Table of Contents
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Service
Instructions
*PH 15 SEER
Multi-Position
Package Heat Pumps
with R-410A Refrigerant
& Accessories
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 © 2007 Goodman Manufacturing Company, L.P.
Model numbers
listed on page 6
RS6300008 Rev. 1
November 2007
1
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Table of Contents
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Summary of Contents for Goodman R-410A
- Page 1 Instructions *PH 15 SEER Multi-Position Package Heat Pumps with R-410A Refrigerant & Accessories 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.
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Page 2: Table Of Contents
ONCE A MONTH ... 20 ONCE A YEAR ... 20 TEST EQUIPMENT ... 20 SERVICING ... 22 COOLING /HEAT PUMP- SERVICE ANALYSIS GUIDE ... 21 S-1 CHECKING VOLTAGE ... 22 S-2 CHECKING WIRING ... 23 S-3 CHECKING THERMOSTAT, WIRING, AND ANTICIPATOR ... 23 S-3A Thermostat and Wiring ... - Page 3 S-11 CHECKING LOSS OF CHARGE PROTECTOR ... 25 S-15 CHECKING CAPACITOR ... 25 S-15A Resistance Check ... 26 S-15B Capacitance Check ... 26 S-16 CHECKING MOTORS ... 27 S-16B Checking Fan & Blower Motor (ECM Motors) ... 27 S-16C Checking ECM Motor Windings ... 30 S-16D Checking GEX13™...
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Page 4: Important Information
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. -
Page 5: Safe Refrigerant Handling
IMPORTANT INFORMATION SAFE REFRIGERANT HANDLING While these items will not cover every conceivable situation, they should serve as a useful guide. WARNING EFRIGERANTS ARE HEAVIER THAN AIR. OXYGEN IN YOUR LUNGS OR IN ANY ENCLOSED SPACE. POSSIBLE DIFFICULTY IN BREATHING OR DEATH: •... -
Page 6: Product Identification - *Ph15**M4
Configuration 24: 24,000 BTUH M: Multi-Position 36: 36,000 BTUH 48: 48,000 BTUH 60: 60,000 BTUH Description Amana/Goodman Package Heat Pump 15 Seer R410A Multiposition heat pump units. Initial release. Models Chassis 2 - 3 Ton Medium 4 - 5 Ton... -
Page 7: Accessories
ACCESSORIES Part Number GPH13MED103 Economizer Downflow PGEH102 Economizer Horizontal PGEH103 Economizer Horizontal PGMDD102 Downflow Manual 25% Fresh Air Damper PGMDD103 Downflow Manual 25% Fresh Air Damper PGMDH102 Horizontal Manual 25% Fresh Air Damper PGMDH103 Horizontal Manual 25% Fresh Air Damper PGMDMH102 Horizontal Motorized 25% Fresh Air Damper PGMDMH103... -
Page 8: Gpghfr101-103
ACCESSORIES EXTERNAL HORIZONTAL FILTER RACK 4" 17 1/4" PANEL SIDE VIEW FILTER PLATFORM RIGHT SIDE DOWNFLOW R/A DUCT OPENING Filter Size: 14" x 25" x 2" (Requires 2 filters) - Measurement in inches (GPGHFR101-103) 24" 16" x 25" x 2" FILTER DOWNFLOW FILTER RACK (GPH13MFR) EVAPORATOR... -
Page 9: Gph13Mfr Filter Rack
ACCESSORIES MOTORIZED/MANUAL FRESH AIR DAMPERS - Manual Fresh Air Dampers MODEL PGMDD101/102 PGMDD103 Motorized Fresh Air Dampers MODEL PGMDMD102 PGMDMD103 MOTORIZED/MANUAL FRESH AIR DAMPERS (DOWNFLOW APPLICATIONS) (HORIZONTAL APPLICATIONS) 12 1/8 PGMDD103 12 1/8 PGMDD101/102 *PH15[24-60]M4* 7 5/8 5 3/4 11 7/8 BOTTOM VIEW 5 3/4 11 7/8... -
Page 10: Pgmdd101-103 Downflow Manual Fresh Air Dampers
ACCESSORIES MODEL SQRPG101/102 SQRPG103 SQUARE TO ROUND CONVERTER (DOWNFLOW APPLICATIONS) 22 3/4 22 3/4 22 3/4 12 1/4 22 1/4 22 3/4 12 1/4 22 1/4 SQUARE TO ROUND CONVERTER (HORIZONTAL APPLICATIONS) Measurements are in inches. *PH15[24-60]M4* 12 1/4 14 3/4 ø... -
Page 11: Sqrpg101-103 Square To Round Converter, Downflow
ACCESSORIES Louver Assembly MODEL PGEH102 PGEH103 ECONOMIZER GPH13MED103 (DOWNFLOW APPLICATIONS ) ECONOMIZER PGEH102-103 (HORIZONTAL APPLICATIONS ) 25 1/4 18 18 13 3/4 35 1/4 18 1/8 18 1/4 Measurements in inches *PH15[24-60]M4* Blockoff External Hood Panel 16 1/8 FILTER 16 1/8 16 X 25 X1 16 1/8 16 X 25 X1... -
Page 12: Roof Curbs
*PH15[24-60]M4* 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* *Inside Dimensions... -
Page 13: Pgc101-103 Roof Curbs
PRODUCT DESIGN LOCATION & CLEARANCES In installations where the unit is installed above ground level and not serviceable from the ground (Example: Roof Top in- stallations) the installer must provide a service platform for the service person with rails or guards in accordance with local codes or ordinances. -
Page 14: Compresseor
COMPRESSORS The *PH15 4 and 5 ton M series package heat pump units use a two-stage scroll compressor. The two-step modulator has an internal unloading mechanism that opens a bypass port in the first compression pocket, effectively reducing the displace- ment of the scroll. -
Page 15: Electrical Wiring
PRODUCT DESIGN ELECTRICAL WIRING The units are designed for operation at the voltages and hertz as shown on the rating plate. All internal wiring is complete. Ensure the power supply to the compressor contactor is brought to the unit as shown on the supplied unit wiring diagram. The 24V wiring must be connected between the unit control panel and the room thermostat. -
Page 16: System Operation
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. -
Page 17: Defrost Cycle
Each ECM blower motor has been preprogrammed for opera- tion at 4 distinct airflow levels when operating in Cooling/ Heat Pump mode or Electric Heat mode. These 4 distinct levels may also be adjusted slightly lower or higher if de- sired. - Page 18 SYSTEM OPERATION Dip Switch Number Electric Heat Indoor Thermostat Cooling & Heat Pump CFM CFM Trim Adjust Table 1 CFM Delivery Tables 2 and 4 show the CFM output for dip switch combi- nations 1-2 (Electric Heat), and 5-6 (Cooling/Heating).
- Page 19 SYSTEM OPERATION Typical Heat Pump System in Cooling Indoor Coil Accumulator Typical Heat Pump System in Heating Indoor Coil Accumulator Reversing Valve (Energized) Outdoor Coil Reversing Valve (De-Energized) Outdoor Coil...
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Page 20: Scheduled Maintenance
SCHEDULED MAINTENANCE Package heat pumps require regularly scheduled mainte- nance 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;... -
Page 21: Cooling /Heat Pump- Service Analysis Guide
SERVICING SERVICING COOLING /HEAT PUMP- SERVICE ANALYSIS GUIDE Complaint No Cooling POSSIBLE CAUSE DOTS IN ANALYSIS GUIDE INDICATE SYMPTOM "POSSIBLE CAUSE" • Pow er Failure • • Blow n Fuse • Unbalanced Pow er, 3PH • • Loose Connection •... -
Page 22: Servicing
SERVICING S-1 CHECKING VOLTAGE WARNING 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. -
Page 23: Checking Wiring
SERVICING S-2 CHECKING WIRING WARNING 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. -
Page 24: Checking Transformer And Control Circuit
SERVICING S-4 CHECKING TRANSFORMER AND CONTROL CIRCUIT A step-down transformer (208/240 volt primary to 24 volt sec- ondary) is provided with each package unit. This allows ample capacity for use with resistance heaters. WARNING 1. Remove control panel cover or etc. to gain access to trans- former. -
Page 25: Checking Loss Of Charge Protector
(Three-phase) S-11 CHECKING LOSS OF CHARGE PROTECTOR (Heat Pump Models) The loss of charge protector senses the pressure in the liquid line and will open its contacts on a drop in pressure. The low pressure control will automatically reset itself with a rise in pressure. -
Page 26: S-15A Resistance Check
SERVICING These capacitors have a 15,000 ohm, 2 watt resistor wired across its terminals. The object of the resistor is to discharge the capacitor under certain operating conditions, rather than having it discharge across the closing of the contacts within the switching device such as the Start Relay, and to reduce the chance of shock to the servicer. -
Page 27: Checking Motors
SERVICING S-16 CHECKING MOTORS S-16B CHECKING FAN AND BLOWER MOTOR (ECM MOTORS) APH15 M Series Only An ECM is an Electronically Commutated Motor which offers many significant advantages over PSC motors. The ECM has near zero rotor loss, synchronous machine operation, variable speed, low noise, and programmable air flow. - Page 28 SERVICING...
- Page 29 SERVICING...
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Page 30: S-17 Checking Compressor Windings
SERVICING S-16C CHECKING ECM MOTOR WINDINGS APH15 M Series Only WARNING 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. -
Page 31: Checking Compressor Windings
SERVICING If the compressor terminal PROTECTIVE COVER and gasket (if required) is not properly in place and secured, there is a remote possibility if a terminal vents, that the vaporous and liquid discharge can be ignited, spouting flames several feet, causing potentially severe or fatal injury to anyone in its path. -
Page 32: S-17C Unloader Test Procedure
SERVICING 2. Identify the leads and using a Megger, Hi-Potential Ground Tester, or other suitable instrument which puts out a volt- age between 300 and 1500 volts, check for a ground sepa- rately between each of the three leads and ground (such as an unpainted tube on the compressor). -
Page 33: Testing Crankcase Heater
SERVICING S-18 TESTING CRANKCASE HEATER Note: Not all compressors use crankcase heaters. The crankcase heater must be energized a minimum of four (4) hours before the compressor is operated. Crankcase heaters are used to prevent migration or accumula- tion of refrigerant in the compressor crankcase during the off cycles and prevents liquid slugging or oil pumping on start up. -
Page 34: S-100 Refrigeration Repair Practice
SERVICING WARNING 1. Disassemble and remove the heating element(s). 2. Visually inspect the heater assembly for any breaks in the wire or broken insulators. 3. Using an ohmmeter, test the element for continuity - no reading indicates the element is open. Replace as neces- sary. -
Page 35: S-103 Charging
SERVICING Moisture chemically reacts with the refrigerant and oil to form corrosive hydrofluoric and hydrochloric acids. These attack motor windings and parts, causing breakdown. The equipment required to thoroughly evacuate the system is a high vacuum pump, capable of producing a vacuum equiva- lent 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... -
Page 36: S-104 Checking Compressor Efficiency
SERVICING 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. -
Page 37: S-106 Overfeeding
SERVICING S-106 OVERFEEDING Overfeeding by the expansion valve results in high suction pres- sure, cold suction line, and possible liquid slugging of the com- pressor. If these symptoms are observed: 1. Check for an overcharged unit by referring to the cooling performance charts in the servicing section. -
Page 38: Two Speed Application
SUBCOOLING = SAT. LIQUID TEMP. - LIQUID LINE TEMP. Heat Pump - Heating Cycle The proper method of charging a heat pump in the heat mode is by weighing the charge according to the total charge listed on the rating plate. - Page 39 31.2 202.0 32.2 204.0 33.2 206.0 34.1 208.0 35.1 210.0 35.5 212.0 36.9 214.0 *Based on ALLIED SIGNAL Data Pressure vs. Temperature Chart R-410A °F °F PSIG PSIG 37.8 216.0 74.3 318.0 38.7 74.9 218.0 320.0 39.5 220.0 75.5 322.0 40.5...
- Page 40 SERVICING REQUIRED LIQUID LINE TEMPERATURE LIQUID PRESSURE AT SERVICE VALVE (PSIG) REQUIRED SUBCOOLING TEMPERATURE (°F)
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Page 41: S-110 Checking Expansion Valve Operation
SERVICING S-110 CHECKING EXPANSION VALVE OPERATION 1. Remove the remote bulb of the expansion valve from the suction line. 2. Start the system and cool the bulb in a container of ice water, closing the valve. As you cool the bulb, the suction pressure should fall and the suction temperature will rise. -
Page 42: S-122 Reversing Valve Replacement
SERVICING NOTE: The Flushing Method using R-11 refrigerant is no longer approved by Goodman Manufacturing Company, L.P. ® Suction Line Drier Clean-Up Method The POE oils used with R410A refrigerant is an excellent sol- vent. In the case of a burnout, the POE oils will remove any burnout residue left in the system. -
Page 43: S-200 Checking External Static Pressure
SERVICING S-200 CHECKING EXTERNAL STATIC PRESSURE The minimum and maximum allowable duct static pressure is found in the Technical Information Manual. Too great of an external static pressure will result in insuffi- cient air that can cause icing of the coil, whereas too much air can cause poor humidity control, and condensate to be pulled off the evaporator coil causing condensate leakage. -
Page 44: Wiring Diagrams
WIRING DIAGRAMS PACKAGE SYSTEM WIRING DIAGRAM - 1 STAGE ELECTRIC HEAT SEE NOTE 1 #18 GAUGE 7 WIRE REQUIRED FOR HEAT PUMPS OUTDOOR THERMOSTAT CLOSE ON TEMPERATURE FALL PACKAGE SYSTEM WIRING DIAGRAM - 2 STAGE ELECTRIC HEAT SEE NOTE 1 #18 GAUGE 8 WIRE FOR HEAT PUMPS SEE NOTE 2... -
Page 45: Ot18-60A Outdoor Thermostat
For outdoor temperatures below 0° F with 50% or higher relative humidity, set outdoor thermostat at 0° F NOTE 1: OT18 #2 CAN BE CONNECTED BETWEEN W2 OF THERMOSTAT AND BROWN WIRE IF DESIRED. OT18-60A OUTDOOR THERMOSTAT TYPICAL H/P #18 GAUGE 8 WIRE PACKAGE HEAT PUMP YELLOW GREEN ORANGE WHITE BROWN... -
Page 46: Hkr** Heat Kits
WIRING DIAGRAMS HTR1 L1 L2 ONE (1) ELEMENT ROWS 5 KW HTR1 TL HTR2 HTR3 TL L2 L1 L2 THREE (3) ELEMENT ROWS 15 KW SINGLE PHASE HKR** HEAT KIT *PH15**M4* HTR2 HTR1 TL TWO (2) ELEMENT ROWS 10 KW HTR1 HTR2 HTR3... -
Page 47: Gph13Med Economizer For Gph15**M4
WIRING DIAGRAMS *PH15**M4* GPH13MED ECONOMIZER FOR *PH15**M4*...
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