Service Manual - Alpine Home Air Products

Service Instructions

APG/GPG 14 SEER

Gas Electric Package Units with R-410A Refrigerant

& Accessories

This Forced Air Central Unit Design Complies With

Requirements Embodied in The American National

Standard / National Standard of Canada Shown Below.

ANSI Z21.47•CSA-2.3 Central Furnaces

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.

Copyright © 2014 Goodman Manufacturing Company, L.P.

RS6300012

November 2014

TABLE OF CONTENTS

IMPORTANT INFORMATION ......................... 2 - 3 SCHEDULED MAINTENANCE .................. 23 - 25

PRODUCTION IDENTIFICATION .................. 4 - 5

ACCESSORIES ........................................... 6 - 13

PRODUCT DESIGN .................................. 14 - 19

SERVICING TABLE OF CONTENTS ............... 28

SERVICING ................................................ 29 - 53

ACCESSORIES WIRING DIAGRAMS ....... 54 - 55

SYSTEM OPERATION .............................. 20 - 22

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

This unit should not be connected to, or used in conjunction with, any devices that are not design certified for use with this unit or have not been tested and approved by Goodman. Serious property damage or personal injury, reduced unit performance and/or hazardous conditions may result from the use of devices that have not been approved or certified by

Goodman.

WARNING

Do not store combustible materials or use gasoline or other flammable liquids or vapors in the vicinity of this appliance as property damage or personal injury could occur. Have your contractor point out and identify the various cut-off devices, switches, etc., that serves your comfort equipment.

WARNING

Goodman will not be responsible for any injury or property damage arising from improper service or service procedures. If you perform service on your own product, you assume responsibility for any personal injury or property damage which may result.

HIGH VOLTAGE!

Disconnect ALL power before servicing or installing this unit. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

To locate an authorized servicer, please consult your telephone book or the dealer from whom you purchased this product. For further assistance, please contact:

GOODMAN

®

BRAND PRODUCTS

TOLL FREE

1-877-254-4729 (U.S. only) email us at: [email protected] fax us at: (713) 856-1821

(Not a technical assistance line for dealers.)

AMANA ® BRAND PRODUCTS

TOLL FREE

1-877-254-4729 (U.S. only) email us at: [email protected] fax us at: (713) 856-1821

(Not a technical assistance line for dealers.)

Outside the U.S., call 1-713-861-2500.

(Not a technical assistance line for dealers.) Your telephone company will bill you for the call.

is a registered trademark of Maytag Corporation or its related entities and is used under license. All rights reserved.

2

IMPORTANT INFORMATION

SAFE REFRIGERANT HANDLING

While these items will not cover every conceivable situation, they should serve as a useful guide.

WARNING

Refrigerants are heavier than air. They can "push out" the oxygen in your lungs or in any enclosed space.To

avoid possible difficulty in breathing or death:

• Never purge refrigerant into an enclosed room or

space. By law, all refrigerants must be reclaimed.

• If an indoor leak is suspected, thoroughly ventilate

the area before beginning work.

• Liquid refrigerant can be very cold. To avoid possible

frostbite or blindness, avoid contact with refrigerant

and wear gloves and goggles. If liquid refrigerant

does contact your skin or eyes, seek medical help

immediately.

• Always follow EPA regulations. Never burn refrig-

erant, as poisonous gas will be produced.

WARNING

To avoid possible explosion:

• Never apply flame or steam to a refrigerant cylinder.

If you must heat a cylinder for faster charging,

partially immerse it in warm water.

• Never fill a cylinder more than 80% full of liquid

refrigerant.

• Never add anything other than R-22 to an R-22 cylinder

or R-410A to an R-410A cylinder. The service equipment

used must be listed or certified for the type of

refrigerant used.

• Store cylinders in a cool, dry place. Never use a

cylinder as a platform or a roller.

WARNING

To avoid possible injury, explosion or death, practice safe handling of refrigerants.

WARNING

The compressor POE oil for R-410A units is extremely susceptible to moisture absorption and could cause compressor failure. Do not leave system open to atmosphere any longer than necessary for installation.

WARNING

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

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.

3

PRODUCT IDENTIFICATION

The model number is used for positive identification of component parts used in manufacturing. Please use this number when requesting service or parts information.

G / A P G 14 24 060 M 4 1 * *

BRAND:

G: Goodman ®

Brand or

Distinctions

A: Amana ®

Brand

PRODUCT

TYPE:

Single Package

Cooling/Heating

CONFIGURATION:

M: Multi-position

PRODUCT

SERIES:

14: Up to 14 SEER

HEATING INPUT

040: 40,000 BTUH

060: 60,000 BTUH

080: 80,000 BTUH

100: 100,000 BTUH

120: 120,000 BTUH

REFRIGERANT:

4: R-410A

PRODUCT

FAMILY:

G: Gas/Electric

NOMINAL

CAPACITY:

24: 24,000 BTUH

30: 30,000 BTUH

36: 36,000 BTUH

42: 42,000 BTUH

48: 48,000 BTUH

60: 60,000 BTUH

MAJOR

REVISION:

VOLTAGE:

1: 208-230V/1ph/60Hz

3: 208-230v/3ph/ 60Hz

4: 460v/3ph/60Hz

MINOR

REVISION:

4

PRODUCT IDENTIFICATION

Single Phase Package Gas Units

Model # Description

APG14[24-60]***M41AA

Amana

®

Brand Package Gas up to 14 Seer R410A Multi-Position gas/electric units. Initial release of single phase models.

Model #

GPG14[24-60]***M41AA

Single Phase Package Gas Units

Description

Goodman

®

Brand Package Gas up to 14 Seer R410A Multi-Position gas/electric units. Initial release of single phase models.

These units have R410A refrigerant

5

ACCESSORIES

Part Number

LPM-07

LPM-08

HA-03

ACCESSORIES

Description

Propane Conversion Kit (*PG14 Single Stage Models)

Propane Conversion Kit (*PG14 Two Stage Models)

High Altitude Kit

PGC101/102/103

PGEDJ101/102

PGEDJ103

DHZECNJPGCHM

DHZECNJPGCHL

PGMDD101/102

PGMDD103

PGMDH101

PGMDH102

PGMDH103

PGMDMD101/102

PGMDMD103

PGMDMH101

PGMDMH102

PGMDMH103

SQRPG101/102

SQRPG103

SQRPGH101/102

SQRPGH103

PGFR101/102/103

GPGHFR101-103

CDK36

CDK36515

CDK36530

CDK36535

Roof Curb

Goodman Downflow Jade Economizer M Series Gas Package Unit, Medium Chassis

Goodman Downflow Jade Economizer M Series Gas Package Unit, Large Chassis

Goodman/Daikin Horizontal Jade Economizer M Series Package Unit All Fuels,

Medium Chassis, H Series All Chassis

Goodman/Daikin Horizontal Jade Economizer M Series Package Unit All Fuels, Large Chassis

Manual 25% Fresh Air Damper Downflow Application, Small and Medium Chassis

Manual 25% Fresh Air Damper Downflow Application, Large Chassis

Manual 25% Fresh Air Damper Horizontal Application, Small Chassis

Manual 25% Fresh Air Damper Horizontal Application, Medium Chassis

Manual 25% Fresh Air Damper Horizontal Application, Large Chassis

Motorized 25% Fresh Air Damper Downflow Application,Small and Medium Chassis

Motorized 25% Fresh Air Downflow Application, Large Chassis

Motorized 25% Fresh Air Damper Horizontal Application, Small Chassis

Motorized 25% Fresh Air Damper Horizontal Application, Medium Chassis

Motorized 25% Fresh Air Damper Horizontal Application, Large Chassis

Square to Round Adapter w/ 16" Round Downflow Application, Small and Medium Chassis

Square to Round Adapter w/ 18" Round Downflow Application, Large Chassis

Square to Round Adapter w/ 16" Round Horizontal Application, Small and Medium Chassis

Square to Round Adapter w/ 18" Round Horizontal Application, Large Chassis

Internal Filter Rack All Chassis

External Horizontal Filter Rack for Goodman/Amana Gas/Electric

& Multi-position Package Units All Chassis

Flush Mount Concentric Duct Kit

Flush Mount Concentric Duct Kit w/ Filter

Step Down Concentric Duct Kit

Step Down Concentric Duct Kit w/ Filter

CDK4872

CDK4872515

CDK4872530

Flush Mount Concentric Duct Kit

Flush Mount Concentric Duct Kit w/ Filter

Step Down Concentric Duct Kit

6

CDK4872535 Step Down Concentric Duct Kit w/ Filter

NOTE: Complete lineup of thermostats can be found in the Thermostat Specification Sheets.

LIGHTING INSTRUCTIONS *PG14[24-48]***M41AA

FOR YOUR SAFETY R EAD BEFORE OPERATI NG

If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burners. Do not try to light the burners by hand.

B. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance.

Do not touch any electric switch; do not use any telephone in your building.

Immediately call your gas supplier from a neighbor’s phone. Follow the gas suppliers instructions.

If you cannot reach your gas supplier, call the fire department.

C. Use only your hand to move the gas control switch or knob. Never use tools. If the gas control switch or knob will not operate, 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.

WARNING:

Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage.

Refer to the user’s information manual provided with this furnace. For assistance or additional information consult a qualified installer, service agency or the gas supplier.

This furnace must be installed in accordance with the manufacturers instructions and local codes. In the absence of local codes, follow the National Fuel Gas

Code, ANSI Z223.1.

OPERATI NG INSTRUCTIONS

1. STOP! Read the safety information above on this label.

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an automatic ignition system which automatically lights the burners. Do not try to light the burners by hand.

5. Remove control access panel.

6. Move the gas control switch or knob to "OFF".

GAS CONTROL

SWITCH SHOWN

IN "ON" POSITION

7. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP!

Follow "B" in the safety information above on this label. If you don’t smell gas, go to the next step.

8. Move the gas control switch or knob to "ON".

9. Replace control access panel.

10. Turn on all electric power to the appliance.

11. Set the thermostat to the desired setting.

12. If the appliance will not operate, follow the instructions "To Turn Off Gas

To Appliance" and call your service technician or gas supplier.

TO TURN OFF G AS TO APPL IANCE

1. Set the thermostat to its lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. Remove control access panel.

4. Move the gas control switch or knob to "OFF". Do not force.


WARNING:

If not installed, operated and maintained in accordance with the manufacturer’s instructions, this product could expose you to substances in fuel combustion which can cause death or serious illness and which are known to the

State of California to cause cancer, birth defects or other reproductive harm.

This product contains fiberglass insulation.

Fiberglass insulation contains a chemical known by the State of

California to cause cancer.

FOR YOUR SAFETY

or any other appliance.

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this

0140F01902-A

7

LIGHTING INSTRUCTIONS

FOR YOUR SAFETY

READ BEFORE OPERATING

WARNING: exactly,a fire or damage, personal injury or

A. This appliance does not have a pilot. It is equipped

with an ignition device which automatically lights

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.

*PG1460***M41AA

LIRE AVANT DE METTRE

EN MARCHELIRE

AVERTISSEMENT:

Quiconque ne respecte pas à la lettre les instructions dans le presént manuel risque de déclencher un incendie ou une explosion entraînant des dommages matériels, des lesions corporelles ou la perte de vies humaines.

A.

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 decéler

une odeur de gaz. Renifler prés du plancher, car

certains gaz sont plus lourds que l'air et

peuvent s'accumuler au niveau du sol.

QUE FAIRE S'IL Y A UNE ODEUR DE GAZ

Ne pas tenter d'allumer d'appareils.

Ne toucher à aucun interrupteur; ne pas vous servir

des téléphones dans le bâtiment.

Appelez immédiatement votre fournisseur de gaz depuis

un voisin. Suivez les instructions du fournisseur de gaz

Si vous ne pouvez rejoindre le fournisseur de gaz,

appelez le service des incendies.»

C. Ne pousser ou tourner la manette d'admission du gaz

qu'à la main. Ne jamais emploer d'outil à cette fin.

Si la manette reste coincée, ne tenter pas de la

réparer; appelez un technicien qualifié. Quiconque

tente de forcer la manette ou de la réparer peut

provoquer une explosion ou un incendie.»

D. Ne pas se servir de cet appareil s'il a été plongé dans

l'eau, même partiellement. Faire inspecter l'appareil

par un technicien qualifié et remplacer toutr partie du

systéme de contrôle et toute commande qui ont été

plongées dans l'eau.»

MISE EN MARCHE OPERATING INSTRUCTIONS

this label.


3. Turn off all electric power to the appliance.

4. This appliance is equipped with an ignition

device which automatically lights the burner.

Do not try to light the burner by hand.

Do not force.

6. Wait five (5) minutes to clear out any gas. Then

smell for gas, including near the floor. If you

in the safety. information above

on this label if you don't smell

gas, go to next step.

7. Push gas control lever

GAS

INLET

8. Replace access panel.

9. Turn on all electric

power to the appliance.

ARRIVEE

DU GAZ

10. Set thermostat to desired setting.

11. If the appliance will not operate,

follow the instructions "To Turn

Off Gas To Appliance" and call your

service technician or gas company.

.

section 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 menager etant dote d'un systeme

d'allumage automatique, ne pas essayer à

allumer le brûleur manuellement.

5. Pousse le levier du contrÔle du gaz a

position.

"OFF/ ARRET"

6. Attendre cinq (5) minutes pour laisser echapper tout le

gaz. Renifler tout autour de l'appareil, y compris prés du

plancher, pour déceler une odeur de gaz. Si c'est le cas,

ROBINET A GAZ

MANUEL, EN POS

"ON/MARCHE"

MANUAL GAS

LEVER SHOWN

IN "ON" POS

sur la portion superieure de cette etiquette.

S'il n'y a pas d'odeur de gaz, passer à l'etàpe suivante.

7. Pousse le levier du contrôle du gaz à

position.

"ON/MARCHE"

8. Remettre en place le panneau d'accés.

9. Mettre l'appareil sous tension.

10. Régler le thermostat à la température désirée.

11. Si l'appareil ne se met pas en marche, suivre les

instructions intitulées Comment couper l'admission

de gaz de l'appareil et appeler un technicien

qualifié ou le fournisseur de gaz.

TO TURN OFF GAS TO APPLIANCE


2. Turn off all electric power to the appliance

if service is to be performed.

Do not force.


POUR COUPER L'ADMISSION

DE GAZ DE L'APPAREIL

1. Régler le thermostat à la température la plus bassé.

2. Couper l'alimentation électrique de l'appareil s'il

faut procéder à des operations d'entretien.

3. Pousse le levier du contrôle du gaz à

"OFF/ ARRET"

position.

Ne pas forcer.

4. Remettre en place le panneau d'accés.

0140F00000P REV D

8

ACCESSORIES

A

ROOF CURBS

B

S

R

C

1 5/8

14 1/2

1 3/8

MODEL A

PGC101/102/103 46 1/4

B

39 3/8

C RETURN SUPPLY

14 1/2 12 1/2 x 23 15 x 22 1/2

DOWNFLOW FILTER RACK

(PGFR101/102/103)

25

3

2

1 1/2

26 1/2

Filter Size: 14" x 25" x 2"

Measurement in inches.

NOTE: PGFR cannot be used with downflow economizers.

14

9

ACCESSORIES

PGEDJ101/102

(DOWNFLOW ECONOMIZER)

E

C

D

F

A

B

PGED101/102

A B

C D

E F

20 16.25 16 23.5 12.5 45.75

PGEDJ103

(DOWNFLOW ECONOMIZER)

A

PGEDJ103

A B

16 18

14 X 25 FILTER ATTACHMENT

25

B

10

16 X 20 x 2”

FILTER

+

16 X 20

MIST ELIMINATOR

ACCESSORIES

ECONOMIZER

(HORIZONTAL APPLICATIONS)

B

16 1/8

18

A

MODEL

MANUAL

A

PGMDH101 26 1/2 29 3/4

PGMDH102 31 1/2 29 3/4

PGMDH103 30

MOTORIZED

MODEL A

B

29 3/4

B

PGMDMH101 26 1/2 29 3/4

PGMDMH102 31 1/2 29 3/4

PGMDMH103 30 29 3/4

D

A

E

C

MODEL A

DHZECNJPGCHM 25 1/4

DHZECNJPGCHL 35 1/4

B

18 1/8

18 1/8

Measurement in inches.

C

18

18

D

13 3/4

18 1/4

E FILTER

16 1/8 16 x 25 x 1

16 1/8 16 x 25 x 1

MOTORIZED/MANUAL FRESH AIR DAMPERS -


A

B

7 5/8

5 3/4

11 7/8

B

11

ACCESSORIES

MOTORIZED/MANUAL FRESH AIR DAMPERS

(DOWNFLOW APPLICATIONS)

BOTTOM VIEW

12 1/8

10

6

A

5 3/4

11 7/8

1

PGMDD103

B

BOTTOM VIEW

12 1/8

10

6

A

5 3/4

11 7/8

A

B

1

PGMDD101/102

B

MODEL

MANUAL

A

PGMDD101/102

PGMDD103

16

18

MOTORIZED

MODEL A

PGMDMD101/102

PGMDMD103

16

18

SQUARE TO ROUND CONVERTER

(DOWNFLOW APPLICATIONS)

12 1/4

C

B

16

16

B

16

16

14 3/4

16

ø

16

ø

S

D

22 3/4 22 1/4

A

R

12 1/4 14 3/4

B

22 3/4

18

ø 22 1/4

18

ø

MODEL A

SQRPG101/102 22 3/4

SQRPG103 22 3/4

B

12 1/4

12 1/4

C

22 1/4

22 1/4

D

14 3/4

14 3/4

RETURN SUPPLY

16 16

18 18

12

ACCESSORIES

SQUARE TO ROUND CONVERTER


B

C

MODEL

SQRPG101/102

SQRPG103

A

16

18

B

16 1/2

18 1/2

Measurements are in inches.

C

16 1/2

18 1/2

A

GPGHFR101-103

(EXTERNAL HORIZONTAL FILTER RACK)

16” x 25" x 2" FILTER

13

PRODUCT DESIGN

Locations and Clearances

NOTE: To ensure proper condensate drainage, unit must be installed in a level position.

In installations where the unit is installed above ground level and not serviceable from the ground (Example: Roof Top installations) the installer must provide a service platform for the service person with rails or guards in accordance with local codes or ordinances or in their absence with the latest edition of the National Fuel Gas Code ANSI Z223.1.

IMPORTANT NOTE: If using bottom discharge with roof curb, ductwork should be attached to the curb prior to installing the unit.

Refer to Roof curb Installation Instructions for proper curb installation. Curbing must be installed in compliance with the

National Roofing Contractors Association Manual.

Lower unit carefully onto roof mounting curb. While rigging unit, center of gravity will cause condenser end to be lower than supply air end.

NOTE: Roof overhang should be no more than 36".

Minimum clearances are required to avoid air recirculation and keep the unit operating at peak efficiency. A minimum

12 inch clearance is required to the condenser coil.

NOTE: The flue outlet hood is packaged separately inside the unit and must be installed prior to operation.

WARNING

TO PREVENT POSSIBLE DAMAGE, THE UNIT SHOULD

REMAIN IN AN UPRIGHT POSITION DURING ALL

RIGGING AND MOVING OPERATIONS. TO FACILITATE

LIFTING AND MOVING IF A CRANE IS USED, PLACE

THE UNIT IN AN ADEQUATE CABLE SLIDE.

NOTE: A roof curb can be used to utilize bottom discharge.

APG/GPG Package Units are designed for outdoor installations only in either residential or light commercial applications.

NOTE: To ensure proper condensate drainage, unit must be

installed in a level position.

The connecting ductwork (Supply and Return) can be connected for either horizontal or down discharge airflow. In the down discharge applications a matching Roof Curb is recommended .

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.

14

PRODUCT DESIGN

A 3/4" - 14 NPT drain connector is provided for removal of condensate water from the indoor coil. In order to provide proper condensate flow, do not reduce the drain line size.

NOTE: Tighten drain to a maximum torque of 10 in-lbs.

Refrigerant flow control is achieved by use of thermostatic expansion valves (TXV) or flowrator.

The single phase models 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.

A/GPG Package Gas Units are designed for outdoor installations only in either residential or light commercial applications and are available in 2, 2.5, 3, 3.5, 4 & 5 ton sizes. They are designed for 208/230 volt single phase applications.

The connecting ductwork (Supply and Return) can be connected for either horizontal or vertical airflow. In the vertical application, a matching Roof Curb is recommended.

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/GPG model units use EEM type indoor blower motors.

EEM motors are constant torque motors with very low power consumption and are energized by a 24V signal from the ignition control board. The EEM motors feature an integrated control module.

Air for condensing (cooling cycle) is drawn through the outdoor coil by 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.

Most A/GPG series 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 flood back or flooded start conditions may wash oil from the bearing surfaces causing premature bearing failure.

- These Scroll compressors use "POE" or polyolester oil which is NOT compatible with mineral oilbased lubricants like 3GS. "POE" oil must be used if additional oil is required.

- Compliant scroll compressors perform “quiet” shutdowns that allow the compressor to restart immediately without the need for a time delay. This compressor will restart even if the system has not equalized.

- Operating pressures and amp draws may differ from standard reciprocating compressors. This information may be found in the “Cooling Performance Data” section.

A scroll is an involute spiral which, when matched with a mating scroll form as shown, generates a series of crescent shaped gas pockets between the two members.

During compression, one scroll remains stationary (fixed scroll) while the other form (orbiting scroll) is allowed to orbit

(but not rotate) around the first form.

As this motion occurs, the pockets between the two forms are slowly pushed to the center of the two scrolls while simultaneously being reduced in volume. When the pocket reaches the center of the scroll form, the gas, which is now at a high pressure, is discharged out of a port located at the center.

During compression, several pockets are being compressed simultaneously, resulting in a very smooth process. Both the suction process (outer portion of the scroll members) and the discharge process (inner portion) are continuous.

ELECTRICAL WIRING

The units are designed for operation on 60 hertz current and at voltages as shown on the rating plate. All internal wiring is complete. Ensure the power supply to the compressor contactor is brought to the unit as shown on the supplied unit wiring diagram. The 24V wiring must be connected between the unit control panel and the room thermostat.

LINE VOLTAGE WIRING

Power supply to the unit must be N.E.C. Class 1, and must comply with all applicable codes. The unit must be 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.

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.

15

PRODUCT DESIGN

WARNING

DO NOT EXCEED THE MAXIMUM OVERCURRENT

DEVICE SIZE SHOWN ON THE UNIT DATA PLATE.

All line voltage connections must be made through weather proof fittings. All exterior power supply and ground wiring must be in approved weather proof conduit. Low voltage wiring from the unit control panel to the thermostat requires coded cable. See the following figures for ground level and rooftop wiring.

Note: Junction box location shown is optional and is for illustration purposes only.

JUNCTION BOX

Electrical Power Routed Through Bottom of Unit

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.

Electrical Power Directly To Junction Box

WARNING

TO AVOID THE RISK OF PROPERTY DAMAGE,

PERSONAL INJUSRY OR FIRE, USE ONLY COPPER

CONDUCTORS

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

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 unit control box.

16

PRODUCT DESIGN

GAS SUPPLY AND PIPING

CAUTION

THIS PACKAGE GAS UNIT IS FACTORY SET TO

OPERATE ON NATURAL GAS AT THE ALTITUDES

SHOWN ON THE RATING PLATE. IF OPERATION

ON PROPANE IS REQUIRED, OBTAIN AND INSTALL

THE PROPER CONVERSION KIT(S) BEFORE

OPERATING THIS UNIT. FAILURE TO DO SO

MAY RESULT IN UNSATISFACTORY OPERATION

AND/OR EQUIPMENT DAMAGE.

The rating plate is stamped with the model number, type of gas, and gas input rating. Make sure the unit is equipped to operate on the type of gas available.

Natural

Propane

Inlet Gas Pressure Must Not Exceed the Maximum Value

Shown in the table above.

The minimum supply pressure must not be varied downward because this could lead to unreliable ignition. In addition, gas input to the burners must not exceed the rated input shown on the rating plate. Overfiring of the unit could result in premature heat exchanger failure.

GAS PIPING

Inlet Gas Pressure

Min. 5.0" W.C., Max. 10.0" W.C.

Min. 11.0" W.C., Max. 13.0" W.C.

CAUTION

TO AVOID POSSIBLE UNSATISFACTORY OPERATION

OR EQUIPMENT DAMAGE DUE TO UNDERFIRING OF

EQUIPMENT, DO NOT UNDERSIZE THE NATURAL

GAS/PROPANE PIPING FROM THE METER/TANK TO

THE FURNACE. WHEN SIZING A TRUNK LINE PER

THE TABLES, INCLUDE ALL APPLIANCES ON THAT

LINE THAT COULD BE OPERATED SIMULTANEOUSLY.

The gas pipe supplying the unit 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

NOMINAL BLACK PIPE SIZE

40

50

60

70

80

10

20

30

90

100

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

CFH =

BTUH FURNACE INPUT

CALORIFIC VALUE OF GAS

CONNECTING THE GAS PIPING - NATURAL GAS

1. Use black iron or steel pipe and fittings for the building piping.

2. 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.

8. Connect the unit to the building piping by one of the following methods.

a.

Rigid metallic pipe and fittings.

b.

Semi-rigid metallic tubing and metallic fittings.

Aluminum alloy tubing shall 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.

NOTE: In "b" and "c", the connector or tubing must be installed so as to be protected against physical and thermal damage. Aluminum-alloy tubing and connectors must be coated to protect against external corrosion where they are in contact with masonry, plaster, or insulation or are subject to repeated wettings by such liquids as water

(except rain water), detergents, or sewage.

17

PRODUCT DESIGN

TANKS AND PIPING - PROPANE UNITS

DRIP LEG

MANUAL

SHUT-OFF

VALVE

GROUND JOINT UNION

(INSTALLED AHEAD OF GAS VALVE)

WARNING

PERSONAL INJURY HAZARD

IRON OXIDE (RUST) CAN REDUCE THE LEVEL OF

ODORANT IN PROPANE GAS. A GAS DETECTING

DEVICE IS THE ONLY RELIABLE METHOD TO DETECT

A PROPANE GAS LEAK. CONTACT YOUR LOCAL

PROPANE SUPPLIER ABOUT INSTALLING A GAS

DETECTING WARNING DEVICE TO ALERT YOU IN

THE EVENT THAT A GAS LEAK SHOULD DEVELOP.

FAILURE TO DETECT A PROPANE GAS LEAK COULD

RESULT IN AN EXPLOSION OR FIRE WHICH COULD

CAUSE SERIOUS PERSONAL INJURY OR DEATH.

GROMMET

NOTE: The unit gas supply entrance is factory sealed with plugs. Keep plugs in place until gas supply is ready to be installed. Once ready, replace the plugs with the supplied grommets and install gas supply line.

CHECKING THE GAS PIPING

CAUTION

TO AVOID THE POSSIBILITY OF PROPERTY DAMAGE,

PERSONAL INJURY OR FIRE, THE FOLLOWING

INSTRUCTIONS MUST BE PERFORMED REGARDING

GAS CONNECTIONS AND PRESSURE TESTING.

The unit and its gas connections must be leak tested before placing in operation. Because of the danger of explosion or fire, never use a match or open flame to test for leaks. Never exceed specified pressure for testing. Higher pressure may damage the gas valve and cause overfiring which may result in heat exchanger failure.

This unit must be isolated from the gas supply system by closing its individual 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).

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 unit manifold with all gas appliances in operation. Maintaining proper gas pressure depends on three main factors.

1. Vaporization rate, which depends on (a) temperature of the liquid, and (b) "wetted surface" area of the container or containers.

2. Proper pressure regulation. (Two-stage regulation is recommended from the standpoint of both cost and efficiency.)

3. Pressure 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.

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

Clyde's or John Crane are satisfactory.

® , Stalactic ® ,

18

PRODUCT DESIGN

TYPICAL PROPANE PIPING

First Stage

Regulator

5 to 15 PSIG

(20 PSIG Max.)

200 PSIG

Maximum

Continuous

11" W.C.

Second Stage

Regulator

WARNING

PROPANE GAS PIPING CHARTS

Sizing Between First and Second Stage Regulator

Maximum Propane Capacities listed are based on 1 PSIG Pressure Drop at 10

PSIG Setting. Capacities in 1,000 BTU/HR

PIPE OR

TUBING

LENGTH,

FEET

90

100

150

200

250

300

350

400

60

70

80

30

40

50

3/8"

309

265

235

213

196

182

171

161

130

111

90

89

82

76

TUBING SIZE, O.D., TYPE L

1/2"

700

599

531

481

446

412

386

365

293

251

222

201

185

172

5/8"

1,303

1,115

988

896

824

767

719

679

546

467

414

378

345

321

To convert to Capacities at 15 PSIG Settings -- Multiply by 1.130

To convert to Capacities at 5 PSIG Settings -- Multiply by 0.879

1,217

1,149

923

790

700

634

584

543

3/4"

2,205

1,887

1,672

1,515

1,394

1,297

1,873

1,769

1,421

1,216

1,078

976

898

836

7/8"

3,394

2,904

2,574

2,332

2,146

1,996

NOMINAL PIPE SIZE,

SCHEDULE 40

1/2"

1,843

1,577

1,398

1,267

1,165

1,084

1,017

961

772

660

585

530

488

454

2,127

2,009

1,613

1,381

1,224

1,109

1,020

949

3/4"

3,854

3,298

2,923

2,649

2,437

2,267

PROPANE TANK SIZING (MINIMUM)

TANK SIZE REQUIRED IF LOWEST OUTDOOR

MAXIMUM GAS TEMPERATURE (AVG. FOR 24 HOURS) REACHES

NEEDED TO

VAPORIZE*

125K BTU/HR

(50 CFH)

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)

375K BTU/HR

(150 CFH)

250

GAL

300

GAL

250

GAL

400

GAL

250

GAL

500

GAL

400

GAL

500

GAL

500

GAL

1000

GAL

1000

GAL

1500

GAL

1500

GAL

2500

GAL

500K BTU/HR

(200 CFH)

750K BTU/HR

(300 CFH)

400

GAL

750

GAL

500

GAL

1000

GAL

750

GAL

1500

GAL

1000

GAL

2000

GAL

1500

GAL

2500

GAL

2000

GAL

4000

GAL

3500

GAL

5000

GAL

* AVERAGE RATE/HOUR WITHDRAWL IN 8 HOUR PERIOD

Sizing Between Single or Second Stage Regulator and Appliance*

Maximum Propane Capacities Listed are Based on 1/2" W.C. Pressure Drop at

11" W.C. Setting. Capacities in 1,000 BTU/HR

PIPE OR

TUBING

LENGTH,

FEET

50

60

80

100

10

20

30

40

125

150

200

250

TUBING SIZE, O.D., TYPE L

3/8" 1/2"

49

34

27

23

20

19

16

14

12

11

10

9

110

76

61

52

46

42

36

32

28

26

22

19

5/8"

206

141

114

97

86

78

67

59

52

48

41

36

3/4"

348

239

192

164

146

132

113

100

89

80

69

61

7/8"

539

368

296

253

224

203

174

154

137

124

106

94

1/2"

291

200

300

350

8

7

18

16

33

30

55

51

85

78

46

43

400 7 15 28 47 73

*DATA IN ACCORDANCE WITH NFPA PAMPHLET NO. 54

40

74

67

58

51

161

137

122

110

94

84

NOMINAL PIPE SIZE,

3/4"

608

418

155

141

120

107

336

284

255

231

198

175

97

89

83

SCHEDULE 40

1"

1,146

788

292

265

227

201

632

541

480

436

372

330

182

167

156

1-1/4"

2,353

1,617

1,299

1,111

985

892

764

677

600

544

465

412

374

344

320

1-1/2"

3,525

2,423

1,946

1,665

1,476

1,337

1,144

1,014

899

815

697

618

560

515

479

19

SYSTEM OPERATION

COOLING

The refrigerant used in the system is R-410A. It is a clear, colorless, non-toxic and non-irritating liquid. R-410A is a

50:50 blend of R-32 and R-125. The boiling point at atmospheric pressure is -62.9°F.

A few of the important principles that make the refrigeration cycle possible are: heat always flows from a warmer to a cooler body. Under lower pressure, a refrigerant will absorb heat and vaporize at 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 conditioned spaces through the evaporative process taking place within the coil tubes.

NOTE: The pressures and temperatures shown in the refrigerant cycle illustrations on the following pages are for demonstration purposes only. Actual temperatures and pressures are to be obtained from the "Expanded Performance

Chart".

Liquid refrigerant at condensing pressure and temperatures,

(270 psig and 122°F), leaves the outdoor condensing coil through the drier and is metered into the indoor coil through the metering device. As the cool, low pressure, saturated refrigerant enters the tubes of the indoor coil, a portion of the liquid immediately vaporizes. It continues to soak up heat and vaporizes as it proceeds through the coil, cooling the indoor coil down to about 48°F.

Heat is continually being transferred to the cool fins and tubes of the indoor evaporator coil by the warm system air. This warming process causes the refrigerant to boil. The heat removed from the air is carried off by the vapor.

As the vapor passes through the last tubes of the coil, it becomes superheated. That is, it absorbs more heat than is necessary to vaporize it. This is assurance that only dry gas will reach the compressor. Liquid reaching the compressor can weaken or break compressor valves.

The compressor increases the pressure of the gas, thus adding more heat, and discharges hot, high pressure superheated gas into the outdoor condenser coil.

In the condenser coil, the hot refrigerant gas, being warmer than the outdoor air, first loses its superheat by heat transferred from the gas through the tubes and fins of the coil. The refrigerant now becomes saturated, part liquid, part vapor and then continues to give up heat until it condenses to a liquid alone. Once the vapor is fully liquefied, it continues to give up heat which subcools the liquid, and it is ready to repeat the cycle.

HEATING

The heating cycle is accomplished by using a unique tubular design heat exchanger which provides efficient gas heating on either natural gas or propane gas fuels. The heat exchangers 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 allows for field adjustment of the blower delay at the end of the heating cycle. The range of adjustment is for

90, 120, 150 or 180 seconds. The factory delay setting is 30 seconds delay on 150 seconds delay off.

Direct Spark Ignition (DSI) Systems

APG/GPG units are equipped with a direct spark ignition system. Ignition is provided by 22,000 volt electronic spark.

A flame sensor then monitors for the presence of flame and closes the gas valve if flame is lost.

20


PCBAG123 IGNITION CONTROL SEQUENCE OF OPERATION

Continous Fan

1. When the thermostat calls for continuous fan (G) with out a call for heat or cooling, the indoor the fan has a

7 second delay on make and energizes the “HEAT” speed. The fan remains energized as long as the call for fan remains without a call for heat or cooling. The fan call “G” has a 60 second delay on break. Note: When the Configuration tab is broken, the continuous fan mode “G” will have a 7 second delay on make and a 60 second delay on break and the “COOL” speed tap will be energized.

2.

If a call for cool (Y) occurs during continuous fan, the blower will switch over to “COOL” speed.

3.

If a call for heat (W) occurs during continuous fan, the blower will remain energized through the heat cycle or until “G” is de-energized.

4.

The continuous fan operation will function while the control is in heat mode lockout.

Cool Mode

1.

When the thermostat calls for cooling (“Y”), the control energizes the cooling speed fan after a 7 second on delay. The control provides a 3 minute anti-short cycle protection for the compressor. If the compressor has been off for 3 or more minutes, the compressor immediately energizes when the thermostat calls for cool. If the compressor has not been off for at least 3 minutes when a call for cool occurs, the control waits until 3 minutes has elapsed from the time the compressor was last de-energized before re-energizing the compressor.

2.

When the thermostat removes the call for cooling (“Y”) the compressor is deenergized and the control deenergizes the cooling speed fan after a cooling off delay period of 60 seconds.

Note: A call for cooling has priority over continuous fan. If

G is energized while Y is energized, during the cooling fan on delay, the fan will remain off until the delay is over.

Note: The cooling fan operation will continue to function while the control is in heat lockout.

Note: If a call for heat exist with a call for cooling, the call for heat shall proceed as normal except the fan remains energized on cool speed.

Heat Mode

1.

CALL FOR HEAT - The thermostat calls for heat by energizing the “W” terminal. The control checks to see if the pressure switch is open. If the pressure switch is closed, the control will flash code “3” on the LED and wait indefinitely for the pressure switch to open. The control will lockout the call for heat if the pressure switch is closed before the induced draft motor is energized.

L2 L2 L2

L2

COOL HEAT

UNUSED

L1

L1 D1

FS

3

6

9

12

5

2

8 7

11 10

1

4

A/GPG14

2.

PRE-PURGE - The control energizes the induced draft motor, flashes code “2” on LED, and waits for the pressure switch to close. When the pressure switch has closed, the control stops flashing the LED and begins timing the 15 second pre-purge period. (Note:

Under normal operation, the LED will not flash if the pressure switch closes immediately after energizing the induced draft motor.)

3.

IGNITION - The control energizes the gas valve and spark. If flame is not established within 7 seconds, the gas valve and spark are de-energized and the control goes to an inter-purge. If flame is established, the spark is de-energized and the control goes to heat blower on delay.

4.

Heat Blower On Delay - The control waits for 30 second heat fan on delay and then energizes the indoor blower heat speed. If the blower is already energized by a call for cooling or continuous fan, or in a blower off delay period, the on delay is skipped and control goes to steady heat.

5.

STEADY HEAT - Control inputs are continuously monitored to ensure limit and pressure switches are closed, flame is established, and the thermostat call for heat remains.

6.

POST PURGE - When the thermostat demand for heat is satisfied, the control immediately deenergizes the gas valve. The inducer output remains on for a 29 second post-purge period.

7.

Heat Blower Off Delay - The indoor blower motor is deenergized after the selected blower off delay time.

Blower timing begins when the thermostat is satisfied.

Blower Off Delay Settings speed up

Transformer

21


Pin

5

6

7

8

9

3

4

1

2

10

11

12

Voltage Function

24VAC 24VAC Input (from Transformer)

24VAC 24VAC Common (Chassis Ground)

24VAC Gas Valve Output

24VAC Limit Switch Output

24VAC Limit Switch Input (Common with Pin 9)

24VAC Pressure Switch Input

24VAC Thermostat Fan (G) Input

24VAC Pressure Switch Output (Common with Pin 10)

24VAC Thermostat "R" (Common with Pin 5)

24VAC Thermostat Heat Input (W) (Common with Pin 8)

24VAC Thermostat Cool Input (Y)

24VAC Compressor Contactor Output

Table 1: PCBAG123 Single Stage Control Circuit Definitions for 12-Circuit Connector

Terminal Label

230VAC Line 1 Input (x2)

230VAC Line 2 Input (x4)

Indoor Blower Heat Speed

Indoor Blower Cool Speed

Induced Drafter Blower Output

L1

L2

HEAT

COOL

DI

Unused/Motor Speed Park Terminals (x2) UNUSED

Flame Sensor FS

Continuous Fan (G) / Economizer

Spark Igniter Output

ECON

SPARK

Table 2: PCBAG123 Single Stage Control Terminal Definitions

22

Pre-Purge

Inter-Purge

Post Purge

Period

Trial-for-Ignition (TFI)

Flame Stabilization Period

Heat ON Delay

Heat OFF Delay

Timing

15 Seconds

15 Seconds

29 Seconds

7 Seconds

10 Seconds

30 Seconds

Selectable 120, 135 or 150 Seconds

7 Seconds Cool ON Delay

Cool OFF Delay

Ignition Attempts

60 Seconds

3 Attempts

Recycles Infinite

Automatic Restart

4 Recycles

(5 Flame Losses)

60 Minutes

Compressor Short Cycle Delay 3 Minutes

Table 3: PCBAG123 Single Stage Control

Timings

System Status

Normal

Internal Fault/Gas Valve Fault

Ignition Lockout

Pressure Switch Stuck Closed

Pressure Switch Stuck Open

Open High Temperature Limit

Flame Detected with Gas Valve

De-Energized

Compressor Short Cycle Delay Active

LED Flashes

On

Off

1

2

3

4

5

6

Table 4: PCBAG123 Single Stage Control

LED Status Codes


PCBAG127 IGNITION CONTROL SEQUENCE OF OPERATION

A/GPG14

A. Heating Operation: Low stage heat

1.

Thermostat type is set to two-stage.

2.

Thermostat “W1” input initiates low stage heating.

3.

Induced draft blower is energized at high speed for the pre-purge period. Pre-purge timer begins after control recognizes pressure switch has closed.

4.

Trial-for-ignition period begins after pre-purge period expires. Low and high stage gas valves are energized along with the igniter for trial-for-ignition period. Igniter is de-energized when flame is detected.

5.

Flame is achieved and detected during trial-for-ignition period. Flame stabilization period begins when flame is detected.

6.

De-energize high stage gas valve and switch induced draft blower to low speed within five seconds of flame detection.

7.

Air circulating blower is energized at low heat speed after heat ON delay time expires. Heat ON delay timer begins when flame is detected.

8.

Control monitors thermostat, flame, limit, and pressure switch inputs during low stage heating.

9.

Thermostat “W1” input is removed.

10. Low stage gas valve is de-energized.

11. Induced draft blower remains energized at low speed for post purge period.

12. Air circulating blower remains energized at low heat speed for heat OFF delay. Heat OFF delay begins when “W1” input is removed.

13. Control returns to Standby and awaits next thermostat request.

B. Heating Operation: High stage heat

1.


2.

Thermostat “W1” and “W2” inputs initiate high stage heating.

3.

Induced draft blower is energized at high speed for the pre-purge period. Pre-purge timer begins after control recognizes pressure switch has closed.

4.

Trial-for-ignition period begins after pre-purge period expires. Low and high stage gas valves are energized along with the igniter for trial-for-ignition period. Igniter is de-energized when flame is detected.

5.

Flame is achieved and detected during trial-for-ignition period. Flame stabilization period begins when flame is detected.

6.

Gas valve and induced draft blower remain at high stage and high speed.

7.

Air circulating blower is energized at high heat speed after heat ON delay time expires. Heat ON delay timer begins when flame is detected.

8.

Control monitors thermostat, flame, limit, and pressure switch inputs during high stage heating.

9.

Thermostat “W1” and “W2” inputs are removed.

10. High and low stage gas valves are de-energized.

11. Induced draft blower switches from high speed to low speed and remains energized for post purge period.

12. Air circulating blower remains energized at high heat speed for High Stage Heat OFF Delay period then switches to low heat speed for the remainder of the selected heat OFF delay. Heat OFF delay begins when “W1” and “W2” inputs are removed.


23


PCBAG127 IGNITION CONTROL SEQUENCE OF OPERATION (CONT.)

A/GPG14

A. Cooling Operation: Low stage cool

1.


2.

Thermostat “Y1” or thermostat “Y1” and “G” input initiates low stage cooling.

3.

IDT/ODT/Pressure/Loss of Charge Switch circuits are checked for closed condition. Cooling operation can proceed only if these circuits are closed.

4.

Low stage compressor output is energized.

5.

Condenser fan motor is energized at low speed.

6.

Air circulating blower is energized at low cool speed after cool ON delay expires. Cool ON delay timer begins when thermostat inputs are detected.

7.

Control monitors thermostat, gas valve, flame, and IDT/

ODT/Pressure/Loss of Charge Switches during low stage cooling.

8.

Thermostat “Y1” or “Y1” and “G” inputs are removed.

9.

Low stage compressor output is de-energized. Low speed condenser fan motor is de-energized.

10. Air circulating blower remains energized at low cool speed for the cool OFF delay. Cool OFF delay timer begins when thermostat input is removed.


B. Cooling Operation: High stage cool


Thermostat “Y1” and “Y2” or “Y1”, “Y2” and “G” inputs initiate high stage cooling.

IDT/ODT/Pressure/Loss of Charge Switch circuits are checked for closed condition. Cooling operation can proceed only if these circuits are closed.

1.

Low and high stage compressor outputs are energized.

2.

Condenser fan motor is energized at high speed.

3.

Air circulating blower is energized at high cool speed after cool ON delay expires. Cool ON delay timer begins when thermostat inputs are detected.

Control monitors thermostat, gas valve, flame, and

IDT/ODT/Pressure/Loss of Charge Switches during high stage cooling operation.

Thermostat “Y1” and “Y2” or “Y1”, “Y2” and “G” inputs are removed.

Low and high stage compressor outputs are deenergized.

High speed condenser fan motor is de-energized.

4.

Air circulating blower switches to low cool speed for the cool OFF delay. Cool OFF delay timer begins when thermostat input is removed.

Control returns to Standby and awaits next thermostat request.

A. Continuous Fan Operation

1.

Thermostat “G” input initiates Continuous Fan operation.

2.

Air circulation blower shall be immediately energized at the continuous fan speed. For purposes of this specification, the continuous fan speed shall be the low heat speed.

3.

Thermostat “G” input is removed.

4.

Air circulation blower is immediately de-energized.

5.

Control returns to Standby and awaits next thermostat request.

24


PCBAG127 CONTROL BOARD

DESCRIPTION

The ignition control is designed for use in gas heating/electric cooling package equipment (rooftop applications) and operates with a two stage heat and two stage cooling system. It is a direct spark ignition system that uses a 22,000 volt spark to ignite the burners. A flame sensor is used to monitor the flame.

The board has the option of using a single or two stage thermostat. The board also controls the indoor blower and has an adjustable heat fan off delay.

There is also a fault recall button for recalling the last 5 fault codes. To recall the fault codes, depress the fault recall button for at least 2 seconds but not more than 4 seconds. To clear the fault code memory, depress the fault recall button for at least 5 seconds.

The following tables list the functions for the connectors and terminals, the timings, and the fault codes for the

PCBAG127 control board.

HIGH VOLTAGE!


FS

L2

INDUCER

T1

K4

Q3

LOW HIGH

K3

L1

K5

OD F

LOW HIGH

PARK

K6

T2

C9

K7

P2

U1

U2

3

2

1

5

4

U6

U7

U4

U5

U3

K2

K1

SPEED UP

SW1

FAULT

RECALL

180

150

120

90

NONE

5 MIN

10MIN

BLOWER

DELAY

STAGE

DELAY

F1

ECON

R C W1W2 G Y1 Y2

25


4

5

6

Pin

1

2

3

Voltage

24VAC

24VAC

24VAC

24VAC

24VAC

24VAC

Function

Indoor/Outdoor Thermostat (IDT/ODT) Output

High Stage Compressor Output

Pressure Switch/Loss of Charge Switch Input

Indoor/Outdoor Thermostat (IDT/ODT) Input

Pressure Switch/Loss of Charge Switch Output

Low Stage Compressor Output

Table 1: Circuit Definitions and Voltage Ratings for the 6-Circuit Connector Circuits

Pin Voltage Function

7

8

5

6

3

4

1

2

24VAC

24VAC

24VAC

24VAC

24VAC

24VAC

24VAC

24VAC

Limit Switch Output

24VAC Input to Control

Limit Switch Input

Unused

24VAC Common

Pressure Switch Output

Main Valve High Output

Pressure Switch Input

9 Unused Main Valve Low Output

Table 2: Circuit Definitions and Voltage Ratings for the 9-Circuit Connector Circuits

Terminal

Line Voltage L1

Transformer Line L1

Air Circulating Blower Line 1

Induced Draft Blower Low Speed

Label

L1

L1

L1

DI Low or "Inducer Low"

Induced Draft Blower High Speed

Condenser Fan Motor Low Speed

Condenser Fan Motor High Speed

Line Voltage L2

Transformer Line L2

Air Circulating Blower Line 2

Induced Draft Blower Line 2

Condenser Fan Motor Line 2

DI High or "Inducer High"

ODF Low

ODF High

Direct Spark Igniter

Flame Detection

Table 3: High Voltage Terminals

L2

L2

L2

L2

L2

T1

FS

26


Period

Pre-Purge

Inter-Purge

Post Purge

Trial-for-Ignition (TFI)

Flame Stabilization Period

Flame Failure Response Time

Low to High Stage Delay

Heat ON Delay

Heat OFF Delay

High Stage Heat OFF Delay

Cool ON Delay

Cool OFF Delay

Continuous Fan ON Delay

Continuous Fan OFF Delay

Ignition Attempts

Recycles

Automatic Restart

Pressure Switch Lockout Delay

Factory Test Mode Active Time

Timing

15 Seconds

30 Seconds

30 Seconds

7 Seconds

10 Seconds

2 Seconds within Flame Stabilization Period

2 Seconds or Per ANSI Z21.20 Outside of Flame Stabilization Period

Selectable 5 minutes or 10 minutes (Default = 10 minutes)

30 Seconds

Selectable 90, 120, 150, or 180 Seconds

(Default = 150 Seconds)

30 Seconds

6 Seconds

45 Seconds

0 Seconds

0 Seconds

3

Infinite

60 Minutes

5 Minutes

2 Minutes Maximum

Table 4: Control Timings

Color

Red

Function

Normal

Intrnal/Gas Valve Fault

Lockout




Flame Detected with Gas Valve De-Energized

Compressor Short Cycle Delay Active

LED Flashes/Status

On

Off

1

4

5

2

3

6

Limit Opened 5 Times in Same Call For Heat

Indoor Thermostat/Outdoor Thermostat is Open

Pressure Switch/Loss of Charge Switch is Open

Normal Flame

7

8

9

On

Amber

No Flame Present

Low Flame Current

Off

1

Flame Detected with Gas Valve De-energized 2

Table 5: LED Status Codes and Corresponding System Condition

27


Typical Package Cooling or Package Gas

Indoor

Coil

Outdoor

Coil

Thermostatic

Expansion

Valve

Restrictor

Orifice

Assy

Either a thermostatic expansion valve or restrictor orifice assembly may be used depending on model, refer to the parts catalog for the model being serviced.

Restrictor Orifice Assembly in Cooling Operation

In the cooling mode the orifice is pushed into its seat forcing refrigerant to flow through the metered hole in the center of the orifice.

28

SCHEDULED MAINTENANCE

Package gas units require regularly scheduled maintenance to preserve high performance standards, prolong the service life of the equipment, and lessen the chances of costly failure.

In many instances the owner may be able to perform some of the maintenance; however, the advantage of a service contract, which places all maintenance in the hands of a trained serviceman, should be pointed out to the owner.

HIGH VOLTAGE!


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 or replace the filters more often. If permanent type filters are used, they should be washed with warm water and dried.

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 cabinet 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.

6. Check the contacts of the compressor contactor. If they are burned or pitted, replace the contactor.

7. Using a halide or electronic leak detector, check all piping and etc. for refrigerant leaks.

8. Check the combustion chamber (Heat Exchanger) for soot, scale, etc. Inspect all burners for lint and proper positioning.

9. Start the system, using the proper instrumentation check gas inlet and manifold pressures, burner flame and microamp signal. Adjust if necessary.

10. Start the system and run a Heating Performance Test.

If the results of the test are not satisfactory, see the

"Service Problem Analysis" Guide for the possible cause.

TEST EQUIPMENT

Proper test equipment for accurate diagnosis is as 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 current.

4. Volt-Ohm Meter - testing continuity, capacitors, motor windings and voltage.

5. Accurate Leak Detector - testing for refrigerant leaks.

6. High Vacuum Pump - evacuation.

7. Electric Vacuum Gauge, Manifold Gauges and high vacuum hoses - to measure and obtain proper vacuum.

8. Accurate Charging Cylinder or Electronic Scale - measure proper refrigerant charge.

9. Inclined Manometer - measure static pressure and pressure drop across coils.

Other recording type instruments can be essential in solving abnormal problems, however, in many instances they may be rented from local sources.

Proper equipment promotes faster, more efficient service, and accurate repairs with less call backs.

HEATING PERFORMANCE TEST

Before attempting to diagnose an operating fault, run a

Heating Performance Test and apply the results to the

Service Problem Analysis Guide.

To conduct a heating performance test, the BTU input to the package gas unit must be calculated.

After the heating cycle has been in operation for at least fifteen minutes and with all other gas appliances turned off, the gas meter should be clocked.

To find the BTU input, multiply the number of cubic feet of gas consumed per hour by the heating value of the gas being used. (The calorific value of the gas being used is found by contacting your local utility.)

29


2

1

3

0

9

4

5

1 Million

6

8

7

8

9 1

2

7

6 4

5

100 Thousand

3

2

1

0

9

8

3

4

5

6

10 Thousand

7

9 1

8

2

7

6

4

5

1 Thousand

3

Quarter

One

Foot

CUBIC

FEET

Foot

Seconds for One

Revolution

22

23

24

25

26

27

18

19

20

21

14

15

16

17

10

11

12

13

28

29

30

31

32

33

34

35

1/4 cu/ft

41

39

37

36

34

33

50

47

45

43

64

60

56

53

90

82

75

69

32

31

30

--

28

--

26

--

82

78

75

72

69

67

100

95

90

86

180

164

150

138

129

120

113

106

64

62

60

--

56

--

53

--

GAS RATE -- CUBIC FEET PER HOUR

Size of Test Dial

1/2 cu/ft

1 cu/ft

2 cu/ft

5 cu/ft

Seconds for One

Revolution

1/4 cu/ft

200

189

180

171

164

157

150

144

138

133

360

327

300

277

257

240

225

212

129

124

120

116

113

109

106

103

400

379

360

343

327

313

300

288

277

265

720

655

600

555

514

480

450

424

257

248

240

232

225

218

212

206

1000

947

900

857

818

783

750

720

692

667

1800

1636

1500

1385

1286

1200

1125

1059

643

621

600

581

563

545

529

514

48

49

50

51

52

53

44

45

46

47

40

41

42

43

36

37

38

39

54

55

56

57

58

59

60

--

--

36

--

--

34

41

40

--

38

45

--

43

--

50

--

47

--

--

--

32

--

31

--

30

--

--

18

--

--

17

--

20

--

19

22

--

21

--

25

--

23

--

--

--

16

--

--

--

15

Size of Test Dial

1/2 cu/ft

1 cu/ft

2 cu/ft

75

--

72

--

69

--

82

80

78

76

90

--

86

--

100

97

95

92

67

--

64

--

62

--

60

164

160

157

153

150

147

144

141

138

136

200

195

189

185

180

176

172

167

133

131

129

126

124

122

120

5 cu/ft

409

400

391

383

375

367

360

355

346

340

500

486

474

462

450

439

429

419

333

327

321

316

310

305

300

30


Example:

It takes forty-five (45) seconds on the gas meter for the hand on the cubic foot dial to make one complete revolution, with all appliances off, except the unit. Using the gas rate chart, observe the forty-five (45) seconds, locate and read across to the one (1) cubic foot dial column. There you will find the number 80, which shows that eighty (80) cubic feet of gas will be consumed in one (1) hour.

Let's assume the local gas utility has stated that the calorific value of the gas is 1025 BTU per cubic foot.

Multiplying the eighty (80) cubic feet by 1025 BTU/ft 3 an input of 82,000 BTU/HR.

gives us

Checking the BTU input on the rating plate of the unit being tested.

EXAMPLE: GPG143608041**

INPUT: 80,000 BTU/HR

OUTPUT CAP: 63,400 BTU/HR

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 propane gas is not normally installed with a gas meter, clocking will be virtually impossible. The gas orifices used with propane are calculated for 2500 BTU gas per cubic foot and with proper inlet pressures and correct piping size, full capacity will be obtained.

With propane gas, no unit gas valve regulator is used; however, the second stage supply line pressure regulator should be adjusted to give 11" water column with all other gas consuming appliances running.

The dissipation of the heat transferred to the heat exchanger is now controlled by the amount of air circulated over its surface.

The flow rate (CFM) of air circulated is governed by the external static pressure in inches of water column of duct work, cooling coil, registers and etc., applied externally to the unit versus the motor speed tap.

A properly operating unit must have the BTU input and flow rate (CFM) of air, within the limits shown to prevent short cycling of the equipment. As the external static pressure goes up, the temperature rise will also increase. 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

Com plaint No Cooling

COOLING ANALYSIS CHART

Unsatisfactory

Cooling

Sys te m

Operating

Pres sure s

POSSIBLE CAUSE

DOTS IN ANALYSIS

GUIDE INDICATE

"POSSIBLE CAUSE"

Test Method

Remedy

Pow er Failure

Blow n Fuse

Loose Connection

Shorted or Broken Wires

Open Overload

Faulty Thermostat

Faulty Transformer

Shorted or Open Capacitor

Shorted or Grounded Compressor

Compressor Stuck

Faulty Compressor Contactor

2nd Stage Compressor Not Energized

Faulty Ignition Control

Open Control Circuit

Low Voltage

Faulty Evap. Fan Motor

Shorted or Grounded Fan Motor

Improper Cooling Anticipator

Shortage of Ref rigerant

Restricted Liquid Line

Dirty Air Filter

Dirty Indoor Coil

Not enough air across Indoor Coil

Too much air across Indoor Coil

Overcharge of Ref rigerant

Dirty Outdoor Coil

Noncondensibles

Recirculation of Condensing Air

Inf iltration of Outdoor A ir

Improperly Located Thermostat

Air Flow Unbalanced

System Undersized

Broken Internal Parts

Inef ficient Compressor

High Pressure Control Open

Unbalanced Pow er, 3PH

Wrong Type Expansion Valve

Expansion Device Restricted

Expansion V alve Bulb Loose

Inoperative Expansion Valve

Loose Hold-dow n Bolts

•

• • •

• • •

•

•

• •

•

• •

•

• •

•

• • •

•

•

• •

•

•

•

•

•

•

•

•

• •

•

Test Voltage

Inspect Fuse Size & Type

Inspect Connection - Tighten

Test Circuits With Ohmmeter

Test Continuity of Overload

Test continuity of Thermostat & Wiring

Check control circuit w ith voltmeter

Test Capacitor

Test Motor Windings

Use Test Cord S-17D

Test continuity of Coil & Contacts S-7, S-8

• •

Test Unloader Solenoid (2 stage compressor only) S-17C

Test Ignition Control S-313

S-1

S-4

S-2

S-3

S-17A

S-3

S-4

S-15

S-17B

• •

•

Test Control Circuit w ith Voltmeter

Test Voltage

Repair or Replace

•

Test Motor Windings

Check resistance of Anticipator

•

•

• •

•

•

• •

• •

• •

• • • •

• •

• • • •

• • • •

• • •

•

•

•

•

•

•

• •

•

•

•

•

•

• •

•

•

•

•

Speed Blow er, Check Duct Static Press

•

Reduce Blow er Speed

• •

Recover Part of Charge

•

Inspect Coil - Clean

•

Recover Charge, Evacuate, Recharge

•

Remove Obstruction to Air Flow

Check Window s, Doors, Vent Fans, Etc.

Relocate Thermostat

Readjust Air Volume Dampers

Ref igure Cooling Load

Replace Compressor

• •

Test Compressor Eff iciency

Reset And Test Control

Test Voltage

•

Test For Leaks, Add Ref rigerant

Replace Restricted Part

Inspect Filter-Clean or Replace

Inspect Coil - Clean

Replace Valve

Remove restriction or replace expansion device

Tighten Bulb Bracket

Check V alve Operation

Tighten Bolts

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

32

SERVICING

Com plaint

GAS HEATING ANALYSIS CHART

No He at Uns atis factor y He at

POSSIBLE CAUSE

DOTS IN ANALYSIS

GUIDE INDICATE

"POSSIBLE CAUSE"

Test Me thod

Rem e dy

Pow er Failure

Blow n Fuse

Loose Connection

Shorted or Broken Wires

No Low V oltage

Faulty Thermostat

Faulty Transf ormer

Poor or High Resistance Ground

Improper Heat A nticipator Setting

Improper Thermostat Location

Faulty Limit or Roll Out Sw itch

Faulty Flame Sensor

Faulty Ignition Control

Gas Valve or Gas Supply Shut Of f

Faulty Induced Draft Blow er

Dirty Flame Sensor, Low uA

Flame Sensor not in Flame, Low uA

Faulty Gas V alve

No High Stage Heat (2 Stage Only)

Open A uxillary Limit

Improper A ir Flow or Distribution

Locking out on Main Limit

Delayed Ignition

Flashback

Orifice Size

Gas Pressure

Cracked Heat Exchanger

Stuck Gas V alve

Furnace Undersized

Faulty Pressure Sw itch

Blocked or Restricted Flue

Open Roll Out Sw itch

Bouncing On Pressure Sw itch

•

•

•

•

•

•

•

•

• •

•

•

• • •

Test Voltage

Test Voltage

Check Wiring

Check Wiring

Check Transformer

• • •

Check Thermostat

Check Transformer

Measure Ground Resistance

• • • •

Adjust Heat A nticipator Setting

• • • •

Relocate Thermostat

Test Control

•

•

Test Flame Sensor

Test Control

Turn Valves to On Position

Test Blow er

Clean Flame Sensor

S-1

S-4

S-2

S-3

S-4

S-3

S-4

S-313

S-3

S-300,S-301,S-302

S-314

S-313

S-304

S-303

S-314

• •

Test/Adjust Position of Flame Sensor

Replace Gas V alve

Check Thermostat, Control, Gas Valve

S-314

S-304

S-3,S-313,S-304

S-301

•

Reset Control

Check Duct Static

•

Check Controls, Gas Press., & Temp. Rise

Test for Delayed Ignition

•

Test for Flashback

Check Orifices

S-300

S-308

S-309

S-306

• • •

Check Gas Pressure

• •

•

Check Burner Flames

Replace Gas V alve

Replace w ith Proper Size Furnace

Test Pressure Sw itch

•

Check Flue/Draw dow n Pressure

Test Control

•

Test Negative Pressure

S-307

S-302

S-304

S-310

S-310

S-302

S-310

33

SERVICING

Table of Contents

S-1

S-2

Checking Voltage .......................................... 29

Checking Wiring ............................................ 30

S-3 Checking Thermostat, Wiring & Anticipator .. 30

S-3A Thermostat & Wiring ..................................... 30

S-3B Cooling Anticipator ........................................ 30

S-3C Heating Anticipator........................................ 30

S-4

S-7

Checking Transformer & Control Circuit ....... 31

Checking Contactor and/or Relays ................ 31

S-8

S-9

Checking Contactor Contacts ....................... 31

Checking Fan Relay Contact ........................ 32

S-12 Checking High Pressure Control ................... 32

S-13 Checking Low Pressure Control .................... 32

S-15 Checking Capacitor ....................................... 32

S-15A Resistance Check ......................................... 33

S-15B Capacitance Check ....................................... 33

S-16C Checking ECM Motor Windings .................... 34

S-16D Checking EEM Motors .................................. 34

S-17 Checking Compressor Windings ................... 35

S-17A Resistance Test ............................................ 35

S-17B Ground Test .................................................. 36

S-17D Operation Test .............................................. 36

S-18 Testing Crankcase Heater (optional item) ..... 37

S-100 Refrigeration Repair Practice......................... 37

S-101 Leak Testing ................................................. 37

S-102 Evacuation .................................................... 37

S-103 Charging ........................................................ 38

S-104 Checking Compressor Efficiency .................. 39

S-105B Thermostatic Expansion Valve ...................... 39

S-106 Overfeeding ................................................... 41

S-107 Underfeeding ................................................. 41

S-108 Superheat ..................................................... 41

S-109 Checking Subcooling .................................... 43

S-110 Checking Expansion Valve Operation ........... 43

S-111 Fixed Orifice Restriction Devices .................. 43

S-112 Checking Restricted Liquid Line .................... 44

S-113 Refrigerant Overcharge .................................. 44

S-114 Non-condensables ........................................ 44

S-115 Compressor Burnout ..................................... 44

S-200 Checking Extedrnal Static Pressure ............. 45

S-201 Checking Temperature Rise .......................... 45

S-300 Testing Primary Limit .................................... 46

S-301 Testing Auxiliary Limit ................................... 46

S-302 Checking Flame Rollout Switch .................... 47

S-303 Testing Inducer Motor .................................... 48

S-304 Testing Gas Valve ......................................... 48

S-305 Checking Main Burners ................................. 48

S-306 Checking Orifices .......................................... 49

S-307 Checking Gas Pressure ................................ 49

S-308 Checking For Delayed Ignition ...................... 50

S-309 Checking for Flashback ................................. 50

S-310 Checking Pressure Control ........................... 50

S-311 High Altitude Application ............................... 51

S-313 Testing Ignition Control Module ..................... 51

S-314 Checking Flame Sensor ................................ 53

34

HIGH VOLTAGE!


SERVICING

S-1 CHECKING VOLTAGE

HIGH VOLTAGE!


1. Remove doors, control panel cover, etc. from unit being tested.

With power ON:

WARNING

Line Voltage now present.

2. Using a voltmeter, measure the voltage across terminals

L1 and L2 of the contactor for single phase units, and L3, for 3 phase units.

3. No reading - indicates open wiring, open fuse(s) no power or etc. from unit to fused disconnect service. Repair as needed.

4. With ample voltage at line voltage connectors, energize the unit.

5. Measure the voltage with the unit starting and operating, and determine the unit Locked Rotor Voltage.

Locked Rotor Voltage is the actual voltage available at the compressor during starting, locked rotor, or a stalled condition. Measured voltage should be above minimum listed in chart below.

To measure Locked Rotor Voltage attach a voltmeter to the run "R" and common "C" terminals of the compressor, or to the T

1

and T

2

terminals of the contactor. Start the unit and allow the compressor to run for several seconds, then shut down the unit. Immediately attempt to restart the unit while measuring the Locked Rotor Voltage.

6. Voltmeter should read within the voltage tabulation as shown. If the voltage falls below the minimum voltage, check the line wire size. Long runs of undersized wire can cause low voltage. If wire size is adequate, notify the local power company in regards to either low or high voltage.

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.

% Voltage =

Imbalance

Max. Voltage Deviation

From Average Voltage X 100

Average Voltage

To find the percentage of imbalance, measure the incoming power supply.

L1 - L2 = 240V

L1 - L3 = 232V Avg. V = 710 = 236.7

L2 - L3 = 238V 3

Total 710V

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

= 1.99%

236.7

If the percentage of imbalance had exceeded 3%, it must be determined if the imbalance is in the incoming power supply or the equipment. To do this rotate the legs of the incoming power and retest voltage as shown below.

L1 L2 L3

L1 - L2 = 240V

L1 - L3 = 227V

L2 - L3 = 238V

Rotate all 3 incoming legs as shown.

L1 - L2 = 227V

L1 - L3 = 238V

L2 - L3 = 240V

Unit Supply Voltage

Voltage

460

208/230

Min.

437

198

Max.

506

253

L1 L2 L3

By the voltage readings we see that the imbalance rotated or traveled with the switching of the incoming legs. Therefore the imbalance lies within the incoming power supply.

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!


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

THERMOSTAT WIRE SIZING CHART

LENGTH OF RUN

25 feet

50 feet

75 feet

100 feet

125 feet

150 feet

MIN. COPPER WIRE

GAUGE (AWG)

18

16

14

14

12

12

S-3A THERMOSTAT AND WIRING

1. Set fan selector switch at thermostat to "ON" position.

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.

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 changed.

S-3C HEATING ANTICIPATOR

The heating anticipator is a wire-wound adjustable heater, which is energized during the "ON" cycle to help prevent overheating of the conditioned space.

The anticipator is a part of the thermostat and if it should fail for any reason, the thermostat must be replaced. See the following for recommended heater anticipator setting.

To determine the proper setting, use an ammeter to measure the current on the "W" wire going to the thermostat.

Use an amprobe as shown below. Wrap 10 turns of thermostat wire around the stationary jaw of the amprobe and divide the reading by 10.

WARNING


10 TURNS OF

THERMOSTAT WIRE

(From "W" on thermostat)

With power ON, thermostat calling for cooling

1. Use a voltmeter to check for 24 volts at thermostat wires

C and Y in the condensing unit control panel.

2. No voltage indicates trouble in the thermostat, wiring or external transformer source.

3. Check the continuity of the thermostat and wiring. Repair or replace as necessary.

Indoor Blower Motor

With power ON:

STATIONARY JAW

OF AMPROBE

READS 4 AMPS

CURRENT DRAW

WOULD BE .4 AMPS

Checking Heat Anticipator Amp Draw

36

SERVICING

S-4 CHECKING TRANSFORMER AND CON-

TROL CIRCUIT

HIGH VOLTAGE!


NOTE: Most single phase contactors break only one side of

the line (L1), leaving 115 volts to ground present at most internal components.

1. Remove the leads from the holding coil.

2. Using an ohmmeter, test across the coil terminals.

If the coil does not test continuous, replace the relay or contactor.

S-8 CHECKING CONTACTOR CONTACTS

SINGLE PHASE

A step-down transformer (208/240 volt primary to 24 volt secondary) is provided with each indoor unit. This allows ample capacity for use with resistance heaters. The outdoor sections do not contain a transformer.

WARNING

Disconnect ALL power before servicing.

1. Remove control panel cover, or etc., to gain access to transformer.

With power ON:

HIGH VOLTAGE!


1. Disconnect the wire leads from the terminal (T) side of the contactor.

2. With power ON, energize the contactor.

WARNING


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.

5 If line voltage available at primary voltage side of transformer and wiring and splices good, transformer is inoperative. Replace.

S-7 CHECKING CONTACTOR AND/OR RELAYS

VOLT/OHM

METER

T2

L2

CC

T1

L1

Ohmmeter for testing holding coil

Voltmeter for testing contacts

TESTING COMPRESSOR CONTACTOR

(Single Phase)

HIGH VOLTAGE!


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.

3. Using a voltmeter, test across terminals.

A. L1 - L2 - No voltage. Check breaker or fuses on main power supply.

B. L2 - T1 - No voltage indicates CC1 contacts open.

If a no voltage reading is obtained - replace the contactor.

37

SERVICING

S-9 CHECKING FAN RELAY CONTACTS

The fan relays are incorporated into the control board. See section S-313 for checking control board.

S-12 CHECKING HIGH PRESSURE CONTROL

HIGH VOLTAGE!


The high pressure control senses the pressure in the liquid line. If abnormally high condensing pressures develop, the contacts of the control open, breaking the control circuit before the compressor motor overloads. This control is automatically reset.

1. Using an ohmmeter, check across terminals of high pressure control, with wire removed. If not continuous, the contacts are open.

3. Attach a gauge to the dill valve port on the base valve.

With power ON:

4. Start the system and place a piece of cardboard in front of the condenser coil, raising the condensing pressure.

5. Check pressure at which the high pressure control cutsout.

If it cuts-out at 660 PSIG ± 10 PSIG, it is operating normally

(See causes for high head pressure in Service Problem

Analysis Guide). If it cuts out below this pressure range, replace the control. The control should reset at 420 PSIG ±

25 PSIG.

S-13 CHECKING LOW PRESSURE CONTROL

The low pressure control senses the pressure in the suction line and will open its contacts on a drop in pressure. The low pressure control will automatically reset itself with a rise in pressure.

The low pressure control is designed to cut-out (open) at approximately 7 PSIG ± 3 PSIG. It will automatically cut-in

(close) at approximately 25 PSIG ± 5 PSIG.

Test for continuity using a VOM and if not as above, replace the control.

S-15 CHECKING CAPACITOR

CAPACITOR, RUN

A run capacitor is wired across the auxiliary and main windings of a single phase permanent split capacitor motor.

The capacitors primary function is to reduce the line current while greatly improving the torque characteristics of a motor.

This is accomplished by using the 90° phase relationship between the capacitor current and voltage in conjunction with the motor windings so that the motor will give two phase operation when connected to a single phase circuit. The capacitor also reduces the line current to the motor by improving the power factor.

CAPACITOR, START

SCROLL COMPRESSOR MODELS

Hard start components are not required on Scroll 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.

Your unit comes with a 180-second anti-short cycle to prevent the compressor from starting and running backwards.

MODELS EQUIPPED WITH A HARD START DEVICE

A start capacitor is wired in parallel with the run capacitor to increase the starting torque. The start capacitor is of the 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.

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.

38

SERVICING

RELAY, START

A potential or voltage type relay is used to take the start capacitor out of the circuit once the motor comes up to speed.

This type of relay is position sensitive. The normally closed contacts are wired in series with the start capacitor and the relay holding coil is wired parallel with the start winding. As the motor starts and comes up to speed, the increase in voltage across the start winding will energize the start relay holding coil and open the contacts to the start capacitor.

Two quick ways to test a capacitor are a resistance and a capacitance check.

S-15B CAPACITANCE CHECK

Using a hookup as shown below, take the amperage and voltage readings and use them in the formula:

VOLTMETER

S-15A RESISTANCE CHECK

15 AMP

FUSE

HIGH VOLTAGE!


AMMETER

CAPACITOR

1. Discharge capacitor and remove wire leads.

WARNING

Discharge capacitor through a 20 to 30 OHM resistor before handling.

TESTING CAPACITANCE

WARNING

Discharge capacitor through a 20 to 30 OHM resistor before handling.

OHMMETER

Capacitance (MFD) = 2650 X Amperage

Voltage

CAPACITOR

TESTING CAPACITOR RESISTANCE

2. Set an ohmmeter on its highest ohm scale and connect the leads to the capacitor a.

Good Condition - indicator swings to zero and slowly returns to infinity. (Start capacitor 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-16A CHECKING FAN AND BLOWER MOTOR

WINDINGS (PSC MOTORS)

The auto reset fan motor overload is designed to protect the motor against high temperature and high amperage conditions by breaking the common circuit within the motor, similar to the compressor internal overload. However, heat generated within the motor is faster to dissipate than the compressor, allow at least 45 minutes for the overload to reset, then retest.

39

SERVICING

S-16D CHECKING EEM MOTORS

HIGH VOLTAGE!


1. Remove the motor leads from its respective connection points and capacitor (if applicable).

2. Check the continuity between each of the motor leads.

3. Touch one probe of the ohmmeter to 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.

S-16C CHECKING ECM MOTOR WINDINGS

HIGH VOLTAGE!


Applies to *PG14*****41A*

The EEM motor is a one piece, fully encapsulated, 3 phase brushless DC (single phase AC input) motor with ball bearing construction. The EEM motor features an integral control module.

Note: The GE TECMate will not currently operate the EEM motor.

1. Using a voltmeter, check for 230 volts to the motor connections L and N. If 230 volts is present, proceed to step 2. If 230 volts is not present, check the line voltage circuit to the motor.

2. Using a voltmeter, check for 24 volts from terminal C to either terminal 1, 2, 3, 4, or 5, depending on which tap is being used, at the motor. If voltage present, proceed to step 3. If no voltage, check 24 volt circuit to motor.

3. If voltage was present in steps 1 and 2, the motor has failed and will need to be replaced.

Note: When replacing motor, ensure the belly band is between the vents on the motor and the wiring has the proper drip loop to prevent condensate from entering the motor.

1. Disconnect the 5-pin and the 16-pin connectors from the

ECM power head.

2. Remove the 2 screws securing the ECM power head and separate it from the motor.

3. Disconnect the 3-pin motor connector from the power head and lay it aside.

4. Using an ohmmeter, check the motor windings for continuity to ground (pins to motor shell). If the ohmmeter indicates continuity to ground, the motor is defective and must be replaced.

5. Using an ohmmeter, check the windings for continuity

(pin to pin). If no continuity is indicated, the thermal limit

(over load) device may be open. Allow motor to cool and retest.

High Voltage

Connections

3/16"

C L G N

1 2 3 4 5

Motor

Connector

(3-pin)

Low Voltage Connections

1/4”

EEM MOTOR CONNECTIONS

Motor OK when

R > 100k ohm

(3-pin)

WINDING TEST

40

SERVICING

S-17 CHECKING COMPRESSOR

WARNING

Hermetic compressor electrical terminal venting can be dangerous. When insulating material which supports a hermetic compressor or electrical terminal suddenly disintegrates due to physical abuse or as a result of an electrical short between the terminal and the compressor housing, the terminal may be expelled, venting the vapor and liquid contents of the compressor housing and system.

HIGH VOLTAGE!


1. Remove the leads from the compressor terminals.

If the compressor terminal PROTECTIVE COVER and gasket

(if required) are not properly in place and secured, there is a remote possibility if a terminal vents, that the vaporous and liquid discharge can be ignited, spouting flames several feet, causing potentially severe or fatal injury to anyone in its path.

This discharge can be ignited external to the compressor if the terminal cover is not properly in place and if the discharge impinges on a sufficient heat source.

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.

See warnings S-17 before removing compressor terminal cover.

2. Using an ohmmeter, test continuity between terminals S-

R, C-R, and C-S, on single phase units or terminals T1,

T2 and T3, on 3 phase units.

OHMMETER

S

C

COMP

TESTING COMPRESSOR WINDINGS

R

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-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.

Heat generated within the compressor shell, usually due to recycling of the motor, high amperage or insufficient gas to cool the motor, is slow to dissipate. Allow at least three to four hours for it to cool and reset, then retest.

Fuse, circuit breaker, ground fault protective device, etc. has not tripped -

41

SERVICING

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.

WARNING


WARNING

Damage can occur to the glass embedded terminals if the leads are not properly removed. This can result in terminal and hot oil discharging.

Carefully retest for ground, directly between compressor terminals and ground.

5. If ground is indicated, replace the compressor.

S-17D OPERATION TEST

If the voltage, capacitor, overload and motor winding test fail to show the cause for failure:

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.

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 voltohmmeter.

HI-POT

HIGH VOLTAGE!


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 as shown.

4. With power ON, close the switch.

COMPRESSOR GROUND TEST

3. If a ground is indicated, then carefully remove the compressor terminal protective cover and inspect for loose leads or insulation breaks in the lead wires.

4. If no visual problems indicated, carefully remove the leads at the compressor terminals.

WARNING


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.

42

SERVICING

S-18 TESTING CRANKCASE HEATER

(OPTIONAL ITEM)

The crankcase heater must be energized a minimum of four

(4) hours before the condensing unit is operated.

Crankcase heaters are used to prevent migration or accumulation of refrigerant in the compressor crankcase during the off cycles and prevents liquid slugging or oil pumping on start up.

A crankcase heater will not prevent compressor damage due to a floodback or over charge condition.

WARNING


1. Disconnect the heater lead in wires.

2. Using an ohmmeter, check heater continuity - should test continuous. If not, replace.

S-100 REFRIGERATION REPAIR PRACTICE

S-101 LEAK TESTING

(NITROGEN OR NITROGEN-TRACED)

WARNING

To avoid the risk of fire or explosion, never use oxygen, high pressure air or flammable gases for leak testing of a refrigeration system.

WARNING

To avoid possible explosion, the line from the nitrogen cylinder must include a pressure regulator and a pressure relief valve. The pressure relief valve must be set to open at no more than 150 psig.

DANGER

Always remove the refrigerant charge in a proper manner before applying heat to the system.

Pressure test the system using dry nitrogen and soapy water to locate leaks. If you wish to use a leak detector, charge the system to 10 psi using the appropriate refrigerant then use nitrogen to finish charging the system to working pressure, then apply the detector to suspect areas. If leaks are found, repair them. After repair, repeat the pressure test. If no leaks exist, proceed to system evacuation.

S-102 EVACUATION

When repairing the refrigeration system:

WARNING


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.

5. When brazing, sweep the tubing with dry nitrogen to prevent the formation of oxides on the inside surfaces.

6. Complete any repair by replacing the liquid line drier in the system, evacuate and charge.

BRAZING MATERIALS

Copper to Copper Joints - Sil-Fos used without flux (alloy of 15% silver, 80% copper, and 5% phosphorous). Recommended heat 1400°F.

Copper to Steel Joints - Silver Solder used without a flux

(alloy of 30% silver, 38% copper, 32% zinc). Recommended heat - 1200°F.

Aluminum to Aluminum & Copper to Aluminum Joints –

ZA-1 Brazing Rods use Flux System Cesium-Based Polymer

System (alloy of 78% Zinc and 22% Aluminum). Melting point

826*F Flow point 905*F.

WARNING

REFRIGERANT UNDER PRESSURE!

Failure to follow proper procedures may cause property damage, personal injury or death.

This is the most important part of the entire service procedure. The life and efficiency of the equipment is dependent upon the thoroughness exercised by the serviceman when evacuating air (non-condensables) and moisture from the system.

Air in a system causes high condensing temperature and pressure, resulting in increased power input and reduced performance.

Moisture chemically reacts with the refrigerant oil to form corrosive acids. These acids attack motor windings and parts, causing breakdown.

The equipment required to thoroughly evacuate the system is 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.

43

SERVICING

WARNING

Do not front seat the service valve(s) with the compressor open, with the suction line of the comprssor closed or severely restricted.

1. Connect the vacuum pump, vacuum tight manifold set with high vacuum hoses, thermocouple vacuum gauge and charging cylinder as shown.

2. 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.

3. 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.

4. Evacuate the system to at least 29 inches gauge before opening valve to thermocouple vacuum gauge.

5. Continue to evacuate to a maximum of 250 microns.

Close valve to vacuum pump and watch rate of rise. If vacuum does not rise above 1500 microns in three to five minutes, system can be considered properly evacuated.

6. If thermocouple vacuum gauge continues to rise and levels off at about 5000 microns, moisture and noncondensables are still present. If gauge continues to rise a leak is present. Repair and re-evacuate.

7. Close valve to thermocouple vacuum gauge and vacuum pump. Shut off pump and prepare to charge.

S-103 CHARGING

LOW SIDE

GAUGE

AND VALVE

HIGH SIDE

GAUGE

AND VALVE

WARNING

REFRIGERANT UNDER PRESSURE!

* Do not overcharge system with refrigerant.

* Do not operate unit in a vacuum or at negative

pressure.

Failure to follow proper procedures may cause property damage, personal injury or death.

EVACUATION

CAUTION

Use refrigerant certified to ARI standards. Used refrigerant may cause compressor damage and will void the warranty. Most portable machines cannot clean used refrigerant to meet ARI standards.

CAUTION

Operating the compressor with the suction valve closed will void the warranty and cause serious compressor damage.

44

SERVICING

Charge the system with the exact amount of refrigerant.

Refer to the specification section or check the unit nameplates for the correct refrigerant charge.

An inaccurately charged system will cause future problems.

1. Using a quality set of charging scales, weigh the proper amount of refrigerant for the system. Allow liquid refrigerant only to enter the high side.

2. After the system will take all it will take, close the valve on the high side of the charging manifold.

3. Start the system and charge the balance of the refrigerant through the low side.

NOTE: R410A should be drawn out of the storage container or drum in liquid form due to its fractionation properties, but should be "Flashed" to its gas state before entering the system. There are commercially available restriction devices that fit into the system charging hose set to accomplish this.

DO NOT charge liquid R410A into the compressor.

4. With the system still running, close the valve on the 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.

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.

S-104 CHECKING COMPRESSOR EFFICIENCY

The reason for compressor inefficiency is broken or damaged scroll flanks on Scroll compressors, reducing the ability of the compressor to pump refrigerant vapor.

The condition of the scroll flanks is checked in the following manner.

1. Attach gauges to the high and low side of the system.

2. Start the system and run a “Cooling Performance Test.

If the test shows: a. Below normal high side pressure.

b. Above normal low side pressure.

c. Low temperature difference across coil.

d. Low amp draw at compressor.

And the charge is correct. The compressor is faulty - replace the compressor.

S-105B THERMOSTATIC EXPANSION VALVE

The expansion valve is designed to control the rate of liquid 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:

(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 ARE DESIGNED TO MEET THE

SPECIFICATION REQUIREMENTS FOR OPTIMUM PROD-

UCT OPERATION. DO NOT USE SUBSTITUTES.

45

SERVICING

92

94

96

98

100

102

104

68

70

72

74

60

62

64

66

76

78

80

82

84

86

88

90

38

40

42

44

46

PSIG

°F

12 -37.7

14 -34.7

16

18

20

22

24

26

28

30

-32.0

-29.4

-36.9

-24.5

-22.2

-20.0

-17.9

-15.8

-13.8

32

34

36

-11.9

-10.1

-8.3

-6.5

48

50

52

-4.5

-3.2

-1.6

0.0

1.5

54

56

58

3.0

4.5

5.9

7.3

8.6

10.0

11.3

12.6

13.8

15.1

16.3

17.5

18.7

19.8

21.0

22.1

23.2

24.3

25.4

26.4

27.4

28.5

106

108

110

112

29.5

30.5

31.2

32.2

33.2

34.1

35.1

35.5

36.9

*Based on ALLIED SIGNAL Data

194.0

196.0

198.0

200.0

202.0

204.0

206.0

162.0

164.0

166.0

168.0

170.0

172.0

174.0

176.0

178.0

180.0

182.0

184.0

186.0

188.0

190.0

192.0

PSIG

°F

114.0

37.8

116.0

38.7

118.0

120.0

122.0

124.0

126.0

128.0

130.0

132.0

39.5

40.5

41.3

42.2

43.0

43.8

44.7

45.5

46.3

134.0

136.0

138.0

140.0

142.0

144.0

146.0

148.0

150.0

152.0

154.0

47.1

47.9

48.7

49.5

50.3

51.1

51.8

52.5

53.3

156.0

158.0

160.0

54.0

54.8

55.5

56.2

57.0

57.7

58.4

59.0

59.8

60.5

61.1

61.8

62.5

63.1

63.8

64.5

65.1

65.8

66.4

67.0

67.7

68.3

208.0

210.0

212.0

214.0

68.9

69.5

70.1

70.7

71.4

72.0

72.6

73.2

73.8

Pressure vs. Temperature Chart

R-410A

264.0

266.0

268.0

270.0

272.0

274.0

276.0

278.0

280.0

282.0

284.0

286.0

288.0

290.0

292.0

294.0

PSIG

°F

216.0

74.3

218.0

74.9

220.0

222.0

224.0

226.0

228.0

230.0

232.0

234.0

75.5

76.1

76.7

77.2

77.8

78.4

78.9

79.5

80.0

236.0

238.0

240.0

242.0

244.0

246.0

248.0

250.0

252.0

254.0

256.0

80.6

81.1

81.6

82.2

82.7

83.3

83.8

84.3

84.8

258.0

260.0

262.0

85.4

85.9

86.4

86.9

87.4

87.9

88.4

88.9

89.4

89.9

90.4

90.9

91.4

91.9

92.4

92.8

93.3

93.8

94.3

94.8

95.2

95.7

296.0

298.0

300.0

302.0

304.0

306.0

308.0

310.0

312.0

314.0

316.0

96.2

96.6

97.1

97.5

98.0

98.4

98.9

99.3

99.7

366.0

110.4

368.0

110.8

370.0

111.2

372.0

111.6

374.0

112.0

376.0

112.4

378.0

112.6

380.0

113.1

382.0

113.5

384.0

113.9

386.0

114.3

388.0

114.7

390.0

115.0

392.0

115.5

394.0

115.8

396.0

116.2

398.0

116.6

400.0

117.0

402.0

117.3

404.0

117.7

406.0

118.1

408.0

118.5

410.0

118.8

412.0

119.2

414.0

119.6

416.0

119.9

418.0

120.3

PSIG

°F

318.0

100.2

320.0

100.7

322.0

101.1

324.0

101.6

326.0

102.0

328.0

102.4

330.0

102.9

332.0

103.3

334.0

103.7

336.0

104.2

338.0

104.6

340.0

105.1

342.0

105.4

344.0

105.8

346.0

106.3

348.0

106.6

350.0

107.1

352.0

107.5

354.0

107.9

356.0

108.3

358.0

108.8

360.0

109.2

362.0

109.6

364.0

110.0

468.0

129.0

470.0

129.3

472.0

129.7

474.0

130.0

476.0

130.3

478.0

130.7

480.0

131.0

482.0

131.3

484.0

131.6

486.0

132.0

488.0

132.3

490.0

132.6

492.0

132.9

494.0

133.3

496.0

133.6

498.0

133.9

500.0

134.0

502.0

134.5

504.0

134.8

506.0

135.2

508.0

135.5

510.0

135.8

512.0

136.1

514.0

136.4

516.0

136.7

518.0

137.0

520.0

137.3

PSIG

°F

420.0

120.7

422.0

121.0

424.0

121.4

426.0

121.7

428.0

122.1

430.0

122.5

432.0

122.8

434.0

123.2

436.0

123.5

438.0

123.9

440.0

124.2

442.0

124.6

444.0

124.9

446.0

125.3

448.0

125.6

450.0

126.0

452.0

126.3

454.0

126.6

456.0

127.0

458.0

127.3

460.0

127.7

462.0

128.0

464.0

128.3

466.0

128.7

46

600.0

149.0

604.0

149.5

608.0

150.1

612.0

150.6

616.0

151.2

620.0

151.7

624.0

152.3

628.0

152.8

632.0

153.4

636.0

153.9

640.0

154.5

644.0

155.0

648.0

155.5

652.0

156.1

656.0

156.6

660.0

157.1

664.0

157.7

668.0

158.2

672.0

158.7

676.0

159.2

680.0

159.8

684.0

160.3

688.0

160.8

692.0

161.3

696.0

161.8

PSIG

°F

522.0

137.6

524.0

137.9

526.0

138.3

528.0

138.6

530.0

138.9

532.0

139.2

534.0

139.5

536.0

139.8

538.0

140.1

540.0

140.4

544.0

141.0

548.0

141.6

552.0

142.1

556.0

142.7

560.0

143.3

564.0

143.9

568.0

144.5

572.0

145.0

576.0

145.6

580.0

146.2

584.0

146.7

588.0

147.3

592.0

147.9

596.0

148.4

SERVICING

S-106 OVERFEEDING

Overfeeding by the expansion valve results in high suction pressure, cold suction line, and possible liquid slugging of the compressor.

If these symptoms are observed:

1. Check for an overcharged unit by referring to the cooling performance charts in the servicing section.

2. 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.

S-108 SUPERHEAT

The expansion valves are factory adjusted to maintain 12 to

15 degrees superheat of the suction gas. Before checking the superheat or replacing the valve, perform all the 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 when 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 on following page.

CAUTION

To prevent personal injury, carefully connect and disconnect manifold gauge hoses. Escaping liquid refrigerant can cause burns. Do not vent refrigerant to atmosphere. Recover during system repair or final unit disposal.

1. Run system at least 10 minutes to allow pressure to stabilize.

2. Temporarily install thermometer on suction (large) line near compressor with adequate contact and insulate for best possible reading.

3. Refer to the superheat table provided for proper system superheat. Add charge to lower superheat or recover charge to raise superheat.

Superheat Formula = Suct. Line Temp. - Sat. Suct. Temp.

EXAMPLE:

a. Suction Pressure = 143 b. Corresponding Temp. °F. = 50 c. Thermometer on Suction Line = 61°F.

To obtain the degrees temperature of superheat, subtract

50.0 from 61.0°F.

The difference is 11° Superheat. The 11° Superheat would fall in the ± range of allowable superheat.

SUPERHEAT AND SUBCOOLING ADJUSTMENT

ON TXV APPLICATIONS

1. Run system at least 10 minutes to allow pressure to stabilize.

2. Temporarily install thermometer on liquid (small) line near pressure switches with adequate contact and insulate for best possible reading.

3. Check subcooling and superheat. Systems with TXV application should have a subcooling and superheat of

12 - 15 ºF.

a.

If subcooling and superheat are low, adjust TXV to 9 ± 3ºF then check subcooling.

b.

If subcooling is low and superheat is high, add charge to raise subcooling to 10ºF then check superheat.

c.

If subcooling and superheat are high, adjust TXV valve to 12 - 15 ºF then check subcooling.

d.

If subcooling is high and superheat is low, adjust

TXV valve to 12 - 15 ºF superheat and remove charge to lower the subcooling to 2 - 15 ºF.

The TXV should NOT be adjusted at light load conditions

55º to 60ºF, under such conditions only the subcooling can be evaluated. This is because suction pressure is dependent on the indoor coil match, indoor airflow, and wet bulb temperature. NOTE: Do NOT adjust charge based on suction pressure unless there is a gross undercharge.

4. Disconnect manifold set. Installation is complete.

47

SERVICING

REQUIRED LIQUID LINE TEMPERATURE

LIQUID PRESSURE

AT SERVICE VALVE (PSIG)

189

195

202

208

215

222

229

236

243

251

259

266

345

354

364

374

384

395

406

274

283

291

299

308

317

326

335

416

427

439

450

462

474

486

499

511

98

100

102

104

106

108

110

90

92

94

96

82

84

86

88

112

114

116

118

120

122

124

126

128

68

70

72

74

76

78

80

8

58

60

62

64

66

96

98

100

102

104

106

108

88

90

92

94

80

82

84

86

REQUIRED SUBCOOLING TEMPERATURE (°F)

10

56

58

12

54

56

14

52

54

16

50

52

18

48

50

60

62

64

58

60

62

56

58

60

54

56

58

52

54

56

66

68

70

72

74

76

78

64

66

68

70

72

74

76

62

64

66

68

70

72

74

60

62

64

66

68

70

72

58

60

62

64

66

68

70

110

112

114

116

118

120

122

124

126

78

80

82

84

86

88

90

92

94

96

98

100

102

104

106

108

110

112

114

116

118

120

122

124

76

78

80

82

84

86

88

90

92

94

96

98

100

102

104

106

108

110

112

114

116

118

120

122

74

76

78

80

82

84

86

88

90

92

94

96

98

100

102

104

106

108

110

112

114

116

118

120

102

104

106

108

110

112

114

116

118

88

90

92

94

96

98

100

80

82

84

86

72

74

76

78

48

SERVICING

S-109 CHECKING SUBCOOLING

Refrigerant liquid is considered subcooled when 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 close to the pressure switch.

2. Install a high side pressure gauge on the high side (liquid) service valve at the front of the unit.

3. Record the gauge pressure and the temperature of the line.

4. Compare the hi-pressure reading to the "Required Liquid

Line Temperature" chart on the following page. Find the hi-pressure value on the left column. Follow that line right to the column under the design subcooling value. Where the two intersect is the required liquid line temperature.

Alternately you can convert the liquid line pressure gauge reading to temperature by finding the gauge reading in Temperature - Pressure Chart and reading to the left, find the temperature in the °F. Column.

5. The difference between the thermometer reading and pressure to temperature conversion is the amount of subcooling.

Add charge to raise subcooling. Recover charge to lower subcooling.

Subcooling Formula = Sat. Liquid Temp. - Liquid Line Temp.

EXAMPLE:

a. Liquid Line Pressure = 417 b. Corresponding Temp. °F. = 120° c. Thermometer on Liquid line = 109°F.

To obtain the amount of subcooling subtract 109°F from

120°F.

The difference is 11° subcooling. See the specification sheet or technical information manual for the design subcooling range for your unit.

S-110 CHECKING EXPANSION VALVE OPERA-

TION

1. Remove the remote bulb 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. Capture the charge, replace the valve and drier and evacuate.

S-111 FIXED ORIFICE RESTRICTOR DEVICES

The fixed orifice restrictor device (flowrator) used in conjunction with the indoor coil is a predetermined bore (I.D.).

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 restrictor device is regulated by the pressure difference between the high and low sides of the system.

In the cooling cycle when the outdoor air 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 restrictor device is inoperative. Replace, install a liquid line drier, evacuate and recharge.

49

SERVICING

S-112 CHECKING RESTRICTED LIQUID LINE

When the system is operating, the liquid line is warm to the touch. If the liquid line is restricted, a definite temperature drop will be noticed 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.

Locate the restriction, replace the restricted part, replace drier, evacuate and recharge.

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.

NOTICE

Violation of EPA regulations may result in fines or other penalties.

S-113 OVERCHARGE OF REFRIGERANT

An overcharge of refrigerant is normally indicated by an excessively high head pressure.

An evaporator coil, using an expansion valve metering device, will basically modulate and control a flooded evaporator and prevent liquid return to the compressor.

An evaporator coil, using a fixed orifice restrictor device

(flowrator) metering device, could allow refrigerant to return to the compressor under extreme overcharge conditions.

Also with a fixed orifice restrictor device (flowrator) metering device, extreme cases of insufficient indoor air can cause icing of the indoor coil and liquid return to the compressor, but the head pressure would be lower.

There are other causes for high head pressure which may be found in the "Service Problem Analysis Guide."

If other causes check out normal, an overcharge or a system containing non-condensables would be indicated.

If this system is observed:

1. Start the system.

2. Remove and capture small quantities of refrigerant as from the suction line access fitting until the head pressure is reduced to normal.

3. Observe the system while running a cooling performance test. If a shortage of refrigerant is indicated, then the system contains non-condensables.

S-114 NON-CONDENSABLES

If non-condensables are suspected, shut down the system and allow the pressures to equalize. Wait at least 15 minutes. Compare the pressure to the temperature of the coldest coil since this is where most of the refrigerant will be.

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, evacuating and recharging.

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 clean-up is not necessary.

If acid level is unacceptable, the system must be cleaned by using the clean-up drier method.

CAUTION

Do not allow the sludge or oil to contact the skin.

Severe burns may result.

NOTE: The Flushing Method using R-11 refrigerant is no longer approved by Amana

®

Brand Heating-Cooling.

Suction Line Drier Clean-Up Method

The POE oils used with R410A refrigerant is an excellent solvent. In the case of a burnout, the POE oils will remove any burnout residue left in the system. If not captured by the refrigerant filter, they will collect in the compressor or other system components, causing a failure of the replacement compressor and/or spread contaminants throughout the system, damaging additional components.

Use part number RF000127 suction line filter drier kit. This drier should be installed as close to the compressor suction fitting as possible. The filter must be accessible and be rechecked for a pressure drop after the system has operated for a time. It may be necessary to use new tubing and form as required.

NOTE: At least twelve (12) inches of the suction line immediately out of the compressor stub must be discarded due to burned residue and contaminates.

1. Remove compressor discharge line strainer.

2. 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 line drier.

5. Braze all joints, leak test, evacuate, and recharge system.

50

SERVICING

6. Start up the unit and record the pressure drop across the drier.

7. Continue to run the system for a minimum of twelve (12) hours and recheck the pressure drop across the drier.

Pressure drop should not exceed 6 PSIG.

8. Continue to run the system for several days, repeatedly checking pressure drop across the suction line drier. If the pressure drop never exceeds the 6 PSIG, the drier has trapped the contaminants. Remove the suction line drier from the system.

9. If the pressure drop becomes greater, then it must be replaced and steps 5 through 9 repeated until it does not exceed 6 PSIG.

NOTICE: Regardless, the cause for burnout must be determined and corrected before the new compressor is started.

S-200 CHECKING EXTERNAL STATIC PRESSURE

The minimum and maximum allowable duct static pressure is found in the Technical Information Manual.

Too great of an external static pressure will result in 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: Both readings may be taken simultaneously and read directly on the manometer if so desired.

4. Consult proper table for quantity of air.

If the external static pressure exceeds the minimum or maximum allowable statics, check for closed dampers, dirty filters, undersized or poorly laid out ductwork.

S-201 CHECKING TEMPERATURE RISE

Temperature rise is related to the BTUH output of the unit and the amount of air (CFM) circulated over the heat exchanger.

All units are designed for a given range of temperature increase. This is the temperature of the air leaving the unit minus the temperature of the air entering the unit.

The more air (CFM) being delivered through a given unit the less the rise will be; so the less air (CFM) being delivered, the greater the rise. The temperature rise should be adjusted in accordance to a given unit specifications and its external static pressure.

1. Check BTUH input to unit do not exceed input rating stamped on rating plate.

2. Take entering and leaving air temperatures.

3. Select the proper speed tap or dip switch setting for direct drive units.

4. Take motor amperage draw to determine that the motor is not overloaded during adjustments.

SUPPLY

INCLINED

MANOMETER

SUPPLY

RETURN

Total External Static

2. Measure the static pressure of the supply duct, (Positive

Pressure).

3. Add the two readings together.

RETURN

T

SUPPLY

T

RETURN

RISE = SUPPLY -

T

RETURN

Checking Temperature Rise

51

SERVICING

S-300 TESTING PRIMARY LIMIT CONTROL

APG/GPG units use a snap-disk type primary limit device.

Sometimes referred to as "stat on a stick". The limit setting is fixed and must not be readjusted in the field.

S-301 TESTING AUXILIARY LIMIT

The auxiliary limit control is a preset nonadjustable control mounted in the blower compartment area.

It is connected in series with the rollout switch wiring to the gas valve. If its temperature should be exceeded, it will open, interrupting the voltage to the gas valve causing it to open.

An additional limit (primary limit) control is required for safety control of high temperature within the furnace or ductwork.

AUX. LIMIT

Volt / Ohm

Meter

COLOR

IDENTIFYING

SLEEVES

TESTING PRIMARY 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.

HIGH VOLTAGE!


HIGH VOLTAGE!


1. Remove electrical power to unit. Some units may have more than one source of power.

2. Remove the wires from the limit control terminals.

3. Using an ohmmeter, test for continuity across the two terminals.

4. If limit test open allow unit to cool and retest.

5. If still open, replace the control.

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.

52

SERVICING

V O LT / O H M

M E T E R

R ED

R E S ET

B U TT O N

C O L O R

ID EN T IFY IN G

T A B

TESTING AUXILIARY LIMIT CONTROL

S-302 CHECKING FLAME ROLLOUT SWITCH

APG/GPG units are equipped with a temperature-activated manual reset control. This control is mounted to the manifold assembly and is wired in series with the auxiliary limit and gas valve. The control is designed to open should a flame roll out occur. An over firing condition or flame impingement on the heat shield can also cause the control to open.

If the rollout control has opened, the circuit between the ignition control and gas valve will be interrupted and the ignition control module will go into lockout. The servicer should reset the ignition control by opening and closing the thermostat circuit. The servicer should look for the ignitor sparking 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 try to power the gas valve.

CHECKING FLAME ROLLOUT SWITCH

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.

1. If no voltage is measured on either side of control it indicates ignition control or wiring to control problem.

2. If voltage is measured on one side of the control and not the other, it indicates the control is open.

3. If voltage is measured on both sides of the control the wiring to gas valve or valve is at fault.

Servicing procedure with furnace not firing.

1. Confirm that the outer door was in place and all screws tightened. (No leaks under the door.)

2. Check to see if any damage was done to the furnace especially the wiring.

3. Confirm that heat exchanger is not obstructed by feeling for 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.

1. Remove the heating compartment door.

2. Turn of the power or open the thermostat circuit.

3. Reset the rollout control.

4. Turn power on and put the unit into a call for heating.

VOLT / OHM

M ETER

CAUTION

Flame rollout could occur. Keep face and hands a safe distance from burner area.

R ED

RE SET

BU TTON

COL OR

ID EN TIFY ING

TA B

53

SERVICING

5.

Look under the heat shield as the unit is running.

Flames should be drawn into firing tubes.

a.

If only one burners flame is not drawn into the tube, that tube is restricted.

b.

If, without the air circulation blower running, all flames are not drawn into the tubes either the collector box, combustion blower, or flue outlet is obstructed. If the combustion blower or flue outlet is obstructed, the pressure switch should have opened preventing the unit from firing, also inspect the unit pressure switch and wiring.

c.

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-303 TESTING INDUCER MOTOR

1. Ensure gas valve and main gas supply are on.

2. Using a voltmeter, check for 24 volts as noted below for

1- and 2- stage gas valves.

a. For 1-stage gas valves, check from the purple and

blue wires.

b. For 2-stage gas valves, check from C and M terminals

on the valve.

3. If 24 volts are present and no gas flows through the valve,

replace valve.

HIGH VOLTAGE!


HIGH VOLTAGE!


1. Disconnect the motor wire leads from its connection point at integrated ignition control module.

2. Using and ohmmeter, test for 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 to ground, replace the motor.

4. After completing check and/or replacement of induced draft blower motor.

5. Turn on electrical power and verify proper unit operation.

S-304 TESTING GAS VALVE

Direct Spark Ignition (DSI) Systems

A combination redundant operator type gas valve which provides all manual and automatic control functions required for gas fired heating equipment is used on single stage models.

A two-stage combination redundant operator type gas valve which provides all manual and automatic control functions required for gas fired heating equipment is used on two stage models.

The valve provides control of main burner gas flow, pressure regulation, and 100 percent safety shut-off.

W/R 36G22-202

WHITE RODGERS MODEL 36G 1-STAGE GAS VALVE

Gas Valve

On/Off

Switch

Inlet Pressure

Tap

Outlet

Inlet

Outlet Pressure

Tap

W/R 36G54-238

WHITE RODGERS MODEL 36G 2-STAGE GAS VALVE

54

SERVICING

Inlet

Pressure

Tap

Pressure Regulator

(under cap screw)

Outlet

Pressure

Tap

S-306 CHECKING ORIFICES

A predetermined fixed gas orifice is used in all of these furnaces. That is an orifice which has a fixed bore and position.

A

Gas Valve On/Off

Selector Switch

HONEYWELL MODEL VR8215 1-STAGE GAS VALVE

S-305 CHECKING MAIN BURNERS

The main burners are used to provide complete combustion of various fuels in a limited space, and transfer this heat of the burning process to the heat exchanger.

Proper ignition, combustion, and extinction are primarily due to burner design, orifice sizing, gas pressure, primary and secondary air, vent and proper seating of burners.

GAS

STREAM B

DENT OR

BURR

GAS

STREAM B

BECKETT BURNER

WARNING

Disconnect gas and electrical power supply.

In checking main burners, look for signs of rust, oversized and undersized carry-over ports restricted with foreign material, etc.

The length of Dimension "A" determines the angle of Gas

Stream Defraction, "B".

A dent or burr will cause severe deflection of gas stream.

No resizing should be attempted until all factors are taken into consideration such as inlet manifold gas pressure, alignment, and positioning, specific gravity and BTU content of the gas being consumed.

The only time resizing is required is when a reduction in firing rate is required for an increase in altitude.

Orifices should be treated with care in order to prevent damage. They should be removed and installed with a boxend 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.

WARNING


1. Check orifice visually for distortion and/or burrs.

2. Check orifice size with orifice sizing drills.

3. If resizing is required, a new orifice of the same physical size and angle with proper drill size opening should be installed.

55

SERVICING

S-307 CHECKING GAS PRESSURE

Gas inlet and manifold pressures should be checked and adjusted in accordance to the type of fuel being consumed.

Open to

Atmosphere

Pressure Regulator

(under cap screw)

Open to

Atmosphere

WARNING


1. Connect a water manometer or adequate gauge to the inlet pressure fitting of the gas valve.

2. Remove the pressure tap fitting at the manifold if provided or check at the gas valve outlet fitting and connect another manometer or gauge.

Inlet

Pressure

Tap

Gas Valve On/Off

Selector Switch

Outlet

Pressure

Tap

Inlet Pressure

Manifold

Pressure

HONEYWELL MODEL VR8215 1-STAGE GAS VALVE

Open to

Atmosphere

Open to

Atmosphere

MEASURING INLET AND MANIFOLD GAS PRESSURE

With Power ON:

WARNING


3. Put furnace into heating cycle and turn on all other gas consuming appliances.

Manifold

Pressure

Inlet Pressure

WHITE ROGERS MODEL 36G 1-STAGE GAS VALVE

For NATURAL GAS: a.

Inlet pressure should be a nominal 7" w.c.

b.

(2 stage heat models only) Manifold pressure on low stage should be 2.0” w.c. ± .3” w.c.

c.

Manifold pressure for 1 stage heat models and high stage for 2 stage heat models should be 3.5” w.c.

± .3” w.c.

Low Pressure

Adjust

Outlet

High Pressure

Adjust

Open to

Atmosphere

Gas Valve

On/Off

Switch

Inlet Pressure

Tap

Manometer

Hose

Open to

Atmosphere

Inlet

For PROPANE GAS: a.

Inlet pressure should be a nominal 11” w.c.

b.

(2 stage heat models only) Manifold pressure on low stage should be 6” w.c.

c.

Manifold pressure for 1 stage heat models and high stage for 2 stage heat models should be 10” w.c.

Manometer

Hose

Outlet Pressure

Tap

Manometer

WHITE ROGERS MODEL 36G 2-STAGE GAS VALVE

56

SERVICING

Manifold Gas Pressure

Natural Gas

Propane Gas

3.5" w.c.

10.0" w.c.

Single Stage

Gas

Manifold Gas Pressure

Range Nominal

Natural Low Stage 1.6 - 2.2" w.c. 2.0" w.c.

High Stage 3.2 - 3.8" w.c. 3.5" w.c.

Propane Low Stage 5.7 - 6.3" w.c. 6.0" w.c.

High Stage 9.7 - 10.3" w.c. 10.0" w.c.

Two Stage

If operating pressures differ from above, make necessary pressure regulator adjustments, check piping size, etc., and/ or consult with local utility.

S-308 CHECKING FOR DELAYED IGNITION

Delayed ignition is a delay in lighting a combustible mixture of gas and air which has accumulated in the combustion chamber.

When the mixture does ignite, it may explode and/or rollout causing burning in the burner venturi.

If delayed ignition should occur, the following should be checked:

1. Improper gas pressure - 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.

S-309 CHECKING FOR FLASHBACK

Flashback will also cause burning in the burner venturi, but is caused by the burning speed being greater than the gas-air flow velocity coming from a burner port.

Flashback may occur at the moment of ignition, after a burner heats up or when the burner turns off. The latter is known as extinction pop.

Since the end results of flashback and delayed ignition can be the same (burning in the burner venturi) a definite attempt should be made to determine which has occurred.

If flashback should occur, check for the following:

1. Improper gas pressure - adjust to proper pressure. See

S-307.

2. Check burner for proper alignment and/or replace burner.

3. Improper orifice size - check orifice for obstruction.

S-310 CHECKING PRESSURE CONTROL

A pressure control device is used to measure negative pressure at the induced draft blower motor inlet to detect a partial or blocked flue.

Pressure Switch Operation (DSI Direct Spark System)

The pressure switch is ignored unless there is a call for heat.

When the control receives a call for heat, the control checks to see that the pressure switch is open. If the control sees that the pressure switch is closed before the induced draft blower is energized, the LED will flash a code of "2" (to indicate the pressure switch is stuck closed) and the inducer will remain off until the pressure switch opens.

If the pressure switch opens before the ignition period, the induced draft blower will remain on and the control will stay in pre-purge until the pressure switch is closed for an entire

15 second pre-purge period. The LED will flash a code of "3" 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.

HIGH VOLTAGE!


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:

57

SERVICING

HOSE

TO J-TUBE

PRESSURE SWITCH

1/4" COPPER TEE altitude range. High altitude kits are not approved for use in

Canada. For installations above 2,000 feet, use kit HA-03.

The HA-03 kit is used for both Natural and LP gas at high altitudes.

Use LPM-08 (2 stage heat models) or LPM-07 (1 stage heat models) propane conversion kit for propane conversions at altitudes below 2000 feet. Natural gas installations below

2000 feet do not require a kit.

For propane conversions above 2000 feet, high altitude kit

HA-03 is required in addtion to the propane conversion kit.

INCLINED

MANOMETER

Reconnect wires to the Common and NO terminals.

With Power ON:

WARNING


4. Energize furnace for heating cycle. The induced draft blower motor will begin to run. The inclined manometer should read approximately -1.2" ± 0.3" W.C with no combustion.

5. Remove and 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 pressure control.

6. Reconnect all wires to the control and place in heating cycle.

7. As the unit fires on high stage, the inclined manometer negative pressure will drop to -1.0" ± 0.3" W.C.

8. If not as listed, replace control.

Note: the pressure switch must be mounted with the diaphragm in a vertical position.

Natural gas and LP gas installations at altitudes > 2000 ft

INPUT/BURNER

U.S. BURNER ORIFICE

CANADA BURNER ORIFICE

HIGH ALTITUDE

KIT

HA-03

2000 3000

46/1.25MM 47/1.25MM

-

20,000 BTUH NAT/18,OOO BTUH LP

ELEVATION ABOVE SEA-LEVEL (FEET)

4000

47/56

-

4500

-

48/57

5000

48/56

-

6000

48/57

-

7000

49/57

-

8000

49/57

-

S-313 TESTING IGNITION CONTROL MODULE

NOTE: Failure to earth ground the unit, or a high resistance connection in the ground may cause the control to lockout due to failure to flame sense.

NOTE: The flash rate is 0.25 seconds on, 0.25 seconds off, with a 2-second pause between codes.

S-311 HIGH ALTITUDE APPLICATION

High Altitude Derate - U.S. Installations Only

IMPORTANT NOTE: The gas/electric units naturally derate with altitude. Do not attempt to increase the firing rate by changing orifices or increasing the manifold pressure. This can cause poor combustion and equipment failure. At all altitudes, the manifold pressure must be within 0.3 inches

W.C. of that listed on the nameplate for the fuel used. At all altitudes and with either fuel, the air temperature rise must be within the range listed on the unit nameplate. Refer to the

Installation Manual provided with the LP kit for conversion from natural gas to propane gas and for altitude adjustments.

When this package unit is installed at high altitude, the appropriate High Altitude orifice kit must be installed. As altitude increases, there is a natural reduction in the density of both the gas fuel and combustion air. This kit will provide the proper design certified input rate within the specified

Testing Direct Spark Ignition (DSI) systems

Thermostat calling for heat (15 second prepurge time and

7 second trial for ignition).

1. Check for 230 VAC from L1 terminal of control module to L2. No voltage - check wire connections, continuity, etc.

2. Check for 24 VAC at "R" to "C" thermostat terminals.

a.

No voltage - check 3 amp automotive type fuse on control board. A blown fuse would indicate a short in the 24 VAC circuit (thermostat or limit circuit).

b.

Voltage Present - check limit, auxiliary limit and rollout (S-300, S-301 and S-302). If limit, auxiliary limit and rollout are closed, then check for 24

VAC at the gas valve terminals.

No 24 VAC at gas valve - replace Control board.

58

SERVICING

PCBAG123 Ignition Board Fault Codes

Status Light Equipment Status

On Normal Operation

Off

1 Blink

Check

No Power or

Internal Control Fault

Ignition Failure,

Open Rollout Switch, or Open Aux. Limit

Switch

Check Input Power,

Check Fuse on Control,

Replace Control

Check Gas Flow,

Check Gas Pressure,

Check Gas Valve,

Check Flame Sensor,

Check Flame Rollout,

Check Aux. Limit.

2 Blinks

3 Blinks

4 Blinks

Pressure Switch

Open

Pressure Switch

Closed

Open Main Limit

Switch

5 Blinks False Flame Sensed

6 Blinks

Compressor Output

Delay

Check Pressure Switch

Check Pressure Switch

Main Limit Switch Open

Sticking Gas Valve

3 Minute Compressor

Anti-Cycle Timer

Testing Direct Spark Ignition (DSI) Systems

PCBAG127 Board

Heating Mode

Indoor thermostat calling for heat (15 second prepurge time and 7 second trial for ignition).

1. Check for 230 volts from L1 terminal of control module to

L2. No voltage - check wire connections, continuity, etc.

2. Check for 24 volts at "R" to "C" thermostat terminals.

a.

No voltage - check 3 amp automotive type fuse on control board. A blown fuse could indicate a short in the 24 volt circuit (thermostat or limit circuit).

b.

Voltage Present - check limit and rollout (S-301 and S-302). If limit and rollout are closed, then check for 24 VAC at the gas valve terminals.

c.

No 24 VAC at gas valve - check 9 pin connector and wires from ignition control to gas valve. If wires and connections at 9 pin connector check good, replace ignition control.

d.

Voltage present at gas valve - replace gas valve.

NOTE: The flash rate is 0.25 seconds on, 0.25 seconds off, with a 2-second pause between codes.

Blower Off Delay Settings

L2 L2 L2 L2

COOL HEAT

UNUSED

L1

L1 D1

FS

3

6

9

2

5

8 7

12 11 10

1

4

speed up

Transformer

PCBAG123 DSI Control Board

LED

Fla she s/Sta tus

Syste m Condition

Off

1

2

3

Internal Control Fault, Micro Controller

Detected Hardware Failure, or Gas Valve

Detected Energized W hen it Should be

De-energized

Lockout Due to Excessive Retries



4

5


Flame Present Outside the Flame

Detect Mode

Compressor Short Cycle Delay Active 6

7

8

9

Limit Opened Five Times within the

Same Call for Heat

Indoor Thermostat/Outdoor Therm ostat is Open

Pressure Switch/Loss of Charge Switch is Open

Steady ON Normal

Red LED Fault Codes

LED

Flashes/Status

2

1

Steady ON

OFF

Flame Condition

Flame Present Outside the Flame Detect

Mode

Low Flame Signal Current

Normal Flame

No Flame Present

Amber LED Flame Status Codes

59

SERVICING

L2 INDUCER

T1

K4

Q3

LOW HIGH

K3 FS

L1

K5

T2

C9

OD F

LOW HIGH

PARK

K6

K7

Flame

Sensor

P2

U1

U2

5

4

3

2

1

U6

U7

U4

U5

U3

K2

Flame Sensor

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.

4. Turn on Power.

K1

WARNING


SPEED UP

SW1

FAULT

RECALL

180

150

120

90

NONE

5 MIN

10MIN

BLOWER

OFF DELAY

STAGE

DELAY

F1

ECON

R C W1W2 G Y1 Y2

PCBAG127 DSI Control Board

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.

DSI Direct Spark Ignition Systems

HIGH VOLTAGE!


1. Disconnect the flame sensor wire from terminal FS of the ignition control module.

5. With Power ON, Place the unit into a heating cycle.

6. 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.

7. The nominal microamp reading is 4 microamps.

8. If the microamp current is less than 0.5 microamp the control will lockout and flash a code of 1 flash after attempting to reestablish flame sense.

9. 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, dirty flame sensor or poor grounding.

10. If no reading, check for continuity on all components and if good - replace ignition control module.

NOTE: Contaminated fuel or combustion air can create a nearly invisible coating on the flame sensor. This coating works as an insulator causing a loss in the flame sense signal. If this situation occurs the flame sensor must be cleaned with steel wool. Do not use sand paper, the silicone in sand paper will further contaminate the sensor.

60

ACCESSORIES WIRING DIAGRAMS ECONOMIZER

TAT OS RM HE M T ROO

C VD .10

2..

24V AC/DC

PGEDJ (Downflow) and DHZECHJPGCH (Horizontal)

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

61

WIRING DIAGRAMS

*PG14[24-42]***M41A*

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.

YL

RD

RD

BK

R C S

PU

BK

BL

T1 T2

L1 CC L2

GND

BK

BK

CH OPTIONAL

CONNECTED AT L1, L2

NOTE 3

COMP

PU

BK

BR

BK

BK BK PU PU

BK

BK

YL

CH OPTIONAL

SEE NOTE 3

POWER SUPPLY

208-230/1/60

SEE NOTE 6

CM

BK

NOTE 2

PU

YL

BL

BK

GR

PU

1

C

2

208

TR

24V

3

240

3

4

2

VMR

RD

1

WH

BL

YL

C L G N

EM

T1T2 T3 T4 T5

LS

RD

BL

PU

RD YL

RD

RD

RD

NOTE 4

WH

YL

YL

T1

PU

PLM-A

1

2

1

2

PLF-A

PU

135

120

150

P2

P3

X P MA SE 3 AM FU

OR

YL

F1

ALS

RD

RD

RD

BL

GR

PS

PU

YL

YL

PU

YL

YL

RD

WH

YL

OR

RD

BR

WH

RD

WH

BL YL

RD

PU

W. R.

GAS VALVE

GV

PU

(ALT.)

HONEYWELL

GAS VALVE

MV

GV

BL

MV

YL

RD

WH

GR

Y RD WH GR C

BL

BL

BL

BL

BL

RD

SEE

NOTE 7

IIC

TO THERMOSTAT

BL

VM

FS

IGN

RD

OR

YL WH

RD

PU

RD

PU

BL

RCCF

F H C

RD

YL

WH

BR

BR YL

62


WIRING DIAGRAMS

*PG14[24-42]***M41A*

HIGH VOLTAGE!




4

5

L1

1

L1

9

F

C

NOTE 6

L

EM

N

C

H

IIC

7

ECON

3

6

8

10

T1

FS

D1

SUPPLY VOLTAGE

208-230/1/60

CH

NOTE 3

T2

R

C COMP

S H

RCCF

C

F

CM

IGN

3

NOTE 2

LS

ALS

2

24 V

1

TR

1

RS

FS

VMR

3

4

VMR

2

C

T5

T4

T3

T

EM

2 T 1

GV

C

VM

NOTE 6

L2

2

IIC

L2

COMPONENT LEGEND

ALS AUXILLARY LIMIT SWITCH

C CONTACTOR

CH CRANKCASE HEATER

CM CONDENSER MOTOR

COMP COMPRESSOR

EM EVAPORATOR MOTOR

F FUSE

FS FLAME SENSOR

GND EQUIPMENT GROUND

GV GAS VALVE

HPS HIGH PRESSURE SWITCH

IIC INTEGRATED IGNITION CONTROL

IGN IGNITOR

LS LIMIT SWITCH

PLF-A FEMALE PLUG/CONNECTOR ALS

PLM-A FEMALE PLUG/CONNECTOR ALS

PS PRESSURE SWITCH

RCCF RUN CAPACITOR FOR COMPRESSOR/FAN

RS ROLLOUT SWITCH

TR TRANSFORMER

VM VENT MOTOR

VMR VENT MOTOR RELAY

WIRING

HIGH VOLTAGE

LOW VOLTAGE

FIELD INSTALLED POWER

FIELD INSTALLED CONTROL

OPTIONAL HIGH VOLTAGE

OPTIONAL LOW VOLTAGE

WIRE CODE

BK - BLACK

BL - BLUE

BR - BROWN

GR - GREEN

OR - ORANGE

PK - PINK

PU - PURPLE

RD - RED

WH - WHITE

YL - YELLOW

BL/PK - BLUE/PINK

NOTES :

1. REPLACEMENT WIRE MUST BE THE SAME SIZE AND TYPE OF

INSULATION AS ORIGINAL.(USE COPPER CONDUCTOR ONLY).

2. FOR 208 VOLT TRANSFORMER OPERATION MOVE BLACK WIRE

FROM TERMINAL 3 TO TERMINAL 2 ON TRANSFORMER.

3. CRANKCASE HEATER NOT SUPPLIED ON ALL UNITS.

4. FOR DIFFERENT THAN FACTORY SPEED TAP. CHANGE COOLING

SPEED AT MOTOR T4 AND T5 TERMINALS. CHANGE HEATING

SPEED AT MOTOR T1, T2 AND T3 TERMINALS.

COOLING SPEED (YELLOW WIRE) HEATING SPEED (WHITE WIRE)

T4 - LOW SPEED T1 - LOW SPEED

T5 - HIGH SPEED T2 - MED. SPEED

T3 - HIGH SPEED

5. USE COOPER CONDUCTORS ONLY

6. L1 AND L2 ON IIC CONTROL IS 24V INPUT.

PS

12

11 HPS

C

USE NEC CLASS 2 WIRE.

208-230/1/60

R G

TO THERMOSTAT

W Y C

INSTALLER/SERVICEMAN

THE STATUS LIGHT ON THE FURNACE CONTROL MAY BE USED AS A GUIDE TO

TROUBLESHOOTING THIS APPLIANCE. STATUS LIGHT CODES ARE AS FOLLOWS:

STATUS LIGHT

ON

OFF

1 BLINK

2 BLINKS

3 BLINKS

4 BLINKS

5 BLINKS

6 BLINKS

EQUIP. STATUS

NORMAL OPERATION

NO POWER OR

INTERNAL CONTROL

FAULT

IGNITION FAILURE

OR

OPEN ROLLOUT

SWITCH

OR

OPEN AUX. LIMIT

SWITCH

PRESSURE SWITCH

OPEN

PRESSURE SWITCH CLOSED

WITHOUT INDUCER ON

OPEN LIMIT SWITCH

FALSE FLAME SENSED

COMPRESSOR

OUTPUT DELAY

CHECK

-

CHECK INPUT POWER

CHECK FUSE ON CONTROL

REPLACE CONTROL

GAS FLOW

GAS PRESSURE

GAS VALVE

FLAME SENSOR

FLAME ROLLOUT

BAD SWITCH

AUX. LIMIT OPEN

CHECK

PRESSURE SWITCH

CHECK

PRESSURE SWITCH

MAIN LIMIT OPEN

BAD SWITCH

STICKING GAS VALVE

3 MIN. COMP.

ANTI-CYCLE TIMER

THERMOSTAT FIELD WIRING

NO ECONOMIZER

WH

GR

RD

YL

BL

W

G

R

Y

C

0140G03340-A


63

WIRING DIAGRAMS

*PG1448***M41A*

HIGH VOLTAGE!




YL

RD

RD

BK

PU

R C S

BK

BL

T1 T2

L1 CC L2

GND

BK

BK

CH OPTIONAL

CONNECTED AT L1, L2

NOTE 3

BR

COMP

PU

BK

BL

BL

BK BK

BK PU

PU

BK

BK

YL

CH OPTIONAL

SEE NOTE 3

POWER SUPPLY

208-230/1/60

SEE NOTE 6

CM

BK

NOTE 2

PU

YL

BL

C L G N

EM

T1 T2 T3 T4T5

BK

GR

PU

LS

RD

1

C

2

208

TR

24V

3

240

3

4

2

VMR

RD

1

WH

BL

YL RD YL

NOTE 4

RD

BL

RD

BL

BL

RD RD

RD

PU

RD

YL

WH

YL

C22

T2

T1

P2

ALS

135

150

120

PU

RD

RD

PS

RD

RD

BL

PU

YL

PU

YL

YL YL

YL

YL

BR

BL

WH

YL

6

5

4

9

8

7

PLF

PU

YL

W. R.

GAS VALVE

GV

PU

(ALT.)

HONEYWELL

GAS VALVE

MV

GV

BL

MV

BL

PU

GR

SEE

NOTE 5

YL

PU

BL

RD WH

GR BL BL

Y/Y2 Y1 C RD WH GR

BL

BL

RD

BL

VM

FS

IGN

TO THERMOSTAT

RD

OR

RD

PU

BL

YL

WH

BR

P3

AX

F1

GR

SE 3 AMP M

WH

RD

WH

RD

FU

OR

SEE

NOTE 7

YL

WH

YL

BR

OR RD BL

F

RD

PU

RCCF

H C

YL

RD

YL

64


WIRING DIAGRAMS

*PG1448***M41A*

HIGH VOLTAGE!




4

5

L1

1

L1

9

F

C

NOTE 7

L

EM

N

C

H

IIC

7

ECON

3

6

8

10

T1

FS

D1

L2

SUPPLY VOLTAGE

208-230/1/60

CH

NOTE 3

T2

C COMP

R

S H

RCCF

C

F

CM

IGN

C

4

VMR

2

3

NOTE 2

2

1

TR

24 V

FS

VM

2

NOTE 7

IIC

L2

T5

T4

T3

T 2

EM

T 1

C

1

VMR

3

LS

ALS RS

GV

12

11

PS

HPS

C

COMPONENT LEGEND

ALS AUXILLARY LIMIT SWITCH

COMP COMPRESSOR

CM CONDENSER MOTOR

C CONTACTOR

CH CRANKCASE HEATER

EM EVAPORATOR MOTOR

F FUSE

FS FLAME SENSOR

GND EQUIPMENT GROUND

GV GAS VALVE

IIC INTEGRATED IGNITION CONTROL

IGN IGNITOR

LS LIMIT SWITCH

PLF FEMALE PLUG/CONNECTOR

WIRING

HIGH VOLTAGE

LOW VOLTAGE

FIELD INSTALLED POWER

FIELD INSTALLED CONTROL


OPTIONAL LOW VOLTAGE

PS PRESSURE SWITCH

RCCF RUN CAPACITOR FOR COMPRESSOR/FAN

RS ROLLOUT SWITCH

TR TRANSFORMER

VM VENT MOTOR

VMR VENT MOTOR RELAY

HPS HIGH PRESSURE SWITCH

WIRE CODE

BK - BLACK

BL - BLUE

BR - BROWN

GR - GREEN

OR - ORANGE

PK - PINK

PU - PURPLE

RD - RED

WH - WHITE

YL - YELLOW

BL/PK - BLUE/PINK

NOTES :





3. CRANKCASE HEATER NOT SUPPLIED ON ALL UNITS.

4. FOR DIFFERENT THAN FACTORY SPEED TAP. CHANGE COOLING

SPEED AT MOTOR T4 AND T5 TERMINALS. CHANGE HEATING

SPEED AT MOTOR T1, T2 AND T3 TERMINALS.

COOLING SPEED (YELLOW WIRE) HEATING SPEED (WHITE WIRE)

T4 - LOW SPEED T1 - LOW SPEED

T5 - HIGH SPEED T2 - MED. SPEED

T3 - HIGH SPEED

5. ACCESSORY ECONOMIZER PLUG ADJACENT TO BLOWER HOUSING

IN RETURN AIR COMPARMENT.

6. USE COOPER CONDUCTORS ONLY

USE NEC CLASS 2 WIRE.

208-230/1/60

R G

TO THERMOSTAT

W Y1

Y/Y2

C

NOTE

5

PLF

9 8 7

4

1

5

2

6

3

THERMOSTAT FIELD WIRING

INSTALLER/SERVICEMAN

THE STATUS LIGHT ON THE FURNACE CONTROL MAY BE USED AS A GUIDE TO

TROUBLESHOOTING THIS APPLIANCE. STATUS LIGHT CODES ARE AS FOLLOWS:

STATUS LIGHT

ON

OFF

1 BLINK

2 BLINKS

3 BLINKS

4 BLINKS

5 BLINKS

EQUIP. STATUS

NORMAL OPERATION

NO POWER OR

INTERNAL CONTROL

FAULT

IGNITION FAILURE

OR

OPEN ROLLOUT

SWITCH

OR

OPEN AUX. LIMIT

SWITCH

PRESSURE SWITCH

OPEN


WITHOUT INDUCER ON

OPEN LIMIT SWITCH

CHECK

-

CHECK INPUT POWER

CHECK FUSE ON CONTROL

REPLACE CONTROL

GAS FLOW

GAS PRESSURE

GAS VALVE

FLAME SENSOR

FLAME ROLLOUT

BAD SWITCH

AUX. LIMIT OPEN

CHECK

PRESSURE SWITCH

CHECK

PRESSURE SWITCH

MAIN LIMIT OPEN

BAD SWITCH

STICKING GAS VALVE

6 BLINKS

FALSE FLAME SENSED

COMPRESSOR

OUTPUT DELAY

3 MIN. COMP.

ANTI-CYCLE TIMER

NO ECONOMIZER

WH

GR

RD

YL

BL

W

G

R

Y

C

2 STAGE COOLING WITH ECONOMIZER

WH

GR

RD

PU

YL

BL

W

G

R

Y1

Y2

C

0140G03117-A


65

BR

WIRING DIAGRAMS

*PG1460***M41A*

HIGH VOLTAGE!




YL YL

YL

YL

BK

RD

PU

RD

YL

SEE NOTE 6

R C S

YL

BL

T1 T2

GND

SEE NOTE 3

PU

YL

COMP

SOL YL

L1

CC

L2

SEE NOTE 2

BL

PU

BK

BR

BL BK

PU

POWER SUPPLY

208-230/1/60

SEE NOTE 3

YL

BL

CM

BK

GR

PU

G L

PU

1

C

SEE NOTE 2

2

208

TR

24V

3

240

BK

BK

SEE NOTE 8

YL

3

2

1

PU

6

5

GR

ECON

BL

4

PU

RD

BL

PU

RD

YL

C N

EM

T1 T2 T3 T4 T5

PU

WH

BR

PU

YL

PU

PU

PU

BK

BL

BK

RD

BK

IGN

YL

OR

PU

YL

ALS

PS

RS

OR

OR

FS

YL

YL

OR

OR

W. R.

GAS VALVE

M

GV

H

C

PU

BL

BR

RD

LS

YL

PU

BL

BR

WH

L2

LOW HIGH

INDUCER

L1 LOW HI

ODF

PARK

FS

T1

PU

5

LO COOL

YL

4

24VAC COM

6

5

4

3

2

1

3 HI COOL

2

1

180

150

120

90

HI HEAT

LO HEAT

OR

OR

NONE

5 MIN

10 MIN

1

2

3

P1

F

4

5

6

SEE NOTE 7

7

8

9

BL

BL

BR

YL

PU

SEE NOTE 5

BLOWER

OFF DELAY

STAGE

DELAY

ECON

C W1 G Y1 Y2

YL

YL

P2

YL

YL

BK

RD

YL

VM

BL

BK

RD

RD

PU

PU

BK

66

YL

PU

F H C

RD

BL

BR BR

RCCF

YL


WIRING DIAGRAMS

*PG1460***M41A*

HIGH VOLTAGE!




L1

L1

L1

CC

LO

HI

LO

HI

L1

T1

C

SUPPLY VOLTAGE

208-230/1/60

T2

R

COMP

S

H

RCCF C

CM

F

VM

EM

R

W1

W2

Y2

TO

MICRO

C

P2

Y1

P1

L1

1

2

2

TH

F

5

3

1

3

HLO

HLI

1

4

7

5

6

8

PSW

PSW

9

MVL

MVH

MVC

COM

LPS

ALS

PS

HPS

LS

M

HI

C

GV

3

SEE NOTE 2

TR

RS

SEE NOTE 7

CC

L2

L2

L2

L2

L2

COMPONENT LEGEND

FACTORY WIRING

ALS

COMP

AUXILLARY LIMIT SWITCH

COMPRESSOR

CM CONDENSER MOTOR

ECON ECONOMIZER

CC

CONTACTOR

EM

FS

F

EVAPORATOR MOTOR

FLAME SENSOR

FUSE

GND

GV

IIC

EQUIPMENT GROUND

GAS VALVE

INTEGRATED IGNITION CONTROL

IGN

LS

IGNITOR

LIMIT SWITCH

PS

RCCF

RS

SOL

TR

VM

PRESSURE SWITCH

RUN CAPACITOR FOR COMPRESSOR/FAN

ROLLOUT SWITCH

SOLENOID (2ND STAGE COOL)

TRANSFORMER

VENT MOTOR

ODF OUTDOOR FAN

HPS

HIGH PRESSURE SWITCH

LPS

LOW PRESSURE SWITCH

LINE VOLTAGE

LOW VOLTAGE


FIELD WIRING

HIGH VOLTAGE

LOW VOLTAGE

WIRE CODE

BK BLACK

BL BLUE

BR BROWN

GR GREEN

OR ORANGE

PK PINK

PU PURPLE

RD RED

WH WHITE

YL YELLOW

JUNCTION

TERMINAL

INTERNAL TO

INTEGRATED CONTROL

PLUG CONNECTION

SWITCH (PRESS.)

OVERCURRENT

PROT. DEVICE

NOTES

EQUIPMENT GROUND

FIELD GROUND

FIELD SPLICE

SWITCH (TEMP)

IGNITER

6

2

1

2

ECON

ECON

5

1

CC





3. USE COPPER CONDUCTORS ONLY

4. FOR 208V OPERATION, REMOVE BLUE LEAD FROM INDUCER LOW

TERMINAL. MOVE BLACK LEAD FROM PARK TERMINAL ONTO

INDUCER LOW TERMINAL. PLACE BLUE LEAD ON PARK TERMINAL.

5. USE NEC CLASS 2 WIRE FOR THERMOSTAT FIELD WIRING.

6. COMPRESSOR 2ND STAGE SOLENOID NOT PRESENT ON ALL MODELS.

7. FOR ECONOMIZER, REMOVE PLUG FROM ECONOMIZER HARNESS.

CONNECT PLUG FROM ECONOMIZER TO HARNESS.

ECON

3

ECON 4

LO HEAT

HI HEAT

LO COOL

HI COOL

DIAGNOSTIC

LED - RED

STATUS

CHECK

G

TO

MICRO

DIAGNOSTIC

LED - RED

ON

STATUS

T1

T2

EM C

T3

T4

CHECK

7 FLASHES

8 FLASHES

9 FLASHES

DIAGNOSTIC

LED - AMBER

OFF

ON

LIMIT OPEN 5 TIMES IN SAME

CALL FOR HEAT

IDT/ODT OPEN

PSW/LOC OPEN

CHECK MAIN LIMIT SWITCH

CHECK AUXILIARY LIMIT SW.

CHECK JUMPER BETWEEN 1

AND 4 ON 6-CIRCUIT

CONNECTOR

CHECK OPTIONAL

REFRIGERANT SWITCHES

CHECK REFRIGERANT

SWITCHES FOR LOSS OF

CHARGE OR HIGH HEAD

PRESSURE

OFF

1 FLASH

2 FLASHES

3 FLASHES

4 FLASHES

5 FLASHES

NORMAL OPERATION

NO POWER OR

INTERNAL CONTROL

FAULT

IGNITION FAILURE

PRESSURE SWITCH OPEN


WITHOUT INDUCER ON

OPEN LIMIT SWITCH

FALSE FLAME DETECTED

-

CHECK INPUT POWER

CHECK FUSE(S)

REPLACE CONTROL

GAS FLOW

GAS PRESSURE

GAS VALVE

FLAME SENSOR

CHECK PRESSURE SWITCH

CHECK TUBING

CHECK VENT MOTOR

CHECK PRESSURE SWITCH

CHECK WIRING FOR SHORTS

CHECK AUXILIARY LIMIT SW.

CHECK MAIN LIMIT SWITCH

CHECK ROLLOUT LIMIT SW.

CHECK GAS VALVE

CHECK FOR SHORTS IN

FLAME SENSOR WIRING

1 FLASH

2 FLASHES

STATUS

NO FLAME PRESENT

NORMAL FLAME PRESENT

LOW FLAME SIGNAL

FALSE FLAME DETECTED

CHECK

-

-

GAS FLOW

GAS PRESSURE

GAS VALVE

FLAME SENSOR

CHECK GAS VALVE

CHECK FOR SHORTS IN

FLAME SENSOR WIRING

6 FLASHES

COMPR. SHORT CYCLE DELAY

3 MIN COMP. SHORT

CYCLE DELAY

0140G02360-B


67

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