer gas/electric units. Changed from Smart Valve
P1232101C-P1232107C
system to "DSI" direct spark ignition systems.
P1236501C-P1236513C
PGD**C***2G
P1236514C-P1236521C Package Gas (D) 13 Seer gas/electric units. Changed from tan to new
P1236608C-P1236613C architectrual gray/executive gray color.
Package Gas (D) 13 Seer gas/electric units. New chassis design with
smaller footprint.
PGD**C***2G P1236522C-P1236529C
Package Gas (D) 13 Seer gas/electric units. Changed from TXV to Flowrator
on 2 - 3 1/2 ton models.
PGD**C***2X
Package Gas (D) 13 Seer gas/electric units. Introduce TXV equipped PGD
"2X" models 2 - 3 1/2 ton.
P1236530C-P1236533C
7
COOLERS
HEAT PUMPS
PRODUCT IDENTIFICATION
8
Heat Pumps and Coolers
Model #
Manufacturing #
Description
PHB**C02D
P1214402C-P1214404C
Package Heat Pump (B) 11 Seer heat pump units. New chassis design with smaller
footprint.
PHB**C02E
P1204501C-P1214404C
Package Heat Pump (B) 11 Seer heat pump units. New chassis design with smaller
footprint. Improved heating capacity
PHB**C02E
P1220101C-P1220106C
Package Heat Pump (B) 11 Seer heat pump units. Changed from 26" fan blade to
22" fan blade to improve operating sound.
PHB**CC2E
P1228101C-P1228103C
Package Heat Pump (B) 11 Seer heat pump units. New chassis design with smaller
footprint. With 10 K.W. factory installed heat strips.
PHB**CC2E
P1235801C-P1235803C
Package Heat Pump (B) 11 Seer heat pump units. Changed to Ranco Defrost
Board. Moved low pressure switch to suction side.
PHB**C02E
P1235601C-P1235606C
Package Heat Pump (B) 11 Seer heat pump units. Changed to Ranco Defrost
Board. Moved low pressure switch to suction side.
PHB**C02E1
P1239207C-P1239212C
Package Heat Pump (B) 11 Seer heat pump units. Tubing redesigned to improve
serviceability and reduce the potential for distributor tubes rubbing and leaking.
PHB**CC2E1
P1239904C-P1239906C
Package Heat Pump (B) 11 Seer heat pump units. Tubing redesigned to improve
serviceability and reduce the potential for distributor tubes rubbing and leaking.
PHB**C02E1
P1239214C-P1239219C
Package Heat Pump (B) 11 Seer heat pump units. Change to UTEC Defrost Board.
Moved low pressure switch to liquid line and changed pressure setting from 5 PSIG
to 15 PSIG. Moved ECM interface board to return air section.
PHB**CC2E1
P1239908C-P1239910C
P1240008C-P1240010C
Package Heat Pump (B) 11 Seer heat pump units. Change to UTEC Defrost Board.
Moved low pressure switch to liquid line and changed pressure setting from 5 PSIG
to 15 PSIG. Moved ECM interface board to return air section.
Package Heat Pump (B) 11 Seer heat pump units. Changed from tan to new
corporate colors.
Package Heat Pump (B) 11 Seer heat pump units. Changed from tan to new
corporate colors.
Package Heat Pump (D) 13 Seer heat pump units. New chassis design with smaller
footprint.
Package Heat Pump (D) 13 Seer heat pump units. Changed to Ranco Defrost
Board. Moved low pressure switch to suction side.
Package Heat Pump (D) 13 Seer heat pump units. New chassis design with smaller
footprint. With 10 K.W. factory installed heat strips.
Package Heat Pump (D) 13 Seer heat pump units. Changed to Ranco Defrost
Board. Moved low pressure switch to suction side.
PHB**C02F1
P1239220C-P1239225C
PHB**CC2F1
P1239911C-P1239913C
PHD**C02E
P1224301C-P1224305C
PHD**C02E
P1235701C-P1235705C
PHD**CC2E
P1228201C-P1228203C
PHD**CC2E
P1235901C-P1235903C
PHD**C02E1
P1239706C-P1239710C
Package Heat Pump (D) 13 Seer heat pump units. Tubing redesigned to improve
serviceability and reduce the potential for distributor tubes rubbing and leaking.
PHD**CC2E1
P1240004C-P1240006C
Package Heat Pump (D) 13 Seer heat pump units. Tubing redesigned to improve
serviceability and reduce the potential for distributor tubes rubbing and leaking.
PHD**C02E1
PHD**CC2E1
P1239711C
P1240007C
PHD**C02F1
P1239718C-P1239723C
PHD**CC2F1
P1240011C-P1240013C
Model #
Manufacturing #
PCC**C02E
P1231101C-P1231106C
PCC**C02F
P1231107-P1231112C
PCA**C02E
P1234801C-P1234806C
PCA**C02F
P1234807C-P1234811C
Package Heat Pump (D) 13 Seer heat pump units. Scroll compressor.
Package Heat Pump (D) 13 Seer heat pump units. Scroll compressor.
Package Heat Pump (D) 13 Seer heat pump units. Changed from tan to new
corporate colors.
Package Heat Pump (D) 13 Seer heat pump units. Changed from tan to new
corporate colors.
Description
Package Cooling (C) 12 Seer electric heat electric cooling units. New chassis design
with smaller footprint.
Package Cooling (C) 12 Seer electric heat electric cooling units. Changed from tan
to new corporate colors.
Package Cooling (A) 10 Seer electric heat electric cooling units. Changed from tan
to new corporate colors.
Package Cooling (A) 10 Seer electric heat electric cooling units. New condenser
fan/motor.
ACCESSORIES
Additional Amana® brand accessories, as described below, can be purchased to fit specific application needs. Accessories
can be ordered by the following part numbers and each accessory includes its own separate instructions.
ACCESSORY
PART NUMBER
DESCRIPTION
Duct Transition Round
RSDK01A (24-60)
Converts existing round duct connections to rectangular. Used to install
the horizontal duct cover kit on heat pump units.
Duct Transition
Over/Under
PDTR0U4A (Sm Chassis)
PDTR0U6A (LG Chassis)
Converts existing side by side duct connections to over & under
ductwork. (For replacement purposes). Some Amana preceding units
had over & under ductwork. For use on all Amana® brand Package Units.
Roof Curbs
PRC06A1
PRC07A1
PRC08A1
Roof top mounting/support system for package units. Must be used when
unit is installed in downflow applications. PRC06A fits Package heat
pump and coolers. PRC07A1 fits Package gas/electric units. PRC08A1
is a combo roof curb adaptable to either footprint.
Horizontal Duct Cover
Kits
CHK001A
CHK002A
CHK601A (6 PACK)
Blocks off horizontal discharge. Used for downflow applications. For use
on all Amana® brand Package
. Units.
50°F Compressor
Lockout
LOK501A
Prevents mechanical cooling at ambients below 50°F. For use on all
. Units.
Amana® brand Package
Ambient Thermostat Kit
ATK01
This kit controls the staging of electric heat and allows supplemental
heat to be energized only when a set outdoor temperature is reached.
This will allow the system's heat output to more closely match the
building's load. For use on heat pump and cooling package units .
Compressor Sound
Blankets
CSB04A
CSB07A
CSB08A
CSB09A
Compressor sound blankets reduce the ambient noise level of the
package units. Used in installations where extra quite operation is
desired. For use on all Amana® brand Package
. Units.
Propane Gas Conversion LPTK07A
Kit
LPTK09
Converts package gas units from natural gas to propane gas operation
Electric Heater Kits
PHCB05C1
PHCB10C1
PHCB15C1
PHCB20C1
4.8KW
1ph - 30 Amp Circuit Breaker
9.6KW
1ph - 50 Amp Circuit Breaker
14.4KW 1ph - 30 & 50 Amp Circuit Breakers
19.2KW 1ph - 2-50 Amp Circuit Breakers
For use on heat pump and cooling package units.
Single Point Wiring Kits
SPK04A
SPK05A
SPK06A
SPK07A
SPK08A
SPK09A
Single point wiring kit allows one electrical supply connection to power
both heater kit and package unit. For use on heat pump and cooling
package units.
9
ACCESSORIES
Accessories
PHCB**C1
SPK**A
P1219401C-P1219406C Package Heat kit with Circuit Breakers. Electric heat kits include breakers
P1219408C-P1219412C for electric heat only.
Single Point power connection Kit. Kit allows for one circuit to provide
P1221701C-P1221706C
power supply for package heat pumps (PHB/PHD**C) and coolers
P1221708C-P1221712C
(PCC**C). Kit includes circuit breaker for compressor.
PRC06A1
PRC07A1
PRC07A1
Package Roof Curb Kit. Accessory roof curb for roof top/down discharge
installations. PRC06A1 is designed for package heat pumps and coolers.
P1219801C-P1219803C
PRC07A1 is designed for package gas units. PRC07A1 is a combo curb
and will adapt to either footprint.
PDTROU4A
PDTROU6A
Package Duct TRansition Over-Under kit. Transition converts side by side
P9850603C-P9850604C to over-under duct connections. Early model Amana units (EPCG, EPHO,
EP, and PHK) had over-under duct connections.
THERMOSTATS
THSMEC1H2BA
THSADC1H2BA
THSMDC1H2BA
THSMDC1H3BA
1213401
1213403
1213404
1213405
1213701
1214901
C5200607
M0380101
D6853512
D6853510
D9945801
D9807604
1213402
1213406
1213407
1213408
1213410
1213411
1213412
1213431
10
Manual changeover - 2 Stage Heat
Auto changeover - 2 Stage Heat
Manual changeover - 2 Stage Heat
Auto changeover - 3 Stage Heat
Electronic programmable - 1 Stage Heat, 1 Stage Cool
Electronic non-programmable - 2 Stage Heat, 1 Stage Cool
Electronic non-programmable - 2 Stage Heat, 1 Stage Cool
Electronic programmable - 2 Stage Heat, 1 Stage Cool
Electronic programmable - 1 Stage Heat, 1 Stage Cool
Electronic programmable - 2 Stage Heat, 2 Stage Cool
Manual changeover - 1 Stage Heat, 1 Stage Cool
Manual changeover - 1 Stage Heat, 1 Stage Cool
Auto changeover - 1 Stage Heat, 1 Stage Cool
Auto changeover - 2 Stage Heat, 1 Stage Cool
Manual changeover - 2 Stage Heat, 1 Stage Cool
Electronic programmable - 1 Stage Heat, 1 Stage Cool
Manual Changeover - Nonprogrammable Digital - 1 Stage Heat, 1 Stage Cool
Manual/Auto Changeover - 5 + 2 Programming Digital - 3 Stage Heat, 2 Stage Cool
Manual Changeover - 5 + 2 Programming Digital - 2 Stage Heat, 2 Stage Cool
Manual/Auto Changeover -7 Day Programming Digital - 1 Stage Heat, 1 Stage Cool
Manual Changeover - 5 + 2 Programming Digital - 2 Stage Heat, 1 Stage Cool
Manual Changeover - Nonprogrammable Digital - 2 Stage Heat, 2 Stage Cool
Manual/Auto Changeover - 7 Day Programming Digital - 3 Stage Heat, 2 Stage Cool
Manual/Auto Changeover - 7 Day Programming Digital - 3 Stage Heat, 2 Stage Cool
ACCESSORIES
1"
42-3
/8"
"
35
14"
SUPPLY
19-3
RETURN
/16"
19-3
"
19
/16"
PRC06A1 ROOF CURB
12"
42
"
3/8
47"
2"
SUPPLY
RETURN
"
25
14"
25"
"
12
2"
PRC07A1 ROOF CURB
11
ACCESSORIES
1
14
42 3/8
24 3/8
47
2
RETURN
SUPPLY
14
12
14
35
INSULATED PLATFORM
UNIT SUPPORT
PRC08A ROOF CURB
J
A
H
1.00"
G
B
F
E
D
C
OVER/UNDER DUCT TRANSITION
®
AMANA BRAND
MODEL
PDTROU4A
PDTROU6A
Duct Transition
Over/Under
12
"A" DIM "B" DIM "C" DIM "D" DIM "E" DIM "F" DIM "G" DIM "H" DIM "J" DIM
42"
26 7/16"
12"
26 1/4"
15"
6 7/8" 20 11/16" 9/16"
9/16"
42"
32"
12"
39 1/2"
15"
10"
20 11/16"
1"
9/16"
PDTROU4A
PDTROU6A
Converts existing side by side duct connections to over/under ductwork.
(For replacement purposes. The Amana® brand's preceding units had
over/under ducts.)
LIGHTING INSTRUCTIONS
FOR YOUR SAFETY
READ BEFORE OPERATING
WARNING If you do not follow these instructions
LIRE AVANT DE METTRE
EN MARCHELIRE
AVERTISSEMENT: Ouiconque ne respcte pas `a
la lettre les instructions dans le present manuel risque
de declencher un incendie ou une explosion entrainant
des dommages materiels, des lesions corporelles ou la
perte de vies humaines.
exactly, a fire or explosion may result causing property
damage, personal injury or loss of life.
A. This appliance is equipped with an ignition device
which automatically lights the pilot. Do not try
to light the pilot by hand.
B. BEFORE OPERATING smell all around the appliance
area for gas. Be sure to smell next to the floor
because some gas is heavier than air and will
settle on the floor.
A.Cet appareil est muni d'un dispositif d'allumage
qui allume automatiqement la veilleuse. Ne pas
tenter d'allumer la veillese manuellement.
B. AVANT DE LE FAIRE FONCTIONNER,
renifler tout autour de l'appariel pour deceler
une odeur de gaz. Renifler pres du plancher, car
certains gaz sont plus lourds que l'air et
peuvent s'accmuler a niveau du sol.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
Do not touch any electric switch;
Do not use any phone in your building.
Immediately call your gas spplier from a neighbor's
phone. Follow the gas supplier's instructions.
If you cannot reach your gas spplier,
call the fire department.
C. Use only your hand to push in or turn the gas control knob.
Never use tools. If the knob will not push in or turn by
hand, don't try to repair it, call a qualified service
technician. Force or attempted repair may result in a fire
or explosion.
D. Do not use this appliance if any part has been underwater.
Immediately call a qualified service technician to inspect
the appliance and to replace any part of the control
system and any gas control which has been underwater.
QUE FAIRE S'IL Y A UNE ODEUR DE GAZ
Ne pas tenter d'allumer l'appariel.
Ne toucher aucun interrupteur electrique;
n'utiliser aucun telephone dans le batiment.
Appeler immediatement le fournisseur de gaz
en employant le telephone dun voisin.
Respecter a la lettre les instructions du
fournisseur de gaz.
Si personne ne repond, appeler le service des
incendies.
C. Ne pousser ou tourner la manette d'admission du gaz
qu'a la main; ne jamais emploer d'outil a cet effet.
Si la manette reste coincee, ne pas tenter de la
reparer; appeler un technicien qalifie. Quiconque
tente de forcer la manette ou de la reparer peut
declencher une explosion ou un incendie.
D. Ne pas se servir de cet appareil s'il a ete plonge
dans l'eau, completement ou en partie. Appeler un
technicien qualifie pour inspecter l'appareil et
remplacer tout partie du systeme de controle et
toute commande qui ont ete plonges dans l'eau.
MISE EN MARCHE
OPERATING INSTRUCTIONS
1.
1. STOP. Read the safety information above on
this label.
2. Set the thermostat to lowest setting.
3. Turn off all electric power to the appliance.
OFF
4. This appliance is equipped with an ignition
device which automatically lights the pilot.
Do not try to light the pilot by hand.
5. Turn the gas control knob clockwise
to
"OFF" position. Do not force.
6. Wait five (5) mintes to clear ot any gas. Then
smell for gas, including near the floor. If you
then smell gas, STOP. Follow "B" in the safety
information above on this label.
ROBINET A GAZ
if you don't smell gas, go to
MANUEL, EN POS
next step.
"ON/MARCHE"
7. Turn gas control knob
GAS
counterclockwise
to "ON".
INLET
8. Replace access panel.
9. Turn on all electrical
power to the appliance.
ARRIVEE
10. Set thermostat to desired setting.
DU GAZ
11. If the appliance will not operate,
MANUAL GAS
follow the instrctions "To Turn
KNOB SHOWN
Off Gas To Appliance" and call your
IN "ON" POS
service technician or gas company.
ON
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. Turn off all electrical power to the appliance
if service is to be performed.
3. Turn the gas control knob clockwise
to
"OFF" position. Do not force.
4. Replace control access panel.
ARRETER!. Lisez les instrcutions de securite sur
la portion superleure de cette etiquette.
2. Regler le thermostat a la temperature la plus basse.
3. Couper l'alimentation electrique de l'appareil.
4. Cet appareil est muni d'un dispositif d'allumage qui
allume automatiquement la veilleuse. Ne pas tenter
d'allumer la veilleuse manuellement.
5. Torner le robinet a gaz dans le sens des aiguilles
d'une montre
en position "OFF/ARRET"
Ne pas forcer.
6. Attendre cinq (5) minutes pour laisser echapper tout le
gaz. Renifler tout autour de l'appareil, y compris pres du
plancher, pour deceler une odeur de gaz. Si c'est le cas,
ARRETER!. Passer a l'etape B des instructions de secuurite
sur la portion superieure de cette etiquette.
S'il n'y a pas d'odeur de gaz, passer a l'etape sulvante.
7. Tourner le robinet a gaz dans le sens inverse des
aiguilles d'une montre
en pos "ON/MARCHE".
8. Remettre en place le panneau d'acces.
9. Mettre l'appareil sous tension.
10. Regler le thermostat a la temperature desiree.
11. Si l'appareil ne se met pas en marche, suivre les
instrcutions intitulees Comment couper l'admission
de gaz de l'appareil et appeler un technicien
qualifie ou le fournisseur de gaz.
POUR COUPER L'ADMISSION
DE GAZ DE L'APPAREIL
1. Regler le thermostat a la temperature la plus basse.
2. Couper l'alimentation electrique de l'appareil s'il
faut proceder a des operations d'entretien.
3. Tourner le robinet a gaz dans le sens des aiguilles
d'une montre
en position "OFF/ARRET".
Ne pas forcer.
4. Remettre en place le panneau d'acces.
11072705
13
LIGHTING INSTRUCTIONS
FOR YOUR SAFETY
READ BEFORE OPERATING
WARNING If you do not follow these instructions
LIRE AVANT DE METTRE
EN MARCHELIRE
AVERTISSEMENT: Ouiconque ne respcte pas `a
la lettre les instructions dans le present manuel risque
de declencher un incendie ou une explosion entrainant
des dommages materiels, des lesions corporelles ou la
perte de vies humaines.
exactly, a fire or explosion may result causing property
damage, personal injury or loss of life.
A. This appliance is equipped with an ignition device
which automatically lights the pilot. Do not try
to light the pilot by hand.
A.Cet appareil est muni d'un dispositif d'allumage
qui allume automatiqement la veilleuse. Ne pas
tenter d'allumer la veillese manuellement.
B. BEFORE OPERATING smell all around the appliance
area for gas. Be sure to smell next to the floor
because some gas is heavier than air and will
settle on the floor.
B. AVANT DE LE FAIRE FONCTIONNER,
renifler tout autour de l'appariel pour deceler
une odeur de gaz. Renifler pres du plancher, car
certains gaz sont plus lourds que l'air et
peuvent s'accmuler a niveau du sol.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
Do not touch any electric switch;
Do not use any phone in your building.
Immediately call your gas spplier from a neighbor's
phone. Follow the gas supplier's instructions.
If you cannot reach your gas supplier,
call the fire department.
QUE FAIRE S'IL Y A UNE ODEUR DE GAZ
Ne pas tenter d'allumer l'appariel.
Ne toucher aucun interrupteur electrique;
n'utiliser aucun telephone dans le batiment.
Appeler immediatement le fournisseur de gaz
en employant le telephone dun voisin.
Respecter a la lettre les instructions du
fournisseur de gaz.
Si personne ne repond, appeler le service des
incendies.
C. Ne pousser ou tourner la manette d'admission du gaz
qu'a la main; ne jamais emploer d'outil a cet effet.
Si la manette reste coincee, ne pas tenter de la
reparer; appeler un technicien qalifie. Quiconque
tente de forcer la manette ou de la reparer peut
declencher une explosion ou un incendie.
C. Use only your hand to push in or turn the gas control knob.
Never use tools. If the knob will not push in or turn by
hand, don't try to repair it, call a qualified service
technician. Force or attempted repair may result in a fire
or explosion.
D. Do not use this appliance if any part has been under water.
Immediately call a qualified service technician to inspect
the appliance and to replace any part of the control
system and any gas control which has been under water.
D. Ne pas se servir de cet appareil s'il a ete plonge
dans l'eau, completement ou en partie. Appeler un
technicien qualifie pour inspecter l'appareil et
remplacer tout partie du systeme de controle et
toute commande qui ont ete plonges dans l'eau.
MISE EN MARCHE
OPERATING INSTRUCTIONS
1. STOP! Read the safety information above on
this label.
2. Set the thermostat to lowest setting.
Gas Valve
On/Off
Control Knob
4. This appliance is equipped with an ignition
device which automatically lights the pilot.
Do not try to light the pilot by hand.
"OFF"position. Do not force.
6. Wait five (5) mintes to clear ot any gas. Then
smell for gas, including near the floor. If you
then smell gas, STOP! Follow "B" in the safety
information above on this label.
ROBINET A GAZ
If you don't smell gas, go to
MANUEL, EN POS
next step.
"ON/MARCHE"
7. Turn gas control knob
GAS
counterclockwise
to "ON".
INLET
8. Replace access panel.
9. Turn on all electrical
power to the appliance.
ARRIVEE
10. Set thermostat to desired setting.
DU GAZ
11. If the appliance will not operate,
MANUAL GAS
follow the instrctions "To Turn
KNOB SHOWN
Off Gas To Appliance" and call your
IN "ON" POS
service technician or gas company.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. Turn off all electrical power to the appliance
if service is to be performed.
3. Turn the gas control knob clockwise
to
"OFF" position. Do not force.
4. Replace control access panel.
1.
ARRETER!. Lisez les instrcutions de securite sur
la portion superleure de cette etiquette.
2. Regler le thermostat a la temperature la plus basse.
3. Couper l'alimentation electrique de l'appareil.
4. Cet appareil est muni d'un dispositif d'allumage qui
allume automatiquement la veilleuse. Ne pas tenter
d'allumer la veilleuse manuellement.
5. Torner le robinet a gaz dans le sens des aiguilles
en position "OFF/ARRET"
d'une montre
Ne pas forcer.
6. Attendre cinq (5) minutes pour laisser echapper tout le
gaz. Renifler tout autour de l'appareil, y compris pres du
plancher, pour deceler une odeur de gaz. Si c'est le cas,
ARRETER!. Passer a l'etape B des instructions de secuurite
sur la portion superieure de cette etiquette.
S'il n'y a pas d'odeur de gaz, passer a l'etape sulvante.
7. Tourner le robinet a gaz dans le sens inverse des
aiguilles d'une montre
en pos "ON/MARCHE".
8. Remettre en place le panneau d'acces.
9. Mettre l'appareil sous tension.
10. Regler le thermostat a la temperature desiree.
11. Si l'appareil ne se met pas en marche, suivre les
instrcutions intitulees Comment couper l'admission
de gaz de l'appareil et appeler un technicien
qualifie ou le fournisseur de gaz.
POUR COUPER L'ADMISSION
DE GAZ DE L'APPAREIL
1. Regler le thermostat a la temperature la plus basse.
2. Couper l'alimentation electrique de l'appareil s'il
faut proceder a des operations d'entretien.
3. Tourner le robinet a gaz dans le sens des aiguilles
d'une montre
en position "OFF/ARRET".
Ne pas forcer.
4. Remettre en place le panneau d'acces.
11072704
14
LIGHTING INSTRUCTIONS
LIRE AVANT DE METTRE
EN MARCHELIRE
AVERTISSEMENT: Quiconque ne respecte pas á
FOR YOUR SAFETY
READ BEFORE OPERATING
WARNING: If you do not follow these instructions
explosion may result causing property damage,
personal injury or loss of life.
la lettre les instructions dans le présent manuel
risque de déclecher un incendie ou une explosion
entraînant des dammages matériels, des lésions
corporelles ou la perte de vies humaines.
A. This appliance does not have a pilot. It is equipped
with an ignition device which automatically lights
the burner. Do not try to light the burner by hand.
A.
B. BEFORE OPERATING smell all around the appliance
area for gas. Be sure to smell next to the floor
because some gas is heavier than air and will
settle on the floor.
Cet appareil ne comporte pas de veilleuse. Il est
muni d'un dispositif d'allumage qui allume
automatiquement le brûleur. Ne pas tenter
d'allumer le brûleur manuellement.
B. AVANT DE LE FAIRE FONCTIONNER,
renifler tout autour de l'appariel pour déceler
une odeur de gaz. Renifler près du plancher, car
certains gaz sont plus lourds que l'air et
peuvent s'accumuler au niveau du so.l
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
Do not touch any electric switch;
do not use any phone in your building.
Immediately call your gas supplier from a neighbor's
phone. Follow the gas supplier's instructions.
If you cannot reach your gas supplier,
call the fire department.
QUE FAIRE S'IL Y A UNE ODEUR DE GAZ
Ne pas tenter d'allumer l'appariel
Ne toucher aucun interrupteur électrique;
n'utiliser aucun téléphone dans le bâtiment.
Appeler immédiatement le fournisseur de gaz
en employant le téléphone dún voisin.
Respecter à la lettre les instructions du
fournisseur de gaz.
Si personne ne répond, appeler le service des
incendies.
C. Ne pousser ou tourner le levier d'admission du gaz
qu'à la main; ne jamais emploer d'outil à cet effet.
Si la manette reste coincée, ne pas tenter de la
réparer; appeler un technicien qualifié. Quiconque
tente de forcer la manette ou de la reparer peut
déclencher une explosion ou un incendie.
C. Use only your hand to push in or turn the gas control lever.
Never use tools. If the lever will not push in or turn by
hand, don't try to repair it, call a qualified service
technician. Force or attempted repair may result in a fire
or explosion.
D. Do not use this appliance if any part has been underwater.
Immediately call a qualified service technician to inspect
the appliance and to replace any part of the control
system and any gas control which has been underwater.
D. Ne pas se servir de cet appareil s'il a été plongé
dans l'eau, complètement ou en partie. Appeler un
technicien qualifié pour inspecter l'appareil et
remplacer tout partie du système de contrôle et
toute commande qui ont été plongés dans l'eau.
MISE EN MARCHE
OPERATING INSTRUCTIONS
1. STOP! Read the safety information above on
this label.
2. Set the thermostat to lowest setting.
3. Turn off all power to the appliance.
4. This appliance is equipped with an ignition.
device which automatically lights the burner.
Do not try to light the burner by hand.
5. Push the gas control lever to "OFF" Position.
Do not force.
6. Wait five (5) minutes to clear out any gas. Then
smell for gas, including near the floor. If you
ROBINET A GAZ
then smell gas, STOP! Follow "B"
MANUEL, EN POS
in the safety. information above
"ON/MARCHE"
on this label if you don't smell
GAS
gas, go to next step.
INLET
7. Push gas control lever
to "ON".
8. Replace access panel.
ARRIVEE
9. Turn on all electric
DU GAZ
power to the appliance.
10.Set thermostat to desired setting.
MANUAL GAS
11.If the appliance will not operate,
LEVER SHOWN
follow the instructions "To Turn
IN ON POSITION
Off Gas To Appliance" and call your
service technician or gas company.
*
*
O
F
F
*
M
1
P
3
C
*
2
ON
*
*
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. Turn off all electric power to the appliance
if service is to be performed.
3. Push the gas control lever to "OFF" Position.
Do not force.
4. Replace control access panel.
*
1. ARRETÊR! Lisez les instructions de sécurité sur
la portion supérieure de cette étiquette.
2.
. Régler le thermostat à la température la plus basse
3. Couper l'alimentation électrique de l'appareil.
4. Cet appareil ménager étant doté d'un système
d'allumage automatique, ne pas essayer à
allumer le brûleur manuellement.
5. Pousse le levier du contrôle du gaz à "OFF/ ARRET"
position.
6. Attendre cinq (5) minutes pour laisser echapper tout le
gaz. Renifler tout autour de l'appareil, y compris près du
plancher, pour déceler une odeur de gaz. Si c'est le cas,
ARRETER! Passer à l'étape B des instructions de sécuritié
sur la portion supérieure de cette étiquette.
S'il n'y a pas d'odeur de gaz, passer à l'étape suivanté.
7. Pousse le levier du contrôle du gaz à "ON/MARCHE"
position.
8. Remettre en place le panneau d'accés.
9. Mettre l'appareil sous tension.
10. Régler le thermostat à la température desirée.
11. Si l'appareil ne se met pas en marche, suiyre les
instructions intitulées. Comment coupler l'admission
de gaz de l'appereil et appeler un technicien
qualifié ou le fourrnisseur de gaz.
POUR COUPER L'ADMISSION
DE GAZ DE L'APPAREIL
1. Régler le thermostat à la température la plus basse.
2. Couper l'alimentation électrique de l'appareil s'il
faut procéder à des opérations d'entretien.
3. Pousse le levier du contrôle du gaz à "OFF / ARRET"
position.
Ne pas forcer.
4. Remettre en place le panneau d'accès.
11072707
15
LIGHTING INSTRUCTIONS
IN
2
PSI
OFF
ON
ROBINET A GAZ
MANUEL, EN POS
"ON/MARCHE"
GAS
INLET
ARRIVEE
DU GAZ
MANUAL GAS
SWITCH SHOWN
IN "ON" POS
16
LIGHTING INSTRUCTIONS
FOR YOUR SAFETY
READ BEFORE OPERATING
WARNING: If you do not follow these instructions
explosion may result causing property damage,
personal injury or loss of life.
LIRE AVANT DE METTRE
EN MARCHELIRE
AVERTISSEMENT: Quiconque ne respecte pas á
la lettre les instructions dans le présent manuel
risque de déclecher un incendie ou une explosion
entraînant des dammages matériels, des lésions
corporelles ou la perte de vies humaines.
A. This appliance does not have a pilot. It is equipped
with an ignition device which automatically lights
the burner. Do not try to light the burner by hand.
A.
B. BEFORE OPERATING smell all around the appliance
area for gas. Be sure to smell next to the floor
because some gas is heavier than air and will
settle on the floor.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
Do not touch any electric switch;
do not use any phone in your building.
Immediately call your gas supplier from a neighbor's
phone. Follow the gas supplier's instructions.
If you cannot reach your gas supplier,
call the fire department.
C. Use only your hand to push in or turn the gas control lever.
Never use tools. If the lever will not push in or turn by
hand, don't try to repair it, call a qualified service
technician. Force or attempted repair may result in a fire
or explosion.
D. Do not use this appliance if any part has been underwater.
Immediately call a qualified service technician to inspect
the appliance and to replace any part of the control
system and any gas control which has been underwater.
Cet appareil ne comporte pas de veilleuse. Il est
muni d'un dispositif d'allumage qui allume
automatiquement le brûleur. Ne pas tenter
d'allumer le brûleur manuellement.
B. AVANT DE LE FAIRE FONCTIONNER,
renifler tout autour de l'appariel pour déceler
une odeur de gaz. Renifler près du plancher, car
certains gaz sont plus lourds que l'air et
peuvent s'accumuler au niveau du so.l
QUE FAIRE S'IL Y A UNE ODEUR DE GAZ
Ne pas tenter d'allumer l'appariel
Ne toucher aucun interrupteur électrique;
n'utiliser aucun téléphone dans le bâtiment.
Appeler immédiatement le fournisseur de gaz
en employant le téléphone dún voisin.
Respecter à la lettre les instructions du
fournisseur de gaz.
Si personne ne répond, appeler le service des
incendies.
C. Ne pousser ou tourner le levier d'admission du gaz
qu'à la main; ne jamais emploer d'outil à cet effet.
Si la manette reste coincée, ne pas tenter de la
réparer; appeler un technicien qualifié. Quiconque
tente de forcer la manette ou de la reparer peut
déclencher une explosion ou un incendie.
D. Ne pas se servir de cet appareil s'il a été plongé
dans l'eau, complètement ou en partie. Appeler un
technicien qualifié pour inspecter l'appareil et
remplacer tout partie du système de contrôle et
toute commande qui ont été plongés dans l'eau.
MISE EN MARCHE
OPERATING INSTRUCTIONS
1. STOP! Read the safety information above on
this label.
2. Set the thermostat to lowest setting.
3. Turn off all power to the appliance.
4. This appliance is equipped with an ignition.
device which automatically lights the burner.
Do not try to light the burner by hand.
5. Push the gas control lever to "OFF" Position.
Do not force.
6. Wait five (5) minutes to clear out any gas. Then
smell for gas, including near the floor. If you
then smell gas, STOP! Follow "B"
in the safety. information above
on this label if you don't smell
gas, go to next step.
GAS
7. Push gas control lever
INLET
to "ON".
8. Replace access panel.
9. Turn on all electric
ARRIVEE
DU GAZ
power to the appliance.
10.Set thermostat to desired setting.
11.If the appliance will not operate,
follow the instructions "To Turn
Off Gas To Appliance" and call your
service technician or gas company.
ROBINET A GAZ
MANUEL, EN POS
"ON/MARCHE"
MANUAL GAS
LEVER SHOWN
IN ON POSITION
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. Turn off all electric power to the appliance
if service is to be performed.
3. Push the gas control lever to "OFF" Position.
Do not force.
4. Replace control access panel.
1. ARRETÊR! Lisez les instructions de sécurité sur
la portion supérieure de cette étiquette.
2.
. Régler le thermostat à la température la plus basse
3. Couper l'alimentation électrique de l'appareil.
4. Cet appareil ménager étant doté d'un système
d'allumage automatique, ne pas essayer à
allumer le brûleur manuellement.
5. Pousse le levier du contrôle du gaz à "OFF/ ARRET"
position.
6. Attendre cinq (5) minutes pour laisser echapper tout le
gaz. Renifler tout autour de l'appareil, y compris près du
plancher, pour déceler une odeur de gaz. Si c'est le cas,
ARRETER! Passer à l'étape B des instructions de sécuritié
sur la portion supérieure de cette étiquette.
S'il n'y a pas d'odeur de gaz, passer à l'étape suivanté.
7. Pousse le levier du contrôle du gaz à "ON/MARCHE"
position.
8. Remettre en place le panneau d'accés.
9. Mettre l'appareil sous tension.
10. Régler le thermostat à la température desirée.
11. Si l'appareil ne se met pas en marche, suiyre les
instructions intitulées. Comment coupler l'admission
de gaz de l'appereil et appeler un technicien
qualifié ou le fourrnisseur de gaz.
POUR COUPER L'ADMISSION
DE GAZ DE L'APPAREIL
1. Régler le thermostat à la température la plus basse.
2. Couper l'alimentation électrique de l'appareil s'il
faut procéder à des opérations d'entretien.
3. Pousse le levier du contrôle du gaz à "OFF / ARRET"
position.
Ne pas forcer.
4. Remettre en place le panneau d'accès.
11072 712
17
LIGHTING INSTRUCTIONS
ROBINET A GAZ
MANUEL, EN POS
"ON/MARC HE"
ON
*
ARRIVEE
DU GAZ
**
*
OFF
GAS
INLET
*
*
MANUAL GAS
LEVER SHOWN
IN "ON" POS
18
*
PRODUCT DESIGN
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
36" Side
Clearance
for Servicing
Recommended
24" Clearance
(Condenser End)
CABLE SLIDE.
36"
Maximum
Overhang
48" Minimum
Overhang
IMPORTANT: If using bottom discharge with roof curb,
ductwork should be attached to the curb prior to installing
the unit.
Vinyl Coated
Canvas
Connections
Insulated
Return
Duct
Minimum 9" Clearance
to Combustibles
36" Clearance for
Service Required
0" Minimum
Clearance to
Combustibles
Insulated
Supply
Duct
Refer to Roof curb Installation Instructions for proper curb
installation. Curbing must be installed in compliance with
the National Roofing Contractors Association Manual.
Lower unit carefully onto roof mounting curb. While rigging
unit, center of gravity will cause condenser end to be lower
than supply air end.
Amana® brand Package Units are designed for outdoor installations only in either residential or light commercial apIn installations where the unit is installed above ground level and plications.
not serviceable from the ground (Example: Roof Top installaThe connecting ductwork (Supply and Return) can be contions) the installer must provide a service platform for the
nected for either horizontal or down discharge airflow.
service person with rails or guards in accordance with local
140,000 BTU PGB gas package units and PHB60C packcodes or ordinances or in their absence with the latest edition
age units are not recommended for down discharge airflow
of the National Fuel Gas Code ANSIZ223.1.
applications. In the down discharge applications a matchNOTE: The flue outlet hood and air inlet hood (Package Gas Units) are ing Roof Curb is recommended
packaged separately inside the unit and must be installed prior to operation.
A return air filter must be installed behind the return air
grille(s) or provision must be made for a filter in an accessible location within the return air duct. The minimum filter
area should not be less than those sizes listed in the Specification Section. Under no circumstances should the unit
be operated without return air filters.
A 3/4" tube is provided for removal of condensate water
from the indoor coil. In order to provide proper condensate
flow, a drain trap is built into the unit. (Do not reduce the
drain line size).
Refrigerant flow control is achieved by use of restrictor orifices or thermostatic expansion valves (TXV)
Package Heat Pump models use a combination of restrictor
orifices and thermostatic expansion valves for refrigerant
flow control.
Some heat pump models also have a suction line accumulator installed between the reversing valve and the compressor. The object of the accumulator is to:
1. Provide a liquid refrigerant storage vessel during prolonged system off cycles.
2. Store excess liquid refrigerant not needed by the system while running.
NOTE: Units can also use roof curb (and platform for leveling, where
necessary) to utilize bottom discharge.
3. Return oil and saturated vapor to the compressor at a
controlled rate .
4. Retain stored excess refrigerant during a sudden system pressure fluctuation such as seen in defrost cycles.
19
PRODUCT DESIGN
The single phase units use permanent split capacitors (PSC)
design compressors. Starting components are therefore not
required. A low MFD run capacitor assists the compressor
to start and remains in the circuit during operation.
The outdoor fan and indoor blower motors are single phase
capacitor type motors.
Air for condensing (cooling cycle) or evaporation (heating
cycle) is drawn through the outdoor coil by a propeller fan,
and is discharged vertically out the top of the unit. The outdoor coil is designed for .0 static. No additional restriction
(ductwork) shall be applied.
Conditioned air is drawn through the filter(s), field installed,
across the coil and back into the conditioned space by the
indoor blower.
Package Heat Pump indoor sections are designed to accept
optional components such as auxiliary electric heaters and
circuit breakers. Provisions for these components have been
made at time of manufacture.
Some models of package units use the Compliant Scroll compressor, there are a number of design characteristics which
are different from the traditional reciprocating compressor.
-
-
-
Due to their design Scroll compressors are inherently more
tolerant of liquid refrigerant. NOTE: Even though the compressor section of a Scroll compressor is more tolerant
of liquid refrigerant, continued floodback or flooded start
conditions may wash oil from the bearing surfaces causing premature bearing failure.
These Scroll compressors use white oil which is compatible with 3GS. 3GS oil may be used if additional oil is
required.
Phase 1 Scroll compressors (ZR**K1 or ZR**K2), the compressor may run backwards (noisy operation) for 1 or 2
seconds at shutdown. This is normal and does not harm
the compressor.
-
Phase 2 Scroll compressors (ZR**K3). On shutdown, the
scroll flanks will separate allowing the compressor to
equalize internally within 0.4 seconds after shutdown.
-
Operating pressures and amp draws may differ from standard reciprocating compressors. This information may
be found in the "Cooling Performance Data" section.
The scroll is a simple compression concept first patented in
1905. A scroll is an involute spiral which, when matched
with a mating scroll form as shown (next page), 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.
20
As this motion occurs, the pockets between the two forms
are slowly pushed to the center of the two scrolls while simultaneously being reduced in volume. When the pocket
reaches the center of the scroll form, the gas, which is now
at a high pressure, is discharged out of a port located at the
center.
During compression, several pockets are being compressed
simultaneously, resulting in a very smooth process. Both
the suction process (outer portion of the scroll members)
and the discharge process (inner portion) are continuous.
ELECTRICAL WIRING
WARNING
T O AVOID THE
RISK OF ELECTRICAL SHOCK, WIRING TO THE UNIT MUST BE
PROPERLY POLARIZED AND GROUNDED.
WARNING
HIGH VOLTAGE
T O AVOID ELECTRICAL SHOCK, INJURY OR DEATH,
DISCONNECT ALL ELECTRICAL POWER BEFORE
CHANGING ANY ELECTRICAL WIRING TO THIS UNIT.
The units are designed for operation on 60 hertz current and
at voltages as shown on the rating plate. All internal wiring in
the unit is complete. It is necessary to bring in the power
supply to the pigtails or power block, which is located in the
junction box or circuit breaker box assembly (or compressor
contactor on package gas units) , as shown on the unit wiring diagram which is supplied with the unit. The 24V wiring
must be connected between the unit control panel and the
room thermostat.
LINE VOLTAGE WIRING
Power supply to the furnace must be N.E.C. Class 1, and
must comply with all applicable codes. The furnace must be
electrically grounded in accordance with the local codes or,
in their absence, with the latest edition of the National Electrical Code, ANSI/NFPA No. 70, or in Canada, Canadian Electrical Code, C22.1, Part 1. A fused disconnected must be
provided and sized in accordance with the unit minimum circuit ampacity.
PRODUCT DESIGN
The best protection for the wiring is the smallest fuse or breaker
which will hold the equipment on line during normal operation
without nuisance trips. Such a device will provide maximum
circuit protection.
DO NOT EXCEED THE MAXIMUM OVERCURRENT DEVICE
SIZE SHOWN ON THE UNIT DATA PLATE.
All line voltage connections must be made through weather
proof fittings. All exterior power supply and ground wiring
must be in approved weather proof conduit. Low voltage wiring from the unit control panel to the thermostat requires coded
cable. Unit knock out sizes are shown in the specification
tables.
The unit transformer is connected for 230V operation. If the
unit is to operate on 208V, reconnect the transformer primary lead and the induced draft blower leads as shown on
the unit wiring diagram.
WARNING
T O AVOID
GAS PIPING
CAUTION
TO AVOID POSSIBLE UNSATISFACTORY OPERATION OR EQUIPMENT DAMAGE
DUE TO UNDERFIRING OF EQUIPMENT, DO NOT UNDERSIZE THE NATURAL
GAS/PROPANE PIPING FROM THE METER/TANK TO THE FURNACE.
LINE THAT COULD BE OPERATED SIMULTANEOUSLY.
The gas pipe supplying the furnace must be properly sized
based on the cubic feet per hour of gas flow required, specific
gravity of the gas and length of the run. The gas line installation must comply with local codes, or in the absence of local
codes, with the latest edition of the National Fuel Gas Code
ANSI Z223.1.
NATURAL GAS CAPACITY OF PIPE IN CUBIC FEET OF
GAS PER HOUR (CFH)
LENGTH OF
PIPE IN FEET
THE RISK OF FIRE, PROPERTY DAMAGE OR PERSONAL INJURY,
USE ONLY COPPER CONDUCTORS.
If it is necessary for the installer to supply additional line
voltage wiring to the inside of the package unit, the wiring
must comply with all local codes. This wiring must have a
minimum temperature rating of 105°C. and must be routed
away from the burner compartment. All line voltage splices
must be made inside the furnace junction box.
GAS SUPPLY AND PIPING
10
20
30
40
50
60
70
80
90
100
NOMINAL BLACK PIPE SIZE
1/2"
132
92
73
63
56
50
46
43
40
38
3/4"
278
190
152
130
115
105
96
90
84
79
1"
520
350
285
245
215
195
180
170
160
150
1 1/4"
1050
730
590
500
440
400
370
350
320
305
1 1/2"
1600
1100
980
760
670
610
560
530
490
460
BTUH FURNACE INPUT
CFH = CALORIFIC VALUE OF GAS
Package Gas Units
CAUTION
THIS PACKAGE GAS UNIT
WHEN
SIZING A TRUNK LINE PER THE TABLES, INCLUDE ALL APPLIANCES ON THAT
IS FACTORY SET TO OPERATE ON NATURAL
GAS AT THE ALTITUDES SHOWN ON THE RAITNG PLATE. IF OPERATION ON
PROPANE IS REQUIRED, OBTAIN AND INSTALL THE PROPER CONVERSION
KIT(S) BEFORE OPERATING THIS FURNACE.
FAILURE TO DO SO MAY RESULT
IN UNSATISFACTORY OPERATION AND/OR EQUIPMENT DAMAGE.
The rating plate is stamped with the model number, type of
gas, and gas input rating. Make sure the furnace is equipped
to operate on the type of gas available.
INLET GAS PRESSURE
NATURAL
MIN. 5.0", MAX. 10.0"
PROPANE
MIN. 11.0", MAX. 14.0"
Inlet Gas Pressure Must Not Exceed the Maximum Value
Shown in the table Above.
The minimum supply pressure must not be varied downward
because this could lead to unreliable ignition. In addition,
gas input to the burners must not exceed the rated input
shown on the rating plate. Overfiring of the furnace could
result in premature heat exchanger failure.
CONNECTING THE GAS PIPING - NATURAL GAS
Refer to the figure 1 for the general layout of the furnace. The
following rules apply:
1. Use black iron or steel pipe and fittings for the building
piping.
2. Use pipe joint compound on male threads only. Pipe
joint compound must be resistant to the action of the fuel
used.
3. Use ground joint unions.
4. Install a drip leg to trap dirt and moisture before it can
enter the gas valve. The drip leg must be a minimum of
three inches long.
5. Use two pipe wrenches when making connection to the
gas valve to keep it from turning.
6. Install a manual shut off valve. This shut off valve should
be conveniently located within six (6) feet of the unit, and
between the meter and unit.
7. Tighten all joints securely.
21
PRODUCT DESIGN
8.
The furnace shall be connected to the building piping by
one of the following.
a.
Rigid metallic pipe and fittings.
b.
Semirigid metallic tubing and metallic fittings. Aluminum alloy tubing shall not be used in exterior
locations.
c.
Listed gas appliance connectors used in accordance with the terms of their listing that are completely in the same room as the equipment.
d.
In "b" and "c" above, the connector or tubing shall
be installed so as to be protected against physical and thermal damage. Aluminum-alloy tubing
and connectors shall be coated to protect against
external corrosion where they are in contact with
masonry, plaster, or insulation or are subject to
repeated wettings by such liquids as water (except rain water), detergents, or sewage.
TANKS AND PIPING - PROPANE UNITS
All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters (See NBFU
Manual 58) or Natural Standards of Canada B149.2, Installation Code for Propane Gas Burning Appliances and Equipment.
For satisfactory operation, propane gas pressure must be 10
inch W.C. at the furnace manifold with all gas appliances in
operation. Maintaining proper gas pressure depends on three
main factors.
1. Vaporization rate, which depends on (a) temperature of
the liquid, and (b) "wetted surface" area of the container
or containers.
2. Proper pressure regulation. (Two-stage regulation is recommended from the standpoint of both cost and efficiency.)
3. Pressure drop in lines between regulators, and between
second stage regulator and the appliance. Pipe size required will depend on length of pipe run and total load of
all appliances.
Figure 1
CHECKING THE GAS PIPING
CAUTION
TO
AVOID THE POSSIBILITY OF PROPERTY DAMAGE, PERSONAL INJURY OR
FIRE, THE FOLLOWING INSTRUCTIONS MUST BE PERFORMED REGARDING
GAS CONNECTIONS AND PRESSURE TESTING.
The unit and its gas connections must be leak tested before
placing in operation. Because of the danger of explosion or
fire, never use a match or open flame to test for leaks. Never
exceed specified pressure for testing. Higher pressure may
damage the gas valve and cause overfiring which may result
in heat exchanger failure.
This unit and its individual shutoff valve must be disconnected
from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psig
(3.48 kPa).
This unit must be isolated from the gas supply system by
closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psig (3.48 kPa).
22
Complete information regarding tank sizing for vaporization,
recommended regulator settings, and pipe sizing is available
from most regulator manufacturers and propane gas suppliers.
Propane is an excellent solvent, and special pipe dope must
be used when assembling piping for this gas as it will quickly
dissolve white lead or most standard commercial compounds.
Shellac base compounds resistant to the actions of liquefied
petroleum gases such as Gasolac, Stalactic, Clyde's or John
Crane are satisfactory.
Refer to Figure 2 for typical propane gas installations.
PRODUCT DESIGN
TYPICAL PROPANE PIPING
Sizing Between Single or Second Stage Regulator and Appliance
Maximum Propane Capacities listed are based on 1/2" W.C. Pressure
5 to 15 PSIG
(20 PSIG Max.)
First Stage
Regulator
200 PSIG
Maximum
Drop at 11" W.C. Setting. Capacities in 1000 BTU/HR
Continuous
11" W.C.
PIPE OR
TUBING
TUBING SIZE, O.D., TYPE L
NOMINAL PIPE SIZE, SCH 40
LENGTH
FEET
3/8" 1/2" 5/8" 3/4" 7/8" 1 7/8" 1/2" 3/4"
1" 1 1/4" 1 1/2"
Second Stage
Regulator
Figure 2
WARNING
IF
YOUR PROPANE GAS FURNACE IS INSTALLED IN A BASEMENT, AN
EXCAVATED AREA OR A CONFINED SPACE, WE STRONGLY RECOMMEND
10
39
92
199
329
501
935
275
567 1071 2205 3307
20
26
62
131
216
346
630
189
393
732
1496 2299
30
21
50
107
181
277
500
152
315
590
1212 1858
40
19
41
90
145
233
427
129
267
504
1039 1559
50
18
37
79
131
198
376
114
237
448
913
1417
60
16
35
72
121
187
340
103
217
409
834
1275
80
13
29
62
104
155
289
89
185
346
724
1086
100
11
26
55
90
138
255
78
162
307
630
976
125
10
24
48
81
122
224
69
146
275
567
866
150
9
21
43
72
109
202
63
132
252
511
787
200
250
8
8
19
17
39
36
66
60
100
93
187
172
54
48
112
100
209
185
439
390
665
590
*DATA IN ACCORDANCE WITH NFPA PAMPHLET NO. 54
PROPANE TANK SIZING (MINIMUM)
THAT YOU CONTACT YOUR PROPANE SUPPLIER ABOUT INSTALLING A
WARNING DEVICE THAT WOULD ALERT YOU TO A GAS LEAK.
TANK SIZE REQUIRED IF LOWEST OUTDOOR
...... Propane gas is heavier than air and any leaking
gas can settle in any low areas or confined spaces.
...... Propane gas odorant may fade, making the gas
undetectable except with a warning device.
An undetected gas leak would create a danger of explosion or fire. If you suspect the presence of gas, follow the instructions on Page 13. Failure to do so could
result in SERIOUS PERSONAL INJURY OR DEATH.
PROPANE GAS PIPING CHARTS
MAXIMUM GAS
NEEDED TO
VAPORIZE*
125K BTU/HR
(50 CFH)
TEMPERATURE (AVG. FOR 24 HOURS) REACHES
32°F
115
GAL
20°F
115
GAL
10°F
115
GAL
0°F
250
GAL
-10°F
250
GAL
-20°F
400
GAL
-30°F
600
GAL
250K BTU/HR
(100 CFH)
250
GAL
250
GAL
250
GAL
400
GAL
500
GAL
1000
GAL
1500
GAL
375K BTU/HR
(150 CFH)
300
GAL
400
GAL
500
GAL
500
GAL
1000
GAL
1500
GAL
2500
GAL
500K BTU/HR
(200 CFH)
400
GAL
500
GAL
750
GAL
1000
GAL
1500
GAL
2000
GAL
3500
GAL
750K BTU/HR
(300 CFH)
750
GAL
1000
GAL
1500
GAL
2000
GAL
2500
GAL
4000
GAL
5000
GAL
* AVERAGE RATE/HOUR WITHDRAWL IN 8 HOUR PERIOD
Sizing Between First and Second Stage Regulator
Maximum Propane Capacities listed are based on 2 PSIG Pressure
Drop at 10 PSIG Setting. Capacities in 1000 BTU/HR
PIPE OR
TUBING
LENGTH,
FEET
10
20
30
40
50
60
80
100
125
150
175
200
NOMINAL PIPE
SIZE, SCH 40
TUBING SIZE, O.D., TYPE L
3/8"
730
500
400
370
330
300
260
220
200
190
170
160
1/2"
1700
1100
920
850
770
700
610
540
490
430
400
380
5/8"
3200
2200
2000
1700
1500
1300
1200
1000
900
830
780
730
3/4"
5300
3700
2900
2700
2400
2200
1900
1700
1400
1300
1200
1100
7/8"
8300
5800
4700
4100
3700
3300
2900
2600
2300
2100
1900
1800
1/2"
3200
2200
1800
1600
1500
1300
1200
1000
900
830
770
720
3/4"
7500
4200
4000
3700
3400
3100
2600
2300
2100
1900
1700
1500
To Convert to Capacities at 15 PSIG Settings -- Multiply by 1.130
To Convert to Capacities at 5 PSIG Settings -- Multiply by 0.879
23
SYSTEM OPERATION
COOLING
The refrigerant used in the system is R-22. It is clear, colorless, non-toxic, non-irritating, and non-explosive liquid. The
chemical formula is CHCLF2. The boiling point, at atmospheric
pressure is -41.4°F.
A few of the important principles that make the refrigeration
cycle possible are: heat always flows from a warmer to a
cooler body, under lower pressure a refrigerant will absorb
heat and vaporize at a low temperature, the vapors may be
drawn off and condensed at a higher pressure and temperature to be used again.
The indoor evaporator coil functions to cool and dehumidify
the air through the evaporative process taking place within
the coil tubes.
NOTE: The pressures and temperatures shown are for demonstration purposes only. Actual temperatures and pressures are to be obtained from the "Cooling Performance
Chart."
High temperature, high pressure vapor leaves the compressor through the discharge line, through the reversing valve on
heat pump models, and enters the condenser coil. Air drawn
through the condenser coil by the condenser fan causes the
refrigerant to condense into a liquid by removing heat from
the refrigerant. As the refrigerant is cooled below its condensing temperature it becomes subcooled.
The subcooled high pressure liquid refrigerant now leaves the
condenser coil via the liquid line until it reaches the indoor
expansion device. (Heat pump models will also have an outdoor expansion valve/check valve assembly or a restrictor
orifice installed in the liquid line).
As the refrigerant passes through the expansion device and
into the evaporator coil a pressure drop is experienced causing the refrigerant to become a low pressure vapor. Low pressure saturated refrigerant enters the evaporator coil where
heat is absorbed from the warm air drawn across the coil by
the evaporator blower. As the refrigerant passes through the
last tubes of the evaporator coil it becomes superheated,
that is, it absorbs more heat than is necessary for the refrigerant to vaporize. Maintaining proper superheat assures that
liquid refrigerant is not returning to the compressor which
can lead to early compressor failure.
Low pressure superheated vapor leaves the evaporator coil
and returns through the suction line to the compressor where
the cycle begins again. On heat pump models the refrigerant must travel through the reversing valve and accumulator
before returning to the compressor.
HEATING - Heat Pump Models
The heating portion of the refrigeration cycle is similar to the
cooling cycle. The reversing valve reverses the flow of the
refrigerant. The indoor coil now becomes the condenser coil
and the outdoor coil becomes the evaporator coil. The reversing valve is energized in the cooling mode not in the heating
mode as some previous models were.
24
The restrictor orifice or check valve at the indoor coil will open
by the flow of refrigerant letting the now condensed liquid
refrigerant bypass the indoor expansion device. The orifice
or check valve at the outdoor coil will be forced closed by the
refrigerant flow, thereby utilizing the outdoor expansion device.
COOLING CYCLE
All Models
When the contacts of the room thermostat close making terminals R to Y & to G, on the control board. Heat pumps
thermostat make the R to O terminals also.
The control board recognizes this as a demand for cooling
and energizes the compressor contactor and indoor blower
motor. The blower delay is an integral part of the control board.
When the thermostat is satisfied, it opens its contacts, breaking the low voltage circuit, causing the compressor contactor
to open and indoor fan to stop after a 30 second delay.
If the room thermostat fan selector switch should be set to
the "on" position then the indoor blower would run continuous rather than cycling with the compressor.
HEATING CYCLE
Package Heat Pumps
When the thermostat calls for heat, making terminals R to Y,
the low voltage circuit of the transformer is completed. The
control board applies power to the contactor starting the compressor and outdoor fan motor. This also energizes the indoor blower relay (control board) through the room thermostat, starting the indoor blower motor.
When auxiliary electric heaters are used, a two stage heating single stage cooling thermostat would be installed.
Should the second stage heating contacts in the room thermostat close, which would be wired to W at the unit control
board, this would energize the coil of the electric heat relay(s).
Contacts within the relay(s) will close, bringing on the resistance heaters.
If electric heaters should be used, they may be controlled by
outdoor thermostats. (ATK01)
NOTE: Refer to the specifications section for the maximum
heaters that may be installed for a specific unit.
DEFROST CYCLE
Package Heat Pumps
The defrosting of the outdoor coil is jointly controlled by the
defrost control board, defrost (30/60) control and compressor
run time.
Solid State Timer
The defrost timer board can be connected for one of three (3)
time intervals. 30 minutes, 60 minutes, and 90 minutes (Factory connected @ 60 min.). Package heat pumps manufactured after May 1999 (9905 Serial date code) will be factory
set @ 30 min.
SYSTEM OPERATION
Typical Package Cooling or Package Gas
Indoor
Coil
Outdoor
Coil
Thermostatic
Expansion
Valve
Either a thermostatic expansion valve or restrictor orifice assy
may be used depending on model, refer to the parts catalog
for the model being serviced.
Expansion Valve/Check Valve Assy in Cooling Operation
Chatleff
Orifice
Assy
Expansion Valve/Check Valve Assy in Heating Operation
Most expansion valves used in current Amana® brand Heat Pump products use an internally checked expansion valve. This
type of expansion valve does not require an external check valve as shown above.
Restrictor Orifice Assy in Cooling Operation
Restrictor Orifice Assy in Heating 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.
In the heating mode the orifice moves back off its seat allowing refrigerant to flow unmetered around the outside of the
orifice.
25
SYSTEM OPERATION
Typical Heat Pump System in Cooling
Reversing Valve
(Energized)
Indoor
Coil
Outdoor
Coil
Accumulator
Expansion device may not be as
shown. Refer to product parts
manual for actual part description.
Thermostatic
Expansion
Valve
Check Valve
Typical Heat Pump System in Heating
Reversing Valve
(De-Energized)
Indoor
Coil
Outdoor
Coil
Accumulator
Expansion device may not be as
shown. Refer to product parts
manual for actual part description.
26
Thermostatic
Expansion
Valve
Check Valve
SYSTEM OPERATION
The timing interval can not begin until the outdoor coil temperature reaches approximately 30°F. (initiation temperature)
at the defrost (30/60) control point of contact. As long as
this point of contact does not reach 60°F. (termination temperature) the defrost timer board will count the number of
minutes that the compressor runs.
The system may be controlled by most good heating and
cooling thermostats with an adjustable heat anticipator. Some
night setback thermostats that do not have a common terminal, use a power robbing circuit in the off cycle to maintain
the batteries. This type of thermostat may interfere with the
operation of the ignition control and should not be used.
At the end of this (one of three) time interval, the defrost
board will call for defrost and enter the defrost mode. In this
mode the control board will energize the reversing relay, deenergize the outdoor fan motor and energize the supplemental electric heat relay (if installed). When this occurs, the
outdoor fan motor stops and the reversing valve changes to
the cooling position sending hot refrigerant gas to the outdoor coil, which will melt any frost accumulation.
Direct Spark Ignition (DSI) Systems
Amana® brand PGA__C, PGB__C and PGD__C units built
after July, 1999, are equipped with a direct spark ignition
system. Ignition is provided by 20,000 volt electronic spark.
A flame sensor then monitors for the presence of flame and
closes the gas valve if flame is lost.
The defrost control board will stay in the defrost mode until
the outdoor coil temperature reaches approximately 60°F. at
the point of contact with the defrost (30/60 control or a maximum of 10 minutes compressor run time.
If the defrost cycle is terminated by temperature, then a new
time interval count can not begin until the defrost (30/60) control
again reaches approximately 30°F. at the point of contact. If
the defrost cycle was terminated by time, then a new time
interval could would begin immediately.
HEATING CYCLE
The system may be controlled by most good heating and
cooling thermostats with an adjustable heat anticipator. Some
night setback thermostats that do not have a common terminal, use a power robbing circuit in the off cycle to maintain
the batteries. This type of thermostat may interfere with the
operation of the ignition control module and should not be
used.
HEATING SEQUENCE (Smart Valve and DSI Systems)
In order to illustrate the heating sequence, the following has
been simplified to give a better understanding of the pressure
switch operation.
Package Gas Units
The heating cycle is accomplished by using a unique tubular
design heat exchanger which provides efficient gas heating
on either natural gas or propane gas fuels. The heat exchangers compact tubular construction provides excellent
heat transfer for maximum operating efficiency.
Inshot type gas burners with integral cross lighters are used
eliminating the need for adjustable air shutters. The same
burner is designed for use on either natural or propane gas
fuels.
The Induced Draft blower draws fuel and combustion air into
the burners and heat exchanger for proper combustion. A
pressure switch is used in conjunction with the I. D. blower
to detect a blocked flue condition.
Blower operation is controlled by the ignition control module.
The module provides for field adjustment of the blower delay
at the end of the heating cycle. The range of adjustment is for
60, 90, 120, or 180 seconds. The factory delay setting is 30
seconds delay on, 120 seconds delay off.
Honeywell Smart Valve Systems
Ignition is provided by an electronic ignition control and ceramic glow bar or direct spark ignitor which heats to approximately 2500°F. A flame sensor then monitors for the presence of flame and closes the gas valve if flame is lost.
Pressure Tap
Figure 8
Figure 8 is a view of the induced draft blower showing the
location of the pressure tap. The induced draft blower is
mounted on the collector box, the Heat Exchanger terminates into the collector box.
The pressure tap has a predetermined orifice size for reading
static pressures. The induced draft blower motor assembly
is mounted to the collector box. When the motor is in operation, a negative pressure will be created on the pressure tap,
collector box and heat exchanger flue passages.
A pressure control using a single pole, single throw electrical
switch is used as a safety device in case of a blocked flue.
27
SYSTEM OPERATION
Figure 9 illustrates the pressure control in an off position.
NEGATIVE PRESSURE
CONNECTOR
NORMALLY OPEN
TERMINAL
OFF
COMMON
TERMINAL
ON
Figure 9
With the furnace in the off position the induced draft blower
motor will not be running. Atmospheric pressure will therefore be on both sides of the diaphragm and the electrical
switch will be open between (C) common and (NO) normally
open terminals.
When the induced draft blower motor is in operation, the Jtube hose will create a negative pressure on one side of the
diaphragm and atmospheric pressure will be on the other
side causing the diaphragm to move toward the negative pressure.
Figure 10
7. Wait five minutes to clear out any gas.
8. Smell for gas, including near the ground. This is important because some types of gas are heavier than air. If
you have waited five minutes and you do smell gas, immediately follow the instructions on the Page 13 of this
manual. If having waited for five minutes and no gas is
smell is noted, turn the gas control valve knob to the ON
position.
9. Replace the heat exchanger door on the side of the unit.
This in turn will close the switch and make the (C) common
to the (NO) normally open terminals.
10. Open the manual gas valve external to the unit.
In the event of partially restricted or blocked flue the induced
draft blower will create less negative pressure and at approximately -0.32" +.06 W.C. negative pressure would open the
contacts (C) to (NO).
12. Set the thermostat to desired setting.
OPERATING INSTRUCTIONS
1. Close the manual gas valve external to the unit.
2. Turn off the electrical power supply to the unit.
3. Set the room thermostat to its lowest possible setting.
4. Remove the heat exchanger door on the side of the unit
by removing screws.
5. This unit is equipped with an ignition device which automatically lights the pilot. DO NOT try to light burner by
any other method.
6. Turn the gas control valve knob to the OFF position. Do
not force. Some Gas valves may have a different off/on
style switch.
28
11. Turn on the electrical power supply to the unit.
NOTE: There is approximate 20 second delay between thermostat energizing and burner firing.
FAN OPERATION
Continuous Fan Mode
If the thermostat calls for continuous fan without a call for
heat or cool, the indoor blower will be energized at the heat
speed after a 7 second on delay. The fan remains energized
as long as there is not a call for heat or cool. Once the call
for continuous fan is de-energized, the indoor blower will go
through a 30 second off delay.
If a call for cool occurs during continuous fan operation, the
blower will switch to the cooling speed after the 7 second
cool on delay.
If a call for heat occurs during continuous fan operation, the
indoor blower will de-energize when the heat on blower delay
begins. The heat cycle will control the indoor blower operation until the heat blower off delay is over. The continuous
fan mode will function normally even while the control is in
heat lockout.
SYSTEM OPERATION
ELECTRIC HEATERS
Optional electric heaters may be added, in the quantities
shown in the specifications section to provide electric resistance heating. Under no condition shall more heaters than
the quantity shown be installed.
The low voltage circuit in the blower section is factory wired
and terminates at the location provided for the electric
heater(s). A minimum of field wiring is required to complete
the installation.
Other components such as a Heating/Cooling Thermostat,
Outdoor Thermostat, and Compressor sound blankets are
available to complete the installation.
The system CFM can be determined by measuring the static
pressure external to the unit. The installation manual supplied with the unit shows the CFM for the static measured.
Alternately, the system CFM can be determined by operating the electric heaters and indoor blower WITHOUT having
the compressor in operation. Measure the temperature rise
as close to the blower inlet and outlet as possible.
If other than a 240V power supply is used, refer to the BTUH
CAPACITY CORRECTION FACTOR chart below.
EXAMPLE: Five (5) heaters provide 24.0 KW at the rated
240V. Our actual measured voltage is 220V, and our measured temperature rise is 42°F. Find the actual CFM:
TEMPERATURE RISE (F°) @ 240V
C FM
4.8
K.W.
7.2
K.W.
9.6
K.W.
14.4
K.W.
19.2
K.W.
24.0
K.W.
28.8
K.W.
600
25
38
51
-
-
-
-
700
22
33
43
-
-
-
-
800
19
29
38
57
-
-
-
900
17
26
34
51
-
-
-
1000
15
23
30
46
-
-
-
1100
14
21
27
41
55
-
-
1200
13
19
25
38
50
-
-
1300
12
18
23
35
46
-
-
1400
11
16
22
32
43
54
65
1500
10
15
20
30
40
50
60
1600
9
14
19
28
38
47
57
1700
9
14
18
27
36
44
53
1800
8
13
17
25
34
42
50
1900
8
12
16
24
32
40
48
2000
8
12
15
23
30
38
45
2100
7
11
14
22
29
36
43
2200
7
11
14
21
27
34
41
2300
7
10
13
20
26
33
39
Answer: 24.0 KW, 42°F Rise, 240 V = 1800 CFM from the
TEMPERATURE RISE chart below.
Heating output at 220 V = 24.0 x 3.413 x .84 - 68.8 MBh.
Actual CFM = 1800 x .84 = 1400 CFM.
NOTE: The temperature rise table is for sea level installations. The temperature rise at a particular KW and CFM will
be greater at high altitudes, while the external static pressure at a particular CFM will be less.
BTUH CAPACITY CORRECTION FACTOR
SUPPLY VOLTAGE
480 460 440 250 230 220 208
MULTIPLICATION FACTOR 1.09 1.00 .91 1.08 .92 .84 .75
FORMULAS:
Heating Output = KW x 3413 x Corr. Factor
Actual CFM = CFM (from table) x Corr. Factor
BTUH = KW x 3413
Heater Kit
BTUH = CFM x 1.08 x Temperature Rise (ΔT)
CFM = KW x 3413
1.08 x ΔT
ΔT = BTUH
CFM x 1.08
PHCB05C1
PHCB10C1
PHCB15C1
PHCB20C1
Heater Capacity @ 240 VAC
Minimum
Maximum
kW BTUH
Circuit
Overcurrent
Ampacity
Protection
L1 - L2 L3 - L4 L1 - L2 L3 - L4
25
-30
-4.8 16,400
50
-60
-9.6 32,800
50
25
60
30
14.4 49,100
50
50
60
60
19.2 65,500
29
SCHEDULED MAINTENANCE
The owner should be made aware of the fact, that, as with
any mechanical equipment the package unit requires regularly scheduled maintenance to preserve high performance
standards, prolong the service life of the equipment, and
lessen the chances of costly failure.
In many instances the owner may be able to perform some
of the maintenance; however, the advantage of a service contract, which places all maintenance in the hands of a trained
serviceman, should be pointed out to the owner.
WARNING
HIGH VOLTAGE
DISCONNECT ALL POWER BEFORE SERVICING OR
INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY
BE PRESENT. F AILURE 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 condensate line piping from the evaporator coil. Make sure
the piping is clear for proper condensate flow.
ONCE A YEAR
Qualified Service Personnel Only
1. Clean the indoor and outdoor coils.
2. Clean the casing of the outdoor unit inside and out .
3. Motors are permanently lubricated and do not require
oiling. TO AVOID PREMATURE MOTOR FAILURE, DO
NOT OIL.
4. Manually rotate the outdoor fan and indoor blower to be
sure they run freely.
5. Inspect the control panel wiring, compressor connections,
and all other component wiring to be sure all connections are tight. Inspect wire insulation to be certain that
it is good.
10. Start the system and run both a Cooling & Heating Performance 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. Refrigeration Test Cord - check compressors, motors,
and continuity testing.
5
Volt-Ohm Meter - testing continuity, capacitors, and motor
windings.
6. Accurate Leak Detector - testing for refrigerant leaks.
7. High Vacuum Pump - evacuation.
8. Electric Vacuum Gauge, Manifold Gauges and high
vacuum hoses - to measure and obtain proper vacuum.
9. Accurate Charging Cylinder or Electronic Scale - measure proper refrigerant charge.
10. Inclined Manometer - measure static pressure and pressure drop across coils.
Other recording type instruments can be essential in solving
abnormal problems, however, in many instances they may
be rented from local sources.
Proper equipment promotes faster, more efficient service, and
accurate repairs with less call backs.
COOLING & HEATING PERFORMANCE TEST
Package Cooling and Package Heat Pumps
Before attempting to diagnose an operating fault, run a Cooling and/or Heating Performance Test and apply the results to
the Service Problem Analysis Guide.
6. Check the contacts of the compressor contactor. If they
are burned or pitted, replace the contactor.
Package Gas Units
Before attempting to diagnose an operating fault, run a heating performance test and apply the results to the Service
Problem Analysis Guide.
7. Using a halide or electronic leak detector, check all piping and etc. for refrigerant leaks.
To conduct a heating performance test, the BTU input to the
furnace must be calculated.
8. Check the combustion chamber (Heat Exchanger) for
soot, scale, etc. Inspect all burners for lint and proper
positioning.
After the heating cycle has been in operation for at least
fifteen minutes and with all other gas appliances turned off,
the gas meter should be clocked.
9. Start the system, using the proper instrumentation check
gas inlet and manifold pressures, burner flame and
microamp signal. Adjust if necessary.
30
SERVICING
To find the BTU input, multiply the number of cubic feet of
gas consumed per hour by the heating value of the gas being
used. (The calorific value of the gas being used is found by
contacting your local utility.)
Example:
It is found by the gas meter, that it takes forty (40) seconds
for the hand on the cubic foot dial to make one complete
revolution, with all appliances off, except the furnace. Take
this information and locate it on the gas rate chart. Observe
the forty (40) seconds, locate and read across to the one (1)
cubic foot dial column. There we find the number 90, which
shows that ninety (90) cubic feet of gas will be consumed in
one (1) hour.
Let's assume the local gas utility has stated that the calorific
value of the gas is 1025 BTU.
Multiplying the ninety (90) cubic feet by 1025 BTU gives us
an input of 92,250 BTUH.
Checking the BTU input on the rating plate of the furnace
being tested.
EXAMPLE:
PGB30C0902D
INPUT: 90,000 BTU/HR
OUTPUT CAP: 72,000
Should the figure you calculated not fall within five (5) percent
of the nameplate rating of the unit, adjust the gas valve pressure regulator or resize orifices. In no case should the
input exceed that shown on the rating plate.
To adjust the pressure regulator on the gas valve, turn down
(clockwise) to increase pressure and input, and out (counterclockwise) to decrease pressure and input.
Since normally propane gas is not installed with a gas meter,
clocking will be virtually impossible. The gas orifices used
with propane are calculated for 2500 BTU gas and with proper
inlet pressures and correct piping size, full capacity will be
obtained.
With propane gas, no unit gas valve regulator is used; however, the second stage supply line pressure regulator should
be adjusted to give 11" water column with all other gas consuming appliances running.
The dissipation of the heat transferred to the heat exchanger
is now controlled by the amount of air circulated over its surface.
The amount (CFM) of air circulated is governed by the external static pressure in inches of water column of duct work,
cooling coil, registers and etc., applied externally to the unit
versus the motor speed tap.
A properly operating unit must have the BTU input and CFM
of air, within the limits shown to prevent short cycling of the
equipment. As the external static pressure goes up, the
temperature rise will also increase. Consult the proper tables
for temperature rise limitation.
CAUTION
ALWAYS CONNECT A MANOMETER TO THE 1/8" PIPE TAP AT THE GAS VALVE
BEFORE ADJUSTING THE PRESSURE REGULATOR. IN NO CASE SHOULD THE
FINAL MANIFOLD PRESSURE VARY MORE THAN PLUS OR MINUS .3 INCHES
WATER COLUMN FROM 3.5 INCHES WATER COLUMN FOR NATURAL GAS OR
10 INCHES WATER COLUMN FOR PROPANE GAS.
31
SERVICING
1
0
9
2
8
3
7 7
4
6
5
1 Million
Quarter
1
1
9
2
8
5
4
100 Thousand
8
2
7 7
3
8
3 3
6
4
5
1
9
9
2
6
6
5
4
1 Thousand
10 Thousand
CUBIC
FEET
One
Foot
Foot
0
GAS RATE -- CUBIC FEET PER HOUR
32
Seconds
for One
Revolution
1/4
cu/ft
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
90
82
75
69
64
60
56
53
50
47
45
43
41
39
37
36
34
33
32
31
30
-28
-26
--
Size of Test Dial
1/2
1
2
cu/ft
cu/ft
cu/ft
5
cu/ft
Seconds
for One
Revolution
1/4
cu/ft
180
164
150
138
129
120
113
106
100
95
90
86
82
78
75
72
69
67
64
62
60
-56
-53
--
1800
1636
1500
1385
1286
1200
1125
1059
1000
947
900
857
818
783
750
720
692
667
643
621
600
581
563
545
529
514
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
25
-23
-22
-21
--20
-19
--18
--17
--16
---15
360
327
300
277
257
240
225
212
200
189
180
171
164
157
150
144
138
133
129
124
120
116
113
109
106
103
720
655
600
555
514
480
450
424
400
379
360
343
327
313
300
288
277
265
257
248
240
232
225
218
212
206
Size of Test Dial
1/2
1
2
cu/ft
cu/ft
cu/ft
50
-47
-45
-43
-41
40
-38
--36
--34
--32
-31
-30
100
97
95
92
90
-86
-82
80
78
76
75
-72
-69
-67
-64
-62
-60
200
195
189
185
180
176
172
167
164
160
157
153
150
147
144
141
138
136
133
131
129
126
124
122
120
5
cu/ft
500
486
474
462
450
439
429
419
409
400
391
383
375
367
360
355
346
340
333
327
321
316
310
305
300
SERVICING
COOLING OR HEAT PUMP - SERVICE ANALYSIS GUIDE
Power Failure
Blown Fuse
Loose Connection
Shorted or Broken W ires
Open Overload
Faulty Thermostat
Faulty Transformer
Shorted or Open Capacitor
Shorted or Grounded Compressor
Compressor Stuck
Faulty Compressor Contactor
Faulty Fan Relay
Open Control Circuit
Low Voltage
Faulty Evap. Fan Motor
Shorted or Grounded Fan Motor
Improper Cooling Anticipator
Shortage or Refrigerant
Restricted Liquid Line
Dirty Air Filter
Dirty Indoor Coil
Not enough air across Indoor Coil
Too much air across Indoor Coil
Overcharge of Refrigerant
Dirty Outdoor Coil
Noncondensibles
Recirculation of Condensing Air
Infiltration of Outdoor Air
Improperly Located Thermostat
Air Flow Unbalanced
System Undersized
Broken Internal Parts
Inefficient Compressor
High Pressure Control Open
Unbalanced Power, 3PH
W rong Type Expansion Valve
Expansion Device Restricted
Expansion Valve Bulb Loose
Inoperative Expansion Valve
Loose Hold-down Bolts
Faulty Reversing Relay
Faulty Defrost Relay
Faulty Reversing Valve
Leaking Check Valve/Orifice
Faulty Defrost Timer
Faulty 30/60 Control
Additional Opt Elect. Heat Req.
Open fuse or limit in Elect. Htr
O.D. Thermostat setting to Low
•
• •
•••
••
•
••
•
•
••
•
•
•
••
•
•
•
••
••
•
•
•
••
••
•
•
•
•
•
•
•
•
••
••
•••
• •
♦
• Clg or Htg Cycle
•
•
♦
♦
♦
♦
♦
•
•
•
••
••
•
•
•
••
••
••
•
•
•
••
•
• •
•
•
•
•
•
•
•
•
♦
•
••
•
•
•
••
♦
••
•
•
♦
♦♦
♦♦♦
♦♦
♦
♦
♦
♦
••
••
Test Method
Remedy
Test Voltage
Imspect Fuse Size & Type
Inspect Connection - Tighten
Test Circuits W ith Ohmmeter
Test Continuity of Overload
Test continuity of Thermostat & W iring
Check control circuit with voltmeter
Test Capacitor
Test Motor W indings
Use Test Cord
Test continuity of Coil & Contacts
Test continuity of Coil And Contacts
Test Control Circuit with Voltmeter
Test Voltage
Repair or Replace
Test Motor W indings
Check resistance of Anticipator
Test For Leaks, Add Refrigerant
Replace Restricted Part
Inspect Filter-Clean or Replace
Recover
part -ofClean
charge
Inspect Coil
Speed Blower, Check Duct Static Press
Reduce Blower Speed
Release Part of Charge
Inspect Coil - Clean
Remove Charge, Evacuate, Recharge
Remove Obstruction to Air Flow
Check W indows, Doors, Vent Fans, Etc.
Relocate Thermostat
Readjust Air Volume Dampers
Refigure Cooling Load
Replace Compressor
Test Compressor Efficiency
Reset And Test Control
Test Voltage
Replace Valve
Replace Valve
Tighten Bulb Bracket
Check Valve Operation
Tighten Bolts
Test continuity of Coil And Contacts
Test continuity of Coil And Contacts
Test Valve Operation
Replace Check Valve
Test Timer Operation
Test Control
Run Load Calculation, Add Heaters
Inspect Fuses and Limits
Raise Setting
See Service Procedure Ref.
High head pressure
High suction pressure
Low head pressure
System
Operating
Pressures
Low suction pressure
Unit will not defrost
Unit will not terminate defrost
System run blows cold air (Heating)
Compressor is noisy
Certain areas to cool others to warm
Too cool and then too warm
Not cool enough on warm days
Unsatisfactory Clg / Htg
System runs continuously - little clg / htg
Compressor cycles on overload
Compressor runs - goes off on overload
Condenser fan will not start
•
• •
•
•••
•
•
• •
•
•
•
••
Evaporator fan will not start
DOTS IN ANALYSIS
GUIDE INDICATE
"POSSIBLE CAUSE"
SYMPTOM
System will not start
POSSIBLE CAUSE
Comp. and Cond. Fan will not start
No Cooling / Heating
Compressor will not start - fan runs
Complaint
S-1
S-1,
S-4
S-4
S-2
S-3
S-17A
S-3
S-4
S-15
S-17B
S-17C
S-7, S-8
S-7
S-4
S-1
S-16
S-16
S-3
S-103
S-112
S-200
S-200
S-113
S-114
S-104
S-12
S-110
S-7
S-7
S-21
S-23/24
S-24
S-25
S-50
S-53
Heat Pump Cycle only
33
SERVICING
GAS HEATING - SERVICE ANALYSIS GUIDE
Power Failure
Blown Fuse
Loose Connection
Shorted or Broken Wires
No Low Voltage
Faulty Thermostat
Faulty Transformer
• •
•
Improper Heat Anticipator Setting
Faulty Limit or Roll Out Switch
Faulty Flame Sensor
Faulty Ignition Control
Gas Valve or Gas Supply Shut Off
Faulty Induced Draft Blower
Broken or Shorted Ignitor
Faulty Combustion Relay
Dirty Flame Sensor, Low uA
Flame Sensor not in Flame, Low uA
Faulty Gas Valve
Open Auxillary Limit
Improper Air Flow or Distribution
Cycling on Limit
•
•
Flashback
Gas Pressure
Cracked Heat Exchanger
Stuck Gas Valve
Furnace Undersized
Faulty Pressure Switch
Blocked or Restricted Flue
Open Roll Out Switch
Collector Box "J" Tube Position
Bouncing On Pressure Switch
34
•
•
• • •
• •
• •
•
• •
• •
Test Voltage
S-1
S-1,
S-4
S-4
Check Wiring
S-2
Check Wiring
S-3
Check Transformer
S-4
Check Thermostat
S-3
Check Transformer
S-4
Measure Ground Resistance
Adjust Heat Anticipator Setting
•
•
•
•
•
•
• • •
• • •
•
• •
•
•
S-313
S-3
Relocate Thermostat
Test Control
•
See Service Procedure Reference
Not Enough Heat
To Much Heat
•
• •
• •
•
• •
•
•
•
•
•
•
•
•
•
•
•
• •
Delayed Ignition
Orifice Size
Soot and /or Fumes
Test Voltage
Poor or High Resistance Ground
Improper Thermostat Location
Test Method
Remedy
Long Cycles
Burner Ignites-Locks Out
•
•
•
•
•
•
•
Burner Won't Ignite
SYMPTOM
DOTS IN ANALYSIS
GUIDE INDICATE
"POSSIBLE CAUSE"
System Will Not Start
POSSIBLE CAUSE
Unsatisfactory Heat
Short Cycles
No Heat
Burner Shuts Off prior to T'Stat being Satasfied
Complaint
S-300-302
Test Flame Sensor
S-314
Test Control
S-313
Turn Valves to On Position
S-304
Test Blower
S-309
S-16
Test Ignitor
S-315
S-312
Test Relay
S-20
S-7
Clean Flame Sensor
S-314
Test/Adjust Position of Flame Sensor
S-314
Replace Gas Valve
S-304
Reset Control
S-301
Check Duct Static
S-200
Check Controls & Temperature Rise
S-300
Test for Delayed Ignition
S-308
Test for Flashback
S-309
Check Orifices
S-306
Check Gas Pressure
S-307
Check Burner Flames
S-302
Replace Gas Valve
S-304
Replace with
with Proper
proper Size
size Furnce
furnace
Test Pressure Switch
S-310
Check Flue/Drawdown Pressure
S-310
Test Control
S-302
Test Negative Pressure
S-310
Test Negative Pressure
S-310
SERVICING
NOTE: When operating electric heaters on voltages other
than 240 volts refer to the System Operation section on electric heaters to calculate temperature rise and air flow. Low
voltage may cause insufficient heating.
S-1 CHECKING VOLTAGE
WARNING
HIGH VOLTAGE
DISCONNECT ALL POWER BEFORE SERVICING OR
INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY
BE PRESENT. F AILURE TO DO SO MAY CAUSE PROPERTY
Three phase units require a balanced 3 phase power supply
to operate. If the percentage of voltage imbalance exceeds
3% the unit must not be operated until the voltage condition
is corrected.
DAMAGE, PERSONAL INJURY OR DEATH.
Max. Voltage Deviation
From Average Voltage X 100
Average Voltage
1. Remove doors, control panel cover, etc. from unit being
tested.
% Voltage =
Imbalance
With power ON:
To find the percentage of imbalance, measure the incoming
power supply.
L1 - L2 = 240V
WARNING
L INE
L1 - L3 = 232V
Avg. V = 710 = 236.7
VOLTAGE NOW PRESENT.
L2 - L3 = 238V
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. No reading - indicates open wiring, open fuse(s), or no
power to unit from 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. NOTE: If
checking heaters, be sure all heating elements are energized.
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.
Total
3
710V
To find Max. deviation:
240 - 236.7 = +3.3
232 - 236.7 = -4.7
238 - 236.7 = +1.3
Max deviation was 4.7V
% Voltage Imbalance = 4.7
236.7
If the percentage of imbalance had exceeded 3%, it must be
determined if the imbalance is in the incoming power supply
or the equipment. To do this rotate the legs of the incoming
power and retest voltage as shown below.
To measure Locked Rotor Voltage attach a voltmeter to
the run "R" and common "C" terminals of the compressor, or to the T1 and T2 terminals of the contactor. Start
the unit and allow the compressor to run for several seconds, then shut down the unit. Immediately attempt to
restart the unit while measuring the Locked Rotor Voltage.
6. Should read within the voltage tabulation as shown. If
the voltage falls below the minimum voltage, check the
line wire size. Long runs of undersized wire can cause
low voltage. If wire size is adequate, notify the local
power company in regards to either low or high voltage.
L1 - L2 = 240V
L1 - L3 = 227V
L2 - L3 = 238V
L1
L2
L3
MIN.
MAX.
460
437
506
208/230
198
253
Rotate all 3 incoming
legs as shown.
L1 - L2 = 227V
L1 - L3 = 238V
L2 - L3 = 240V
UNIT SUPPLY VOLTAGE
VOLTAGE
= 1.99%
L1
L2
L3
By the voltage readings we see that the imbalance rotated or
traveled with the switching of the incoming legs. Therefore
the problem lies within the incoming power supply.
35
SERVICING
If the imbalance had not changed then the problem would lie
within the equipment. Check for current leakage, shorted
motors, etc.
S-2 CHECKING WIRING
WARNING
HIGH VOLTAGE
DISCONNECT ALL POWER BEFORE SERVICING OR
INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY
BE PRESENT. F AILURE 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
WARNING
3. No voltage, indicates the trouble is in the thermostat or
wiring.
4. Check the continuity of the thermostat and wiring. Repair or replace as necessary.
NOTE: Consideration must be given as to how the heaters
are wired (O.D.T. and etc.). Also safety devices must be
checked for continuity.
S-3B Cooling Anticipator
The cooling anticipator is a small heater (resistor) in the thermostat. During the "off" cycle it heats the bimetal element
helping the thermostat call for the next cooling cycle. This
prevents the room temperature from rising too high before the
system is restarted. A properly sized anticipator should
maintain room temperature within 1 1/2 to 2 degree range.
The anticipator is supplied in the thermostat and is not to be
replaced. If the anticipator should fail for any reason, the
thermostat must be replaced.
S-3C Heating Anticipator
The heating anticipator is a wire-wound adjustable heater,
which is energized during the "ON" cycle to help prevent overheating of the conditioned space.
The anticipator is a part of the thermostat and if it should fail
for any reason, the thermostat must be replaced. See the
following for recommended heater anticipator setting.
With power ON and thermostat calling for cooling.
The first stage heat anticipator setting for heat pump models
is .40. The heat anticipator setting for the package gas models is .80.
1. Use a voltmeter to check for 24 volts at thermostat wires
C and Y in the control panel.
S-4 CHECKING TRANSFORMER AND CONTROL CIRCUIT
2. No voltage indicates trouble in the thermostat, wiring or
external transformer source.
A step-down transformer (208/240 volt primary to 24 volt secondary) is provided with each package unit. This allows ample
capacity for use with resistance heaters.
L INE
VOLTAGE NOW PRESENT.
3. Check the continuity of the thermostat and wiring. Repair or replace as necessary.
WARNING
Indoor Blower Motor
With power ON:
D ISCONNECT
WARNING
L INE
VOLTAGE NOW PRESENT.
ELECTRICAL POWER SUPPLY.
1. Remove control panel cover or etc. to gain access to transformer.
With power ON:
1. Set fan selector switch at thermostat to "ON" position.
WARNING
2. With voltmeter, check for 24 volts at wires C and G.
3. No voltage, indicates the trouble is in the thermostat or
wiring.
4. Check the continuity of the thermostat and wiring. Repair or replace as necessary.
Resistance Heaters
1. Set room thermostat to a higher setting than room temp
so both stages call for heat.
2. With voltmeter, check for 24 volts at each heater relay.
36
L INE
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. Check transformer primary voltage at incoming line voltage connections and/or splices.
SERVICING
5. If line voltage available at primary voltage side of transformer and wiring and splices good, transformer is inoperative. Replace.
3. Using a voltmeter, test across terminals.
A. L2 - T1 - No voltage indicates CC1 contacts open.
If a no voltage reading is obtained - replace the contactor.
S-6 CHECKING TIME DELAY RELAY
Time delay relays are used in Amana® brand Package Units
to improve efficiency by delaying the blower off time. This
feature is incorporated into the electronic controls. See S23 to check control board.
S-7 CHECKING CONTACTOR AND/OR RELAYS
The compressor contactor and other relay holding coils are
wired into the low or line voltage circuits. When the control
circuit is energized the coil pulls in the normally open contacts or opens the normally closed contacts. When the coil
is de-energized, springs return the contacts to their normal
position.
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.
2. Using an ohmmeter, test across the coil terminals.
If the coil does not test continuous, replace the relay or
contactor.
S-8 CHECKING CONTACTOR CONTACTS
NOTE: Some variation over time has occurred in the fan relays used. Refer to the unit wiring diagram for terminal identification.
S-15 CHECKING CAPACITOR
CAPACITOR, RUN
A run capacitor is wired across the auxiliary and main windings of a single phase permanent split capacitor motor. The
capacitors primary function is to reduce the line current while
greatly improving the torque characteristics of a motor. This
is accomplished by using the 90° phase relationship between
the capacitor current and voltage in conjunction with the motor
windings so that the motor will give two phase operation when
connected to a single phase circuit. The capacitor also reduces the line current to the motor by improving the power
factor.
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
characteristics.
This check valve closes off high side pressure to the compressor 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.
WARNING
ELECTRICAL POWER SUPPLY.
1. Disconnect the wire leads from the terminal (T) side of
the contactor.
2. With power ON, energize the contactor.
To prevent the compressor from starting and running backwards a Time Delay Relay (Cycle Protector) has been added
to the low voltage circuit.
NOTE: K3 series scroll compressors have an anti-rotation
device and equalizing mechanism incorporated into the compressor and will equalize in 0.2 to 0.3 seconds. These compressors will operate correctly without a Time Delay Relay.
WARNING
L INE
The fan relays are incorporated into the control board. See
sections S-23 for checking control board.
CAPACITOR, START
1. Remove the leads from the holding coil.
D ISCONNECT
S-9 CHECKING FAN RELAY CONTACTS
VOLTAGE NOW PRESENT.
T2
T1
CC
VOLT/OHM
METER
L2
L1
Ohmmeter for testing holding coil
Voltmeter for testing contacts
MODELS EQUIPPED WITH A HARD START DEVICE
A start capacitor is wired in parallel with the run capacitor to
increase the starting torque. The start capacitor is of the
electrolytic type, rather than metallized polypropylene as used
in the run capacitor.
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.
TESTING COMPRESSOR CONTACTOR
37
SERVICING
These capacitors have a 15,000 ohm, 2 watt resistor wired
across its terminals. The object of the resistor is to discharge the capacitor under certain operating conditions, rather
than having it discharge across the closing of the contacts
within the switching device such as the Start Relay, and to
reduce the chance of shock to the servicer. See the Servicing Section for specific information concerning capacitors.
RELAY, START
A potential or voltage type relay is used to take the start
capacitor out of the circuit once the motor comes up to speed.
This type of relay is position sensitive. The normally closed
contacts are wired in series with the start capacitor and the
relay holding coil is wired parallel with the start winding. As
the motor starts and comes up to speed, the increase in
voltage across the start winding will energize the start relay
holding coil and open the contacts to the start capacitor.
Two quick ways to test a capacitor are a resistance and a
capacitance check.
A. Good Condition - indicator swings to zero and slowly
returns to infinity. (Start capacitor with bleed resistor will
not return to infinity. It will still read the resistance of the
resistor).
B. Shorted - indicator swings to zero and stops there replace.
C. Open - no reading - replace. (Start capacitor would
read resistor resistance).
S-15B Capacitance Check
Using a hookup as shown below, take the amperage and
voltage readings and use them in the formula:
Capacitance (MFD) = 2650 X Amperage
Voltage
S-15A Resistance Check
WARNING
HIGH VOLTAGE
DISCONNECT ALL POWER BEFORE SERVICING OR
INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY
BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY
Volt / Ohm
Meter
15 AMP FUSE
DAMAGE, PERSONAL INJURY OR DEATH.
C
AMMETER
ap
ac
ito
r
1. Discharge capacitor and remove wire leads.
TESTING CAPACITANCE
S-16 CHECKING FAN AND BLOWER MOTOR
An auto reset fan motor overload is designed to protect the
motor against high temperature and high amperage conditions similar to the compressor internal overload. It also breaks
the common circuit within the motor shell; however, heat generated within the motor is faster to dissipate than the compressor, allow at least 45 minutes for the overload to reset,
then retest.
Volt / Ohm
Meter
D ISCONNECT
ELECTRICAL POWER SUPPLY.
C
ap
a
ci
to
r
WARNING
1. Remove the motor leads from its respective connection
points and capacitor (if applicable).
TESTING CAPACITOR RESISTANCE
2. Set an ohmmeter on its highest ohm scale and connect
the leads to the capacitor -
38
2. Check the continuity between each of the motor leads.
3. Touch one probe of the ohmmeter to the motor frame
(ground) and the other probe in turn to each lead.
If the windings do not test continuous or a reading is obtained from lead to ground, replace the motor.
SERVICING
S-16B ECM/ICM Motors
ECM/ICM Features
Many of the Amana® brand high efficiency package units incorporate the GE© ICM or variable speed blower motors for
greater efficiency. ECM/ICM motors vary the motor RPMs to
provide a set volume of air over a wide range of conditions.
ECM/ICM Control Connections
Control functions (G, Y1, Y2) May be Active at less than 1/2
control voltage. (i.e. 12 volts). Relay contacts on control functions must reliably switch low currents (less than 5 MA).
Some thermostats (with triac switches) and Solid State Relays may allow enough "leakage" current to Turn on "G".
Thermostats that "steal" power thru "Y" or other functions
are not compatible.
The ECM control interface can be as simple as a direct connection to the thermostat. For example: R to G will cause fan
to come on at "fan-only" CFM. R to G to Y will cause fan to
come on at cooling speed. The ECM/ICM control requires a
common connection from the transformer (transformer common to C1, C2 on control). In typical applications C1 and C2
will be tied together. Additional features can be utilized with
an interface control board (speed tap board), these features
include; 2 Cool CFMs, 2 Dehumidification CFMs, 2 Heat
CFMs, emergency heat CFM, separate Fan-Only CFM, and
feed back information (CFM demand).
Testing ECM/ICM Motors
ECM/ICMs connect directly to the Line. DO NOT Insert
Contactors in Series with the ECM/ICM Motor AC line. Control is powered continuously to Insure reliable start-up. Plug
is polarized, verify and reverify correct connector orientation
before applying power. DO NOT force plug into motor and
make sure power is off before inserting power connector. DO
NOT apply voltage to terminals 1 or 2.
Power
Conditioning
HVAC System Control
INPUTS
24 Volts A/C
Compressor
On/Hi/Low
Fan On
Reversing Valve
Aux./Emergency Heat
Capacity Select
AC to DC
Conversion
WARNING
L INE
VOLTAGE NOW PRESENT.
Check for line voltage on terminals 4 and 5. Verify terminal 3
is ground. Terminals 1 and 2 should be connected only if
motor is operating on 120 Volts.
1
2
}
Lines 1 and 2 will be connected
for 12OVAC Power Connector
applications only
3
Gnd
4
AC Line Connection
5
AC Line Connection
POWER CONNECTOR
"Motor Half“
Control connections
Do not apply 24 volts to terminals "Out +" or "Out-".
Make sure connector is fully seated.
Make Sure Pins are Fully Seated in Connector Housing.
Verify C1 and C2 are connected to transformer common.
Verify "R" is connected to transformer hot.
After verifying above connections, motor can be tested by
applying 24 volts to control pins. Example: R to G will cause
fan to come on at "Fan-Only" CFM. R to G to Y will cause fan
to come on at cooling speed.
If motor does not respond as noted, ECM control unit is bad
and should be replaced.
Inverter
ECM
Blower
Motor
Motor
Control
Outputs
CFM Demand
ICM/ECM CONTROL FLOW CHART
39
SERVICING
OUT -
8
16
OUT +
ADJUST +/-
7
15
G (fan)
Y1
6
14
Y/Y2
COOL
5
13
EM HT/W2
DELAY
4
12
24VAC (R)
COMMON 2
3
11
HEAT
W/W1
2
10
BK/Pwm (Speed)
COMMON 1
1
9
O (Rev Valve)
CONTROL CONNECTOR
"Motor Half“
CAUTION
HIGH VOLTAGE ON CONTROL
PINS WILL DESTROY MOTOR.
Replacing ICM Control Module
Use the following steps to replace the control module for the
GE© variable speed indoor blower motor.
1. You must have the correct replacement module. The controls are factory programmed for specific operating modes.
Even though they look alike, different modules may have
completely different functionality. Using the wrong control module voids all product warranties and may produce
unexpected results.
2. Remove all power from the unit being serviced. Do not
work on the motor with power applied. Wait at least 5
minutes after disconnecting power from the equipment
before opening the motor.
3. It is usually not necessary to remove the motor from the
blower assembly. However it is recommended that the
whole blower assembly, with the motor, be removed.
Unplug the two cable connectors to the motor. There are
latches on each connector. Do not pull on the wires. The
plugs remove easily when properly released.
4. Observe the flat end of the motor control module casting
and located the two standard ¼" hex head bolts. Remove
these bolts from the motor while holding the control module. Do not remove the two torx head screws.
5. The control module is now free of the motor but still attacked by a plug and cable. Carefully rotate the control
so as to gain access to the plug on the end of the cable.
Squeeze the release latch and gently pull the plug out of
the control module. Do not pull on the wires. Grip the
plug only.
40
6. The control module is now completely detached from the
motor. Verify with a standard ohmmeter that the resistance from each motor lead (in the motor plug just removed) to the motor shell is greater than 100k ohms.
(Measure resistance to unpainted motor end plate). If any
motor lead fails this test do not proceed to install the
control module. The motor is defective and must be replaced. Installing the new control module will cause it to
fail also.
7. Verify that the replacement control module is correct for
your application. If so, orient the new module next to the
motor and carefully insert the plug removed in step 5. Be
sure the plug latches. It will click when properly inserted.
8. Install the new control module back on the motor being
careful to engage the locating pin into the appropriate
mating motor hole. Replace the two 1/4" hex head bolts.
Tighten the bolts snugly. It is not necessary to overtighten.
Note: Before replacing the blower/motor assembly, it is important to look at the installation to see if some application
fault has caused the motor to fail.
Is there any evidence of water damage to the failed control?
(Corrosion on the inside or outside of the casting.) If yes, do
moisture check.
9. Re-install the blower/motor assembly into the package
unit.
10. Plug the 16-pin control plug into the motor. The plug is
keyed. Make sure the connector is properly seated and
latched.
11. Plug the 5 pin power connector into the motor even though
the plug is keyed, observe the proper orientation. Do not
force the connector. It plugs in very easily when properly
oriented. Reversing this plug will cause immediate
failure of the control module.
12. Final installation check. Make sure the motor is installed
as follows:
A.
B.
As far into the blower housing as possible
Belly bands not covering vent holes or on the control module
C. Motor connectors should oriented as to prevent
the accumulation of moisture in the control.
D. Use wire ties to create a drip loop in the motor
cables.
13. The installation is now complete. Reapply power to the
package unit and verify that the new motor control module is working properly.
SERVICING
S-16E Testing Interface Board
Fan Only
With thermostat set to the “Fan” position, and system switch
“Off”:
4. If no voltage present from “C” to “G” and “C” to “Y/Y2”,
check low voltage wiring in unit and thermostat and thermostat wiring.
1. Check for 24 volts from “C” to “R2” or “R3”.
5. If 24 volts present from “C” to “G” and “C” to “Y/Y2”, check
for 24 volts from pin 1 to pin 6 and from pin 3 to pin 6 in
the 16 pin connector at the interface board.
2. If no 24 volts from “C” to “R2” or “R3”, check low voltage
wiring in unit and transformer.
6. If no voltage present from pin 1 to pin 6 and from pin 3 to
pin 6, replace interface board.
3. If 24 volts present from “C” to “R2” or “R3”, check for 24
volts from “C” to “G”.
7. If 24 volts present from pin 1 to pin 6 and from pin 3 to pin
6, check the 16 pin harness and the ECM motor.
4. If no voltage present from “C” to “G”, check low voltage
wiring in unit and thermostat and thermostat wiring.
5. If 24 volts present from “C” to “G”, check from pin 1 to pin
15 and from pin 3 to pin 15 in the 16 pin connector at the
interface board.
6. If no voltage present from pin 1 to pin 15 and from pin 3 to
pin 15, replace interface board.
7. If 24 volts present from pin 1 to pin 15 and from pin 3 to
pin 15, check the 16 pin harness and the ECM motor.
Cooling/Heat Pump
With thermostat set to the “Cool” position and
thermostat set below room temperature (or for
Heat Pump 1st stage heat, thermostat set to the
“Heat” position and thermostat set above room
temperature):
Heating (Gas, Electric Heat, or Emergency Heat)
With thermostat set to the “Heat” position and thermostat
set above room temperature:
1. Check for 24 volts from “C” to “R2” or “R3”.
2. If no 24 volts from “C” to “R2” or “R3”, check low voltage
wiring in unit and transformer.
3. If 24 volts present from “C” to “R2” or “R3”, check for 24
volts from “C” to “W1”.
4. If no voltage present from “C” to “W1”, check low voltage
wiring in unit and thermostat and thermostat wiring.
5. If 24 volts present from “C” to “W1”, check for 24 volts
from pin 1 to pin 2 and from pin 3 to pin 2 in the 16 pin
connector at the interface board.
1. Check for 24 volts from “C” to “R2” or “R3”.
6. If no voltage present from pin 1 to pin 2 and from pin 3 to
pin 2, replace interface board.
2. If no 24 volts from “C” to “R2” or “R3”, check low voltage
wiring in unit and transformer.
7. If 24 volts present from pin 1 to pin 2 and from pin 3 to pin
2, check the 16 pin harness and the ECM motor.
3. If 24 volts present from “C” to “R2” or “R3”, check for 24
volts from “C” to “G” and from “C” to “Y/Y2”.
41
42
Check for undercharged condition.
-
Arrange harnesses with "drip loop" under motor.
-
You must use the correct replacement control motor module since they are factory programmed for specific operating modes. Even though
they look alike, different modules may have completely different functionality. The ECM variable speed motors are currently the only motors that
can have the motor/control module replaced.
- Turn power OFF prior to repair.
Wait 5 minutes after disconnecting
power before opening motor.
- Handle electronic motor/control
with care.
- Check low voltage (Thermostat) wires
and connections.
- Verify fan is not in delay mode - wait until delay
complete.
- Perform motor/control replacement check,
ECM motors only.
IMPORTANT NOTE: Using the wrong motor/control module voids all product warranties and may produce unexpected results.
NOTE:
- Turn power OFF prior to repair.
- Turn power OFF prior to repair.
----
- Turn power OFF prior to repair.
Wait 5 minutes after disconnecting
power before opening motor.
- Handle electronic motor/control
with care.
- Turn power OFF prior to repair.
Wait 5 minutes after disconnecting
power before opening motor.
- Handle electronic motor/contro
with care.
----
Cautions and Notes
- Does removing panel or filter reduce "puffing"?
- Check/replace filter.
- Check/correct duct restrictions.
- Adjust to correct blower speed setting.
- Check line voltage for variation or "sag".
- Check low voltage connections (G, Y, W, R, C)
at motor, unseated pins in motor
harness connectors.
- Check-out system controls - Thermostat.
- Perform Moisture Check.*
----
CHART CONTINUED ON NEXT PAGE.
Check and plug leaks in return ducts, cabinet.
Check for low airflow (too much latent capacity).
-
Is condensate drain plugged?
-
Connectors are oriented "down" (or as recommended
by equipment manufacturer).
- 24 Vac wires miswired or loose.
- "R" missing/not connected at motor.
- Fan in delay mode.
- Stays at low CFM
despite system call for
cool or heat CFM.
-
- Incorrect or dirty filter(s).
- Incorrect supply or return ductwork.
- Incorrect blower speed setting.
- "Hunts" or "puffs" at
high CFM (speed).
- Varies up and down
or intermittent.
- Variation in 230 Vac to motor.
- Unseated pins in wiring harness
connectors.
- Erratic CFM command from "BK" terminal.
- Improper thermostat connection
or setting.
- Moisture present in
motor/control module.
----
- Motor rocks,
but won't start.
- It is normal for motor to
oscillate with no
load on shaft.
- Check for loose motor mount.
- Make sure blower wheel is tight on shaft.
- Perform motor/control replacement check,
ECM motors only.
- Loose motor mount.
- Blower wheel not tight on motor shaft.
- Bad motor/control module.
- No movement.
----
- Check 230 Vac power at motor.
- Check low voltage (24 Vac R to C)
at motor.
- Check low voltage connections (G, Y, W, R, C)
at motor.
- Check for unseated pins in connectors on
motor harness.
- Test with a temporary jumper between R - G.
- Check motor for tight shaft.
----
Corrective Action
- Manual disconnect switch off or
door switch open.
- Blown fuse or circuit breaker.
- 24 Vac wires miswired.
- Unseated pins in wiring harness
connectors.
- Bad motor/control module.
- Moisture present in motor or
control module.
- This is normal start-up
for variable speed motor.
Possible Causes
TROUBLESHOOTING CHART FOR ECM VARIABLE SPEED AIR CIRCULATOR BLOWER MOTORS
Fault Description(s)
*MOISTURE CHECK:
- Motor starts,
but runs
erratically.
- Motor oscillates
up & down while
being tested off
of blower.
- Motor won't start.
- Motor rocks
slightly when
starting.
Symptom
SERVICING
Check and plug leaks in return ducts, cabinet.
Check for undercharged condition.
-
Arrange harnesses with "drip loop" under motor.
-
Check for low airflow (too much latent capacity).
You must use the correct replacement control motor module since they are factory programmed for specific operating modes. Even though
they look alike, different modules may have completely different functionality. The ECM variable speed motors are currently the only motors that
can have the motor/control module replaced.
- Turn power OFF prior to repair.
Wait 5 minutes after disconnecting
power before opening motor.
- Handle electronic motor/control
with care.
- Turn power OFF prior to repair.
- Turn power OFF prior to repair.
- Turn power OFF prior to repair.
- Turn power OFF prior to repair.
- Turn power OFF prior to repair.
Wait 5 minutes after disconnecting
power before opening motor.
- Handle electronic motor/control
with care.
Cautions and Notes
IMPORTANT NOTE: Using the wrong motor/control module voids all product warranties and may produce unexpected results.
NOTE:
- Motor failure or
malfunction has
occurred and
moisture is present.
Is condensate drain plugged?
- Moisture in motor/control module.
- "Hunts" or "puffs" at
high CFM (speed).
-
- High static creating high blower speed.
- Incorrect or dirty filter(s).
- Incorrect supply or return ductwork.
- Incorrect blower speed setting.
- Noisy blower or cabinet.
-
- Does removing panel or filter reduce "puffing"?
- Check/replace filter.
- Check/correct duct restrictions.
- Adjust to correct blower speed setting.
- Loose blower housing, panels, etc.
- High static creating high blower speed.
- Air leaks in ductwork, cabinets,
or panels.
- Air noise.
Connectors are oriented "down" (or as recommended
by equipment manufacturer).
- Check for loose blower housing, panels, etc.
- Check for air whistling thru seams in ducts,
cabinets or panels.
- Check for cabinet/duct deformation.
- High static creating high blower speed.
- Incorrect supply or return ductwork.
- Incorrect or dirty filter(s).
- Incorrect blower speed setting.
-
- Check/replace filter.
- Check/correct duct restrictions.
- Adjust to correct blower speed setting.
- Current leakage from controls
into G, Y, or W.
- Blower won't shut off.
- Replace motor and perform Moisture Check.*
- Check for Triac switched t'stat or
solid state relay.
- "R" missing/not connected at motor.
- Fan in delay mode.
- Stays at high CFM.
Corrective Action
- Is fan in delay mode? - wait until delay
time complete.
- Perform motor/control replacement check,
ECM motors only.
Possible Causes
TROUBLESHOOTING CHART FOR ECM VARIABLE SPEED AIR CIRCULATOR BLOWER MOTORS
Fault Description(s)
*MOISTURE CHECK:
- Evidence of
Moisture.
- Excessive noise.
- Motor starts,
but runs
erratically.
Symptom
CHART CONTINUED FROM PREVIOUS PAGE.
SERVICING
43
SERVICING
ECM VARIABLE SPEED CIRCULATOR BLOWER MOTORS
DO
DON'T
- Check-out motor, controls, wiring,
and connections before replacing motor.
- Orient connectors down to prevent water
infiltration.
- Install "drip loops".
- Use authorized motor and control model #'s
for replacement.
- Automatically assume the motor is bad.
- Keep static pressure to a minimum:
- Use high pressure drop filters - some have
1/2" H2O drop!
- Use restricted returns.
- Recommend high efficiency, low static
filters.
- Recommend keeping filters clean.
- Design ductwork for min. static, max
comfort.
- Look for and recommend ductwork
improvement, where necessary, in
replacement.
- Size the equipment wisely.
- Check orientation before inserting motor
connectors.
- Locate connectors above 7 and 4 o'clock
positions.
- Replace one motor or control model # with
another (unless an authorized replacement).
- Oversize system then compensate with low
airflow.
- Plug in power connector backwards.
- Force plugs.
44
SERVICING
S-17 CHECKING COMPRESSOR WINDINGS
WARNING
HERMETIC COMPRESSOR ELECTRICAL TERMINAL VENTING CAN BE DANGEROUS. WHEN INSULATING MATERIAL, WHICH SUPPORTS A HERMETIC
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.
COMPRESSOR ELECTRICAL TERMINAL, SUDDENLY DISINTEGRATES DUE TO
PHYSICAL ABUSE OR AS A RESULT OF AN ELECTRICAL SHORT BETWEEN
1. Remove the leads from the compressor terminals.
THE TERMINAL AND THE COMPRESSOR HOUSING, THE TERMINAL MAY BE
EXPELLED, VENTING THE VAPOROUS AND LIQUID CONTENTS OF THE
COMPRESSOR 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.
WARNING
SEE WARNINGS S-17 BEFORE REMOVING COMPRESSOR TERMINAL COVER.
2. Using an ohmmeter, test continuity between terminals
S-R, C-R, and C-S, on single phase units or terminals
T1, T2 and T3, on 3 phase units.
This discharge can be ignited external to the compressor if
the terminal cover is not properly in place and if the discharge
impinges on a sufficient heat source.
Ignition of the discharge can also occur at the venting terminal or inside the compressor, if there is sufficient contaminant air present in the system and an electrical arc occurs
as the terminal vents.
Ignition cannot occur at the venting terminal without the presence of contaminant air, and cannot occur externally from
the venting terminal without the presence of an external ignition source.
Therefore, proper evacuation of a hermetic system is essential 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 windings, see procedures 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
amperage 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.
C
OHMMETER
R
S
COMP
TESTING COMPRESSOR WINDINGS
If either winding does not test continuous, replace the compressor.
NOTE: If an open compressor is indicated allow ample time
for the internal overload to reset before replacing compressor.
S-17B Ground Test
If fuse, circuit breaker, ground fault protective device, etc.,
has tripped, this is a strong indication that an electrical problem exists and must be found and corrected. The circuit protective device rating must be checked and its maximum rating should coincide with that marked on the equipment nameplate.
With the terminal protective cover in place, it is acceptable to
replace the fuse or reset the circuit breaker ONE TIME ONLY
to see if it was just a nuisance opening. If it opens again, DO
NOT continue to reset.
Disconnect all power to unit, making sure that all power legs
are open.
1. DO NOT remove protective terminal cover. Disconnect
the three leads going to the compressor terminals at the
nearest point to the compressor.
45
SERVICING
WARNING
DAMAGE CAN OCCUR TO
THE EMBEDDED TERMINALS AT THIS POINT IF THE
WARNING
L INE
VOLTAGE NOW PRESENT.
LEADS ARE NOT PROPERLY REMOVED, WHICH CAN RESULT IN THE
TERMINAL VENTING AND HOT OIL DISCHARGING.
A.
If the compressor starts and continues to run, the
cause for failure is somewhere else in the system.
B.
If the compressor fails to start - replace.
Compressor Serial Number Identification
COPELAND COMPRESSOR
HI-POT
E
COMPRESSOR GROUND TEST
2. Identify the leads and using a Megger, Hi-Potential Ground
Tester, or other suitable instrument which puts out a voltage between 300 and 1500 volts, check for a ground separately between each of the three leads and ground (such
as an unpainted tube on the compressor). Do not use a
low voltage output instrument such as a volt-ohmmeter.
3. If a ground is indicated, then carefully remove the compressor terminal protective cover and inspect for loose
leads or insulation breaks in the lead wires.
4. If no visual problems indicated, carefully remove the leads
at the compressor terminals.
Carefully retest for ground, directly between compressor
terminals and ground.
5. If ground is indicated, replace the compressor.
S-17D Operation Test
If the voltage, capacitor, overload and motor winding test fail
to show the cause for failure:
WARNING
HIGH VOLTAGE
DISCONNECT ALL POWER BEFORE SERVICING OR
INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY
BE PRESENT. F AILURE TO DO SO MAY CAUSE PROPERTY
·
93
J
123456
Motor Shift Year Month Serial No
TECUMSEH COMPRESSOR
T:
G
22
93C
123456
Month Day Year
Serial No
BRISTOL COMPRESSOR
291
93
123456
Day of
Year
Year
Serial No
S-18 TESTING CRANKCASE HEATER
The crankcase heater must be energized a minimum of four
(4) hours before the condensing unit is operated.
Crankcase heaters are used to prevent migration or accumulation of refrigerant in the compressor crankcase during the
off cycles and prevents liquid slugging or oil pumping on start
up. Scroll Compressors are not equipped with a crankcase
heaters.
A crankcase heater will not prevent compressor damage due
to a floodback or over charge condition.
DAMAGE, PERSONAL INJURY OR DEATH.
1. Remove unit wiring from disconnect switch and wire a
test cord to the disconnect switch.
NOTE: The wire size of the test cord must equal the line wire
size and the fuse must be of the proper size and type.
2. With the protective terminal cover in place, use the three
leads to the compressor terminals that were disconnected
at the nearest point to the compressor and connect the
common, start and run clips to the respective leads.
3. Connect good capacitors of the right MFD and voltage
rating into the circuit.
4. With power ON, close the switch.
46
WARNING
HIGH VOLTAGE
DISCONNECT ALL POWER BEFORE SERVICING OR
INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY
BE PRESENT. F AILURE TO DO SO MAY CAUSE PROPERTY
DAMAGE, PERSONAL INJURY OR DEATH.
1. Disconnect the heater lead wires.
2. Using an ohmmeter, check heater continuity - should test
continuous, if not, replace.
SERVICING
NOTE: The positive temperature coefficient crankcase heater
is a 40 watt 265 voltage heater. The cool resistance of the
heater will be approximately 1800 ohms. The resistance will
become greater as the temperature of the compressor shell
increases.
Normal sequence of operation, Cooling Mode.
1. If the compressor has been off for at least 3 minutes when
a call for cool is received, the compressor is immediately
energized. The indoor blower is energized at the cooling
speed after a 7 second delay.
S-21 CHECKING REVERSING VALVE AND SOLENOID
2. If the compressor has not been off for at least 3 minutes
when a call for cooling is received, the control waits at
least 3 minutes before energizing the compressor. The
LED will flash 6 times when the compressor is delayed
on the anti-short cycle timer.
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 suction line temperature through the reversing valve
can also be measured. Check operation of the valve by starting the system and switching the operation from COOLING
to HEATING cycle.
If the valve fails to change its position, test the voltage (24V)
at the valve coil terminals, while the system is on the COOLING cycle.
If no voltage is registered at the coil terminals, check the
operation of the reversing relay and the continuity of the connecting wires.
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 valve is inoperative - replace it.
S-22 REVERSING VALVE REPLACEMENT
Remove the refrigerant charge from the system.
When brazing a reversing valve into the system, it is of extreme importance that the temperature of the valve does not
exceed 250°F. at any time.
Wrap the reversing valve with a large rag saturated with water. "Re-wet" the rag and thoroughly cool the valve after each
brazing operation of the four joints involved. The wet rag
around the reversing valve will eliminate conduction of heat to
the valve body when brazing the line connection.
The use of a wet rag sometimes can be a nuisance. There
are commercial grades of heat absorbing paste that may be
substituted.
After the valve has been installed, leak test, evacuate and
recharge.
4. If power to the control is interrupted, the compressor will
be energized after a 3 minute delay after power is reapplied to the control. The control will flash 6 times to
indicate the compressor is delayed on the anti-short cycle
timer.
5. The control de-energizes the indoor blower 60 seconds
after the call for cooling is removed.
This control has a self diagnostic feature. Before performing
any test observe the LED indicators and compare to the chart
below for board status.
DIAGNOSTICS
NORMAL OPERATION
SHORT CYCLE
LOCKOUT
BOARD FAILURE
LED 1
LED 2
BOTH FLASHING
ALTERNATING
FLASHING
ON
OFF
ON
ON
Normal sequence of operation, Heating Mode.
1. If the compressor has been off for at least 3 minutes when
a call for heat is received, the compressor is immediately
energized. The indoor blower is energized at the cooling
speed after a 7 second delay.
2. If the compressor has not been off for at least 3 minutes
when a call for heating is received, the control waits at
least 3 minutes before energizing the compressor. The
LED will flash 6 times when the compressor is delayed
on the anti-short cycle timer.
4. If power to the control is interrupted, the compressor will
be energized after a 3 minute delay after power is reapplied to the control. The control will flash 6 times to
indicate the compressor is delayed on the anti-short cycle
timer.
The following has been simplified in order to illustrate the
Electronic functions:
5. When the defrost thermostat (30/60 control) closes (coil
temperature at approximately 30°F.), the solid state board
becomes programmed.
S-24 TESTING DEFROST BOARD
The Defrost Control Board is an electronic device which is
not field repairable. If a malfunction should occur the complete board must be replaced. The board has anti-short cycle
protection, high and low pressure switch interrupts incorporated into the control.
47
SERVICING
DEFROST CONTROL BOARD
NOTE: If the board is powered up with the jumper connected
to the test pins, the board will ignore test and default to 90
minute time. If the jumper is left on the test connection for
more than ten minutes, the board will ignore test jumper and
default to 90 minute time. If jumper is missing, the board will
default to 90 minute time.
6. Whenever the (CC) compressor contactor is energized,
the solid state timer counts the compressor run time.
Total accumulated minutes (run time) is retained as long
as the Defrost (30/60) control stays closed. With the
jumper connected to the 90 minute pins, the compressor
run time is 90 minutes (factory wired). The board has
jumper pin for 60 and 30 minute times as well.- Timer
count time may be accelerated for testing only, by placing jumper on test pins. (Example: 90 minutes = approximately 21 seconds). Remove the jumper when the
board goes into defrost mode. If the jumper is not removed, the timer will remain accelerated through the defrost period.
7. At end of the programmed time, common circuit (C) is
made to the (OUT) terminal. The reversing solenoid becomes energized and will stay energized until defrost (30/
60) control opens by coil temperature, or after 10 minutes of run time. Maximum defrost time limited to 10 minutes compressor run time. During the defrost time, the
board will apply power to the "W" terminal to bring on
supplemental electric heat (if installed).
Heatcraft Defrost Board
1. Jumper defrost (30/60 control by placing a jumper wire
across "DF" terminals.) terminal at defrost timer 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.
4. Immediately remove jumper from test pins.
5. Using VOM check for voltage across OUT Terminals (BK19 & BK-20). meter should read 24 volts.
6. Using VOM check for voltage across Fan terminals on
the board (VT-62 & VT-16). You should read line voltage
(208-230 VAC) indicating the relay is open in the defrost
mode.
7. Using VOM check for voltage across "W & C" terminals
on the board. You should read 24 volts.
8. If not as above, replace control board.
9. Set thermostat to off position and disconnect power before removing any jumpers or wires.
NOTE: Remove jumper across defrost thermostat and replace
jumper to 30, 60, or 90 minute position before returning system to service.
8. The control de-energizes the indoor blower 60 seconds
after the call for heating is removed.
To check the defrost timer board for proper sequencing, proceed as follows: With power ON; unit not running.
C O O L IN G
S W IT C H
RE LA Y
R D -2 4
+ 24 V
DEFROST
THERMOSTAT
G Y -8
R E V E R S IN G
S O L E N O ID
Ranco Defrost Board
OR
28
COMMON
Y1 OUT
A
PS2
P
S B
1
A
PS1
O
DF
OUT
FUSE
R
Ranco Defrost Board
1. Jumper defrost (30/60) control by placing a jumper wire
across "DFS" terminals at defrost timer board.
GY
55
Y L -5
2. Connect jumper across test pins on defrost control board.
G
2
1
DE FR OS T
CO N TRO L
3. Set thermostat to call for heating. System should go into
defrost within 21 seconds.
D I A G N O S T IC S
LE D
FAN
G
E
C
W
R
O
Y
SE E
D E T A IL 1
60
30
90
TE ST
D E T A IL 1
48
HE ATCR AFT
A D J U S T A B L E D E F R O S T IN T E R V A L
(F A C T O R Y S E T T IN G A S S H O W N )
O . D.
FA N
M OTOR
4. Immediately remove jumper from test pins.
5. Using VOM check for voltage across RV Terminals. Meter
should read 24 volts.
6. Using VOM check for voltage between the "DF1" and
"DF2" terminals on the board. You should read line voltage (208-230 VAC) indicating the relay is open in the
defrost mode.
SERVICING
7. Using VOM check for voltage across "W & C" terminals
on the board. You should read 24 volts.
8. If not as above, replace control board.
9. Set thermostat to off position and disconnect power before removing any jumpers or wires.
NOTE: Remove jumper across defrost thermostat and replace
jumper to 30, 60, or 90 minute position before returning system to service.
S-25 TESTING DEFROST CONTROL (30°/60°)
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
contacts (30°F. ± 5°F.)
3. Raise the temperature of the control until opens
(60°F. ± 5°F.)
4. If not as above, replace control.
S-50 CHECKING HEATER LIMIT CONTROL(S)
(OPTIONAL ELECTRIC HEATERS)
Each individual heater element is protected with an automatic
reset 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. and
close at 110°F,
WARNING
HIGH VOLTAGE
DISCONNECT ALL POWER BEFORE SERVICING OR
INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY
BE PRESENT. F AILURE TO DO SO MAY CAUSE PROPERTY
UTEC Defrost Control
UTEC Defrost Board
1. Jumper defrost (30/60) control by placing a jumper wire
across "DFT" terminals at defrost timer board.
2. Connect jumper across test pins on defrost control board.
DAMAGE, PERSONAL INJURY OR DEATH.
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.
3. Set thermostat to call for heating. System should go into
defrost within 21 seconds.
IF FOUND OPEN - REPLACE - DO NOT WIRE AROUND.
4. Immediately remove jumper from test pins.
S-52 CHECKING HEATER ELEMENTS
5. Using VOM check for voltage between the "C" and "O"
terminals on the board. Meter should read 24 volts.
Optional electric heaters may be added, in the quantities
shown in the specifications section to provide electric resistance heating. Under no condition shall more heaters than
the quantity shown be installed.
6. Using VOM check for voltage between the "DF1" and
"DF2" terminals on the board. You should read line voltage (208-230 VAC) indicating the relay is open in the
defrost mode.
7. Using VOM check for voltage across "W2 & C" terminals
on the board. You should read 24 volts.
8. If not as above, replace control board.
9. Set thermostat to off position and disconnect power before removing any jumpers or wires.
NOTE: Remove jumper across defrost thermostat and replace
jumper to 30, 60, or 90 minute position before returning system to service.
The low voltage circuit in the blower section is factory wired
and terminates at the location provided for the electric
heater(s).
WARNING
HIGH VOLTAGE
DISCONNECT ALL POWER BEFORE SERVICING OR
INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY
BE PRESENT. F AILURE TO DO SO MAY CAUSE PROPERTY
DAMAGE, PERSONAL INJURY OR DEATH.
1. Dissemble and remove the heating element.
2. Visually inspect the heater assembly for any breaks in
the wire or broken insulators.
49
SERVICING
3. Using an ohmmeter, test the element for continuity - no
reading indicates the element is open. Replace as necessary.
See "Electric Heater" in the Product Design Section to verify
heater amperage and temperature rise.
S-53 OUTDOOR TEMPERATURE CONTROL
(OPTIONAL ITEM)
ATK01 This kit includes an ambient thermostat mounted in
a weatherproof box for installation exterior to the unit. This
kit is used for ambient control on all Amana® brand package
models and remote cooling models.
ELECTRICAL POWER SUPPLY.
1. Remove field connected low voltage wires from control
terminals.
2. In ambient temperatures below 60°F, set the knob to correspond with the actual temperature of the control.
3. Using an ohmmeter, test for continuity between the control terminals. It should not test continuous. The control
is designed to open at this point with a manual differential
of approximately 4°F.
4. In ambient temperatures above 60°F., it will be necessary to chill the control.
OUTDOOR TEMPERATURE CONTROL
S-100 REFRIGERATION REPAIR PRACTICE
DANGER
ALWAYS REMOVE THE REFRIGERANT CHANRGE IN A
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, a liquid line
filter dryer must be installed. The dryer should be installed
between the partition panel and the expansion device.
Heat pump models will require a bi-flow dryer.
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.
WARNING
D ISCONNECT
5. When brazing, sweep the tubing with dry nitrogen to prevent the formation of oxides on the inside surfaces.
PROPER MANNER
S-101 LEAK TESTING
Refrigerant leaks are best detected with a halide or electronic leak detector.
However, on outdoor installed systems, provisions must be
made to shield the copper element of an halide torch from
the sun and wind conditions in order to be able to see the
element properly.
NOTE: The flame of the halide detector will glow green in the
presence of R-22 refrigerant.
For a system that contains a refrigerant charge and is suspected of having a leak, stop the operation and hold the exploring 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.
For a system that has been newly repaired and does not
contain a charge, 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
depressors or special adaptor used. Open the valve on the
cylinder 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.
BEFORE APPLYING HEAT TO THE SYSTEM.
When repairing the refrigeration system:
1. Never open a system that is under vacuum. Air and moisture will be drawn in.
2. Plug or cap all openings.
3. Remove all burrs and clean the brazing surfaces of the
tubing with sand cloth or paper. Brazing materials do not
flow well on oxidized or oily surfaces.
4. Clean the inside of all new tubing to remove oils and pipe
chips.
50
S-102 EVACUATION
This is the most important part of the entire service procedure. The life and efficiency of the equipment is dependent
upon the thoroughness exercised by the serviceman when
evacuating air (non-condensable) and moisture from the system.
Air in a system causes high condensing temperature and
pressure, resulting in increased power input and reduced performance.
SERVICING
Moisture chemically reacts with the refrigerant and oil to form
corrosive hydrofluoric and hydrochloric acids. These attack
motor windings and parts, causing breakdown.
The equipment required to thoroughly evacuate the system
is a high vacuum pump, capable of producing a vacuum equivalent to 25 microns absolute and a thermocouple vacuum gauge
to give a true reading of the vacuum in the system
NOTE: Never use the system compressor as a vacuum pump
or run when under a high vacuum. Motor damage could occur.
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 SEVERALLY
RESTRICTED, THE SCROLL COMPRESSOR CAN AND WILL DRAW A DEEP
VACUUM VERY QUICKLY.
THIS VACUUM CAN CAUSE INTERNAL ARCING OF
3. Start the vacuum pump and open the shut off valve to the
high vacuum gauge manifold only. After the compound
gauge (low side) has dropped to approximately 29 inches
of vacuum, open the valve to the vacuum thermocouple
gauge. See that the vacuum pump will blank-off to a
maximum of 25 microns. A high vacuum pump can only
produce a good vacuum if its oil is non-contaminated.
4. If the vacuum pump is working properly, close the valve to
the vacuum thermocouple gauge and open the high and
low side valves to the high vacuum manifold set. With
the valve on the charging cylinder closed, open the manifold valve to the cylinder.
5. Evacuate the system to at least 29 inches gauge before
opening valve to thermocouple vacuum gauge.
6. Continue to evacuate to a minimum of 250 microns. Close
valve to vacuum pump and watch rate of rise. If vacuum
does not rise above 1500 microns in three to five minutes, system can be considered properly evacuated.
THE FUSITE RESULTING IN A DAMAGED OR FAILED COMPRESSOR.
7. If thermocouple vacuum gauge continues to rise and levels off at about 5000 microns, moisture and non-condensables are still present. If gauge continues to rise a leak
is present. Repair and re-evacuate.
R-22
MANIFOLD
LOW SIDE
GAUGE
AND VALVE
8. Close valve to thermocouple vacuum gauge and vacuum
pump. Shut off pump and prepare to charge.
HIGH SIDE
GAUGE
AND VALVE
S-103 CHARGING
Charge the system with the exact amount of refrigerant.
800 PSI
RATED
HOSES
Refer to the specification section or check the unit nameplates for the correct refrigerant charge.
{
CHARGING
CYLINDER
AND SCALE
TO
UNIT SERVICE
VALVE PORTS
VACUUM PUMP
ADAPTER
VACUUM PUMP
EVACUATION
1. Connect the vacuum pump, vacuum tight manifold set
with high vacuum hoses, thermocouple vacuum gauge
and charging cylinder as shown.
2. If the service dill valves are to be used for evacuation, it is
recommended that a core remover be used to lift the core
for greater efficiency.
An inaccurately charged system will cause future problems.
1. When using an ambient compensated calibrated charging cylinder, 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. DO NOT charge in a liquid
form.
4. With the system still running, close the valve on the charging cylinder. At this time, you may still have some liquid
refrigerant in the charging cylinder hose and will definitely
have liquid in the liquid hose. Reseat the liquid line core.
Slowly open the high side manifold valve and transfer the
liquid refrigerant from the liquid line hose and charging
cylinder hose into the suction service valve port. CAREFUL: Watch so that liquid refrigerant does not enter the
compressor.
5. With the system still running, reseat the suction valve
core, remove hose and reinstall both valve core caps.
6. Check system for leaks.
51
SERVICING
NOTE: THIS CHARGING PROCEDURE CAN ONLY BE
DONE IN THE COOLING MODE OF OPERATION. ALL
MODELS WITH COMPRESSOR PROCESS TUBE ACCESS
VALVE CAN BE PROCESSED IN HEATING CYCLE IF THIS
VALVE IS USED.
Units having capillary tubes or flow control restrictors can be
checked against the Desired Superheat vs. Outdoor Temperature Chart in this section. Coils with thermostatic expansion valves (TXV's) must be checked by subcooling. See
"Checking Subcooling and Superheat" sections in this
manual.
If a restriction is located, replace the restricted part, replace
drier, evacuate and recharge.
S-104 CHECKING COMPRESSOR EFFICIENCY
The reason for compressor inefficiency is broken or damaged suction and/or discharge valves, or scroll flanks on Scroll
compressors, reducing the ability of the compressor to pump
refrigerant vapor.
The condition of the valves or scroll flanks is checked in the
following manner.
1. Attach gauges to the high and low side of the system.
2. Start the system and run a "Cooling Performance Test.
If the test shows⇒
Below normal high side pressure.
⇒
Above normal low side pressure.
⇒
Low temperature difference across coil.
⇒
Low amp draw at compressor.
-and the charge is correct. The compressor is faulty - replace the compressor. NOTE: THIS TEST CANNOT BE
DONE IN THE HEATING MODE
S-105 THERMOSTATIC EXPANSION VALVE
The expansion valve is designed to control the rate of liquid
refrigerant flow into an evaporator coil in exact proportion to
the rate of evaporation of the refrigerant in the coil. The amount
of refrigerant entering the coil is regulated since the valve
responds to temperature of the refrigerant gas leaving the
coil (feeler bulb contact) and the pressure of the refrigerant in
the coil.
This regulation of the flow prevents the return of liquid refrigerant to the compressor.
The three forces which govern the operation of the valve are:
52
(1) the pressure created in the power assembly by the feeler
bulb, (2) evaporator pressure, and (3) the equivalent pressure
of the superheat spring in the valve.
0% bleed type expansion valves are used on the indoor coils.
The 0% valve will not allow the system pressures (High and
Low side) to equalize during the shut down period. The valve
will shut off completely at approximately 100 PSIG Pressure.
Good thermal contact between the feeler bulb and the suction line is essential to satisfactory valve control and performance.
The bulb must be securely fastened to a clean straight section of the suction line. Application of the bulb to a horizontal
run of line is preferred. If a vertical installation cannot be
avoided the bulb should be mounted so that the capillary
tubing comes out at the top.
THE VALVES PROVIDED BY AMANA® BRAND ARE DESIGNED TO MEET THE SPECIFICATION REQUIREMENTS
FOR OPTIMUM PRODUCT OPERATION. DO NOT USE
SUBSTITUTES.
S-106 OVERFEEDING
Overfeeding by the expansion valve results in high suction
pressure, cold suction line, and possible liquid slugging of
the compressor.
If these symptoms are observed:
1. Check for an overcharged unit by referring to the cooling
performance charts in the servicing section.
2. Check the operation of the power element in the valve as
explained in S-110 Checking Expansion Valve Operation.
3. Check for restricted or plugged equalizer tube.
S-107 UNDERFEEDING
Underfeeding by the expansion valve results in low system
capacity and low suction pressures.
If these symptoms are observed:
1. Check for a restricted liquid line or drier. A restriction will
be indicated by a temperature drop across the drier.
2. Check the operation of the power element of the valve as
described in S-110 Checking Expansion Valve Operation.
SERVICING
S-108 SUPERHEAT
The expansion valves are factory adjusted to maintain 12 to
18 degrees superheat of the suction gas. Before checking
the superheat or replacing the valve, perform all the procedures outlined under Air Flow, Refrigerant Charge, Expansion Valve - Overfeeding, Underfeeding. These are the most
common causes for evaporator malfunction.
CHECKING SUPERHEAT
Refrigerant gas is considered superheated whenever its temperature is higher than the saturation temperature corresponding to its pressure. The degree of superheat equals the degrees of temperature increase above the saturation temperature at existing pressure. See Temperature - Pressure Chart.
1. Attach an accurate thermometer or preferably a thermocouple type temperature tester to the suction line at a
point at least 6" from the compressor.
5. The difference between the thermometer reading and pressure to temperature conversion is the amount of superheat.
EXAMPLE:
a. Suction Pressure = 84
b. Corresponding Temp. °F. = 50
c. Thermometer on Suction Line = 63°F.
To obtain the degrees temperature of superheat subtract 50.0
from 63.0°F.
The difference is 13° Superheat. The 13° Superheat would
fall in the ± range of allowable superheat.
SUPERHEAT ADJUSTMENT
The expansion valves used on Amana® brand coils are factory set and are not field adjustable. If the superheat setting
becomes disturbed, replace the valve.
2. Install a low side pressure gauge on the suction line service valve at the outdoor unit.
3. Record the gauge pressure and the temperature of the
line.
4. Convert the suction pressure gauge reading to temperature by finding the gauge reading in Temperature - Pressure Chart and reading to the left, find the temperature in
the °F. Column.
DESIRED SUPERHEAT vs OUTDOOR TEMPERATURE
36
34
32
90
°F
28
26
24
75
°F
22
°F
70
20
or
do
In
SUPERHEAT @ O.D. UNIT
30
18
16
80
°F
In
do
or
85
°F
In
do
or
Ind
oo
r
In
do
or
14
12
10
8
6
4
50
60
70
80
90
100
110
120
OUTDOOR TEMPERATURE
53
SERVICING
TEMPERATURE - PRESSURE (R-22)
Temp.
°F.
Gauge Pressure
(PSIG) Freon-22
Temp.
°F.
Gauge Pressure
(PSIG) Freon-22
-40
-38
-36
-34
-32
-30
-28
-26
-24
-22
-20
-18
-16
-14
-12
-10
-8
-6
-4
-2
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
0.61
1.42
2.27
3.15
4.07
5.02
6.01
7.03
8.09
9.18
10.31
11.48
12.61
13.94
15.24
16.59
17.99
19.44
20.94
22.49
24.09
25.73
27.44
29.21
31.04
32.93
34.88
36.89
38.96
41.09
43.28
45.53
47.85
50.24
52.70
55.23
57.83
60.51
63.27
66.11
69.02
71.99
75.04
78.18
81.40
84.70
88.10
91.5
56
58
95.1
98.8
60
62
64
65
68
70
72
74
76
78
80
82
84
86
88
90
92
94
96
96
100
102
104
106
108
110
112
114
116
118
120
122
124
126
128
130
132
134
136
136
140
142
144
146
158
150
152
154
156
158
160
102.5
106.3
110.2
114.2
118.3
122.5
126.8
131.2
135.7
140.5
145.0
149.5
154.7
159.8
164.9
170.1
175.4
180.9
186.5
192.1
197.9
203.8
209.9
216.0
222.3
228.7
235.2
241.9
248.7
255.6
262.6
269.7
276.9
284.1
291.4
298.8
306.3
314.0
321.9
329.9
338.0
346.3
355.0
364.3
374.1
384.3
392.3
401.3
411.3
421.8
433.3
54
S-109 CHECKING SUBCOOLING
Refrigerant liquid is considered subcooled whenever its temperature 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 thermocouple type temperature tester to the liquid line as it leaves
the condensing unit.
2. Install a high side pressure gauge on the high side service valve at the front of the unit.
3. Record the gauge pressure and the temperature of the
line.
4. Convert the discharge pressure gauge reading to temperature by finding the gauge reading in Temperature Pressure Chart and reading to the left, find the temperature in the °F. Column.
5. The difference between the thermometer reading and pressure to temperature conversion is the amount of subcooling.
EXAMPLE:
a. Discharge Pressure = 260
b. Corresponding Temp. °F. = 120°
c. Thermometer on Liquid line = 109°F.
To obtain the amount of subcooling subtract 109°F from 120°F.
The difference is 11° subcooling. The normal subcooling range
is 9° - 13° subcooling for heat pumps units, 14° - 18° for
cooling units and gas packs.
S-110 CHECKING EXPANSION VALVE OPERATION
1. Remove the remote bulb of the expansion valve from the
suction line.
2. Start the system and cool the bulb in a container of ice
water, closing the valve. As you cool the bulb the suction
pressure should fall and the suction temperature will rise.
3. Next warm the bulb in your hand. As you warm the bulb
the suction pressure should rise and the suction temperature will fall.
4. If a temperature or pressure change is noticed, the expansion valve is operating. If no change is noticed, the
valve is restricted, the power element is faulty, or the
equalizer tube is plugged.
5. Remove the charge, replace the valve and drier, evacuate
and recharge.
SERVICING
S-111 FIXED ORIFICE RESTRICTION DEVICES
S-113 OVERCHARGE OF REFRIGERANT
The fixed orifice restriction device (flowrator) used in conjunction with the indoor and outdoor coils are a predetermined
bore (I.D.).
An overcharge of refrigerant is normally indicated by an excessively high head pressure.
It is designed to control the rate of liquid refrigerant flow into
an evaporator coil.
The amount of refrigerant that flows through the fixed orifice
restriction device is regulated by the pressure difference between the high and low sides of the system.
In the cooling cycle when the outdoor air temperature rises,
the high side condensing pressure rises. At the same time,
the cooling load on the indoor coil increases, causing the low
side pressure to rise, but at a slower rate.
Since the high side pressure rises faster when the temperature increases, more refrigerant flows to the evaporator, increasing the cooling capacity of the system.
When the outdoor temperature falls, the reverse takes place.
The condensing pressure falls, and the cooling loads on the
indoor coil decreases, causing less refrigerant flow.
A strainer is placed on the entering side of the tube to prevent any foreign material from becoming lodged inside the
fixed orifice restriction device.
If a restriction should become evident, proceed as follows:
1. Recover refrigerant charge.
2. Remove the orifice or tube strainer assembly and replace.
3. Replace liquid line drier, evacuate and recharge.
CHECKING EQUALIZATION TIME
During the "OFF" cycle, the high side pressure bleeds to the
low side through the fixed orifice restriction device. Check
equalization time as follows:
1. Attach a gauge manifold to the suction and liquid line dill
valves.
2. Start the system and allow the pressures to stabilize.
3. Stop the system and check the time it takes for the high
and low pressure gauge readings to equalize.
If it takes more than seven (7) minutes to equalize, the restriction 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 the liquid line is restricted, a definite temperature
drop will be noticed at the point of restriction. In severe cases,
frost will form at the restriction and extend down the line in
the direction of the flow.
Discharge and suction pressures will be low, giving the appearance 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.
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 metering device, could
allow refrigerant to return to the compressor under extreme
overcharge conditions. Also with a fixed orifice 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 is observed:
1. Start the system.
2. Remove small quantities of gas from the suction line dill
valve until the head pressure is reduced to normal.
3. Observe the system while running a cooling performance
test, if a shortage of refrigerant is indicated, then the system contains non-condensables.
S-114 NON-CONDENSABLES
If non-condensables are suspected shut down the system
and allow the pressures to equalize, wait at least 15 minutes. Compare the pressure, to the temperature of the coldest coil since this is where most of the refrigerant will be. If
the pressure indicates a higher temperature than that of the
coil temperature, non-condensables are present.
Non-condensables are removed from the system by first removing the refrigerant charge, replacing and/or installing liquid line drier, evacuate and recharging.
S-115 COMPRESSOR BURNOUT
When a compressor burns out, high temperature develops
causing the refrigerant, oil and motor insulation to decompose forming acids and sludge.
If a compressor is suspected of being burned-out, attach a
refrigerant hose to the liquid line dill valve and properly remove and dispose of the refrigerant.
Now determine if a burn out has actually occurred. Confirm
by analyzing an oil sample using a Sporlan Acid Test Kit,
AK-3 or its equivalent.
Remove the compressor and obtain an oil sample from the
suction stub. If the oil is not acidic, either a burnout has not
occurred or the burnout is so mild that a complete cleanup is
not necessary.
If acid level is unacceptable the system must be cleaned by
using the cleanup drier method.
55
SERVICING
S-200 CHECKING EXTERNAL STATIC PRESSURE
CAUTION
D O NOT ALLOW THE SLUDGE
OR OIL TO CONTACT THE SKIN.
S EVERE
BURNS MAY RESULT.
NOTE: The Flushing Method using R-11 refrigerant is no
longer approved by Goodman Company, L.P.
Suction Line Drier Clean-Up Method
Use AMANA® brand part number R0157057 Suction Line
Drier Clean-Up Kit (41 cubic inches). This drier should be
installed as close to the compressor as possible, either in a
vertical or horizontal position. It may be necessary to use
new tubing and form as required.
In all applications, the drier inlet must be above the drier outlet to provide proper oil return to the compressor.
The minimum and maximum allowable duct static pressure
is found in the specification section.
Too great of an external static pressure will result in insufficient air that can cause icing of the coil, whereas too much
air can cause poor humidity control, and condensate to be
pulled off the evaporator coil causing condensate leakage.
Too much air can cause motor overloading and in many cases
this constitutes a poorly designed system. To determine
proper air movement, proceed as follows:
1. Using a draft gauge (inclined manometer) measure the
static pressure of the return duct at the inlet of the unit,
(Negative Pressure).
NOTE: At least twelve (12) inches of the suction line immediately out of the compressor stub must be discarded due to
burned residue and contaminates.
1. Remove compressor discharge line strainer, liquid line
strainer and/or dryer and capillary tubes from indoor and
outdoor coils.
2. On an expansion valve coil, remove the liquid line drier
and expansion valve.
3. Purge all remaining components with dry nitrogen or carbon dioxide until clean.
4. Install new components including liquid liner drier.
5. Install suction line drier.
6. Braze all joints, leak test, evacuate, and recharge system.
7. Start up the unit and record the pressure drop across the
cleanup drier.
8. Continue to run the system for a minimum of twelve (12)
hours and recheck the pressure drop across the drier.
Pressure drop should not exceed 6 - 8 PSIG.
9. Continue to run the system for several days repeatedly
checking pressure drop across the suction line drier. If
the pressure drop never exceeds the 6 - 8 PSIG, the drier
must be adequate and is trapping the contaminants and
it is permissible to leave it in the system.
10. If the pressure drop becomes greater, then it must be
replaced and steps 5 through 9 repeated until it does not
exceed 6 - 8 PSIG.
NOTICE: Regardless, the cause for burnout must be determined and corrected before the new compressor is started.
56
INCLINED
MANOMETER
SUPPLY
RETURN
TOTAL EXTERNAL 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 if so desired.
4. Consult proper table for quantity of air.
If the external static pressure exceeds the minimum or maximum allowable statics, check for closed dampers, dirty filters, undersized or poorly laid out ductwork.
S-300 TESTING PRIMARY LIMIT CONTROL
Amana® brand Package Gas Units use a snap-disk type primary limit device. Sometimes referred to as "stat on a stick".
The limit setting is fixed and must not be readjusted in the
field.
SERVICING
AUX. LIMIT
THERMODISC (TOD) LIMIT CONTROL
Refer to the specification section to determine the proper
limit cutout temperature for the model being serviced.
In all instances the limit control is wired in series with the
ignition control.
If the temperature within the furnace should exceed this setting, the control will open, de-energizing the ignition control
which in turn will open the electrical circuit to the gas valve.
The control will automatically reset when the temperature
within the combustion chamber is sufficiently lowered.
WARNING
HIGH VOLTAGE
DISCONNECT ALL POWER BEFORE SERVICING OR
INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY
BE PRESENT. F AILURE TO DO SO MAY CAUSE PROPERTY
DAMAGE, PERSONAL INJURY OR DEATH.
1. Remove electrical power to unit. Some units may have
more than one source of power.
2. Remove the wires from the limit control terminals.
WARNING
D ISCONNECT ELECTRICAL
POWER SUPPLY.
1. Remove the wires from the auxiliary limit control terminals.
2. Using an ohmmeter, test for continuity across the two
terminals. No reading indicates the control is open. Push
the red reset button, test again - if still open, replace the
control.
3. Using an ohmmeter, test for continuity across the two
terminals.
4. If limit test open allow unit to cool and retest.
5. If still open, replace the control.
OHMMETER
S-301 TESTING AUXILIARY LIMIT CONTROL
This control is preset nonadjustable control mounted in the
blower compartment area.
It is connected in series with the limit control wiring to the
ignition control. If its temperature should be exceeded, it will
open, interrupting the voltage to the gas valve causing it to
open.
LIMIT OR AUXILIARY LIMIT CONTROL
S-302 CHECKING FLAME ROLLOUT SWITCH
Package Gas Units with serial numbers beginning 9001 and
later use a temperature activated manual reset control
mounted to the manifold assembly.
This control is wired in series with the primary limit and integrated control. The control is designed to open should a flame
roll out occur. An over firing condition or flame impingement
on the heat shield may also cause the control to open.
57
SERVICING
If the rollout control has opened, the circuit between the ignition control and gas valve will be interrupted and the ignition
control module will go into lockout. The servicer should reset
the ignition control by opening and closing the thermostat
circuit. The servicer should look for the ignitor glowing which
indicates there is power to the ignition control. The servicer
should measure the voltage between each side of the rollout
control and ground while the ignition control is trying to power
the gas valve.
Limit Switch Operation (Applies to Primary, Auxiliary, and
Roll Out Limits) DSI systems
If a limit switch opens, the indoor blower is energized on heat
speed and the induced draft blower is energized. The LED
on the control flashes "4" to indicate an open limit switch.
The blower and inducer remain on while the limit switch is
open. The gas valve is de-energized. Power to the thermostat "R" is removed while the limit switch is open.
When the limit switch re-closes, the induced draft motor runs
through its post purge and the indoor blower goes through
the heat off delay.
If a call for heat exists when the limit switch re-closes, the
control goes through a pre-purge period and then makes an
ignition attempt. The indoor blower remains on (for the delay
off time) during the re-ignition attempt.
5.
Look under the heat shield as the unit is running. Flames
should be drawn into firing tubes.
A.
If only one burner flame is not drawn into the tube,
that tube is restricted.
B.
If with out the air circulation blower running, all
flames are not drawn into the tubes either the collector box, combustion blower, or flue outlet is obstructed. If the combustion blower or flue outlet is
obstructed, the pressure switch should have opened
preventing the unit from firing, also inspect the unit
pressure switch and wiring.
C.
If the burner flame is not drawn into the tube only
when the air circulation blower is running, then a
cracked heat exchanger tube is present.
S-304 TESTING GAS VALVE
Smart Valve Systems
Amana® brand package units utilize Honeywell "Smart Valve"
gas valves which provides all manual and automatic control
functions required for gas fired heating equipment.
UNUSED
1
3
S
1
S
MOTOR
LEADS
2
3
C
4
NEUTRAL
C
O
O
L
2
S
X
XFMR SEC
H
E
A
T
a. If no voltage is measured on either side of control it
indicates ignition control or wiring to control problem.
b. If voltage is measured on one side of the control and
not the other, it indicates the control is open.
c. If voltage is measured on both sides of the control the
wiring to gas valve or valve is at fault.
2. Check to see if any damage was done to the furnace
especially the wiring.
3. Confirm that heat exchanger is not obstructed by feeling
for discharge air from the flue hood when the combustion
blower is running but the unit is not firing.
If the above steps do not suggest the reason the control has
tripped the furnace should be fired.
OFF
C G Y W R
90
HEAT FAN 120
DELAY
150
Servicing procedure with furnace not firing.
1. Confirm that the outer door was in place and all screws
tightened. (No leaks under the door.)
C
Y
60
SMART VALVE FAN TIMER BOARD
NORMAL SEQUENCE OF OPERATION
1. Thermostat calls for heat. The combustion blower is immediately energized.
2. The pressure switch contacts transfer.
1. Remove the heating compartment door.
3. The ignitor is energized and pilot gas begins to flow.
2. Turn off the power or open the thermostat circuit.
4. After pilot flame is proven, the main valve is energized
and the pilot will light the main burners.
3. Reset the roll-out control.
4. Turn power on and put the unit into a call for heating.
CAUTION
ASSUME FLAME ROLL-OUT COULD OCCUR. KEEP FACE AND HANDS
DISTANCE FROM BURNER AREA.
58
5. The control checks the signal from the flame sensor. Gas
flow will continue only if a proper signal is present. As
soon as pilot flame is proven, the ignitor is de-energized.
6. The unit will continue to fire for 30 seconds. The fan control will then start the main circulating air blower.
A SAFE
SERVICING
7. The unit will deliver heat to the conditioned space until
the thermostat is satisfied.
11. Using a microamp meter verify flame sense. Microamp
readings should be 0.3 microamps or greater.
12. Smart Valve will not allow main burner operation until pilot is proven. NOTE: pilot positioning will affect pilot operation and flame sensing characteristics. See S-314 for
proper pilot positioning
13. If pilot looses flame sense, valve will shut off main burners and attempt relight. The "Smart Valve" system will
not lock out from no flame sense, it will continue to attempt relight.
MATES WITH
HONEYWELL
Q3450* PILOT
HARNESS
PRESSURE REGULATOR
ADJUSTMENT (UNDER
CAP SCREW)
MATES WITH
SOCKET HOUSING
CONTROL MODULE
HIGH VOLTAGE
DISCONNECT ALL POWER BEFORE SERVICING OR
INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY
BE PRESENT. F AILURE TO DO SO MAY CAUSE PROPERTY
A-A
IGNITOR
ON
IN
WARNING
10. Ignitor warn up is 5 Seconds. Amp draw to ignitor is 1 to
1.5 amps at 24 VAC. Use an Amprobe to verify current.
PSI
IMPORTANT: If the furnace frequently has to be reset, it
means that a problem exists that should be corrected.
9. Set thermostat to demand for heat.
2
RESET AFTER CONTROL LOCKOUT
Amana® brand PGA__C, PGB__C and PGD__C units built
prior to July, 1999, are equipped with the Honeywell "Smart
Valve" system. If the control senses a loss of flame, the control will automatically attempt to relight. A lockout occurs
only when the ignitor fails, roll-out switch, primary limit or
secondary limit opens. This causes the air circulation blower
to run continuously, and ignition is no longer attempted. When
this occurs, it may be necessary to reset the control by turning the thermostat setting below room temperature for several seconds and then returning the setting to the desired
temperature. The roll-out and secondary limit are manual reset switches and require resetting before normal operation
can continue. A failed ignitor will require replacement. The
control may also be reset after a lockout by turning off the
electrical disconnect switch to the furnace for several seconds.
VOLTAGE NOW PRESENT.
CONT ROL
9. There is an adjustable Heat Fan OFF of approximately
60/90/120/150 second delay (factory set at 120). The control module will de-energize the blower once the selected
time has elapsed. This allows any additional heat in the
heat exchanger to be transferred to the conditioned space.
WARNING
OFF
8. The gas valve and combustion blower will be de-energized
when the thermostat opens.
OUTLET PRESSURE TAP
1/8 N.P.T., PLUGGED
(STEEL)
MATES WITH
HONEYWELL
Q3450* PILOT
HARNESS
DAMAGE, PERSONAL INJURY OR DEATH.
1. Remove wire connections from gas valve terminals.
2. Using an ohmmeter, test across the ignitor terminals,
(Terminals 1 & 2 on the Q3450 harness)
3. Should read continuity, if not replace ignitor.
4. Using an ohmmeter, test from flame sensor to ground on
the Q3450 harness.
6. If continuity is shown, replace pilot assembly.
VIEW A-A
HONEYWELL MODEL SV9502
7. Reconnect harness(es) to gas valve.
8. Restore power to unit.
59
SERVICING
A dent or burr will cause severe deflection of gas stream.
1/2PSI
No resizing should be attempted until all factors are taken
into consideration such as inlet manifold gas pressure, alignment, and positioning, specific gravity and BTU content of
the gas being consumed.
OFF
IN
ON
The only time resizing is required is when a reduction in firing
rate is required for an increase in altitude.
MATES WITH
HONEYWELL
Q3450* PILOT MATES WITH
HARNESS
SOCKET HOUSING
MOLEX 39-01-0240
TO CONTROL
Orifices should be treated with care in order to prevent damage. They should be removed and installed with a box-end
wrench in order to prevent distortion. In no instance should
an orifice be peened over and redrilled. This will change the
angle or deflection of the vacuum effect or entraining of primary air, which will make it difficult to adjust the flame properly. This same problem can occur if an orifice spud of a
different length is substituted.
HONEYWELL
IGNITER
WARNING
CONTROL
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 orifice visually for distortion and/or burrs.
2. Check orifice size with orifice sizing drills.
HONEYWELL MODEL SV9501
S-306 CHECKING ORIFICES
3. If resizing is required, a new orifice of the same physical
size and angle with proper drill size opening should be
installed.
S-307 CHECKING GAS PRESSURE
A predetermined fixed gas orifice is used in all of these furnaces. That is an orifice which has a fixed bore and position.
Gas inlet and manifold pressures should be checked and
adjusted in accordance to the type of fuel being consumed.
A
WARNING
D ISCONNECT
GAS
STREAM B
DENT OR
BURR
GAS
STREAM B
The length of Dimension "A" determines the angle of Gas
Stream Defraction,"B".
60
GAS AND ELECTRICAL POWER SUPPLY.
1. Connect a water manometer or adequate gauge upstream
of the gas valve. (If no provisions are provided, we suggest removing cap from dripleg and install a predrilled
cap with hose fitting as shown in the following drawing.)
SERVICING
S-308 CHECKING FOR DELAYED IGNITION
Delayed ignition is a delay in lighting a combustible mixture
of gas and air which has accumulated in the combustion
chamber.
Gas Line
Gas Shutoff Valve
When the mixture does ignite, it may explode and/or rollout
causing burning in the burner venturi.
If delayed ignition should occur, the following should be
checked:
Gas Line
To Furnace
Open To
Atm ospere
Drip Leg Cap
With Fitting
1. Improper gas pressure - adjust to proper pressure. (See
S-307)
2. Improper burner positioning - burners should be in locating slots, level front to rear and left to right.
3. Carry over (lighter tube or cross lighter) obstructed - clean.
4. Main burner orifice(s) deformed, or out of alignment to
burner - replace.
M anom eter Hose
S-309 CHECKING FOR FLASHBACK
MEASURING INLET GAS PRESSURE
Flashback will also cause burning in the burner venturi, but is
caused by the burning speed being greater than the gas-air
flow velocity coming from a burner port.
2. Remove the pressure tap fitting at the manifold if provided
or from the gas valve and install fitting to connect another
manometer or gauge.
Flashback may occur at the moment of ignition, after a burner
heats up or when the burner turns off. The latter is known as
extinction pop.
M anom eter
Gas Valve Control
ON/Off Switch
INLET
Open to
Atmosphere
WR
O
F
F
1
P
3
C
2
OUTLET
ON
Inlet Pressure Tap
(Side of Valve)
Manometer Hose
M
Outlet (Manifold)Pressure Tap
(Side of Valve)
Pressure Regulator Adjustment
(Under Cap Screw)
If flashback should occur, check for the following:
1. Improper gas pressure - adjust to proper pressure. See
S-307.
2. Check burner for proper alignment and/or replace burner.
3. Improper orifice size - check orifice for obstruction.
Manometer
S-310 CHECKING PRESSURE CONTROL
MEASURING MANIFOLD GAS PRESSURE
A pressure control device is used to measure negative pressure at the induced draft blower motor inlet to detect a partial
or blocked flue.
With Power ON:
WARNING
L INE
Since the end results of flashback and delayed ignition can
be the same (burning in the burner venturi) a definite attempt
should be made to determine which has occurred.
VOLTAGE NOW PRESENT.
3. Put furnace into heating cycle and turn on all other gas
consuming appliances.
For NATURAL GAS:
a.
Inlet pressure should be a nominal 7" w.c.
b.
Manifold pressure should be 3.5 ± .3"w.c.
(Canadian - Sea Level 4.2" ± .3" w.c.)
For PROPANE GAS:
a.
Inlet pressure should be a nominal 11" w.c.
b.
Manifold pressure should be a nominal 10" w.c.
If operating pressures differ from above, make necessary pressure regulator adjustments, check piping size, etc., and/or
consult with local utility.
Pressure Switch Operation (Honeywell Smart Valve
System)
The pressure switch is ignored unless there is a call for heat.
When the control receives a call for heat, power for the smart
valve is routed through the pressure switch (wires VT-18 YL-11). The valve is not energized until the pressure switch
is closed. If at any time the pressures opens power to the
gas valve is removed. The inducer motor will continue to run
as long as there is a call for heat at the thermostat.
Pressure Switch Operation (DSI Direct Spark System)
The pressure switch is ignored unless there is a call for heat.
When the control receives a call for heat, the control checks
to see that the pressure switch is open. If the control sees
that the pressure switch is closed before the induced draft
blower is energized, the LED will flash a code of "3" (to indicate the pressure switch is stuck closed) and the inducer
will remain off until the pressure switch opens.
Continued on page 66
61
SERVICING
Honeywell Smart Valve Sequence of Operation
SV9500
Start
Power to System
Board checks limit circuit
Limit(s) open
Limits closed
Control board applies power to
Air circulating blower (ACB)
cooling speed. Pilot and Igniter
are locked out.
Thermostat calls for heat
Self Check
"Smart Valve" checks Igniter
circuit and valve
Ignition
Igniter
Missing
or Broken
System shuts down..
Igniter and gas
valve check OK
"Smart Valve" powers Igniter,
opens pilot valve.
Pilot Lights, Flame Rod
Senses Flame
No
Igniter stays on
Pilot valve remains
open
Flame outage
occurs during
run cycle
Main valve closes
Yes
Main
Burner
Operation
Igniter Off
Main Valve Opens
Main burner Lights
Smart Valve sends signal
(24V) to control board.
Igniter
opens
Control board times out,
applies power to blower
(ACB) heating speed.
End
Thermostat Ends "Call
for Heat"
Main and Pilot Valves Close
Control board times out.
De-energizes power to
blower (ACB)
62
Pilot and main valves
close.
System shuts down.
SERVICING
Honeywell Smart Valve Sequence of Operation
SV9501
Start
Power to System
Control board applies power to
Air circulating blower (ACB)
cooling speed. Pilot and Igniter
are locked out.
Limit(s)
open
Board checks limit circuit
Limits closed
Five minute retry delay
Thermostat calls for heat
Self Check
Flame signal detected
Yes
No
Pilot valve and Igniter remain
closed. Valve waits for flame
signal to disappear
"Smart Valve" internal check
(valve and igniter) OK?
Trial
For
Ignition
No
Three second flame
Failure recycle delay
Yes
"Smart Valve" powers Igniter,
opens pilot valve.
Pilot Lights, Valve Senses Flame
Yes
Main
Burner
Operation
Igniter Off Main Valve Opens
Main burner Lights Smart Valve
sends signal (24V) to control
board.
No
Pilot valve closes,
Igniter off.
Control board times out, applies
power to blower (ACB) heating
speed.
Flame signal lost
No
90 Second trial for ignition.
Ignter and pilot open, after
30 seconds igniter cycles off
pilot stays on. After 30
Seconds (60 from start),
igniter will cycle on for 30
seconds.
Igniter
opens
Yes
Pilot and main valves close.
EFT (Electronic Fan Timer)
output de-energizes.
Thermostat Ends "Call for Heat"
End
Main and Pilot Valves Close
Control board times out.
De-energizes power to blower
(ACB)
No
Flame signal lost more
than 5 times in one call
for heat
Yes
63
64
YES
Turn gas on.
Pilot burner lights
YES
Igniter warms up and
glows red.
YES
NO
NO
Check gas valve
Check pilot assembly
Check pilot to burner alignment.
Check ingiter
Check gas valve
Check pressure switch operation
Check induced draft blower operation
Check primary, Aux. & roll out limits
NO
NO
NO
YES
NO
NO
Verify that pilot orifice is free of
obstructions and corectly sized for gas
d
d
Verify that pilot adjustment on gas valve
open and adjusted correctly
Clear obstruction or
replace pilot orifice
Open or adjust gas
valve pilot
NO
Correct pilot position
Replace Igniter/Flame
sensor assembly
Replace Smart Valve
Repair wiring or replace pressure switch
Replace I.D. Blower
Replace control board
Reset or replace limit
Repair/replace
thermostat/thermostat
wiring
Correct low voltage
Correct line voltage
ACTION
NO
Verify that pilot is positioned in front of the NO
burner carry-over
Check igniter continuity with Ohm meter
Unplug pilot burner cable
Measure voltage at Terminals 1&2 on
Smart Valve. (19.5 Minimum 27.5 Max.)
Check Voltage @ Yel.-11 at Smart valve
(19.5 volts min. 27.5 Max.)
Check Voltage @ Red & Violet Wires to
ID blower @ Control Board(230 volts)
Measure voltage @ Control board molex
plug "OR-49 to BR-21. Must read 0 volts
Check thermostat & wiring
Smart Valve is
powered. (24volt
nominal- 19.5 volts
minimum. 27.5 Max.
Measure voltage @ Control board
terminals "W" to C 19.5 Min. 27.5 Max.
Check Voltage @ transformer
NO
NO
Measure voltage @ Control board GY-25
& R-1
Check line voltage
Turn gas supply off.
Set thermostat to call
for heat.
NO
NO
Measure voltage @ L1, L2, & GR.
Check
Start
PROCEDURE
SMART VALVE DIAGNOSTIC / TROUBLE SHOOTING CHART
SERVICING
Smart Valve system
OK
YES
Blower runs after 30
Seconds
YES
Main valve opens
NO
NO
Verify unit is properly grounded?
Check flame proving circuits and gas
valve
Check control board
Replace control board
YES
Check for output from gas valve to control
board. 19.5 volts min. at Blue 34 wire to
transformer common.
Discard old Igniter/flame sensor Assembly
YES
Replace Igniter/flame sensor assembly
and restart trouble shooting sequence
Does main burner light?
YES
Verify flames sense circuit. Remove
power to unit and measure ohms from
pilot hood to tramsformer common. 10
ohms max.
YES
NO
Verify that pilot adjustment on gas valve
open and adjusted correctly
Check gas valve
NO
NO
NO
NO
NO
Verify that pilot is positioned in front of the
burner carry-over
Check pilot to burner alignment.
Repair/Replace
harness or gas valve.
Replace Smart Valve.
Reuse ignitor/flame
sensor assembly
Repair or clean pilot
mounting or
transformer grounding.
correct unit grounding
Open or adjust gas
valve pilot
Correct pilot position
SERVICING
65
SERVICING
If the pressure switch opens before the ignition period, the
induced draft blower will remain on and the control will stay in
pre-purge until the pressure switch is closed for an entire 15
second pre-purge period. The LED will flash a code of "2" to
indicate open pressure switch.
If the pressure switch opens after the gas valve has been
energized, the control will de-energize the gas valve and run
the indoor blower through the heat off delay. The inducer
stays on until the pressure switch re-closes. Then the control makes another ignition attempt.
7. As the unit fires, the inclined manometer negative pressure will drop to -.90" W.C. for the small cabinets and 1.90" W.C. for the large cabinets.
8. Begin to restrict the flue outlet until the pressure control
trips, cycling OFF the burner. The control will trip at approximately 0.36" W.C.negative.
9. If not as listed, replace control.
Note: the pressure switch must be mounted with the diaphragm in a vertical position.
S-311 HIGH ALTITUDE APPLICATION
WARNING
HIGH VOLTAGE
DISCONNECT ALL POWER BEFORE SERVICING OR
INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY
BE PRESENT. F AILURE TO DO SO MAY CAUSE PROPERTY
DAMAGE, PERSONAL INJURY OR DEATH.
1. Remove wires from the electrical terminals.
2. Using a VOM check from Common to NO (Normally
Open) - should read open.
If switch reads as noted proceed to Step 3, otherwise replace control.
3. Remove the pressure control hose from the control and
interconnect with an inclined manometer as shown:
HOSE
TO J-TUBE
1/4" COPPER TEE
Package units covered by this manual are approved for use
to 6,000 ft. in the USA. Canada (CSA) certified units are
approved for use to 4,500 ft. High altitude kits provide for
operation to 11,000 ft. in the USA. High altitude kits are not
approved for use in Canada. It is not necessary to change
the pressure switch for high altitude operation.
GAS
NATURAL
L. P. GAS
Orifice
# 45
# 56
NOTE: Failure to earth ground the unit, reversing the neutral
and hot wire connection to the line (polarity), or a high resistance connection in the ground or neutral lines may cause
the control to lockout due to failure to flame sense.
WARNING
TO
INCLINED
MANOMETER
Reconnect wires VT-18 to Common and YL-11 to NO terminals.
With Power ON:
WARNING
VOLTAGE NOW PRESENT.
4. Energize furnace for heating cycle. The induced draft
blower motor will begin to run. The inclined manometer
should read approximately 1.35" W.C. negative on small
cabinets units and approximately 3.50" W.C. negative on
large cabinets with no combustion. Refer to the Product
Design section for pressure tap location.
5. Remove and check the two electrical wires and using the
VOM check from Common to NO (Normally Open), it
should read closed (with I.D. motor running). If not as
above, replace control.
6. Reconnect all wires to the control and place in heating
cycle.
66
Altitude
(Feet)
6001 - 11000
6001 - 11000
S-313 TESTING IGNITION CONTROL MODULE
PRESSURE SWITCH
L INE
Kit
Number
HANG07
HALP09
AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO
THE UNIT MUST BE PROPERLY POLARIZED AND GROUNDED.
D ISCONNECT ALL POWER BEFORE PERFORMING SERRVICE.
M ULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO
SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
The ground wire must run from the furnace all the way back
to the electrical panel. Proper grounding can be confirmed
by disconnecting the electrical power and measuring resistance between the neutral (white) connection and the burner
closest to the flame sensor. Resistance should be less than
10 ohms.
WARNING
TO
AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO
THE UNIT MUST BE PROPERLY POLARIZED AND GROUNDED.
D ISCONNECT ALL POWER BEFORE PERFORMING SERRVICE.
M ULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO
SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
SERVICING
Honeywell Smart Valve Ignition Systems
Blower Off Delay Settings
L2
NORMAL SEQUENCE OF OPERATION (Honeywell
Smart Valve System)
COOL
With Power ON:
HEAT
L2
L2
UNUSED
L1
L1
D1
1
3
2
6
5
4
9
8
7
12
11
10
speed up
FS
Diagnostic LED
Testing Honeywell Smart Valve Systems
The ignition control module is a combination electronic and
electromechanical device and is not field repairable. Complete unit must be replaced.
L2
WARNING
L INE
VOLTAGE NOW PRESENT.
Transformer
Furnace thermostat calling for heat (4 to 5 second preheat
time).
1. Check for 230 volts from L1 terminal of control module to
L2. No voltage - check wire connections, continuity, etc.
2. Check for 24 volts at "C & X terminals on control board.
DSI Control Board
3. The control energizes the spark igniter and gas valve for 7
seconds. If flame is established, the control goes into a
30 second heat on delay.
3. Voltage Present - check for voltage (24 VAC) between
terminals 1 & 3 on gas valve (R-29 & GY-30). No voltage
- replace Control board.
4. The indoor blower is energized at the heat speed after a
30 second on delay.
Note: Voltage to ignitor should read 24 volts.
5. The control monitors the safety circuit inputs, flame, and
thermostat during operation.
4. Main burner will light only after pilot has proved flame. 30
seconds after main burner lights check for voltage between "heat" terminal and "neutral terminals" on board.
No voltage - replace Control board.
DSI Direct Spark Ignition Systems
NORMAL SEQUENCE OF OPERATION (DSI Direct
Spark Ignition System)
1. Thermostat calls for heat by energizing "W". The control
checks the pressure switch for open condition. If the pressure switch is closed the control will flash code "3" and
wait for the pressure switch to open.
2. The induced draft motor is energized and the control
flashes code "2" and waits for the pressure switch to close.
Once the pressure switch is closed, the LED stops flashing and the control begins timing the 15 second pre-purge.
6. When the thermostat is satisfied, the gas valve is deenergized and the induced draft blower remains on for a
29 second post purge. The indoor blower remains on for
the selected heat blower off delay (90, 120, or 150 seconds). Indoor blower off timing begins when thermostat
call for heat ends.
Testing Direct Spark Ignition (DSI) systems
Furnace thermostat calling for heat (15 second prepurge time
and 7 second trial for ignition).
1. Check for 230 volts from L1 terminal of control module to
L2. No voltage - check wire connections, continuity, etc.
2. Check for 24 volts at "R to C" thermostat terminals. No
voltage - check 3 amp automotive type fuse on control
board. A blow fuse would indicate a short in the 24 volt
circuit (thermostat or limit circuit).
3. Voltage Present - check for voltage (24 VAC) between
terminals 1 & 3 on gas valve (R-29 & GY-30). No voltage
- replace Control board.
67
SERVICING
Diagnostics Flash Codes
LED Steady On
Control is OK in standby, heat, cool, or
fan only modes.
LED Steady Off
Internal control fault or no power.
1 Flash
Lockout due to failed ignition or flame
dropouts.
2 Flashes
Pressure switch is open with induced draft
motor energized.
3 Flashes
Pressure switch is stuck closed with induced draft motor de-energized.
4 Flashes
Limit switch is open (primary, auxiliary,
or roll out).
5 Flashes
Flame detected with gas valve closed.
6 Flashes
Compressor output delayed from short
cycle timer.
7 Flashes
Low flame sense current. Control will
flash 7-times while continuing normal
operation.
8 Flashes
Lock out due to five consecutive limit trips
within a single call for heat. Resets in 1/
2 hour.
NOTE: The flash rate is 0.25 seconds on, 0.25 seconds off,
with a 2 second pause between codes.
CORRECT
POSITION
S-314 CHECKING FLAME SENSOR
A flame sensing device is used in conjunction with the ignition control module to prove combustion. If a microamp signal is not present the control will de-energize the gas valve
and "retry" for ignition or lockout.
The drawing below illustrates , the approximate distances for
the pilot assembly to the gas inshot burner. You will note
they are not in the main burner stream, but along the carry
over ports.
"A"
DIMENTION
"A" CANNOT
EXCEED 1/4"
Burner Assembly
68
SERVICING
Honeywell Smart Valve Systems
DSI Direct Spark Ignition Systems
WARNING
WARNING
HIGH VOLTAGE
DISCONNECT ALL POWER BEFORE SERVICING OR
INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY
BE PRESENT. F AILURE TO DO SO MAY CAUSE PROPERTY
DAMAGE, PERSONAL INJURY OR DEATH.
1. The Honeywell "Flame Sense Measurement Kit", Amana®
brand part # R9900026, is required to correctly measure
the microamp flame proving current.
2. Connect the Honeywell "Flame Sense Measurement Kit",
Amana® brand part # R9900026, as instructed in the kit
instructions.
With Power ON:
ELECTRICAL POWER SUPPLY.
1. Disconnect the flame sensor wire from terminal FS of the
ignition control module.
2. Connect a microamp meter in series with this wire and
terminal FS.
3. Be sure the negative side of the meter is to the wire and
the positive of the meter is to terminal FS.
With Power ON:
WARNING
L INE VOLTAGE
WARNING
V OLTAGE
D ISCONNECT
NOW PRESENT.
3. Place the unit into a heating cycle.
4. As soon as flame is established a microamp reading
should be evident once proof of flame (microamp reading)
is established, the hot surface ignitor will be de-energized.
5. The minimum microamp reading is 0.12 microamps for
SV9500 valves and 1.40 microamps for SV9501 valves. If
the microamp reading is less than the minimum specified, check for high resistance wiring connections, the
distance between the sensor and burner, flame sensor
connections or poor grounding.
6. If no reading, check for continuity on all components and
if good - replace ignition control module.
NOTE: Contaminated fuel or combustion air can create a
nearly invisible coating on the flame sensor. This coating
works as an insulator causing a loss in the flame sense signal. If this situation occurs the flame sensor must be cleaned
with emery cloth or steel wool. Do not use sand paper, the
silicone in sand paper will further contaminate the sensor.
NOW PRESENT.
4. Place the unit into a heating cycle.
5. As soon as flame is established a microamp reading
should be evident once proof of flame (microamp reading)
is established, the hot surface ignitor will be de-energized.
6. The nominal microamp reading is 4 microamps.
7. If the microamp current is less than 1 microamp, the ignition control will flash a code of 7 flashes. If the microamp
current is less than 0.4 microamps, the control will lockout and flash a code of 1 flash after attempting to reestablish flame sense.
8. If the microamp reading is less than the minimum specified, check for high resistance wiring connections, the
distance (3/16") between the sensor and burner, flame
sensor connections or poor grounding.
9. If no reading, check for continuity on all components and
if good - replace ignition control module.
NOTE: Contaminated fuel or combustion air can create a
nearly invisible coating on the flame sensor. This coating
works as an insulator causing a loss in the flame sense signal. If this situation occurs the flame sensor must be cleaned
with emery cloth or steel wool. Do not use sand paper, the
silicone in sand paper will further contaminate the sensor.
69
SERVICING
Spark
Igniter
Flame Sensor
DSI Flame Sensor and Spark Ignitor Location
S-315 CHECKING HOT SURFACE IGNITER
"Smart Valve" systems use a silicone carbide restrictive element ignitor is used for ignition. The normal operating temperature is approximately 2550°F. "DSI" systems use a spark
type igniter.
2. Disconnect the ignitor from the Ignition Control Module
and line voltage terminal board.
3. Using an ohmmeter measure the resistance of the ignitor
it should read between 16 to 24 ohms for Norton mini
ignitors. DSI system do not use hot surface ignitors.
4. Reconnect igniter.
WARNING
HIGH VOLTAGE
DISCONNECT ALL POWER BEFORE SERVICING OR
INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY
BE PRESENT. F AILURE TO DO SO MAY CAUSE PROPERTY
DAMAGE, PERSONAL INJURY OR DEATH.
1. Ignitor cool - approximately 70 - 75°F.
70
With Power ON:
WARNING
V OLTAGE NOW
PRESENT.
5. Place unit in heating cycle, measure current draw of ignitor during preheat cycle. Should read approximately 1 to
1.5 amps.
S
1
S
R
COMP
C
H
E
A
T
2
3
0
C
O
M
N
2
L2
T2
N0
PS
NC
C
COMB
BLOWER
2
0
8
D
I
3
1
2
3
4
RL
L
I
M
I
T
A
U
X
L
I
M
I
T
R
6
N
4
1
S
S
HEAT FAN
DELAY
OFF
S
2
3
BK
17
60
120
1
Y
HUM EAC
N
N
MOTOR
LEADS
HUM EAC
DI
UNUSED
4
4
4
4
4
4
2
PGB24C0902D
PGB30C0702D
PGB30C0902D
PGB36C0702D
PGB36C0902D
PGB42C0902D
MOTOR
SPEEDS
HI
HI
MED HI
HI
MED HI
HI
MED HI
LOW
SPEED
BK-26
BK-26
BU-23
BK-26
BU-23
BK-26
BU-23
YL-27
MOTOR TO "HEAT"
* HEATING BLOWER SPEED
3
4
C
C
G
Y
W
6
3
R
WH
WH
5
4
2
1
*
**
RD-13
VT-37
RD-1
208
HI
MED HI
MED HI
MED LOW
MED LOW
LOW
LOW
LOW
SPEED
6
GY-30
DETAIL 1
60
NC
BK-26
BU-23
BU-23
RD-24
RD-24
YL-27
YL-27
YL-27
MOTOR TO "COOL"
1
BR
NO
COM
YL
11
3
4
HONEYWELL
ADJUSTABLE FAN SETTING
(FACTORY SETTING AS SHOWN)
DETAIL 2
2
2
2
1
IGNITOR
FLAME SENSOR
RD
10
CAPACITOR
(CAP)
BR
R
C
RD
13
T1
VT
16
GND
CONTACTOR (CC)
L2
T2
L1
COMPRESSOR
1ø WIRING
S
YL-12
BR
11
VT
20
RD
15
FAN
HERM
COM
GY
25
LOW VOLTAGE
LOW VOLTAGE FIELD
HI VOLTAGE
HI VOLTAGE FIELD
COLOR CODE
BR BROWN
YL YELLOW
WH WHITE
OR ORANGE
BU BLUE
VT VIOLET
GY GRAY
GN GREEN
RD RED
BK BLACK
VT
16
C
A
P
A
C
I
T
O
R
O.D
FAN
MOTOR
11160901 REV. 1
RD
10
BK
27
L1 L2 GND
FIELD CONNECTION
208/230 VAC 1ø
WARNING:DISCONNECT POWER BEFORE
SERVICING.
VT
37
VT
20
BR
4 SPEED
BLOWER
READ BEFORE OPERATING OR SERVICING THIS UNIT.
WARNING: DISCONNECT POWER BEFORE SERVICING.
1. AMANA SPECIFIED REPLACEMENT PARTS MUST BE
USED WHEN SERVICING.
2. IF ANY ORIGINAL WIRE IS REPLACED, 105° C WIRE
MUST BE USED.USE COPPER CONDUCTORS ONLY.
3. EQUIPPED FOR 230 VOLT OR 208 VOLT.
4. HEAT ON/OFF FAN DELAY FACTORY
SETTINGS: 30 SECONDS ON AND 120 SECONDS OFF.
5. UNUSED BLOWER MOTOR LEADS MUST BE PLACED ON
UNUSED MOTOR LEADS TERMINALS OF CONTROL OR TAPED.
6. IF HEATING AND COOLING BLOWER SPEEDS ARE NOT THE
SAME DISCARD JUMPER BEFORE CONNECTING BLOWER LEADS.
7. COOLING ON/OFF FAN DELAY SETTING: 6 SECONDS ON
AND 30 SECONDS OFF.
IMPORTANT:
1
DELAY
1
2
1
GAS VALVE
4
3
AUX LIMIT
CONTROL
OR-19
6
AIR
5 CIRCULATION
BLOWER
4
(ACB)
3
VT-14
YL-27
RD-24
BU-23
BK-26
OFF
PILOT BURNER
GROUND (THRU PILOT)
BU-34
PRIMARY ROLLOUT
LIMIT (RL)
OR-22
LIMIT
BR
2 SPEED
BLOWER
CAPACITOR
(CAP)
OR-49
2
AIR PRESSURE
SWITCH (PS)
120
VT-18
GY-25
RD-29
BR-21
GY-25
LOAD
VT-14
TO INDOOR
BLOWER
YL-27
BK-26
AIR
5 CIRCULATION
BLOWER
4
(ACB)
3
6
HEATCRAFT
ADJUSTABLE FAN SETTING
(FACTORY SETTING AS SHOWN)
GY-70
230
LINE
COM
TRANSFORMER
** COOLING BLOWER SPEED
THERMOSTAT
CIR BLOWER
X
XFMR SEC
C
VT-47
COMBUSTION
BLOWER
(CB)
NEUTRAL
2
VT
(COM)
BK
(208V)
RD
(230V)
VT-14
FOR PROPER OPERATION ON 208 VOLT THE
FOLLOWING CHANGES MUST BE MADE:
MOVE BK17 WIRE FROM TRANSFORMER
230 TERMINAL TO 208 TERMINAL.
UNPLUG RED COMBUSTION BLOWER LEAD FROM
CONTROL BOARD TERMINAL (DI) AND
ATTACH BLACK BLOWER LEAD TO TERMINAL.
TAPE UNUSED RED LEAD.
208 VOLT INSTALLATION
FACTORY WIRED MOTOR CONNECTIONS
4
MODELS
2
1
GAS VALVE
1
4
4
3
2
THERMOSTAT
5
WARNING:DISCONNECT POWER BEFORE SERVICING.
208/230 VAC 1ø
GND
FAN
OD
C
A
P
ACB
C
O
O
L
W
150
PGB24C0452D
CC
HERM
CAP
COM
FAN
C
O
M
2 X
4 F
M
VR
N
1
Y
150
PGB24C0702D
L1
T1
CCOR 2
2
0
8
2
3
0
S
E
C
X
G
HEAT
N
3
C
COOL
C0 Y
X
F
M
R
C
90
CONT
X
F
M
R
HOT
90
CONTROL BOARD
(TERMINAL ORDER REARRANGED)
WIRING DIAGRAMS
PGB24, 30, 36 & 42
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.
71
C
O
M
S
R
COMP
C
C
O
M
N
2
L2
T2
N0
PS
NC
C
COMB
BLOWER
D
I
3
C
Y
1
2
1
2
3
4
GAS VALVE
4
4
3
2
1
W
RL
L
I
M
I
T
A
U
X
L
I
M
I
T
R
6
N
4
1
S
S
HEAT FAN
DELA Y
O FF
S
2
3
BK
17
60
120
1
Y
HUM EAC
N
N
MOTOR
LEADS
HUM EAC
DI
UNUSED
3
3
3
3
3
PGB48C1152D
PGB48C1402D
PGB60C0902D
PGB60C1152D
PGB60C1402D
MOTOR
SPEEDS
HI
MED
LOW
HI
MED
LOW
MED
SPEED
BK-26
BU-23
RD-24
BK-26
BU-23
RD-24
BU-23
MOTOR TO "HEAT"
* HEATING BLOWER SPEED
3
NEUTRAL
2
VT
(COM)
RD
(230)
4
C
C
G
Y
W
6
3
R
WH
WH
5
4
2
1
*
**
RD-13
VT-37
RD-1
208
HI
HI
HI
MED
MED
MED
LOW
SPEED
BU-34
PILOT BURNER
GROUND (THRU PILOT)
1
1
2
DELAY
OFF
2
1
2
3
4
GAS VALVE
4
3
AUX LIMIT
CONTROL
OR-19
BK-26
BK-26
BK-26
BU-23
BU-23
BU-23
RD-24
MOTOR TO "COOL"
BR
LOW PRESSURE
SWITCH (LPS)
IGNITOR
RD
10
RD
13
VT
20
VT
37
R
C
YL/BK
L1
L2
COMPRESSOR
1ø WIRING
S
YL-12
GND
GY
25
VT
16
T1
T2
BR
11
BK
27
RD
10
VT
20
RD
15
FAN
HERM
COM
LOW VOLTAGE
LOW VOLTAGE FIELD
HI VOLTAGE
HI VOLTAGE FIELD
COLOR CODE
YL YELLOW
BR BROWN
OR ORANGE
WH WHITE
VT VIOLET
BU BLUE
GN GREEN
GY GRAY
BK BLACK
RD RED
VT
16
C
A
P
A
C
I
T
O
R
O.D.
FAN
MOTOR
20029901 REV. 1
L2
L1 GND
FIELD CONNECTION
208/230 VAC 1ø
WARNING:DISCONNECT POWER BEFORE
SERVICING.
FLAME SENSOR
BR
READ BEFORE OPERATING OR SERVICING THIS UNIT.
WARNING: DISCONNECT POWER BEFORE SERVICING.
1. AMANA SPECIFIED REPLACEMENT PARTS MUST BE
USED WHEN SERVICING.
2. IF ANY ORIGINAL WIRE IS REPLACED, 105° C WIRE
MUST BE USED.USE COPPER CONDUCTORS ONLY.
3. EQUIPPED FOR 230 VOLT OR 208 VOLT.
4. HEAT ON/OFF FAN DELAY FACTORY
SETTINGS: 30 SECONDS ON AND 120 SECONDS OFF.
5. UNUSED BLOWER MOTOR LEADS MUST BE PLACED ON
UNUSED MOTOR LEADS TERMINALS OF CONTROL OR TAPED.
6. IF HEATING AND COOLING BLOWER SPEEDS ARE NOT THE
SAME DISCARD JUMPER BEFORE CONNECTING BLOWER LEADS.
7. COOLING ON/OFF FAN DELAY SETTING: 6 SECONDS ON
AND 30 SECONDS OFF.
IMPORTANT:
DETAIL 2
NO
YL
11
1
CAPACITOR
(CAP)
2
AIR
CIRCULATION
BLOWER
(ACB)
3
6
HONEYWELL
ADJUSTABLE FAN SETTING
(FACTORY SETTING AS SHOWN)
60
120
NC
COM
AIR PRESSURE
SWITCH (PS)
GY-30
LIMIT
PRIMARY ROLLOUT
LIMIT (RL)
OR-22
OR-49
4
5
DETAIL 1
6
VT-18
GY-25
RD-29
BR-21
GY-25
LOAD
VT-14
RD-24
BU-23
BK-26
HEATCRAFT
ADJUSTABLE FAN SETTING
(FACTORY SETTING AS SHOWN)
YL/BK
230
LINE
COM
TRANSFORMER
** COOLING BLOWER SPEED
THERMOSTAT
CIR BLOWER
X
XFMR SEC
C
VT-47
COMBUSTION
BLOWER
(CB)
FOR PROPER OPERATION ON 208 VOLT THE
FOLLOWING CHANGE MUST BE MADE:
MOVE BK17 WIRE FROM TRANSFORMER
230 TERMINAL TO 208 TERMINAL.
208 VOLT INSTALLATION
FACTORY WIRED MOTOR CONNECTIONS
3
MODELS
G
THERMOSTAT
5
WARNING:DISCONNECT POWER BEFORE SERVICING.
208/230 VAC 1ø
GND
FAN
OD
C
A
P
ACB
H
E
A
T
3
CC
HERM
CAP
COM
2X
4F
M
VR
N
1
C
O
O
L
150
PGB48C0902D
L1
T1
L
P
S
FAN
CCOR 2
2
0
8
2
3
0
N
3
X
F
M
R
C
150
PGB42C1152D
S
1 C0 Y
S
E
C
X
HEAT
X
F
M
R
HOT
CO OL
CONTROL BOARD
(TERMINAL ORDER REARRANGED)
90
CO NT
72
90
WIRING DIAGRAMS
PGA60C, PGB42C115, PGB48, 60
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.
S
1
L
P
S
S
R
COMP
C
C
O
M
L2
T2
PS
N0
NC
C
3
Y
2
4
1
2
3
4
GAS VALVE
1
4
3
2
1
W
RL
L
I
M
I
T
A
U
X
L
I
M
I
T
R
6
N
4
S
3
2
S
S
60
120
1
Y
HUM EAC
N
N
MOTOR
LEADS
UNUSED
HUM EAC
DI
SEE DETAIL
1 OR 2
HEAT FA N
DELAY
OF F
1
BK
17
4
4
4
4
4
4
2
PGD24C0902D
PGD30C0702D
PGD30C0902D
PGD36C0702D
PGD36C0902D
PGD42C0902D
MOTOR
SPEEDS
HI
HI
HI
HI
HI
HI
MED HI
LOW
SPEED
BK-26
BK-26
BK-26
BK-26
BK-26
BK-26
BU-23
YL-27
MOTOR TO "HEAT"
* HEATING BLOWER SPEED
3
4
C
C
G
Y
W
6
3
R
WH
WH
5
4
2
1
RD-13
VT-37
RD-1
208
HI
MED HI
MED HI
MED LOW
MED LOW
LOW
LOW
LOW
SPEED
6
GY-30
DETAIL 1
60
NC
BK-26
BU-23
BU-23
RD-24
RD-24
YL-27
YL-27
YL-27
MOTOR TO "COOL"
YL-27
RD-24
BU-23
BK-26
LIMIT
BU-34
1
2
DETAIL 2
OFF
OR-19
4
3
2
1
2
3
BR
RD
10
LOW PRESSURE
SWITCH (LPS)
VT
37
VT
20
RD
13
R
C
YL/BK
T1
VT
16
GND
CONTACTOR (CC)
L2
T2
L1
COMPRESSOR
WIRING
S
YL-12
BR
11
BK
27
RD
10
VT
20
RD
15
FAN
HERM
COM
GY
25
LOW VOLTAGE
LOW VOLTAGE FIELD
HI VOLTAGE
HI VOLTAGE FIELD
COLOR CODE
BR BROWN
YL YELLOW
WH WHITE
OR ORANGE
BU BLUE
VT VIOLET
GY GRAY
GN GREEN
RD RED
BK BLACK
VT
16
C
A
P
A
C
I
T
O
R
O.D.
FAN
MOTOR
11175001 REV. 0
L1 L2 GND
FIELD CONNECTION
208/230 VAC 1ø
WARNING:DISCONNECT POWER BEFORE
SERVICING.
IGNITOR
FLAME SENSOR
BR
READ BEFORE OPERATING OR SERVICING THIS UNIT.
WARNING: DISCONNECT POWER BEFORE SERVICING.
1. AMANA SPECIFIED REPLACEMENT PARTS MUST BE
USED WHEN SERVICING.
2. IF ANY ORIGINAL WIRE IS REPLACED, 105° C WIRE
MUST BE USED.USE COPPER CONDUCTORS ONLY.
3. EQUIPPED FOR 230 VOLT OR 208 VOLT.
4. HEAT ON/OFF FAN DELAY FACTORY
SETTINGS: 30 SECONDS ON AND 120 SECONDS OFF.
5. UNUSED BLOWER MOTOR LEADS MUST BE PLACED ON
UNUSED MOTOR LEADS TERMINALS OF CONTROL OR TAPED.
6. IF HEATING AND COOLING BLOWER SPEEDS ARE NOT THE
SAME DISCARD JUMPER BEFORE CONNECTING BLOWER LEADS.
7. COOLING ON/OFF FAN DELAY SETTING: 6 SECONDS ON
AND 30 SECONDS OFF.
4
GAS VALVE
DELAY
1
1
AIR
CIRCULATION
BLOWER
CAPACITOR
(CAP)
2
(ACB)
AUX LIMIT
CONTROL
3
4
5
6
HONEYWELL
ADJUSTABLE FAN SETTING
(FACTORY SETTING AS SHOWN)
PILOT BURNER
GROUND (THRU PILOT)
IMPORTANT:
NO
COM
YL
11
PRIMARY ROLLOUT
LIMIT (RL)
OR-22
OR-49
VT-14
AIR PRESSURE
SWITCH (PS)
120
VT-18
GY-25
RD-29
BR-21
GY-25
LOAD
HEATCRAFT
ADJUSTABLE FAN SETTING
(FACTORY SETTING AS SHOWN)
YL/BK
230
LINE
COM
TRANSFORMER
** COOLING BLOWER SPEED
THERMOSTAT
CIR BLOWER
X
XFMR SEC
C
VT-47
COMBUSTION
BLOWER
(CB)
NEUTRAL
2
VT
(COM)
BK
(208V)
RD
(230V)
FOR PROPER OPERATION ON 208 VOLT THE
FOLLOWING CHANGES MUST BE MADE:
MOVE BK17 WIRES FROM TRANSFORMER
230 TERMINAL TO 208 TERMINAL.
UNPLUG RED COMBUSTION BLOWER LEAD FROM
CONTROL BOARD TERMINAL (DI) AND
ATTACH BLACK BLOWER LEAD TO TERMINAL.
TAPE UNUSED RED LEAD.
208 VOLT INSTALLATION
FACTORY WIRED MOTOR CONNECTIONS
4
MODELS
G
THERMOSTAT
5
WARNING:DISCONNECT POWER BEFORE SERVICING.
208/230 VAC 1ø
GND
FAN
OD
C
A
P
ACB
2
3
0
N
2
COMB
BLOWER
2
0
8
D
I
C
150
PGD24C0452D
CC
HERM
CAP
COM
FAN
C
O
M
2X
4F
M
VR
N
1
H
E
A
T
150
PGD24C0702D
L1
T1
CC
2
0
8
2
3
0
N
3
C
O
O
L
HEAT
Y
X
F
M
R
C
COOL
C
S
E
C
X
90
CONT
X
F
M
R
HOT
90
CONTROL BOARD
(TERMINAL ORDER REARRANGED)
WIRING DIAGRAMS
PGD24, 30, 36, 42
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.
73
90
WARNING:DISCONNECT POWER BEFORE SERVICING.
208/230 VAC 1ø
PHB36CO2D
MED-HIGH
LOW
MED-LOW
PHB30C02D
LOW
LOW
LOW
PHCB05C1
MED-LOW
MED-LOW
MED-LOW
PHCB10C1
MED-HIGH
MED-HIGH
MED-HIGH
PHCB15C1
ELECTRIC HEAT BLOWER TAP
G
PHB24C02D
COOLING
BLOWER
SPEED TAP
FUSE
L2
MODEL
NUMBER
E
L1
START
RELAY
O
CAP
5
T2
Y
2
COMP
C
R
W
CC
1
S
R
UNIT POWER WITH
ELECTRIC HEATER ACCESSORIES
C
START
CAP
HERM
FAN
O
COM
OUT
GN
YL-27
OR-49
BR-21
RD-13
BU-34
GY-70
G
GY
55
DIAGNOSTICS
LED
MED-HIGH
MED-HIGH
MED-HIGH
PHCB20C1
RD-2
VT-16
NORMAL
OPERATION
DIAGNOSTICS
BOARD
FAILURE
LOCKOUT
OPEN
PRESSURE
SWITCH
SHORT
CYCLE
BU
1
VT-62
RD-6
HEATCRAFT
ADJUSTABLE DEFROST INTERVAL
(FACTORY SETTING AS SHOWN)
SEE
DETAIL 1
1
BK
RD
2
OD
HI
MED HI
M LO
LO
YL-5
GY-8
COOLING
SWITCH
RELAY
VT-14
FAN
CAP
FAN
CAP
BK-26
VT-18
A
COOLING
SWITCH
RELAY
ACB
DF
DEFROST
CONTROL
OR
28
RD-24
GY-9
BU-23
PS1
1
R
RD-33
GY-9
1
COOLING
TAP 3
BK-26
VT-18
YL-27
OR-49
BR-21
RD-13
BU-34
GY-70
BK-24
BK-13
5
VT-14
RD-24
RD-11
BU-23
LINE
230 208
A
5
TO
HEATER
KIT
PIN 9
PIN 8
PIN 7
PIN 6
PIN 5
PIN 4
PIN 3
PIN 2
PIN 1
6
CAPACITOR
(CAP)
BK-19
BK-20
BR
(ACB)
1
2
3
4
LOAD
COM
TRANSFORMER
PS2
230/208
24V
REVERSING
SOLENOID
(RS)
DEFROST
THERMOSTAT
(DT)
BR
AIR CIRCULATION
BLOWER
FOR PROPER OPERATION ON 208 VOLT THE
FOLLOWING CHANGE MUST BE MADE:
MOVE RD6 WIRE FROM TRANSFORMER
230 TERMINAL TO 208 TERMINAL.
208 VOLT INSTALLATION
Y1 OUT
ELECTRIC
4 HEAT
RELAY
COMMON
Y
COMMON
T1
PS2
COOLING
SPEED
O
R W O
P
S B
HEAT 2
TAP
DEFROST
CONTROL
C
O
E
TO HEATER
E
A
FAN
COM
30
G
A
60 TEST
Y OUT
CC
W
W2 W1 G
R
ELECTRIC
HEAT RELAY
B
Y
OUT
HEAT
KIT
B
G
PS1
C
DF
DT
FUSE
R
74
RS
230 VOLT
60
90
3
5
1
VT-16
2
ON ON
ON OFF
OFF ON
ALTERNATE
FLASHING
BOTH
FLASHING
T1
L1
O.D.
FAN
MOTOR
RD-31
ELECTRIC
HEAT
RELAY
BU
23
VT-20
VT
20
BK-27
FAN
YL
12
S
R
RD RED
HI VOLTAGE FIELD
HI VOLTAGE
LOW VOLTAGE FIELD
LOW VOLTAGE
GY GRAY
BU BLUE
BK BLACK
GN GREEN
WH WHITE
VT VIOLET
BR BROWN
OR ORANGE
YL YELLOW
COLOR CODE
RD-27
HERM
C
COMPRESSOR
1ø WIRING
RD
31
L2D/23
L18/23
GND/230
FIELD CONNECTION
208/230 VAC 1ø
CAPACITOR
COM
BR-11
RD
10
VT
62
20014001 REV. 3
RD
31
RD-27
CONTACTOR
T2
L2
BU-1
RD-10
4
VT-62
GY-8
GY-9
LED 1 LED 2
DETAIL 1
TEST
30
VT-7
GND
WIRING DIAGRAMS
PHB24, 30, 36
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.
90
FAN
CC
START
RELAY
L2
T2
208/230 VAC 1ø
WARNING:DISCONNECT POWER BEFORE SERVICING.
USE COPPER CONDUCTORS ONLY
CAP
5
LOW
MED
PHB48C02E
COOLING
BLOWER
SPEED
TAP
PHB42C02E
MODEL
NUMBER
MED
LOW
MED
LOW
DOWN HORIZ
PHCB07C1
MED
LOW
MED
LOW
DOWN HORIZ
PHCB10C1
MED
LOW
MED
LOW
DOWN HORIZ
PHCB15C1
ELECTRIC HEAT BLOWER TAP
HI
MED
HI
MED
DOWN HORIZ
PHCB20C1
ALTERNATE UNIT POWER REFRIGERANT
LEADS MAY BE USED WITH ELECTRIC
HEATER ACCESSORIES. SEE HEATER
ACCESSORY INSTALLATION INSTRUCTIONS.
Y
2
RD
BK
GN
FUSE
1
C
G
START
COMP
W
S
R
O
HERM
FAN
R
CAP
YL-27
OR-49
BR-21
RD-13
BU-34
GY-70
C
COM
9 8
VIEW A-A
4
7
6 5
DEFROST
CONTROL
OR
28
RD-24
BK-26
YL-5
VT-18
DIAGNOSTICS
LED
G
GY
55
VT-62
VT-16
GY-8
RD-2
RD-6
COOLING
SWITCH
RELAY
GY-9
VT-14
208
BOARD
FAILURE
LOCKOUT
OPEN
PRESSURE
SWITCH
SHORT
CYCLE
NORMAL
OPERATION
DIAGNOSTICS
HEATCRAFT
ADJUSTABLE DEFROST INTERVAL
(FACTORY SETTING AS SHOWN)
SEE
DETAIL 1
1
1
A
R
RD-33
BU-23
GY-9
2
3 2
BK-26
VT-18
YL-27
OR-49
BR-21
RD-13
BU-34
GY-70
A
BK-13
BK-24
VT-14(COMMON)
RD-24(COOL)
RD-11
BU-23(HEAT)
A
FAN
OD
LO
CAP
PIN 1
PIN 2
PIN 3
PIN 4
PIN 5
PIN 6
PIN 7
PIN 8
PIN 9
BK-19
BK-20
5
LOW
MED
HI
COMMON
230
LINE
COM
TRANSFORMER
FAN
CAP
HI
TO
HEATER
KIT
REVERSING
SOLENOID
(RS)
6
1
AIR
CIRCULATION 2
3
BLOWER
(ACB)
4
O
OUT
MED
ACB
BR
BR
DEFROST
THERMOSTAT
(DT)
CAPACITOR
(CAP)
DF
COOLING
SWITCH
RELAY
1
R
LOAD
PS1
ELECTRIC
HEAT
RELAY
230/208
C
FOR PROPER OPERATION ON 208 VOLT THE
FOLLOWING CHANGE MUST BE MADE:
MOVE RD6 WIRE FROM TRANSFORMER
230 TERMINAL TO 208 TERMINAL.
A
5
A
24V
O
O
208 VOLT INSTALLATION
B
B
4
COMMON
TO HEATER KIT
Y
PS2
COOLING
TAP 3
COM
O
P
S
1
HEAT
2
TAP
Y
G
A
W
Y
L1(CAP
PS2
COOLING
SWITCH
RELAY
B
R
FUSE
C
R
E
OUT
W2 W1 G
COMMON
T1
30
LPS
G
DEFROST
CONTROL
B
W
ELECTRIC
HEAT RELAY
PS1
60 TEST
CC
HEATER
KIT
DF
DT
Y
RS
230 VOLT
1
ON ON
ON OFF
OFF ON
ALTERNATE
FLASHING
BOTH
FLASHING
O.D.
FAN
MOTOR
VT
20
FAN
YL
12
S
R
HERM
LOW VOLTAGE
LOW VOLTAGE FIELD
HI VOLTAGE
HI VOLTAGE FIELD
COLOR CODE
YL YELLOW
BR BROWN
OR ORANGE
WH WHITE
VT VIOLET
BU BLUE
GN GREEN
GY GRAY
BK BLACK
RD RED
20234301 REV 1
RD-27
C
COMPRESSOR
1ø WIRING
RD
31
CAPACITOR
COM
BR-11
RD
10
BK-27
RD
31
RD-27
USE COPPER
CONDUCTORS
ONLY75°C MIN
L2
L1
GND
FIELD CONNECTION
208/230 VAC 1ø
VT
62
LOW PRESSURE
SWITCH (LPS)
ELECTRIC
HEAT
RELAY
BU
23
RD-31
LED 1 LED 2
DETAIL 1
4
2
VT-16
5
3
L1
CONTACTOR
T2
L2
T1
VT-20
GY-9
GY-8
YL/BK
RD-10
VT-62
60
30
90
TEST
VT-7
GND
WIRING DIAGRAMS
PHB42, 48
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.
75
FAN
CC
START
RELAY
L2
T2
208/230 VAC 1ø
WARNING:DISCONNECT POWER BEFORE SERVICING.
USE COPPER CONDUCTORS ONLY
CAP
5
LOW
MED-LOW
MED-HIGH
PHD30C02E
PHD36C02E
COOLING
BLOWER
SPEED TAP
PHD24C02E
MODEL
NUMBER
LOW
LOW
LOW
MED
LOW
MED
LOW
MED
LOW
HORIZ
DOWN
PHCB05C1
MED
LOW
MED
LOW
MED
LOW
DOWN
LOW
LOW
LOW
HORIZ
PHCB10C1
MED
HIGH
MED
HIGH
MED
HIGH
DOWN
MED
HIGH
MED
HIGH
MED
HIGH
HORIZ
PHCB15C1
ELECTRIC HEAT BLOWER TAP
ALTERNATE UNIT POWER REFRIGERANT
LEADS MAY BE USED WITH ELECTRIC
HEATER ACCESSORIES. SEE HEATER
ACCESSORY INSTALLATION INSTRUCTIONS.
Y
2
RD
BK
GN
FUSE
1
C
W
START
COMP
YL-27
OR-49
BR-21
RD-13
BU-34
GY-70
O
S
R
7
4
1
R
CAP
8
9
C
HERM
FAN
5
6
VIEW A-A
2
3
YL-5
GY
55
DIAGNOSTICS
LED
G
HIGH
HIGH
HIGH
DOWN
HIGH
HIGH
HIGH
HORIZ
PHCB20C1
RD-2
VT-16
GY-8
VT-62
RD-6
COOLING
SWITCH
RELAY
GY-9
VT-14
BOARD
FAILURE
LOCKOUT
OPEN
PRESSURE
SWITCH
SHORT
CYCLE
NORMAL
OPERATION
DIAGNOSTICS
HEATCRAFT
ADJUSTABLE DEFROST INTERVAL
(FACTORY SETTING AS SHOWN)
SEE
DETAIL 1
1
FAN
CAP
A
BK-26
VT-18
A
COM
OD
ACB
DEFROST
CONTROL
OR
28
RD-24
BU-23
GY-9
208
FA N
CAP
HI
MED HI
M LO
LO
O
OUT
COOLING
SWITCH
RELAY
1
PIN 1
R
RD-33
VT-14(COMMON)
RD-24(COOL)
RD-11
BU-23(HEAT)
2
PIN 2
PIN 3
BK-26
VT-18
YL-27
OR-49
BR-21
RD-13
BU-34
GY-70
A
BK-13
BK-24
LOW
COMMON
DF
PIN 4
PIN 5
PIN 6
PIN 7
PIN 8
PIN 9
5
BK-19
BK-20
6
1
AIR
HIGH
CIRCULATION 2
3 MED HIGH
BLOWER
4
(ACB)
MED LOW
230
LINE
COM
TRANSFORMER
A
COOLING
TAP 3
TO
HEATER
KIT
REVERSING
SOLENOID
(RS)
BR
BR
DEFROST
THERMOSTAT
(DT)
CAPACITOR
(CAP)
LOAD
PS1
ELECTRIC
HEAT
RELAY
230/208
C
FOR PROPER OPERATION ON 208 VOLT THE
FOLLOWING CHANGE MUST BE MADE:
MOVE RD6 WIRE FROM TRANSFORMER
230 TERMINAL TO 208 TERMINAL.
PS2
5
A
24V
O
W
208 VOLT INSTALLATION
B
B
4
COMMON
TO HEATER KIT
Y
P
S
1
HEAT
TAP 2
90
COM
G
A
O
Y
L1
PS2
COOLING
SPEED
B
W
COMMON
T1
30
LPS
G
DEFROST
CONTROL
B
R
Y
C
O
E
FUSE
G
R
W2 W1
R
ELECTRIC
HEAT RELAY
PS1
60 TEST
Y
CC
DF
DT
HEATER
KIT
OUT
76
RS
230 VOLT
1
ON ON
ON OFF
OFF ON
ALTERNATE
FLASHING
BOTH
FLASHING
LED 1 LED 2
DETAIL 1
4
2
VT-16
5
3
BU
23
BK-27
FAN
YL
12
S
R
HERM
RD-27
C
COMPRESSOR
1ø WIRING
CAPACITOR
COM
BR-11
VT
20
RD
31
USE COPPER
CONDUCTORS
ONLY75°C MIN
L2
L1
GND
FIELD CONNECTION
208/230 VAC 1ø
GY GRAY
RD RED
HI VOLTAGE
HI VOLTAGE FIELD
LOW VOLTAGE
LOW VOLTAGE FIELD
GN GREEN
BK BLACK
COLOR CODE
YL YELLOW
BR BROWN
OR ORANGE
WH WHITE
VT VIOLET
BU BLUE
20233401 REV. 1
O.D.
FAN
MOTOR
RD-31
RD
31
RD
10
VT
62
LOW PRESSURE
SWITCH (LPS)
RD-27
ELECTRIC
HEAT
RELAY
RD-10
VT-62
L1
CONTACTOR (CC)
L2
T2
T1
VT-20
GY-8
YL/BK
GY-9
GND
30
90
TEST
60
VT-7
WIRING DIAGRAMS
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.
PHD24, 30 & 36
G
FAN
HEATER
KIT
W2
W1
G
E
CAP
2
5
C
START
RELAY
L2
T2
208/230 VAC 1ø
WARNING:DISCONNECT POWER BEFORE SERVICING.
USE COPPER CONDUCTORS ONLY
CC
1
COMP
5KW
20KW
15KW
10KW
KW (HEAT)
D
C
B
A
1400
1200
1000
800
CFM
(COOL)
DETAIL 2
D
C
B
A
TEST
(-)
(+)
NORM
R
BK
19
ADJUST
FUSE
START
S
R
ALTERNATE UNIT POWER REFRIGERANT
LEADS MAY BE USED WITH ELECTRIC
HEATER ACCESSORIES. SEE HEATER
ACCESSORY INSTALLATION INSTRUCTIONS.
YL-27
OR-49
BR-21
RD-13
BU-34
GY-70
BK
20
REVERSING
SOLENOID
(RS)
BK
13
BK
24
DEFROST
CONTROL
YL-5
SEE
DETAIL 1
NORMAL
OPERATION
BOARD
FAILURE
LOCKOUT
OPEN
PRESSURE
SWITCH
SHORT
CYCLE
VT-7
ON ON
ON OFF
OFF ON
ALTERNATE
FLASHING
BOTH
FLASHING
LED 1 LED 2
DETAIL 1
VT
16
RD-10
L1
BK-27
FAN
YL
12
S
R
HERM
RD-27
C
COMPRESSOR
1ø WIRING
CAPACITOR
COM
BR-11
VT
20
LOW VOLTAGE
LOW VOLTAGE FIELD
HI VOLTAGE
HI VOLTAGE FIELD
COLOR CODE
YL YELLOW
BR BROWN
OR ORANGE
WH WHITE
VT VIOLET
BU BLUE
GN GREEN
GY GRAY
BK BLACK
RD RED
20216301 REV. 2
O.D.
FAN
MOTOR
VT
16
VT
62
RD
10
RD
31
USE COPPER
CONDUCTORS
ONLY75°C MIN
L2
L1
GND
FIELD CONNECTION
208/230 VAC 1ø
VT
62
LOW PRESSURE
SWITCH (LPS)
RD-27
CONTACTOR (CC)
T2
L2
T1
VT-20
GY-9
GY-55
YL/BK
GND
30
90
TEST
60
DIAGNOSTICS
LED
G
DIAGNOSTICS
HEATCRAFT
ADJUSTABLE DEFROST INTERVAL
(FACTORY SETTING AS SHOWN)
C
R
W
O
Y
CAP
C UT TO
ENAB LE
D EH UM ID IFY
G
HERM
( )+
(-)
T EST
NOR M
ADJUST
O
OUT
RD
BK
GN
A
B
C
D
1
FAN
7
COOL
DEFROST
THERMOSTAT
(DT)
2
COM
8
9
4
1
A
A
A
B
C
D
RD
33
GY-9
VT-14
A
FAN
5
6
VIEW A-A
2
3
YL-27
OR-49
BR-21
RD-13
BU-34
GY-70
HEAT
BLOWER
INTERFACE
GY-9
RD-6
A
OD
TO
HEATER
KIT
PIN 1
PIN 2
PIN 3
PIN 4
PIN 5
PIN 6
PIN 7
PIN 8
PIN 9
SEE DETAIL 2
RD-31
208
PS2
CAP
TO HEATER KIT
LINE
230
FAN
L1
T1
PS2
LOAD
Y
230/208
EM/W2
TRANSFORMER
DF
24V
O
FUSE
COM
COMMON
COMMON
G
DEFROST
CONTROL
O
C
C
W1
A
BLOWER
INTERFACE
R2
DF
R
90
COM
C2
W
Y
G
A
R3
R
O
30
LPS
60 TEST
CC
C1
W
HEAT
A
B
C
D
B
G
O
COO L
A
B
C
D
Y
Y
ADJUST
NO RM
( )+
(-)
TES T
B
B
B
PS1
Y/Y2
OUT
AIR
CIRCULATION
BLOWER
(ACB)
W1
EM/W2
O
R2
R3
C1
C2
G
Y/Y2
C UT TO
ENAB LE
DEHUM ID IFY
AIR
CIRCULATION
BLOWER
(ACB)
R
FOR PROPER OPERATION ON 208 VOLT THE
FOLLOWING CHANGE MUST BE MADE:
MOVE RD6 WIRE FROM TRANSFORMER
230 TERMINAL TO 208 TERMINAL.
VT-14
PS1
DT
P
S
1
RS
208 VOLT INSTALLATION
WIRING DIAGRAMS
PHD42C02E
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.
77
78
(ACB)
CIRCULATION
FAN
(-)
A
B
A
B
RD-13
SOLENOID
DIAGNOSTICS
BOARD
OPERATION
DIAGNOSTICS
HEATCRAFT
VT-14
TEST
FAN
OPTIONAL
COMP
RD-13
(- )
INTERFACE
RD-31
VT-14
FOR PROPER OPERATION ON 208 VOLT THE
FOLLOWING CHANGE MUST BE MADE:
MOVE RD6 WIRE FROM TRANSFORMER
COMMON
FAN
OD
24V
PIN 1
PIN 2
PIN 3
PIN 4
PIN 5
PIN 6
PIN 7
PIN 8
PIN 9
(ACB)
CIRCULATION
FLASHING
FLASHING
VT
VT
RD-27
RD RED
CAPACITOR
FAN
HI VOLTAGE
HI VOLTAGE FIELD
VT VIOLET
GN GREEN
VT
RD-27
FAN
MOTOR
VT
VT-20
RD -10
VT
WIRING DIAGRAMS
PHD48, PHB60
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.
FAN
L1
5
STAR T
RE LAY
L2
T2
R
208/230 VAC 1Ø
WARNING:DISCONNECT POWER BEFORE SERVICING.
USE COPPER CONDUCTORS ONLY - 75?C MIN
2
C
CAPACITOR
(CAP)
TO
HEATER
KITS
BR
BR
9
BR-21
RD-13
BU-34
GY-70
BK-26
VT- 18
YL- 27
8 7
4
2 1
LOW
6 5
3
PIN 9
PIN 8
PIN 7
PIN 6
PIN 5
PIN 4
PIN 3
PIN 2
PIN 1
5
VIEW A-A
6
AIR
1 COMMON
CIRCU
LATION
2 HI
BLOWER 3 MED HI
4
(ACB)
MED LOW
FOR PROPER OPERAT ION O N 208 VOLT THE
FOLLOW ING CHANGE MUST BE MADE:
MOVE RD6 W IRE FROM TRANSF ORMER
230 TERMINAL TO 208 TERMINAL.
208 VOLT INSTALLATION
RD
BK
GN
GY-28
BU-34
RD-13
RD
33
WH-7
BU
7
230
NO NC
COM
MED-LO W
MED-HIG H
PCC36C02*
LOW
COOLIN G
BLOWER
SP EED TAP
MED
LOW
MED
LOW
MED
LOW
LOW
LOW
LOW
HO RIZ
PHCB05C1
DO WN
RD-6
MED
LOW
MED
LOW
MED
LOW
DOWN
LOW
LOW
LOW
HORIZ
PHCB10C1
VT-7
MED
HIGH
MED
HIGH
MED
HIGH
DO WN
MED
HIGH
MED
HIGH
MED
HIGH
HO RIZ
PHCB15C1
ELECTRIC HEAT BLOWER TAP
RD-22
COOLING
SWITCH
RELAY
BU-9
VT-14
208
LINE
BU-23
G
YL/BK
VT-18
BK-26
C
XFMR- C
R
XFMR- R
BU-9
LOAD
COM
TRANSFORMER
ALTERNATE UNIT POWER REFRIGERANT
LEADS MAY BE USED WITH ELECTRIC
HEATER ACCESSORIE S. SEE HEATER
ACCESSORY INSTALLATION INSTRUCTIONS.
TERMINAL BOARD
PCC30C02*
PCC24C02*
MO DEL
NUMBER
A
A
BU-23(HEAT)
RD-11
VT-14(CO MMON)
RD-24(CO OL)
G
CC
1
COM P
CAP
R
R
C AP
START
S
R
ACB
CONTACTOR
COIL
LPS
Y
C
T1
HERM
FAN
W
O
CAP
OD
T AP
COO LIN G
G
W
COM
NO
E
Y
FAN
CA P
COOLING
SWITCH
RELAY
MED H I
MED L OW
LO
HI
XF MR R
CO M
NC
4
ELECTRIC
HEAT
RELAY
230/208
24V
FAN RELAY
G
5
C
R
2
C
HEAT
TAP
COMMON
XF MR C
COOLING
G
TO HEAT ER KIT
W
ELECTRIC
HEAT RELAY
W2 W1 C
Y
HEATER
KIT
FUSE
230 VOLT
4
2
1
HIGH
HIGH
HIGH
DOWN
L1
O.D.
FAN
MO TOR
RD-31
HIGH
HIGH
HIGH
HO RIZ
VT
20
FAN
YL
12
S
GY GRAY
RD RED
HI VOLTAGE FIELD
HI VOLTAGE
LO W VO LTAG E FIELD
LO W VO LTAG E
BK BLACK
BU BLUE
WH WHITE
GN GREEN
VT VIOLET
BR BRO WN
YL YELLOW
OR ORANGE
CO LOR CODE
22303801 REV. 1
RD-27
C
HERM
R
COMPRESSOR
1Ø WIRING
RD
31
L2
L1
GND
USE COPPER
CONDUCTORS
ONLY75°C MIN
CAPACITOR
COM
BR-11
BK-27
RD
31
RD
10
LOWPRESSURE
SWITCH (LPS)
RD -27
ELECTRIC
HEAT
RELAY
BU
23
PHCB20C1
VT-16
5
3
T1
CONTACTOR
(CC)
L2
T2
VT-20
RD-10
BU-9
BU-1
YL/BK
GND
FIELD CON
NECTION
208/230 VAC1Ø
WIRING DIAGRAMS
PCC24, 30, 36C02 [E/F]
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.
79
L1
2
5
START
RELAY
L2
T2
R
208/230 VA C 1 Ø
WA RNING:D ISCO NNECT POWER BEFORE SERVICING.
USE COPPER CONDUCTORS ON LY - 75ºC MIN
1
C
208 VOLT INSTALLATION
CAPACITOR
(CAP)
TO
HEATER
KITS
BR
BR
PIN 1
PIN 2
PIN 3
PIN 5
PIN 4
PIN 6
PIN 7
PIN 8
PIN 9
5
2
9
8
7
4
1
BR-21
RD-13
BU-34
GY-70
BK-26
VT-18
YL-27
L OW
M ED
HI
COM MON
6 5
3
4
2
3
1
VIEW A-A
6
AIR
CIRCU
LATION
BLOWER
(ACB)
FOR PROPER OPERATION ON 208 VOLT THE
FOLLOWING CHANGE MUST BE MADE:
MOVE RD6 WIRE FROM TRANSFORMER
230 TERMINAL TO 208 TERMINAL.
RD
BK
GN
BU-34
RD-13
GY-28
RD
33
WH-7
BU
7
230
NO NC
C OM
LOW
MED
MED
PCC48C02*
DOWN
M ED
L OW
HORIZ
PHCB05C1
LOW
COOLING
BLOWER
SPEED TAP
RD-6
M ED
L OW
DOWN
M ED
LOW
HORIZ
PHCB10C1
VT-7
MED
LOW
DOWN
MED
LO W
HORIZ
PHCB15C1
ELECTRIC HEAT BLOWER TAP
RD-22
COOLING
SWITCH
RELAY
BU-9
VT-14
20 8
L INE
C OM
BU-23
G
YL/BK
VT-18
BK-26
C
XFMR-C
R
XFMR-R
BU-9
LOAD
TRANSFORMER
ALTERNATE UNIT POWER REFRIGERANT
LEADS MAY BE USED WITH ELECTRIC
HEATER ACCESSORIES. SEE HEATER
ACCESSORY INSTALLATION INSTRUCTIONS.
TERMINAL BOARD
PCC42C02*
MODEL
NUMBER
A
A
BU-23(HEAT)
RD-11
VT-14(COMMON)
RD-24(COOL)
G
CAP
CO MP
C AP
R
R
CC
STA RT
S
R
ACB
Y
C
T1
HERM
FAN
LO
HI
Y
CONTAC TOR
COIL
LPS
W
W
CAP
OD
TAP
COOLING
G
O
COM
NO
E
Y
FAN
CAP
C OOL ING
SW ITCH
RELAY
M ED
XF MR R
CO M
NC
4
24V
23 0/20 8
ELEC TR IC
HEAT
RELAY
C
TO HEATER KIT
FAN RELAY
G
5
C
2
CO MMO N
C
R
COO LING
XF MR C
HEAT
TAP
ELE CTR IC
HEAT REL AY
W2 W1
G
HEATER
KIT
W
80
FUSE
230 VOLT
4
2
1
HI
MED
DOWN
L1
O.D.
FAN
MOTOR
RD-31
HI
MED
HORIZ
VT
20
R
C
FAN HERM
YL
12
S
COMPRESSOR
1 Ø WIRING
RD
31
USE COPPER
CONDUCTORS
ONLY75 °C MIN
L2
L1
GND
FIELDCONN
ECTION
208/230 VAC1Ø
LOW VOLTAGE
LOW VOLTAGE FIELD
HI VOLTAGE
HI VOLTAGE FIELD
COLOR CODE
BR BROWN
YL YELLOW
WH WHITE
OR ORANGE
VT VIOLET
BU BLUE
GN GREEN
GY GRAY
BK BLACK
RD RED
22303201 REV. 1
RD-27
CAPACITOR
COM
BR-11
BK-27
RD
31
RD
10
LOWPRESSURE
SWITCH (LPS)
RD-27
ELECTRIC
HEAT
RELAY
BU
23
PHCB20C1
VT-16
5
3
T1
CONTA
CTOR(CC)
L2
T2
VT-20
RD-10
BU-9
BU-1
YL/BK
GND
WIRING DIAGRAMS
PCC42, 48C02 [E/F]
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.
L1
EM /W2
CAP
1
2
COMP
5
C
START
RELAY
L2
T2
208/230 VAC 1Ø
WARNING: DISCONNECT POWER BEF ORE SERVICING.
USE COPPER CONDUCTORS ONLY
CC
START
S
R
O
R
HERM
FAN
OD
230/208
24V
C
T1
G
CAP
O
G
R2
A
A
TEST
(-)
(+)
NORM
ADJUST
D
C
B
A
( )+
(- )
TEST
NO R M
ADJUST
COOL
A
B
C
D
BLOWER
INTERFACE
1750
1734
1717
1700
CFM
ALTERNATE UNIT POWER REFRIGERANT
LEADS MAY BE USED WITH ELECTRIC
HEATER ACCESSORIES. SEE HEATER
ACCESSORY INSTALLATION INSTRUCTIONS.
RD
BK
GN
VIEW A-A
9 8 7
6 5 4
3 2 1
BR-21
RD-13
BU-34
GY-70
YL-27
SEE DETAIL 2
HEAT
A
B
C
D
(COOL)
DETAIL 2
D
C
B
A
CUT TO
ENABLE
DEHUMIDIF Y
RD-31
RD-13
BU-34
TERMINAL BOARD
1400(20 KW)
1050(15 KW)
700(10 KW)
525(7.5 KW)
CFM (HEAT)
BU-9
VT-14
208
LINE
COM
230
D
C
B
A
DISCONNECT UNIT POWER
WHEN CHANGING TAPS
RD
33
BU-9
LOAD
W
FAN
TO HEATER KIT
W
COMMON
TO
HEATER
KIT
PIN 1
PIN 2
PIN 3
PIN 4
PIN 5
PIN 6
PIN 7
PIN 8
PIN 9
AIR
CIRCULATION
BLOWER
(ACB)
O
COM
W1
Y
TERMINAL BOARD
G
TRANSFORMER
Y
CAP
HEATER
KIT
W2
W1
G
E
C
R
R3
W
C2
BLOWE R
IN TERFACE
HEAT
A
B
C
D
O
COOL
Y
A
B
C
D
A IR
CIRCULATION
BLOWER
(ACB)
ADJ UST
NORM
( +)
(-)
TEST
C1
FOR PROPER OPERATION ON 208 VOLT THE
FOLLOWING CHANGE MUST BE MADE:
MOVE RD6 WIRE FROM TRANSFORMER
230 TERMINAL TO 208 TERMINAL.
VT-14
W1
EM/W2
O
R2
R3
C1
C2
G
Y/Y2
CUT TO
ENABLE
DEHUMIDIFY
Y/Y2
208 VOLT INSTALLATION
RD-6
BU
7
VT-7
VT-16
L1
T2
O.D.
FAN
MOTOR
VT
16
VT
20
FAN
R
HERM
C
RD-27
CAPACITOR
COM
YL
12
S
COMPRESSOR
1Ø WIRING
RD
31
USE COPPER
CONDUCTORS
ONLY75°C MIN
L2
L1
GND
FIELD CONNECTION
208/230 VAC 1Ø
LOW VOLTAGE
LOW VOLTAGE FIELD
HI VOLTAGE
HI VOLTAGE FIELD
COLOR CODE
YL YELLOW
BR BROWN
OR ORANGE
WH WHITE
VT VIOLET
BU BLUE
GN GREEN
GY GRAY
BK BLACK
RD RED
20283201 REV. 0
BK-27
BR-11
RD
10
LOW PRESSURE
SWITCH (LPS)
RD-27
L2
CO
NTACT OR (CC)(CC)
CONTACTOR
T1
VT-20
RD-10
YL/BK
BU-9
BU-7
GND
WIRING DIAGRAMS
PCC60C02 [E/F]
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.
C
R
81
WIRING DIAGRAMS
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.
E
2
W2
OFF
Y
O
W
AUTO
19 - 21
R
SEQ 1
O
DF
W
COOL
6
Y
Y
7
AUTO
8
ON
G
G
9
R
R
C
C
11
12
DT
Pressure Switches not
used on all models.
PS1
B
B
PS2
A
G
PHB/PHD using ATK to control
2nd stage (3rd,4th bank) of
electric heat.
10
A
DEFROST
CONTROL
PS
COOLING
RELAY
28
34
30
TEST
5
23, 24
OUT
G
SEQ 2
W1
HEAT
RS
C
ATK
HEATER
4
R
W2
O
3
FUSE
O
1
60
90
Y
CC
COM
FAN
33
13
14
15
16
17
18
208
19
ELECTRIC
HEAT
RELAY
SEQ 1
20
28
OL
SEQ 1
HE 1
SEQ 1
HE 2
23
SEQ 2
HE 3
24
SEQ 2
CB
HE 4
21
OL
22
OL
OL
CB
CB
CB
25
208/230-60-1
26
27
ACB
28
COOLING
RELAY
ELECTRIC
HEAT
RELAY
29
30
19
CAP
Hard Start components not used on all models.
START CAP
32
1
5
2
C
FAN MOTOR
R
S
12
COMP
33
CC
34
Fan Relay
on PC Board
CB
RUN CAP
T1
CB
36
208/230-60-1
L1
82
10
START RELAY
31
35
HI
MED HI
M LO
LO
L2
PHB/PHD with ATK Controling Output to 2nd Stage of Heater
WIRING DIAGRAMS
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.
E
2
W2
OFF
Y
O
HEAT
W
AUTO
19 - 21
R
SEQ 1
O
DF
W
COOL
6
Y
Y
7
AUTO
8
ON
G
G
9
R
R
C
C
11
DT
Pressure Switches not
used on all models.
PS1
B
B
PS2
A
G
PHB/PHD using ATK to control
"W2" thermostat input.
10
A
DEFROST
CONTROL
PS
COOLING
RELAY
28
34
30
TEST
5
23, 24
OUT
G
SEQ 2
W1
ATK
RS
C
HEATER
4
R
W2
O
3
FUSE
O
1
60
90
12
Y
CC
COM
FAN
33
13
14
15
16
17
18
208
19
ELECTRIC
HEAT
RELAY
SEQ 1
20
28
OL
SEQ 1
HE 1
SEQ 1
HE 2
SEQ 2
HE 3
SEQ 2
CB
HE 4
21
OL
22
OL
23
OL
24
CB
CB
CB
25
208/230-60-1
26
27
ACB
28
COOLING
RELAY
ELECTRIC
HEAT
RELAY
29
30
10
19
CAP
Hard Start components not used on all models.
START RELAY
31
START CAP
32
1
5
2
C
FAN MOTOR
R
S
12
COMP
33
CC
34
35
HI
MED HI
M LO
LO
Fan Relay
on PC Board
CB
RUN CAP
T1
CB
36
208/230-60-1
L2
L1
PHB/PHD with ATK Controlling 2nd Stage Thermostat Input
83
WIRING DIAGRAMS
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.
E
2
W2
OFF
W
FSK
7
AUTO
8
ON
9
G
G
R
R
C
C
Pressure Switches not
used on all models.
B
DEFROST
CONTROL
B
PS2
A
G
PS
COOLING
RELAY
28
34
30
TEST
11
A
DT
PS1
PHB/PHD with FSK controling
"Y" thermostat input.
10
DF
W
Y
Y
19 - 21
R
SEQ 1
O
COOL
6
23, 24
Y
O
HEAT
RS
OUT
G
SEQ 2
W1
AUTO
5
C
HEATER
4
R
W2
O
3
FUSE
O
1
60
90
12
Y
CC
COM
FAN
33
13
14
15
16
17
18
208
19
ELECTRIC
HEAT
RELAY
SEQ 1
20
28
OL
SEQ 1
HE 1
SEQ 1
HE 2
23
SEQ 2
HE 3
24
SEQ 2
CB
HE 4
21
OL
22
OL
OL
CB
CB
CB
25
208/230-60-1
26
27
ACB
28
COOLING
RELAY
ELECTRIC
HEAT
RELAY
29
30
START RELAY
5
2
1
19
CAP
C
START CAP
32
FAN MOTOR
R
S
12
COMP
33
CC
34
Fan Relay
on PC Board
CB
RUN CAP
T1
CB
36
208/230-60-1
L1
84
10
Hard Start components not used on all models.
31
35
HI
MED HI
M LO
LO
PHB/PHD with Freeze Protection Kit Installed.
L2
WIRING DIAGRAMS
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.
20152201
THERMOSTAT
C
BU
G
GY
Y
YL
R
RD
W
BR
W1
BR
GND
BK
5
4
BK
BK
VT
RD
L2
FIELDPRIN
CONNECTIONED B
208/240 VACD BO
1ø
CB1
BR
W2
BU
O
BK
1
GY
BU
RD
BR
YL
1
2
3
4
5
6
7
8
9
L1
BK
USE COPPERCD B
CONDUCTORSCD B
ONLY-75°C MIN
0R
VT
RD
BK
OL
5KW
PHCB05C1
20152301
THERMOSTAT
BU
G
GY
Y
YL
R
RD
W
BR
W1
BR
BK
BK
BK
5
4
GND
BK
3
1
BK
BR
W2
BU
1
O
0R
GY
BU
RD
BR
2
3
4
5
6
7
8
9
L2
FIELD
CONNECTION
208/240 VAC
1ø
CB1
L1
BK
YL
1
VT
RD
RD
BK
VT
BK
RD
OL
OL
RD
BK
10KW
USE COPPERCD B
CONDUCTORSCD B
ONLY-75°C MIN
C
PHCB10C1
THERMOSTAT
BU
G
GY
Y
YL
R
RD
W
BR
W1
BR
5
4
BK
L4
RD
BR
BK
CB2
BU
2
BK
BK
GND
20152401
BK
5
BK
4
FIELD
CONNNECTION
208/240 VAC
1ø
L3
GND
BK
BK
VT
RD
BU
BK
1
3
L2
FIELD
CONNNECTION
208/240 VAC
1ø
CB1
BR
W2
1
O
0R
GY
BU
RD
BR
YL
1
2
3
4
5
6
7
8
9
L1
BK
VT
BK
RD
OL
OL
RD
BK
OL
RD
BK
15KW
USE COPPERCD B
CONDUCTORSCD B
ONLY-75°C MIN
C
PHBC15C1
C
BU
G
GY
Y
YL
R
RD
W
BR
W1
BR
BK
BK
5
4
3
1
BR
BK
BK
BK
W2
BK
RD
BU
BK
L3
4
3
1
BK
GY
RD
CB1
BK
L1
1
BK
FIELD
CONNECTION
208/240 VAC
1ø
GND
L2
VT
RD
BK
BULY-7
0R
CB2
2
5
O
BR
L4
BK
BR
BU
GND
20152501
FIELD
CONNECTION
208/240 VAC
1ø
YL
1
2
3
4
5
6
7
8
9
VT
RD
BK
OL
OL
BK
RD
RD
BK
OL
OL
BK
RD
20KW
USE COPPERCD B
CONDUCTORSCD B
ONLY-75°C MIN
THERMOSTAT
PHCB20C1
85