Service Instructions Split System Air Conditioners and Split System Heat Pumps with R-22 Refrigerant Blowers, Coils, & Accessories This manual is to be used by qualified HVAC technicians only. Goodman does not assume any responsibility for property damage or personal injury for improper service procedures done by an unqualified person.
TABLE OF CONTENTS AIR HANDLER/COIL IDENTIFICATION ......... 4 - 6 TROUBLESHOOTING CHART ......................... 17 ACCESSORIES ........................................... 7 - 10 SERVICING TABLE OF CONTENTS ................ 18 PRODUCT DESIGN ........................................ 11 SERVICING .................................................19 - 47 SYSTEM OPERATION .............................. 12 - 16 ACCESSORIES WIRING DIAGRAMS ........
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.
PRODUCT IDENTIFICATION G S C 13 036 1 A A Minor Revision Brand Name A: Initial Release G: Goodman/Amana Distinctions S: Goodman (High Feature Set Models) A: Amana Major Revision A: Initial Release Electrical Product Category 1: 2: 3. 4. 5.
PRODUCT IDENTIFICATION A R U F 3642 1 A A Product Type Minor Revision A: Initial Release A: Single Piece Air Handler Application C: Ceiling Mount PSC Motor D: Downflow PSC Motor E: Multi-Position Variable Speed Motor R: Multi-Position PSC Motor W: Wall Mount PSC Motor Major Revision A: Initial Release Electrical 1: 208/230V, 1 Phase, 60 Hz Cabinet Finish U: Unpainted P: Painted N: Uncased Nominal Capacity Range @ 13 SEER Expansion Device F: Flowrater MB E 8 Multi-Position & Downflow Applica
PRODUCT IDENTIFICATION C A P F 1824 A 6 Product Type A Revision A: Initial Release C: Indoor Coil Refrigerant Application 6: R-22 or R-410A 2: R-22 4: R-410A A: Upflow/Downflow Coil H: Horizontal A Coil S: Horizontal Slab Coil Nominal Width For Gas Furnace Cabinet Finish U: Uncased P: Painted C: Unpainted Case Expansion Device F: Flowrator A: Fits 14" Furnace Cabinet B: Fits 17 1/2" Furnace Cabinet C: Fits 21" Furnace Cabinet D: Fits 24 1/2" Furnace Cabinet N: Does Not Apply (Horizontal Slab
ACCESSORIES Model AFE18-60A Description All Fuel Kit GSH13018 GSH13024 GSH13030 GSH13036 GSH13042 GSH13048 GSH13060 X X X X X X X OT18-60A Outdoor Thermostat X X X X X X X FSK01A* Freeze Protection Kit X X X X X X X ASC01 Anti Short Cycle Kit X X X X X X X TX3N2* TXV Kit X X X X TX5N2* TXV Kit X X X X X X X X X X X X X X OT/EHR18-60 Emergency Heat relay kit X X X X X X X X CSR-U-1 Hard Start Kit X X X X CSR-U-2 Hard Start Kit OT18-60A CSR-
ACCESSORIES EXPANSION VALVE KITS For Applications requiring 1/4 FLARE CONNECTION BULB TO BE LOCATED AT 10 OR 2 O'CLOCK a field installed access fitting BULB SUCTION LINE EVAPORATOR COIL PISTON SEAL SUPPLIED W/ KIT SEAL SUPPLIED W/ KIT SEAL DISTRIBUTOR BODY EXPANSION VALVE TAILPIECE REMOVE BEFORE INSTALLING EXPANSION VALVE 3/8"SWEAT 7/8" NUT For Applications not requiring 1/4' FLARE CONNECTION a field installed access fitting BULB TO BE LOCATED AT 10 OR 2 O'CLOCK BULB SUCTION LINE PISTON EX
ACCESSORIES FSK01A FREEZE THERMOSTAT KIT Wire Nut Y Bl ac k Y k ac Bl Wire Nut Install Line Thermostat Here Install Line Thermostat Here Wire Nut Bla ck Y Bla ck Wire Nut Y ASC01A ANTI-SHORT -CYCLE CONTROL KIT SHORT CYCLE PROTECTOR Y1 R1 Y2 R2 YELLOW 1 CONTACTOR T2 T1 Y BLACK 1 THERMOSTAT WIRE L2 L1 C BLACK 1 UNIT TERMINAL BOARD 9
ACCESSORIES COIL ACCESSORIES COIL MODEL TX3N4 TXV KIT TX5N4 TXV KIT FSK01A FREEZE PROTECTION KIT CA*F030B4* X X CA*F036B4* X X CA*F042C4* X X CA*F048C4* X X CA*F057D4* X X CA*F060D4* X X CHPF030A4* X X CHPF036B4* X X CHPF042A4* X X CHPF048D4* X X X X CHPF060D4* CH36FCB X X CH48FCB X X CH60FCB X X ELECTRIC HEAT KIT APPLICATIONS ELECTRIC HEAT KIT BLOWER HKR-03A HKR-05(C)A HKR-06A MBR0800AA-1 X X X X X MBR1200AA-1 X X X X X X X MBR1600AA-1 X X X
PRODUCT DESIGN This section gives a basic description of cooling unit operation, its various components and their basic operation. Ensure your system is properly sized for heat gain and loss according to methods of the Air Conditioning Contractors Association (ACCA) or equivalent. CONDENSING UNIT These units are designed for free air discharge. Condensed air is pulled through the condenser coil by a direct drive propeller fan and then discharged from the cabinet top.
SYSTEM OPERATION COOLING The refrigerant used in the system is R-22. It is a clear, colorless, non-toxic, non-irritating, and non-explosive liquid. The chemical formula is CHCLF2. The boiling point, at atmospheric pressure is -41.4°F. The check valve at the indoor coil will open by the flow of refrigerant letting the now condensed liquid refrigerant bypass the indoor expansion device.
SYSTEM OPERATION COOLING CYCLE Reversing Valve (Energized) Indoor Coil Outdoor Coil Accumulator Thermostatic Expansion Valve Bi-Flow Filter Dryer Check Valve HEATING CYCLE Reversing Valve (De-Energized) Indoor Coil Outdoor Coil Accumulator Thermostatic Expansion Valve Bi-Flow Filter Dryer Check Valve 13
SYSTEM OPERATION EXPANSION VALVE/CHECK VALVE ASSEMBLY IN COOLING OPERATION EXPANSION VALVE/CHECK VALVE ASSEMBLY IN HEATING OPERATION Most expansion valves used in current Amana® Brand Heat Pump products use an internally checked expansion valve. This type of expansion valve does not require an external check valve as shown above. However, the principle of operation is the same.
SYSTEM OPERATION COOLING CYCLE - CONDENSING UNIT Indoor Coil Outdoor Coil Thermostatic Expansion Valve 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.
SYSTEM OPERATION AFE18-60A CONTROL BOARD DESCRIPTION The AFE18 control is designed for use in heat pump applications where the indoor coil is located above/downstream of a gas or fossil fuel furnace. It will operate with single and two stage heat pumps and single and two stage furnaces. The AFE18 control will turn the heat pump unit off when the furnace is turned on. An anti-short cycle feature is also incorporated which initiates a 3 minute timed off delay when the compressor goes off.
TROUBLESHOOTING CHART COOLING/HP ANALYSIS CHART Power Failure Blown Fuse Unbalanced Power, 3PH Loose Connection Shorted or Broken Wires Open Fan Overload Faulty Thermostat Faulty Transformer Shorted or Open Capacitor Internal Compressor Overload Open Shorted or Grounded Compressor Compressor Stuck Faulty Compressor Contactor Faulty Fan Relay Open Control Circuit Low Voltage Faulty Evap.
SERVICING Table of Contents S-1 S-2 S-3 S-3A S-3B S-3C S-3D S-4 S-5 S-6 S-7 S-8 S-9 S-10 S-12 S-13 S-15 S-15A S-15B S-16A S-16B S-16C S-16D S-17 S-17A S-17B S-17D S-18 S-21 Checking Voltage .......................................... 19 Checking Wiring ............................................ 19 Checking Thermostat, Wiring & Anticipator .. 19 Thermostat & Wiring ..................................... 19 Cooling Anticipator ........................................ 20 Heating Anticipator .................
SERVICING S-2 CHECKING WIRING S-1 CHECKING VOLTAGE 1. Remove outer case, control panel cover, etc., from unit being tested. WARNING HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death. With power ON: WARNING Line Voltage now present. 2.
SERVICING Resistance Heaters 1. Set room thermostat to a higher setting than room temperature so both stages call for heat. 2. With voltmeter, check for 24 volts at each heater relay. Note: BBA/BBC heater relays are DC voltage. 3. No voltage indicates the trouble is in the thermostat or wiring. 4. Check the continuity of the thermostat and wiring. Repair or replace as necessary. NOTE: Consideration must be given to how the heaters are wired (O.D.T. and etc.).
SERVICING S-4 CHECKING TRANSFORMER AND CONTROL CIRCUIT With power ON: WARNING WARNING HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death. Line Voltage now present. 1. Apply 24 VAC to terminals R1 and R2. 2. Should read 24 VAC at terminals Y1 and Y2. 3. Remove 24 VAC at terminals R1 and R2. 4. Should read 0 VAC at Y1 and Y2.
SERVICING S-7 CHECKING CONTACTOR AND/OR RELAYS WARNING HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death. The compressor contactor and other relay holding coils are wired into the low or line voltage circuits. When the control circuit is energized, the coil pulls in the normally open contacts or opens the normally closed contacts.
SERVICING S-10 COPELAND COMFORT ALERT™ DIAGNOSTICS Applies to ASC13 & ASH13 WARNING HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death. Comfort Alert™ is self-contained with no required external sensors and is designed to install directly into the electrical box of any residential condensing unit that has a Copeland Scroll™ compressor inside.
SERVICING DIAGNOSTICS TABLE Status LED Green “POWER” Red “TRIP” Status LED Description Module has power Status LED Troubleshooting Information Supply voltage is present at module terminals Thermostat demand signal 1. Compressor protector is open Y1 is present, but the 2. Outdoor unit power disconnect is open compressor is not 3. Compressor circuit breaker or fuse(s) is open running 4. Broken wire or connector is not making contact 5. Low pressure switch open if present in system 6.
SERVICING S-12 CHECKING HIGH PRESSURE CONTROL WARNING HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death. The high pressure control capillary senses the pressure in the compressor discharge 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.
SERVICING B. Shorted - indicator swings to zero and stops there replace. START CAPACITOR C. Open - no reading - replace. (Start capacitor would read resistor resistance.
SERVICING WARNING 7. Check for signal (24 volts) from the thermostat to the "G" terminal at the 16-pin connector. HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death. 8. Using an ohmmeter, check for continuity from the #1 & #3 (common pins) to the transformer neutral or "C" thermostat terminal. If you do not have continuity, the motor may function erratically.
- M o t o r ro cks slig ht ly w hen st art ing . Fault Des c ription(s ) - Evid ence o f M o ist ure. Cautions and Notes ---- ---- ---- - N o mo vement . - M o t o r ro cks, b ut w o n't st art . - Lo o se mo t o r mo unt . - B lo w er w heel no t t ig ht o n mo t o r shaf t . - B ad mo t o r/ co nt ro l mo d ule. M anual d isco nnect sw it ch o f f o r d o o r sw it ch o p en. B lo w n f use o r circuit b reaker. 2 4 V ac w ires misw ired . U nseat ed p ins in w iring harness co nnect o rs.
SERVICING S-16C CHECKING ECM MOTOR WINDINGS WARNING HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death. 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.
SERVICING Cooling/Heat Pump Operation Model Switch 5 MBE1200 MBE1600 MBE2000 AEPT30 AEPT36/60 S-17 CHECKING COMPRESSOR Switch 6 CFM OFF OFF ON OFF OFF 1,200 1,000 800 600 1,600 1,400 1,200 1,000 1,600 1,400 1,200 1,000 1,100 800 600 1,800 1,580 1,480 1,200 ON ON ON OFF OFF ON OFF OFF ON ON OFF OFF ON ON OFF OFF ON OFF OFF ON ON ON OFF ON OFF ON OFF ON OFF OFF ON OFF ON Table 3 THERMOSTAT “FAN ONLY” MODE WARNING Hermetic compressor electrical terminal venting can be dangerous.
SERVICING WARNING HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death. HI-POT 1. Remove the leads from the compressor terminals. 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.
SERVICING If no voltage is registered at the coil terminals, check the operation of the thermostat an the continuity of the connecting wiring from the "O" terminal of the thermostat to the unit. WARNING Line Voltage now present. A. If the compressor starts and continues to run, the cause for failure is somewhere else in the system. B. If the compressor fails to start - replace.
SERVICING SEQUENCE OF OPERATION This document covers the basic sequence of operation for a typical application with a mercury bulb thermostat. When a digital/electronic thermostat is used, the on/off staging of the auxiliary heat will vary. Refer to the installation instructions and wiring diagrams provided with the MBR and AR*F for specific wiring connections and system configuration. AR*F & MBR WITH SINGLE STAGE CONDENSERS AR*F & MBR WITH SINGLE STAGE HEAT PUMPS 3.
SERVICING by the heat pump, the temperature indoors will continue to drop. The room thermostat will then energize “W3” and 24Vac will be supplied to HR2 on the heater assembly. When the “W3” demand is satisfied, the room thermostat will remove the 24Vac from HR2. The contacts on HR2 will open between 30 to 70 seconds and heater elements #3 and #4 will be turned off.
SERVICING Note: If more than two heater elements are on the heater assembly, it will contain a second heat sequencer, HR2, which will control the 3rd and 4th heater elements if available. For the 3rd and 4th heater elements to operate on a second stage heat demand, the PJ4 jumper on the VSTB inside the MBE and AEP* must be cut. With the PJ4 jumper cut, the VSTB will run the blower motor on low speed on a “W1” only demand.
SERVICING heater element(s). The heat pump remains on along with the blower motor because the “Y” demand for first stage heat will still be present. 4.5 When the first stage heat demand “Y” is satisfied, the room thermostat will remove the 24Vac from “G” and “Y/ Y2” of the MBE and AEP*. The VSTB removes the 24Vac from “Y” at the heat pump and the heat pump is turned off. The blower motor will ramp down to a complete stop based on the time and rate programmed in the motor control. 5.
SERVICING S-61A CHECKING HEATER LIMIT CONTROL(S) TEMPERATURE RISE (F°) @ 240V CFM 4.8 KW 7.2 KW 9.6 KW 14.4 KW 19.2 KW 24.0 KW 28.
SERVICING S-100 REFRIGERATION REPAIR PRACTICE DANGER Always remove the refrigerant charge in a proper manner before applying heat to the system. 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 WARNING When repairing the refrigeration system: WARNING REFRIGERANT UNDER PRESSURE! Failure to follow proper procedures may cause property damage, personal injury or death.
SERVICING S-103 CHARGING R-22 MANIFOLD LOW 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. HIGH SIDE GAUGE AND VALVE 800 PSI RATED HOSES { CHARGING CYLINDER AND SCALE TO UNIT SERVICE VALVE PORTS VACUUM PUMP ADAPTER CAUTION Use refrigerant certified to ARI standards.
SERVICING NOTE: This charging procedure can only be done in the cooling mode of operation. (Early production "a" models only.) All models with compressor process tube access valve can be processed in heating cycle if this valve is used. If the test shows: When charging a remote condensing unit with a non-matching evaporator coil, or a system where the charge quantity is unknown, alternate charging methods must be used. These systems must be charged according to subcooling or superheat. d.
SERVICING THERMOSTATIC EXPANSION VALVES Some TXV valves contain an internal check valve thus eliminating the need for an external check valve and bypass loop. The three forces which govern the operation of the valve are: (1) the pressure created in the power assembly by the feeler bulb, (2) evaporator pressure, and (3) the equivalent pressure of the superheat spring in the valve. 0% bleed type expansion valves are used on indoor and outdoor coils.
SERVICING Temp. °F. Gauge Pressure (PSIG) Freon-22 Temp. °F. Gauge Pressure (PSIG) Freon-22 -40 -38 -36 -34 -32 -30 -28 -26 -24 -22 -20 -18 -16 -14 -12 -10 -8 -6 -4 -2 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 0.61 1.42 2.27 3.15 4.07 5.02 6.01 7.03 8.09 9.18 10.31 11.48 12.61 13.94 15.24 16.59 17.99 19.44 20.94 22.49 24.09 25.73 27.44 29.21 31.04 32.93 34.88 36.89 38.96 41.09 43.28 45.53 47.85 50.24 52.70 55.23 57.83 60.51 63.27 66.11 69.02 71.99 75.04 78.18 81.
SERVICING S-111 CAPILLARY TUBES/RESTRICTOR ORIFICES S-112 CHECKING RESTRICTED LIQUID LINE The capillary tubes/restrictor orifices used in conjunction with the indoor and outdoor coil, are a predetermined length and bore (I.D.). They are designed to control the rate of liquid refrigerant flow into an evaporator coil. 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.
SERVICING 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. Now determine if a burn out has actually occurred.
SERVICING • The vertical difference between the condenser and evaporator when the evaporator is below the condenser can approach 150 feet, as long as the equivalent length does not exceed 150 feet. • The distance between the condenser and evaporator in a completely horizontal installation in which the indoor and outdoor unit do not differ more than 10 feet in vertical distance from each other can approach 150 feet, as long as the equivalent length does not exceed 150 feet. 4.
SERVICING Installation Requirements 1. In a completely horizontal installation with a long line set where the evaporator is at the same altitude as (or slightly below) the condenser, the line set should be sloped towards the evaporator. This helps reduce refrigerant migration to the condenser during a system’s off-cycle. 2.
SERVICING S-202 DUCT STATIC PRESSURES AND/OR STATIC PRESSURE DROP ACROSS COILS This minimum and maximum allowable duct static pressure for the indoor sections are found in the specifications section. Tables are also provided for each coil, listing quantity of air (CFM) versus static pressure drop across the coil. Too great an external static pressure will result in insufficient air that can cause icing of the coil.
ACCESSORIES WIRING DIAGRAMS ! WARNING TO AVOID POSSIBLE ELECTRICAL SHOCK, PERSONAL INJURY, OR DEATH, DISCONNECT THE POWER BEFORE SERVICING.
ACCESSORIES WIRING DIAGRAMS ! WARNING TO AVOID POSSIBLE ELECTRICAL SHOCK, PERSONAL INJURY, OR DEATH, DISCONNECT THE POWER BEFORE SERVICING.
ACCESSORIES WIRING DIAGRAMS ! WARNING TO AVOID POSSIBLE ELECTRICAL SHOCK, PERSONAL INJURY, OR DEATH, DISCONNECT THE POWER BEFORE SERVICING.
ACCESSORIES WIRING DIAGRAMS ! WARNING TO AVOID POSSIBLE ELECTRICAL SHOCK, PERSONAL INJURY, OR DEATH, DISCONNECT THE POWER BEFORE SERVICING.
ACCESSORIES WIRING DIAGRAMS BL 5 208 2 3 COM TR 8 240 1 9 9 8 R G 24V BL L2 4 L1 TO AVOID POSSIBLE ELECTRICAL SHOCK, PERSONAL INJURY, OR DEATH, DISCONNECT THE POWER BEFORE SERVICING. R ! WARNING R BL 7 7 BK BK BK 3 PU 3 BL BK EM W 4 1 R BR 6 R 8 BR 4 R R 2 5 4 BK 6 W 5 0 6 R 1 PL2 O PK G R BL BR W Y R BL BR W BR THERMOSTATS OT1 OT2 C W2 ED PK G Y O 24 VAC HEATER W1 C W2 R Y1 W2 OT1 PJ4 OT2 PJ2 HUM PJ6 J1 VSTB PN. B1368270 REV.
