Goodman [A/G]PG Service Instructions Manual
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Goodman [A/G]PG Service Instructions Manual

Goodman [A/G]PG Service Instructions Manual

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Service Instructions
This manual is to be used by qualified, professionally trained HVAC techni-
cians 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
[A/G]PG
PACKAGE GAS
© 2004, 2007 - 2009 Goodman Manufacturing Company, L.P.
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
RS6300005 Rev. 4
February 2009

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Summary of Contents for Goodman [A/G]PG

  • Page 1 ANSI Z21.47•CSA-2.3 This manual is to be used by qualified, professionally trained HVAC techni- RS6300005 Rev. 4 cians only. Goodman does not assume any responsibility for property February 2009 damage or personal injury due to improper service procedures or services performed by an unqualified person.

  • Page 2: Table Of Contents

    For further assistance, please contact: CONSUMER INFORMATION LINE CONSUMER INFORMATION LINE ® AMANA ® BRAND PRODUCTS GOODMAN BRAND PRODUCTS TOLL FREE 1-877-254-4729 (U.S. only) TOLL FREE 1-877-254-4729 (U.S. only) email us at: customerservice@goodmanmfg.com email us at: hac.consumer.affairs@amanahvac.com fax us at: (713) 856-1821 fax us at: (931) 438- 4362 (Not a technical assistance line for dealers.)

  • Page 3: Important Information

    IMPORTANT INFORMATION SAFE REFRIGERANT HANDLING While these items will not cover every conceivable situation, they should serve as a useful guide. 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.

  • Page 4: Production Identification

    PRODUCT IDENTIFICATION P G 10 24 Engineering Revision Product Brand Voltage A: Amana G: Goodman 1: 208-230V/60Hz/1ph 3: 208-230V/60 Hz/3ph 4: 460V/60 Hz/3ph Product Type Heating Input Single Package 045: 46,000 BTUH Cooling/Heating 070: 69,000 BTUH 090: 92,000 BTUH Product Family...
  • Page 5 A mana/ G oodman P ackage G as 13 Seer gas/electric units. Added minor revision to A/GPG1324-60***1AA model number. No change to units. Amana/Goodman Package Gas 13 Seer gas/electric units. Change from a 3 row A/GPG1324***1BA evaporator coil to 2 row.

  • Page 6: Lighting Instructions

    LIGHTING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING Improper WARNING: installation, adjustment, If you do not follow these instructions exactly, WARNING alteration, service or a fire or explosion may result causing property maintenance can damage, personal injury or loss of life. cause injury or property damage.

  • Page 7: Accessories

    Square to Round Adapter w/ 16" Round Horizontal Application, Small and Medium Chassis SQRPGH103 Square to Round Adapter w/ 18" Round Horizontal Application, Large Chassis PGFR101/102/103 Internal Filter Rack All Chassis External Horizontal Filter Rack for Goodman/Amana Gas/Electric GPGHFR101-103 & Multi-position Package Units All Chassis CDK36 Flush Mount Concentric Duct Kit...
  • Page 8 ACCESSORIES ROOF CURBS 1 5/8 14 1/2 1 3/8 MODEL RETURN SUPPLY PGC101/102/103 46 1/4 39 3/8 14 1/2 12 1/2 x 23 15 x 22 1/2 DOWNFLOW FILTER RACK (PGFR101/102/103) 1 1/2 26 1/2 Filter Size: 14" x 25" x 2" Measurement in inches.
  • Page 9 ACCESSORIES ECONOMIZER (DOWNFLOW APPLICATIONS ) MODEL PGED101/102 16 1/4 23 1/2 12 1/2 45 3/4 PGED103 16 1/4 23 1/2 12 1/2 45 3/4 ECONOMIZER (HORIZONTAL APPLICATIONS) 16 1/8 MODEL FILTER PGE H101/102 25 1/4 18 1/8 13 3/4 16 1/8 16 x 25 x 1 PGE H103 35 1/4...
  • Page 10 ACCESSORIES MOTORIZED/MANUAL FRESH AIR DAMPERS - (DOWNFLOW APPLICATIONS) 7 5/8 5 3/4 11 7/8 MANUAL MODEL PGMDD101/102 PGMDD103 MOTORIZED MODEL PGMDMD101/102 PGMDMD103 MOTORIZED/MANUAL FRESH AIR DAMPERS (HORIZONTAL APPLICATIONS) BOTTOM VIEW 12 1/8 5 3/4 11 7/8 PGMDD103 BOTTOM VIEW 12 1/8 5 3/4 11 7/8 PGMDD101/102...
  • Page 11 ACCESSORIES SQUARE TO ROUND CONVERTER (DOWNFLOW APPLICATIONS) 12 1/4 14 3/4 ø ø 22 3/4 22 1/4 12 1/4 14 3/4 22 3/4 22 1/4 ø ø MODEL RETURN SUPPLY SQRPG101/102 22 3/4 12 1/4 22 1/4 14 3/4 SQRPG103 22 3/4 12 1/4 22 1/4...

  • Page 12: Product Design

    PRODUCT DESIGN Locations and Clearances IMPORTANT NOTE: IF USING BOTTOM DISCHARGE WITH ROOF CURB, DUCTWORK SHOULD BE ATTACHED TO THE NOTE: To ensure proper condensate drainage, unit must be in- CURB PRIOR TO INSTALLING THE UNIT. stalled in a level position. Refer to Roof curb Installation Instructions for proper curb in- stallation.
  • Page 13 PRODUCT DESIGN Refrigerant flow control is achieved by use of restrictor orifices During compression, one scroll remains stationary (fixed scroll) or thermostatic expansion valves (TXV). while the other form (orbiting scroll) is allowed to orbit (but not rotate) around the first form. The single phase units use permanent split capacitors (PSC) design compressors.
  • Page 14 PRODUCT DESIGN HIGH VOLTAGE! Disconnect ALL power before changing any electrical wiring. Multiple JUNCTION BOX power sources may be present. Failure to do so may cause property damage, personal injury or death. The units are designed for operation on 60 hertz current and at voltages as shown on the rating plate.
  • Page 15 PRODUCT DESIGN GAS SUPPLY AND PIPING GAS PER HOUR (CFH) NOMINAL BLACK PIPE SIZE LENGTH OF PIPE IN FEET 1/2" 3/4" 1" 1 1/4" 1 1/2" 1050 1600 1100 This Package Gas unit is factory set to operate on natural gas at the altitudes shown on the rating plate.
  • Page 16 PRODUCT DESIGN All propane gas equipment must conform to the safety stan- dards of the National Board of Fire Underwriters (See NBFU Manual 58) or Natural Standards of Canada B149.2, Installa- tion Code for Propane Gas Burning Appliances and Equipment. For satisfactory operation, propane gas pressure must be 10 inch W.C.
  • Page 17 PRODUCT DESIGN PROPANE TANK SIZING (MINIMUM) TANK SIZE REQUIRED IF LOWEST OUTDOOR If your propane gas appliance is installed in an MAXIMUM GAS TEMPERATURE (AVG. FOR 24 HOURS) REACHES excavated area or a confined space, we strongly NEEDED TO recommend that you contact your propane supplier 32°F 20°F 10°F...

  • Page 18: System Operation

    SYSTEM OPERATION COOLING HEATING CYCLE The refrigerant used in the system is R-22. It is clear, color- When the contacts of the room thermostat close, the termi- less, non-toxic, non-irritating, and non-explosive liquid. The nals R to W on the control board are energized. chemical formula is CHCIF .
  • Page 19 SYSTEM OPERATION Typical Package Cooling or Package Gas Indoor Outdoor Coil 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.
  • Page 20 SYSTEM OPERATION The pressure tap has a predetermined orifice size for reading 6. Turn the gas control valve to the OFF position. Do not force. static pressures. The induced draft blower motor assembly is Some Gas valves may have a different off/on style switch. mounted to the collector box.
  • Page 21 SYSTEM OPERATION Heating Timing Chart 100 % Circulator 50 % Blower Gas Valve Igniter Induced Draft Blower Thermostat 120, 135,150 Seconds 180 * [APG/GPG]1348,60 ONLY Legend: [APG/GPG]10,12,24-60, [A/G]PG1324-42 [APG/GPG]1348,60 COOLING TIMING CHART 100 % Circulator 50 % Blower Outdoor Fan Compressor Thermostat Seconds...

  • Page 22: Scheduled Maintenance

    SCHEDULED MAINTENANCE Package gas units requires regularly scheduled maintenance 10. Start the system and run a Heating Performance Test. If to preserve high performance standards, prolong the service the results of the test are not satisfactory, see the "Service life of the equipment, and lessen the chances of costly failure. Problem Analysis"...
  • Page 23 SCHEDULED MAINTENANCE 1 Thousand 1 Million 10 Thousand 100 Thousand CUBIC Quarter FEET Foot Foot GAS RATE -- CUBIC FEET PER HOUR Size of Test Dial Size of Test Dial Seconds Seconds for One cu/ft cu/ft cu/ft cu/ft cu/ft for One cu/ft cu/ft cu/ft...
  • Page 24 SCHEDULED MAINTENANCE Example: To adjust the pressure regulator on the gas valve, turn down (clockwise) to increase pressure and input, and out (counter- It takes forty (40) seconds on the gas meter for the hand on the clockwise) to decrease pressure and input. cubic foot dial to make one complete revolution, with all appli- ances off, except the unit.

  • Page 25: Servicing

    SERVICING COOLING - SERVICE ANALYSIS GUIDE System No Cooling Unsatisfactory Cooling Complaint Operating Pressures POSSIBLE CAUSE Test Method DOTS IN ANALYSIS Remedy GUIDE INDICATE "POSSIBLE CAUSE" • Power Failure Test Voltage • • • Blown Fuse Inspect Fuse Size & Type •...
  • Page 26 SERVICING GAS HEATING - SERVICE ANALYSIS GUIDE Complaint No Heat Unsatisfactory Heat POSSIBLE CAUSE Test Method DOTS IN ANALYSIS Remedy GUIDE INDICATE "POSSIBLE CAUSE" • Power Failure Test Voltage • Blown Fuse Test Voltage • • Loose Connection Check Wiring S-2, S-3 •...

  • Page 27: Servicing Table Of Contents

    SERVICING TABLE OF CONTENTS Checking Voltage .......... 28 S-104 Checking Compressor Efficiency ....39 Checking Wiring ..........29 S-105 Thermostatic Expansion Valve ...... 41 Checking Thermostat, Wiring & Anticipator .. 29 S-106 Overfeeding ........... 41 S-3A Thermostat & Wiring ........29 S-107 Underfeeding ..........

  • Page 28: Checking Voltage

    SERVICING S-1 CHECKING VOLTAGE Unit Supply Voltage Voltage Min. Max. 208/230 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.

  • Page 29: Checking Wiring

    SERVICING By the voltage readings we see that the imbalance rotated or S-3B Cooling Anticipator traveled with the switching of the incoming legs. Therefore the The cooling anticipator is a small heater (resistor) in the ther- imbalance lies within the incoming power supply. mostat.

  • Page 30: Checking Contactor And/Or Relays

    SERVICING 1. Remove control panel cover or etc. to gain access to trans- former. Line Voltage now present. With power ON: Line Voltage now present. 2. Using a voltmeter, check voltage across secondary voltage side of transformer (R to C). VOLT/OHM 3.

  • Page 31: S-15 Capacitor Check

    SERVICING S-15A Resistance Check S-15 CHECKING CAPACITOR CAPACITOR, RUN A run capacitor is wired across the auxiliary and main wind- ings of a single phase permanent split capacitor motor. The capacitors primary function is to reduce the line current while greatly improving the torque characteristics of a motor.

  • Page 32: S-16A Checking Fan & Blower Motor

    SERVICING 2. Using a volt meter, check for line voltage at terminals #4 and #5 at the power connector. If no voltage is present, proceed to step 3. If voltage is present, skip to step 5. Volt / Ohm 3. Check the unit for incoming power. See section S-1. Meter 4.
  • Page 33 SERVICING...
  • Page 34 SERVICING...

  • Page 35: S-16C Checking Ecm Motor Windings

    SERVICING ECM VARIABLE SPEED CIRCULATOR BLOWER MOTORS DON'T - Check-out motor, controls, wiring, - Automatically assume the motor is bad. and connections before replacing motor. - Orient connectors down to prevent water - Locate connectors above 7 and 4 o'clock infiltration.

  • Page 36: S-16D Checking Ge X-13™ Motors

    SERVICING S-16D CHECKING GE X13 MOTORS S-17 CHECKING COMPRESSOR WINDINGS *PG1348***1BA & *PG1360***1BA units The GE X13 Motor is a one piece, fully encapsulated, 3 phase brushless DC (single phase AC input) motor with ball bearing construction. Unlike the ECM 2.3/2.5 motors, the GE X13 features an integral control module.

  • Page 37: S-17B Ground Test

    SERVICING 1. Remove the leads from the compressor terminals. 2. Identify the leads and using a Megger, Hi-Potential Ground Tester, or other suitable instrument which puts out a volt- age between 300 and 1500 volts, check for a ground sepa- rately between each of the three leads and ground (such See warnings S-17 before removing compressor as an unpainted tube on the compressor).

  • Page 38: S-17D Operation Test

    SERVICING S-18 TESTING CRANKCASE HEATER 4. Next check the molded plug. Voltage check: Apply control voltage to the plug wires The crankcase heater must be energized a minimum of four (18 to 28 volt ac). The measured dc voltage at the (4) hours before the package unit is operated.

  • Page 39: Leak Testing

    SERVICING S-101 LEAK TESTING S-102 EVACUATION Refrigerant leaks are best detected with a halide or electronic This is the most important part of the entire service procedure. leak detector. The life and efficiency of the equipment is dependent upon the thoroughness exercised by the serviceman when evacuating However, on outdoor installed systems, provisions must be air (non-condensable) and moisture from the system.

  • Page 40: Charging

    SERVICING R-22 S-103 CHARGING MANIFOLD Charge the system with the exact amount of refrigerant. Refer to the specification section or check the unit nameplates HIGH SIDE LOW SIDE GAUGE GAUGE for the correct refrigerant charge. AND VALVE AND VALVE An inaccurately charged system will cause future problems. 1.

  • Page 41: Thermostatic Expansion Valve

    SERVICING S-108 SUPERHEAT S-105 THERMOSTATIC EXPANSION VALVE The expansion valve is designed to control the rate of liquid The expansion valves are factory adjusted to maintain 12 to 18 refrigerant flow into an evaporator coil in exact proportion to the degrees superheat of the suction gas.

  • Page 42: Checking Expansion Valve Operation

    SERVICING 2. Install a high side pressure gauge on the high side service Temp. Gauge Pressure Temp. Gauge Pressure valve. °F. (PSIG) Freon-22 °F. (PSIG) Freon-22 3. Record the gauge pressure and the temperature of the line. 0.61 102.5 1.42 106.3 4.

  • Page 43: Checking Restricted Liquid Line

    SERVICING 3. Observe the system while running a cooling performance Since the high side pressure rises faster when the tempera- test, if a shortage of refrigerant is indicated, then the sys- ture increases, more refrigerant flows to the evaporator, increas- tem contains non-condensables.

  • Page 44: Checking External Static Pressure

    SERVICING 6. Braze all joints, leak test, evacuate, and recharge system. 3. Add the two readings together. 7. Start up the unit and record the pressure drop across the NOTE: Both readings may be taken simultaneously and read cleanup drier. directly on the manometer if so desired.

  • Page 45: Testing Primary Limit Control

    SERVICING If a call for heat exists when the limit switch re-closes, the S-300 TESTING PRIMARY LIMIT CONTROL control goes through a pre-purge period and then makes an APG/GPG units use a snap-disk type primary limit device. ignition attempt. The indoor blower remains on (for the delay Sometimes referred to as "stat on a stick".

  • Page 46: Checking Flame Rollout Switch

    SERVICING Auxiliary Limit and Rollout Limit Operation DSI Systems If the auxiliary limit and/or rollout limit switch opens, the circuit to the gas valve will be broken and the gas valve will be de- energized. The control will recognize this as a loss of flame and will make an ignition attempt.

  • Page 47: Testing Inducer Motor

    SERVICING S-303 TESTING INDUCER MOTOR Gas Valve On/Off Selector Switch INLET OUTLET Inlet Pressure Tap Outlet (Manifold) Pressure Regulator (Side of Valve) Pressure Tap Adjustment (Under Cap Screw) 1. Disconnect the motor wire leads from its connection point at integrated ignition control module. Pressure Regulator 2.

  • Page 48: Checking Orifices

    SERVICING 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 in- In checking main burners, look for signs of rust, oversized and stalled.

  • Page 49: Checking For Delayed Ignition

    SERVICING For PROPANE GAS: If the pressure switch opens before the ignition period, the in- duced draft blower will remain on and the control will stay in Inlet pressure should be a nominal 11" w.c. pre-purge until the pressure switch is closed for an entire 15 Manifold pressure should be a nominal 10"...

  • Page 50: High Altitude Application

    SERVICING 7. As the unit fires, the inclined manometer negative pressure S-313 TESTING IGNITION CONTROL MODULE will drop to -1.0" ± 0.1" W.C. NOTE: Failure to earth ground the unit, reversing the neutral 8. If not as listed, replace control. and hot wire connection to the line (polarity), or a high resis- tance connection in the ground or neutral lines may cause the Note: The pressure switch must be mounted with the diaphragm...

  • Page 51: Checking Flame Sensor

    SERVICING DSI Direct Spark Ignition Systems 6. When the thermostat is satisfied, the gas valve is de-ener- gized and the induced draft blower remains on for a 29 second post purge. The indoor blower remains on for the selected heat blower off delay (90, 120, or 150 seconds). Indoor blower off timing begins when thermostat call for heat ends.

  • Page 52: Wiring Diagrams

    WIRING DIAGRAM...

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