Amana GSH13018 Service Instructions Manual
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Amana GSH13018 Service Instructions Manual

Amana GSH13018 Service Instructions Manual

Split system air conditioners and split system heat pumps with r-22 refrigerant blowers, coils, & accessories
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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.
Goodman does not assume any responsibility for property damage or personal injury due
to improper service procedures or services performed by an unqualified person.
RS6100004 Rev. 2
May 2007

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  • Page 1 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.

  • Page 2: Table Of Contents

    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.

  • 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 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: •...

  • Page 4: Model Identification

    Major Revision ® S: Goodman Brand (High Feature Set Models) A: Initial Release ® A: Amana Brand Electrical Product Category 1: 208/230V, 1 Phase, 60 Hz 2: 220/240V, 1 Phase, 50 Hz S: Split System 3. 208/230V, 3 Phase, 60 Hz 4.
  • Page 5 PRODUCT IDENTIFICATION Revision Product Category C: Split System Electrical Supply 1: 208-230V/60Hz/1ph Unit Type 2: 220-240V/50Hz/1ph E: Commercial Air Conditioner 3: 208/230V/60Hz/3ph K: Air Conditioner P: Heat Pump 4: 308/415V/50Hz/3ph Nominal Capacity 018: 1.5 tons 048: 4 tons 024: 2 tons 060: 5 tons 030: 2.5 tons...
  • Page 6 PRODUCT IDENTIFICATION Revision Product Category C: Split System Electrical Supply 1: 208-230V/60Hz/1ph Unit Type 2: 220-240V/50Hz/1ph E: Commercial Air Conditioner 3: 208/230V/60Hz/3ph K: Air Conditioner P: Heat Pump 4: 308/415V/50Hz/3ph Nominal Capacity 018: 1.5 tons 048: 4 tons 024: 2 tons 060: 5 tons 030: 2.5 tons...

  • Page 7: Air Handler/Coil Identification

    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...
  • Page 8 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...

  • Page 9: Accessories

    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...
  • Page 10 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...
  • Page 11 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...
  • Page 12 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...
  • Page 13 ACCESSORIES COIL ACCESSORIES COIL MODEL TX2N2 TXV KIT TX3N2 TXV KIT TX5N2 TXV KIT FSK01A FREEZE PROTECTION KIT CA*F030B4* CA*F036B4* CA*F042C4* CA*F048C4* CA*F057D4* CA*F060D4* CHPF030A4* CHPF036B4* CHPF042A4* CHPF048D4* CHPF060D4* CH36FCB CH48FCB CH60FCB CA*F18246* CA*F30306* CA*F36426* CHPF18246* CHPF30306* CHPF36426* CSCF1824N6* CSCF303N6* CSCF3642N6* ELECTRIC HEAT KIT APPLICATIONS ELECTRIC HEAT KIT...

  • Page 14: Product Design

    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.

  • Page 15: System Operation

    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.
  • Page 16 SYSTEM OPERATION COOLING CYCLE Reversing Valve (Energized) Indoor Outdoor Coil Coil Accumulator Thermostatic Expansion Valve Bi-Flow Filter Dryer Check Valve HEATING CYCLE Reversing Valve (De-Energized) Indoor Outdoor Coil Coil Accumulator Thermostatic Expansion Valve Bi-Flow Filter Dryer Check Valve...
  • Page 17 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.
  • Page 18 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.
  • Page 19 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...

  • Page 20: Troubleshooting Chart

    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 •...

  • Page 21: Servicing Table Of Contents

    SERVICING TABLE OF CONTENTS S-18 Testing Crankcase Heater (optional item) ..36 Checking Voltage .......... 22 S-21 Checking Reversing Valve Solenoid ....36 Checking Wiring ..........22 Checking Thermostat, Wiring & Anticipator .. 22 S-40 MBR & AR*F Electronic Blower Time Delay .. 37 S-3A Thermostat &...

  • Page 22: Checking Voltage

    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.

  • Page 23: S-3B Cooling Anticipator

    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.

  • Page 24: Checking Transformer & Control Circuit

    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.

  • Page 25: Checking Contactor And/Or Relays

    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.

  • Page 26: Copeland Comfort™ Alert Diagnostics

    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™...
  • Page 27 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.

  • Page 28: Checking Loss Of Charge Protector

    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.

  • Page 29: S-15A Resistance Check

    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.
  • Page 30 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.
  • Page 31 SERVICING...
  • Page 32 SERVICING...

  • Page 33: S-16C Checking Ecm Motor Windings

    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.

  • Page 34: S-16E Checking Ge X13™ Motors

    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...

  • Page 35: Checking Compressor Windings

    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...

  • Page 36: S-17D Operation Test

    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.

  • Page 37: Mbr & Ar*F Electronic Blower Time Delay

    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-...
  • Page 38 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”...

  • Page 39: Mbe & Aepf With Single Speed Air Conditioning And Heat Pump

    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”...
  • Page 40 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.

  • Page 41: Electric Heater (Optional Item)

    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”...

  • Page 42: S-61A Checking Heater Limit Control(S)

    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.

  • Page 43: Evacuation

    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...

  • Page 44: Checking Compressor Efficiency

    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.

  • Page 45: S-105B Thermostatic Expansion Valve

    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.
  • Page 46 ± 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...

  • Page 47: Checking Subcooling

    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.

  • Page 48: Refrigerant Overcharge

    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.

  • Page 49: Refrigerant Piping

    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.
  • Page 50 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.

  • Page 51: Replacing Reversing Valve

    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.

  • Page 52: Coil Static Pressure Drop

    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.

  • Page 53: Accessories Wiring Diagrams

    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...
  • Page 54 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...
  • Page 55 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...
  • Page 56 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...
  • Page 57 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...
  • Page 58 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...
  • Page 59 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...
  • Page 60 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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