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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, professionally trained HVAC technicians only. RS6100004 Rev. 2 Goodman does not assume any responsibility for property damage or personal injury due May 2007 to improper service procedures or services performed by an unqualified person.
To locate an authorized servicer, please consult your telephone book or the dealer from whom you purchased this product. For further assistance, please contact: CONSUMER INFORMATION LINE 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.
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: •...
PRODUCT IDENTIFICATION THIS NOMENCLATURE IS TO BE USED TRHOUGH JULY 2006 3642 Product Type Minor Revision A: Single Piece Air Handler A: Initial Release Application Major Revision C: Ceiling Mount PSC Motor D: Downflow PSC Motor A: Initial Release E: Multi-Position Variable Speed Motor R: Multi-Position PSC Motor Electrical W: Wall Mount PSC Motor...
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PRODUCT IDENTIFICATION Design Series Voltage/Hz/Phase MB: Modular Blower 1: 208-230/60/1 Motor Types Design Series E: Variable-speed A: First Series R: Constant-speed Circuit Breaker Air Flow Delivered 08: 800 CFM A: No Circuit Breaker 12: 1,200 CFM 16: 1,600 CFM Factory-installed 20: 2,000 CFM Electric Heat 00: No Heat...
ACCESSORIES Model Description GSH13018 GSH13024 GSH13030 GSH13036 GSH13042 GSH13048 GSH13060 All Fuel Kit AFE18-60A OT18-60A Outdoor Thermostat FSK01A* Freeze Protection Kit Anti Short Cycle Kit ASC01 TX2N2* TXV Kit TX3N2* TXV Kit TX5N2* TXV Kit OT18-60A Outdoor Lockout Stat OT/EHR18-60...
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ACCESSORIES Model CPKF24 CPKF36 CPKF42 CPKF48 CPKF60 CPKF61 Description AFE18-60A All Fuel Kit Outdoor Thermostat OT18-60A FSK01A* Freeze Protection Kit ASC01 Anti Short Cycle Kit TX2N2* TXV Kit TX3N2* TXV Kit TX5N2* TXV Kit OT18-60A Outdoor Lockout Stat OT/EHR18-60 Emergency Heat relay kit CSR-U-1 Hard Start Kit CSR-U-2...
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ACCESSORIES EXPANSION VALVE KITS For Applications requiring 1/4 FLARE CONNECTION a field installed access fitting BULB TO BE LOCATED AT 10 OR 2 O'CLOCK BULB SUCTION LINE EVAPORATOR COIL TAILPIECE PISTON SEAL SUPPLIED W/ KIT SEAL SUPPLIED W/ KIT SEAL DISTRIBUTOR EXPANSION VALVE BODY...
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ACCESSORIES FSK01A FREEZE THERMOSTAT Wire Nut Wire Nut Install Line Install Line Thermostat Thermostat Here Here Wire Nut Wire Nut ASC01A ANTI-SHORT -CYCLE CONTROL KIT SHORT CYCLE PROTECTOR YELLOW 1 CONTACTOR T2 T1 BLACK 1 THERMOSTAT L2 L1 WIRE UNIT BLACK 1 TERMINAL BOARD...
PRODUCT DESIGN This section gives a basic description of cooling unit opera- COILS AND BLOWER COILS tion, its various components and their basic operation. MBR/MBE blower cabinets are designed to be used as a two- Ensure your system is properly sized for heat gain and loss piece blower and coil combination.
SYSTEM OPERATION COOLING The check valve at the indoor coil will open by the flow of refrigerant letting the now condensed liquid refrigerant by- The refrigerant used in the system is R-22. It is a clear, pass the indoor expansion device. The check valve at the colorless, non-toxic, non-irritating, and non-explosive liquid.
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EXPANSION VALVE/CHECK VALVE ASSEMBLY IN COOLING OPERATION 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.
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SYSTEM OPERATION COOLING CYCLE - CONDENSING UNIT Indoor Outdoor Coil 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.
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SYSTEM OPERATION AFE18-60A CONTROL BOARD controls, if the outdoor thermostat fails closed in this position during the heating season, it will turn on the furnace during DESCRIPTION the cooling season on a “Y” cooling demand. In this The AFE18 control is designed for use in heat pump applica- situation, the furnace produces heat and increases the tions where the indoor coil is located above/downstream of a indoor temperature thereby never satisfying the cooling...
TROUBLESHOOTING CHART COOLING/HP ANALYSIS CHART System No Cooling Unsatisfactory Cooling/Heating 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 •...
SERVICING S-2 CHECKING WIRING S-1 CHECKING VOLTAGE 1. Remove outer case, control panel cover, etc., from unit being tested. With power ON: WARNING Line Voltage now present. 1. Check wiring visually for signs of overheating, damaged 2. Using a voltmeter, measure the voltage across terminals insulation and loose connections.
SERVICING element helping the thermostat call for the next cooling cycle. 4. Check the continuity of the thermostat and wiring. Repair This prevents the room temperature from rising too high or replace as necessary. before the system is restarted. A properly sized anticipator Resistance Heaters should maintain room temperature within 1 1/2 to 2 degree 1.
SERVICING S-4 CHECKING TRANSFORMER With power ON: AND CONTROL CIRCUIT WARNING Line Voltage now present. 1. Apply 24 VAC to terminals R and R 2. Should read 24 VAC at terminals Y and Y 3. Remove 24 VAC at terminals R and R 4.
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 VOLT/OHM so may cause property damage, personal injury METER or death. The compressor contactor and other relay holding coils are Ohmmeter for testing holding coil wired into the low or line voltage circuits.
SERVICING S-10 COPELAND COMFORT ALERT™ DIAGNOSTICS Applies to ASC13 & ASH13 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. Once attached, Comfort Alert™...
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SERVICING DIAGNOSTICS TABLE Status LED Status LED Description Status LED Troubleshooting Information Green “POWER” Module has power Supply voltage is present at module terminals Red “TRIP” Thermostat demand signal 1. Compressor protector is open Y1 is present, but the 2. Outdoor unit power disconnect is open compressor is not 3.
Only hard start kits of the condenser coil, raising the condensing pressure. ® approved by Amana brand or Copeland should be used. "Kick Start" and/or "Super Boost" kits are not approved start 5. Check pressure at which the high pressure control cuts- assist devices.
SERVICING 2. Set an ohmmeter on its highest ohm scale and connect relay holding coil is wired parallel with the start winding. As the leads to the capacitor - the motor starts and comes up to speed, the increase in voltage across the start winding will energize the start relay A.
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SERVICING 6. Check for signal (24 volts) at the transformer. 7. Check for signal (24 volts) from the thermostat to the "G" terminal at the 16-pin connector. 8. Using an ohmmeter, check for continuity from the #1 & #3 (common pins) to the transformer neutral or "C" thermostat terminal.
SERVICING MOTOR SPEED ADJUSTMENT S-16C CHECKING ECM MOTOR WINDINGS Each ECM™ blower motor has been preprogrammed for operation 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 desired.
SERVICING S-16E CHECKING GE X13 MOTORS Cooling/Heat Pump Operation Model Switch 5 Switch 6 The GE X13 Motor is a one piece, fully encapsulated, 3 1,200 phase brushless DC (single phase AC input) motor with ball bearing construction. Unlike the ECM 2.3/2.5 motors, the 1,000 MBE1200 GE X13...
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 1. Remove the leads from the compressor terminals. 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...
SERVICING WARNING Line Voltage now present. A. If the compressor starts and continues to run, the cause HI-POT for failure is somewhere else in the system. B. If the compressor fails to start - replace. COMPRESSOR GROUND TEST COPELAND COMPRESSOR 3.
SERVICING If the valve fails to change its position, test the voltage (24V) SEQUENCE OF OPERATION at the valve coil terminals, while the system is on the This document covers the basic sequence of operation for a COOLING cycle. typical application with a mercury bulb thermostat. When a If no voltage is registered at the coil terminals, check the digital/electronic thermostat is used, the on/off staging of the operation of the thermostat an the continuity of the connect-...
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SERVICING AR*F & MBR Note: If more than two heater elements are on the heater assembly, it will contain a second heat sequencer, HR2, WITH SINGLE STAGE HEAT PUMPS which will control the 3 and 4 heater elements if available. 3.0 Cooling Operation If the second stage heat demand, “W2”...
SERVICING 5.5 When the temperature of the outdoor coil rises high 2.0 Heating Operation enough to causes the defrost thermostat to open, the 2.1 On a demand for heat, the room thermostat energizes defrost cycle will be terminated. If at the end of the “W1”...
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SERVICING Note: If more than two heater elements are on the heater On heat pump units, when the room thermostat is set to the assembly, it will contain a second heat sequencer, HR2, cooling mode, 24Vac is supplied to terminal “O” of the VSTB which will control the 3 and 4 heater elements if available.
SERVICING Answer: 24.0KW, 42°F Rise, 240 V = 1800 CFM from the 5.4 When a defrost cycle is initiated, the contacts of the TEMPERATURE RISE CHART, Table 5. HVDR relay on the defrost board open and turns off the outdoor fan. The contacts of the LVDR relay on the Heating output at 220 V = 24.0KW x 3.413 x .84 = 68.8 defrost board closes and supplies 24Vac to “O”...
SERVICING S-100 REFRIGERATION REPAIR PRACTICE S-61A CHECKING HEATER LIMIT CONTROL(S) Each individual heater element is protected with a limit DANGER control device connected in series with each element to prevent overheating of components in case of low airflow. Always remove the refrigerant charge in a proper This limit control will open its circuit at approximately 150°F.
SERVICING Pressure test the system using dry nitrogen and soapy R-22 water to locate leaks. If you wish to use a leak detector, MANIFOLD charge the system to 10 psi using the appropriate refrigerant then use nitrogen to finish charging the system to working LOW SIDE HIGH SIDE GAUGE...
SERVICING NOTE: This charging procedure can only be done in the S-103 CHARGING cooling mode of operation. (Early production "a" mod- els only.) All models with compressor process tube WARNING access valve can be processed in heating cycle if this valve is used.
SERVICING If the test shows: THERMOSTATIC EXPANSION VALVES Some TXV valves contain an internal check valve thus elimi- a. Below normal high side pressure. nating the need for an external check valve and bypass loop. b. Above normal low side pressure. The three forces which govern the operation of the valve are: (1) the pressure created in the power assembly by the feeler c.
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± range of allowable superheat. 47.85 276.9 50.24 284.1 SUPERHEAT ADJUSTMENT 52.70 291.4 The expansion valves used on Amana® brand coils are 55.23 298.8 factory set and are not field adjustable. If the superheat 57.83 306.3 setting becomes disturbed, replace the valve. 60.51 314.0...
SERVICING They are designed to control the rate of liquid refrigerant flow S-109 CHECKING SUBCOOLING into an evaporator coil. Refrigerant liquid is considered subcooled when its tempera- The amount of refrigerant that flows through the capillary ture is lower than the saturation temperature corresponding tube/restrictor orifice is regulated by the pressure difference to its pressure.
There are other causes for high head pressure which may be found in the "Service Problem Analysis Guide." Suction Line Drier Clean-Up Method If other causes check out normal, an overcharge or a system Use AMANA ® brand part number RF000127 suction line filter containing non-condensables would be indicated.
SERVICING S-120 REFRIGERANT PIPING • 50 feet is the maximum recommended vertical differ- ence between the condenser and evaporator when the The piping of a refrigeration system is very important in evaporator is above the condenser. Equivalent length relation to system capacity, proper oil return to compressor, is not to exceed 150 feet.
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SERVICING 2. For a system installation where the evaporator is above the condenser, an inverted vapor line trap should be REFRIGERANT LINE LENGTH (Ft) installed on the suction line just before the inlet to the Cond 0-24 25-49 50-74*** evaporator (see Fig 6). The top of the inverted loop must Unit Line Diameter (In.
SERVICING 4. Low voltage wiring. Verify low voltage wiring size is S-202 DUCT STATIC PRESSURES AND/OR adequate for the length used since it will be increased in STATIC PRESSURE DROP a long line application. ACROSS COILS System Charging This minimum and maximum allowable duct static pressure for the indoor sections are found in the specifications R22 condensers are factory charged for 15 feet of line set.
SERVICING S-204 COIL STATIC PRESSURE DROP 1. Using a draft gauge (inclined manometer), connect the positive probe underneath the coil and the negative probe above the coil. 2. A direct reading can be taken of the static pressure drop across the coil. 3.
ACCESSORIES WIRING DIAGRAMS HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. ALL FUEL SYSTEM AFE18-60A CONTROL BOARD 24VAC POWER SUPPLY P1-8 +VD C INPUT...
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ACCESSORIES WIRING DIAGRAMS HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. 10kw and Below, One Stage Electric Heat From Air Handler BLUE WHITE BROWN...
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ACCESSORIES WIRING DIAGRAMS HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. 15kw and Above with Two OT/EHR18-60's, Two Stage Electric Heat and Two Stage Thermostat From Air Handler OT/EHR18-60 #1 BLUE...
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ACCESSORIES WIRING DIAGRAMS HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. HTR1 HTR2 HTR1 HTR1 HTR2 HTR1 TL HTR2 HTR3 HTR3 HTR4...
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ACCESSORIES WIRING DIAGRAMS HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. 208/240 HTR2 HTR3 HTR4 EBTDR XFMR-R XFMR-C SPEEDUP W BR EQUIPMENT GROUND USE COPPER OR ALUMINUM WIRE...
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ACCESSORIES WIRING DIAGRAMS HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. HTR1 HTR2 HTR1 HTR1 TL HTR2 HTR1 TL HTR2 HTR3 HTR3 TL...
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ACCESSORIES WIRING DIAGRAMS HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. HTR2 HTR1 HKR Heat Kit THERMOSTATS HUMIDISTAT E\W1 W/W2 Y/Y2 OUTDOOR...
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ACCESSORIES WIRING DIAGRAMS HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. HTR1 HTR2 HTR1 HTR1 HTR2 HTR1 TL HTR2 HTR3 HTR3 HTR4...
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