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Instructions
GPH13 PACKAGE HEAT PUMPS
GPC13 PACKAGE COOLING
MULTI-POSITION MODELS
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S-15 CHECKING CAPACITOR ................................................................................................................................. 29
S-15A Resistance Check ........................................................................................................................................ 30
S-15B Capacitance Check ..................................................................................................................................... 30
S-16 CHECKING MOTORS ...................................................................................................................................... 30
S-16A CHECKING FAN AND BLOWER MOTOR WINDINGS (PSC MOTORS) ....................................................... 30
S-16D CHECKING GE X13TM MOTORS ................................................................................................................... 30
S-17 CHECKING COMPRESSOR WINDINGS ......................................................................................................... 31
S-17A Resistance Test ........................................................................................................................................... 31
S-17B Ground Test ................................................................................................................................................. 32
S-17D Operation Test ............................................................................................................................................. 32
S-18 TESTING CRANKCASE HEATER .................................................................................................................... 32
S-21 CHECKING REVERSING VALVE AND SOLENOID ......................................................................................... 33
S-24 TESTING DEFROST CONTROL ..................................................................................................................... 33
S-25 TESTING DEFROST THERMOSTAT ............................................................................................................... 33
S-50 CHECKING HEATER LIMIT CONTROL(S) ...................................................................................................... 33
S-52 CHECKING HEATER ELEMENTS .................................................................................................................... 33
S-100 REFRIGERATION REPAIR PRACTICE .......................................................................................................... 34
S-101 LEAK TESTING ............................................................................................................................................. 34
S-102 EVACUATION ................................................................................................................................................ 34
S-103 CHARGING ................................................................................................................................................... 35
S-104 CHECKING COMPRESSOR EFFICIENCY ..................................................................................................... 36
S-108 SUPERHEAT ................................................................................................................................................. 36
S-109 CHECKING SUBCOOLING ............................................................................................................................ 36
S-111 FIXED ORIFICE RESTRICTION DEVICES ..................................................................................................... 38
S-112 CHECKING RESTRICTED LIQUID LINE ........................................................................................................ 38
S-113 REFRIGERANT OVERCHARGE ..................................................................................................................... 38
S-114 NON-CONDENSABLES ................................................................................................................................. 38
S-115 COMPRESSOR BURNOUT ........................................................................................................................... 38
S-122 REVERSING VALVE REPLACEMENT ........................................................................................................... 39
S-200 CHECKING EXTERNAL STATIC PRESSURE ................................................................................................ 39
S-201 CHECKING TEMPERATURE RISE ................................................................................................................ 40
WIRING DIAGRAMS ............................................................................................................................................... 41
OT18-60A OUTDOOR THERMOSTAT ..................................................................................................................... 41
OT18-60A OUTDOOR THERMOSTAT ..................................................................................................................... 42
SINGLE PHASE HKR KITS ..................................................................................................................................... 43
3-PHASE HKR3* HEAT KITS (15KW & 20 KW) ....................................................................................................... 44
3-PHASE HKR4* HEAT KITS (15 KW ) .................................................................................................................... 45
3-PHASE HKR4* HEAT KITS (15 KW) ..................................................................................................................... 45
3-PHASE HKR4* HEAT KITS (20 KW) ..................................................................................................................... 46
GPH13MED ECONOMIZER FOR GPC/GPH13**M2* ................................................................................................ 47
WARNING
THIS UNIT SHOULD NOT BE CONNECTED TO. OR USED IN CONJUNCTION WITH, ANY DEVICES THAT ARE NOT DESIGN CERTIFIED FOR USE WITH THIS UNIT OR HAVE NOT BEEN
TESTED AND APPROVED BY GOODMAN. SERIOUS PROPERTY DAMAGE OR PERSONAL INJURY, REDUCED UNIT PERFORMANCE AND/OR HAZARDOUS CONDITIONS MAY RESULT
FROM THE USE OF DEVICES THAT HAVE NOT BEEN APPROVED OR CERTIFED BY GOODMAN.
WARNING
W ARNING
G OODMAN W ILL NOT BE R ESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES.
I F YOU INSTALL OR PERFORM SERVICE ON THIS UNIT, YOU ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMA GE WHICH
MAY RESULT. M ANY JU RISDICTIONS REQU IRE A LICENSE TO INSTALL OR SERVICE HEATING AN D AIR CONDITIONING EQUIPMENT.
To locate an authorized servicer, please consult your telephone book or the dealer from whom you purchased this
product. For further assistance, please contact:
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IMPORTANT INFORMATION
SAFE REFRIGERANT HANDLING
While these items will not cover every conceivable situation, they should serve as a useful guide.
WARNING WARNING
REFRIGERANTS ARE HEAVIER THAN AIR. THEY CAN "PUSH OUT" THE TO AVOID POSSIBLE EXPLOSION:
OXYGEN IN YOUR LUNGS OR IN ANY ENCLOSED SPACE. TO AVOID • NEVER APPLY FLAME OR STEAM TO A REFRIGERANT CYLINDER. IF YOU
POSSIBLE DIFFICULTY IN BREATHING OR DEATH: MUST HEAT A CYLINDER FOR FASTER CHARGING, PARTIALLY IMMERSE
•NEVER PURGE REFRIGERANT INTO AN ENCLOSED ROOM OR SPACE. BY IT IN WARM WATER.
LAW, ALL REFRIGERANTS MUST BE RECLAIMED. • NEVER FILL A CYLINDER MORE THAN 80% FULL OF LIQUID REFRIGERANT.
•IF AN INDOOR LEAK IS SUSPECTED, THOROUGHLY VENTILATE THE AREA • NEVER ADD ANYTHING OTHER THAN R-22 TO AN R-22 CYLINDER OR
BEFORE BEGINNING WORK. R-410 A TO AN R-410A CYLINDER. THE SERVICE EQUIPMENT USED MUST
•LIQUID REFRIGERANT CAN BE VERY COLD. TO AVOID POSSIBLE FROST- BE LISTED OR CERTIFIED FOR THE TYPE OF REFRIGERANT USED.
BITE OR BLINDNESS, AVOID CONTACT WITH REFRIGERANT AND WEAR • STORE CYLINDERS IN A COOL, DRY PLACE. NEVER USE A CYLINDER
GLOVES AND GOGGLES. IF LIQUID REFRIGERANT DOES CONTACT YOUR AS A PLATFORM OR A ROLLER.
WARNING
TO AVOID POSSIBLE INJURY, EXPLOSION OR DEATH, PRACTICE SAFE
HANDLING OF REFRIGERANTS.
G P H 13 24 M 2 1 * *
Brand
G: Goodman or Minor Revision
Distinctions
Major Revision
Product Type
Package
Cooling/Heating
Voltage
Refrigerant
Product Series
2: R-22
13: 13 SEER Rating
4: R-410A
Nominal Capacity
GPC13**M21 GPH13**M21
Chassis Models Chassis Models
Medium 3 Ton Medium 2 - 3 Ton
Large 4 - 5 Ton Large 4 - 5 Ton
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PRODUCT IDENTIFICATION GPC/GPH13[24-60]M2*
Multiposition Package Heat Pumps
Model # Description
Model # Description
Model # Description
Model # Description
®
GOODMAN BRAND THERMOSTATS
CHTP18-60HD Manual Changeover Digital, Nonprogrammable 2 Heat - 1 Cool
HPT18-60 Manual Changeover Nonprogrammable Analog 2 Heat - 1 Cool
HPTA18-60 Manual/Auto Changeover Nonprogrammable Analog 2 Heat - 1 Cool
®
AMANA BRAND THERMOSTATS
1213403 White Manual Changeover Nonprogrammable Analog 2 Heat - 1 Cool
1213404 White Manual Changeover Nonprogrammable Digital 2 Heat - 1 Cool
1213406 Beige Manual/Auto Changeover 5 + 2 Programming Digital 3 Heat - 2 Cool
1213407 White Manual Changeover 5 + 2 Programming Digital 2 Heat - 2 Cool
1213410 White Manual Changeover 5 + 2 Programming Digital 2 Heat - 1 Cool
1213412 White Manual/Auto Changeover 7 Day Programming Digital 3 Heat - 2 Cool
1213431 White Manual/Auto Changeover 7 Day Programming Digital 3 Heat - 2 Cool
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ACCESSORIES GPC/GPH13[24-60]M2*
EXTERNAL HORIZONTAL FILTER RACK
(GPGHFR101-103)
16"
24"
4"
16" x 25" x 2" FILTER
26 1/2"
FILTER PLATFORM
LEFT SIDE
RIGHT SIDE
EVAPORATOR
DOWNFLOW R/A COIL
DUCT OPENING
7 5/8
5 3/4
A 11 7/8
1
PGMDD103
B
BOTTOM VIEW
12 1/8 5 3/4
6
10 A 11 7/8
1 B
PGMDD101/102
Manual Fresh Air Dampers
MODEL A B
PGMDH102 31 1/2 29 3/4
PGMDH103 39 29 3/4
A PGMDMH103 39 29 3/4
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ACCESSORIES GPC/GPH13[24-60]M2*
SQUARE TO ROUND CONVERTER
(DOWNFLOW APPLICATIONS)
12 1/4 14 3/4
C
D 16 ø 16 ø
S 22 3/4 22 1/4
A R
12 1/4 14 3/4
22 3/4 18 ø 22 1/4 18 ø
C MODEL A B C
SQRPGH101/102 16 16 1/2 16 1/2
SQRPGH103 18 18 1/2 18 1/2
A
Measurements are in inches.
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ACCESSORIES GPC/GPH13[24-60]M2*
ECONOMIZER GPH13MED103
(DOWNFLOW APPLICATIONS )
Blockoff
Louver Assembly
ECONOMIZER PGEH102-103
(HORIZONTAL APPLICATIONS)
B
16 1/8
18
MODEL A B C D E FILTER
PGEH102 25 1/4 18 18 18 13 3/4 16 1/8 16 X 25 X1
PGEH103 35 1/4 18 1/8 18 18 1/4 16 1/8 16 X 25 X1
Measurements in inches
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ACCESSORIES GPC/GPH13[24-60]M2*
PGC101, 102, 103
ROOF CURBS
S
R C
A
1 5/8
14 1/2
1 3/8
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PRODUCT DESIGN
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.
Roof Curb
GPC/GPH13[24-60]M**
GPC/GPH Package Units are designed for outdoor installa-
tions only in either residential or light commercial applications.
The connecting ductwork (Supply and Return) can be connected
for horizontal discharge airflow. In the down discharge applica-
tions, a matching Roof Curb (PGC101/102/103) is recom-
GPC/GPH13[24-60]M** mended.
NOTE: Roof overhang should be no more than 36" and A return air filter must be installed behind the return air grille(s)
provisions made to deflect the warm discharge air out from the or provision must be made for a filter in an accessible location
overhang. within the return air duct. An internal filter rack (GPH13MFR102
& 103) and an external filter rack (GPGHFR101-103) are also
Minimum clearances are required to avoid air recirculation and available as accessories. The minimum filter area should not
keep the unit operating at peak efficiency. be less than those sizes listed in the Specification Section.
Under no circumstances should the unit be operated without
return air filters.
WARNING A 3/4" - 14 NPT drain connector is provided for removal of con-
densate water from the indoor coil. In order to provide proper
TO PREVENT POSSIBLE DAMAGE, THE UNIT SHOULD condensate flow, do not reduce the drain line size.
REMAIN IN AN UPRIGHT POSITION DURING ALL
RIGGING AND MOVING OPERATIONS. TO FACILITATE Refrigerant flow control is achieved by use of restrictor orifices.
LIFTING AND MOVING IF A CRANE IS USED, PLACE These models use the FasTest Access Fitting System, with a
THE UNIT IN AN ADEQUATE CABLE SLIDE. saddle that is either soldered to the suction and liquid lines or
is fastened with a locking nut to the access fitting box (core)
and then screwed into the saddle. Do not remove the core
Refer to Roof curb Installation Instructions for proper curb in- from the saddle until the refrigerant charge has been
stallation. Curbing must be installed in compliance with the removed. Failure to do so could result in property dam-
National Roofing Contractors Association Manual. age or personal injury.
Lower unit carefully onto roof mounting curb. While rigging The single phase units use permanent split capacitors (PSC)
unit, center of gravity will cause condenser end to be lower design compressors. Starting components are therefore not
than supply air end. required. A low MFD run capacitor assists the compressor to
start and remains in the circuit during operation.
The outdoor fan motor is a single phase capacitor type motors.
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PRODUCT DESIGN
Air for condensing (cooling) is drawn through the outdoor coil • Compliant scroll compressors perform "quiet" shutdowns
by a propeller fan, and is discharged vertically out the top of that allow the compressor to restart immediately without
the unit. The outdoor coil is designed for .0 static. No addi- the need for a time delay. This compressor will restart even
tional restriction (ductwork) shall be applied. if the system has not equalized.
Conditioned air is drawn through the filter(s), field installed, NOTE: Operating pressures and amp draws may differ from
across the evaporator coil and back into the conditioned space standard reciprocating compressors. This information can
by the indoor blower. be found in the unit's Technical Information Manual.
COMPRESSORS INDOOR BLOWER MOTOR
Some GPC/GPH series package units use the Compliant Scroll Some GPC/GPH model package units use a GE X13TM blower
compressor, instead of traditional reciprocating compressors. motor while others use the standard PSC type blower motor.
Still other models use reciprocating compressors. The GE X13TM motor is a 3 Phase brushless DC (single phase
A scroll is an involute spiral which, when matched with a mat- AC input), ball bearing construction motor with an integral con-
ing scroll form as shown, generates a series of crescent shaped trol module with an internal FCC B EMI filter.
gas pockets between the two members. The GE X13TM motor is continuously powered with line voltage.
During compression, one scroll remains stationary (fixed scroll) The switched 24 volt control signal is controlled by the thermo-
while the other form (orbiting scroll) is allowed to orbit (but not stat.
rotate) around the first form. 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.
WARNING
TO AVOID PERSONAL INJURY OR DEATH DUE TO
As this motion occurs, the pockets between the two forms are ELECTRIC SHOCK, WIRING TO THE UNIT MUST BE
slowly pushed to the center of the two scrolls while simulta- PROPERLY POLARIZED AND GROUNDED.
neously being reduced in volume. When the pocket reaches
the center of the scroll form, the gas, which is now at a high
pressure, is discharged out of a port located at the center.
During compression, several pockets are being compressed
simultaneously, resulting in a very smooth process. Both the
suction process (outer portion of the scroll members) and the
discharge process (inner portion) are continuous.
Some design characteristics of the Compliant Scroll compres-
sor are:
• Compliant Scroll compressors are more tolerant of liquid
refrigerant.
NOTE: Even though the compressor section of a Scroll
compressor is more tolerant of liquid refrigerant, continued
floodback or flooded start conditions may wash oil from the
bearing surfaces causing premature bearing failure.
• Compliant Scroll compressors use white oil which is com-
patible with 3GS. 3GS oil may be used if additional oil is
required.
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PRODUCT DESIGN
WARNING WARNING
DO NOT EXCEED THE MAXIMUM OVERCURRENT
DEVICE SIZE SHOWN ON THE UNIT DATA PLATE.
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SYSTEM OPERATION GPC/GPH13[24-60]M21*
COOLING If the room thermostat fan selector switch should be set to
The refrigerant used in the system is R-22. It is clear, color- the "on" position then the indoor blower would run continu-
less, non-toxic, non-irritating, and non-explosive liquid. The ous rather than cycling with the compressor.
chemical formula is CHCLF2. The boiling point, at atmospheric Heat Pump Models
pressure is -41.4°F.
Any time the room thermostat is switched to cool, the O
A few of the important principles that make the refrigeration terminal is energized. This energizes the 24 volt coil on the
cycle possible are: heat always flows from a warmer to a reversing valve and switches it to the cooling position.
cooler body, under lower pressure a refrigerant will absorb
When the contacts of the room thermostat close, this closes
heat and vaporize at a low temperature, the vapors may be
the circuit from R to Y and R to G in the unit.
drawn off and condensed at a higher pressure and tempera-
ture to be used again. This energizes the compressor contactor and will energize
the indoor blower following the EBTDR 7 second fan on delay
The indoor evaporator coil functions to cool and dehumidify
on PSC equipped model units, and instantly on models
the air conditioned spaces through the evaporative process
equipped with the GE X13TM motor.
taking place within the coil tubes.
When the thermostat is satisfied, it opens its contacts break-
NOTE: Actual temperatures and pressures are to be obtained ing the low voltage circuit causing the compressor contactor
from the expanded ratings in the Technical Information to open and indoor fan to stop after the EBTDR 65 second
Manual. delay on PSC equipped model units, and after the programmed
60 second off delay on units with the GE X13TM motor.
High temperature, high pressure vapor leaves the compres-
sor through the discharge line and enters the condenser coil. If the room thermostat fan selector switch should be set to
Air drawn through the condenser coil by the condenser fan the "on" position then the indoor blower would run continu-
causes the refrigerant to condense into a liquid by removing ous rather than cycling with the compressor.
heat from the refrigerant. As the refrigerant is cooled below
its condensing temperature it becomes subcooled.
HEATING CYCLE
The subcooled high pressure liquid refrigerant now leaves the Cooling Only Units
condenser coil via the liquid line until it reaches the indoor
NOTE: The following only applies if the cooling only unit has
expansion device.
an approved electric heat kit installed for heating. If auxiliary
As the refrigerant passes through the expansion device and electric heaters should be used, they may be controlled by
into the evaporator coil a pressure drop is experienced caus- outdoor thermostats (OT18-60A or OT/EHR18-60A).
ing the refrigerant to become a low pressure liquid. Low pres-
sure saturated refrigerant enters the evaporator coil where GPC PSC Equipped Model Units
heat is absorbed from the warm air drawn across the coil by With the thermostat set to the heat position and a call for
the evaporator blower. As the refrigerant passes through the heat, R to W will be energized. This will energize the electric
last tubes of the evaporator coil it becomes superheated, heat sequencers. When the normally open contacts of the
that is, it absorbs more heat than is necessary for the refrig- heat sequencers close, this will energize the electric resis-
erant to vaporize. Maintaining proper superheat assures that tance heat and also the 240 volt coil on the isolation relay in
liquid refrigerant is not returning to the compressor which the control panel. The normally open contacts of the isola-
can lead to early compressor failure. tion relay will close energizing the indoor blower motor through
Low pressure superheated vapor leaves the evaporator coil the normally closed contacts of the EBTDR.
and returns through the suction line to the compressor where GPC X13 Equipped Model Units
the cycle begins again.
With the thermostat set to the heat position and a call for
COOLING CYCLE heat, R to W will be energized. This will energize the electric
heat sequencers and the X13 indoor blower motor. When
Cooling Only Models the normally open contacts of the heat sequencers close,
When the contacts of the room thermostat close, making this will energize the electric resistance heat.
terminals R to Y and R to G, the low voltage circuit to the
contactor is completed starting the compressor and outdoor
fan motor. This also energizes the indoor blower through the
normally open contacts of the EBTDR on PSC equipped
models units and through the thermostat Y terminal to the
X13 motor on X13 equipped model units.
When the thermostat is satisfied, breaking the circuit be-
tween R to Y and R to G, the compressor and outdoor fan
motor will stop. The indoor blower will stop after the fan off
delay.
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SYSTEM OPERATION GPC/GPH13[24-60]M21*
GPH13**M21* Heat Pump Units DEFROST CYCLE
On a call for first stage heat, the contacts of the room ther-
mostat close. This energizes terminals R to Y and R to G, Package Heat Pumps
the low voltage circuit to the contactor is completed starting The defrosting of the outdoor coil is jointly controlled by the
the compressor and outdoor fan motor. This also energizes defrost control board and the defrost thermostat.
the indoor blower through the normally open contacts of the Solid State Defrost Control
EBTDR after a 7 second on delay on models with PSC blower
During operation the power to the circuit board is controlled
motors, and instantly on models equipped with the GE X13TM
by a temperature sensor, which is clamped to a feeder tube
motor.
entering the outdoor coil. Defrost timing periods of 30, 60, or
When the thermostat is satisfied, breaking the circuit be- 90 minutes may be selected by connecting the circuit board
tween R to Y and R to G, the compressor and outdoor fan jumper to 30, 60, or 90 respectively. Accumulation of time for
motor will stop. The indoor blower will stop after the EBTDR the timing period selected starts when the sensor closes
65 second off delay on models with PSC blower motors, and (approximately 34° F), and when the room thermostat calls
after the programmed 60 second off delay on models equipped for heat. At the end of the timing period, the unit’s defrost
with the GE X13TM motor. cycle will be initiated provided the sensor remains closed.
When auxiliary electric heaters are used, a two stage heat- When the sensor opens (approximately 60° F), the defrost
ing single stage cooling thermostat would be installed. cycle is terminated and the timing period is reset. If the de-
frost cycle is not terminated due to the sensor temperature,
Should the second stage heating contacts in the room ther-
a ten minute override interrupts the unit’s defrost period.
mostat close, which would be wired to W1 at the unit low
voltage connections, this would energize the coil(s) of the DF2
electric heat relay(s). Contacts within the relay(s) will close, TEST
90 A
If auxiliary electric heaters should be used, they may be con- 60
DF1
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SYSTEM OPERATION GPC/GPH13[24-60]M23*
GPH13**M23* Heat Pump Units DEFROST CYCLE
On a call for first stage heat, the contacts of the room
thermostat close. This energizes terminals R to Y and R to Package Heat Pumps
G, the low voltage circuit to the contactor is completed The defrosting of the outdoor coil is jointly controlled by the
starting the compressor and outdoor fan motor. This also defrost control board and the defrost thermostat.
energizes the indoor blower through the normally open
contacts of the EBTDR after a 7 second on delay on the PSC Solid State Defrost Control
equipped model, and instantly on units with the GE X13™ During operation the power to the circuit board is controlled
motor. by a temperature sensor, which is clamped to a feeder tube
entering the outdoor coil. Defrost timing periods of 30, 60, or
When the thermostat is satisfied, breaking the circuit be-
90 minutes may be selected by connecting the circuit board
tween R to Y and R to G, the compressor and outdoor fan
jumper to 30, 60, or 90 respectively. Accumulation of time for
motor will stop. The indoor blower will stop after the EBTDR
the timing period selected starts when the sensor closes
65 second off delay on PSC equipped units, and after the
(approximately 34° F), and when the room thermostat calls
programmed 60 second off delay on units with the GE X13™
for heat. At the end of the timing period, the unit’s defrost
motor.
cycle will be initiated provided the sensor remains closed.
When auxiliary electric heaters are used, a two stage When the sensor opens (approximately 60° F), the defrost
heating single stage cooling thermostat would be installed. cycle is terminated and the timing period is reset. If the de-
Should the second stage heating contacts in the room frost cycle is not terminated due to the sensor temperature,
thermostat close, which would be wired to W1 at the unit low a ten minute override interrupts the unit’s defrost period.
voltage connections, this would energize the coil(s) of the DF2
electric heat relay(s). Contacts within the relay(s) will close, TEST
90 A
If auxiliary electric heaters should be used, they may be 60
DF1
GPC/GPH X13 Equipped Models Only: If the thermostat is not calling for heat or cool, and the fan
With the thermostat set to the emergency heat position and switch on the thermostat is returned to the automatic
a call for 2nd stage heat, R to W1 will be energized. This will position, the fan will stop after a 65 second delay.
energize the electric heat sequencers and the GE X13TM GPC/GPH X13 Equipped Models Only:
motor. The electric heat will be energized through the nor- If the thermostat calls for continuous fan, the indoor blower
mally open contacts of the electric heat sequencers. The will be energized from the G terminal of the thermostat to the
indoor blower will be energized through W from the thermo- X13 blower motor.
stat. If a call for heat or cool occurs during a continuous fan call,
the GE X13™ motor will always recognize the call for the
highest speed and ignore the lower speed call.
If the thermostat is not calling for heat or cool, and the fan
switch on the thermostat is returned to the automatic
position, the fan will stop after the programmed 60 second off
delay on units with the GE X13™ motor.
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SYSTEM OPERATION GPC/GPH13[24-60]M24*
GPH13**M24* Heat Pump Units Solid State Defrost Control
On a call for first stage heat, the contacts of the room During operation the power to the circuit board is controlled
thermostat close. This energizes terminals R to Y and R to by a temperature sensor, which is clamped to a feeder tube
G, the low voltage circuit to the contactor is completed entering the outdoor coil. Defrost timing periods of 30, 60, or
starting the compressor and outdoor fan motor. This also 90 minutes may be selected by connecting the circuit board
energizes the indoor blower through the normally open jumper to 30, 60, or 90 respectively. Accumulation of time for
contacts of the EMR and EBTDR after a 7 second on delay the timing period selected starts when the sensor closes
on the PSC equipped units, and instantly on units with the (approximately 34° F), and when the room thermostat calls
GE X13™ motor. for heat. At the end of the timing period, the unit’s defrost
When the thermostat is satisfied, breaking the circuit be- cycle will be initiated provided the sensor remains closed.
tween R to Y and R to G, the compressor and outdoor fan When the sensor opens (approximately 60° F), the defrost
motor will stop. The indoor blower will stop after the EBTDR cycle is terminated and the timing period is reset. If the de-
65 second off delay on PSC equipped units, and after the frost cycle is not terminated due to the sensor temperature,
programmed 60 second off delay on units with the GE X13™ a ten minute override interrupts the unit’s defrost period.
motor. When auxiliary electric heaters are used, a two stage DF2
heating single stage cooling thermostat would be installed. TEST
Should the second stage heating contacts in the room JUMPER WIRE
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SYSTEM OPERATION
Typical Package Cooling
Indoor Outdoor
Coil Coil
Chatleff
Orifice
Assy
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
Typical Heat Pump System in Cooling
Reversing Valve
(Energized)
Indoor Outdoor
Coil Coil
Accumulator
Reversing Valve
(De-Energized)
Indoor Outdoor
Coil Coil
Accumulator
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SCHEDULED MAINTENANCE
The owner should be made aware of the fact, that, as with any 7. Using a halide or electronic leak detector, check all piping
mechanical equipment, Package Cooling and Heat Pump units and etc. for refrigerant leaks.
require regularly scheduled maintenance to preserve high per- 8. Check the combustion chamber (Heat Exchanger) for soot,
formance standards, prolong the service life of the equipment, scale, etc. Inspect all burners for lint and proper position-
and lessen the chances of costly failure. ing.
In many instances the owner may be able to perform some of 9. Start the system, using the proper instrumentation check
the maintenance; however, the advantage of a service con- gas inlet and manifold pressures, burner flame and microamp
tract, which places all maintenance in the hands of a trained signal. Adjust if necessary.
serviceman, should be pointed out to the owner.
10. Start the system and run both a Cooling & Heating Perfor-
mance Test. If the results of the test are not satisfactory,
see the "Service Problem Analysis" Chart of the possible
WARNING cause.
TEST EQUIPMENT
Proper test equipment for accurate diagnosis is as essential
as regular hand tools.
The following is a must for every service technician and service
shop:
1. Thermocouple type temperature meter - measure dry bulb
ONCE A MONTH temperature.
1. Inspect the return filters of the evaporator unit and clean or 2. Sling psychrometer- measure relative humidity and wet bulb
change if necessary. temperature.
NOTE: Depending on operation conditions, it may be necessary 3. Amprobe - measure amperage and voltage.
to clean the filters more often. If permanent type filters are 4. Volt-Ohm Meter - testing continuity, capacitors, and motor
used, they should be washed with warm water, dried and windings.
sprayed with an adhesive according to manufacturers
5. Accurate Leak Detector - testing for refrigerant leaks.
recommendations.
6. High Vacuum Pump - evacuation.
2. When operating on the cooling cycle, inspect the conden-
7. Electric Vacuum Gauge, Manifold Gauges and high vacuum
sate line piping from the evaporator coil. Make sure the
hoses - to measure and obtain proper vacuum.
piping is clear for proper condensate flow.
8. Accurate Electronic Scale - measure proper refrigerant
ONCE A YEAR charge.
Qualified Service Personnel Only 9. Inclined Manometer - measure static pressure and pres-
1. Clean the indoor and outdoor coils. sure drop across coils.
2. Clean the casing of the outdoor unit inside and out . Other recording type instruments can be essential in solving
abnormal problems, however, in many instances they may be
3. Motors are permanently lubricated and do not require oil-
rented from local sources.
ing. TO AVOID PREMATURE MOTOR FAILURE, DO NOT
OIL. Proper equipment promotes faster, more efficient service, and
accurate repairs with less call backs.
4. Manually rotate the outdoor fan and indoor blower to be
sure they run freely.
5. Inspect the control panel wiring, compressor connections,
and all other component wiring to be sure all connections
are tight. Inspect wire insulation to be certain that it is
good.
6. Check the contacts of the compressor contactor. If they
are burned or pitted, replace the contactor.
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SERVICING
COOLING /HEAT PUMP- SERVICE ANALYSIS GUIDE
System
Complaint No Cooling Unsatisfactory Cooling/Heating Operating
Pressures
• Cooling or Heating Cycle (Heat Pump) ♦ Heating Cycle Only (Heat Pump) √ 3-Phase Only
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SERVICING
S-1 CHECKING VOLTAGE 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.
WARNING Max. Voltage Deviation
% Voltage = From Average Voltage X 100
Imbalance Average Voltage
To find the percentage of imbalance, measure the incoming
power supply.
L1 - L2 = 240V
L1 - L3 = 232V Avg. V = 710 = 236.7
1. Remove doors, control panel cover, etc. from unit being L2 - L3 = 238V 3
tested. Total 710V
With power ON: To find Max. deviation: 240 - 236.7 = +3.3
232 - 236.7 = -4.7
WARNING 238 - 236.7 = +1.3
Max deviation was 4.7V
LINE VOLTAGE NOW PRESENT.
% Voltage Imbalance = 4.7 = 1.99%
2. Using a voltmeter, measure the voltage across terminals 236.7
L1 and L2 of the contactor for single phase units, and L3,
for 3 phase units. If the percentage of imbalance had exceeded 3%, it must be
determined if the imbalance is in the incoming power supply or
3. No reading - indicates open wiring, open fuse(s) no power the equipment. To do this rotate the legs of the incoming
or etc. from unit to fused disconnect service. Repair as power and retest voltage as shown below.
needed.
4. With ample voltage at line voltage connectors, energize
the unit.
5. Measure the voltage with the unit starting and operating,
and determine the unit Locked Rotor Voltage.
L1 - L2 = 240V
Locked Rotor Voltage is the actual voltage available at
L1 - L3 = 227V
the compressor during starting, locked rotor, or a stalled
L2 - L3 = 238V
condition. Measured voltage should be above minimum
listed in chart below.
To measure Locked Rotor Voltage attach a voltmeter to
the run "R" and common "C" terminals of the compres- Rotate all 3 incoming
L1 L2 L3
sor, or to the T1 and T2 terminals of the contactor. Start legs as shown.
the unit and allow the compressor to run for several sec-
onds, then shut down the unit. Immediately attempt to
restart the unit while measuring the Locked Rotor Volt-
age.
6. Should read within the voltage tabulation as shown. If L1 - L2 = 227V
the voltage falls below the minimum voltage, check the L1 - L3 = 238V
line wire size. Long runs of undersized wire can cause L2 - L3 = 240V
low voltage. If wire size is adequate, notify the local L1 L2 L3
power company in regards to either low or high voltage.
By the voltage readings we see that the imbalance rotated or
traveled with the switching of the incoming legs. Therefore the
Unit Supply Voltage power lies within the incoming power supply.
Voltage Min. Max.
If the imbalance had not changed then the problem would lie
460 437 506
within the equipment. Check for current leakage, shorted mo-
208/230 198 253
tors, etc.
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SERVICING
S-2 CHECKING WIRING 5. No voltage, indicates the trouble is in the thermostat or
wiring.
6. Check the continuity of the thermostat and wiring. Repair
or replace as necessary.
WARNING
S-3B COOLING ANTICIPATOR
The cooling anticipator is a small heater (resistor) in the ther-
mostat. During the "off" cycle it heats the bimetal element
helping the thermostat call for the next cooling cycle. This
prevents the room temperature from rising too high before the
system is restarted. A properly sized anticipator should main-
tain room temperature within 1 1/2 to 2 degree range.
1. Check wiring visually for signs of overheating, damaged
The anticipator is supplied in the thermostat and is not to be
insulation and loose connections.
replaced. If the anticipator should fail for any reason, the ther-
2. Use an ohmmeter to check continuity of any suspected mostat must be changed.
open wires.
S-3C HEATING ANTICIPATOR
3. If any wires must be replaced, replace with comparable
gauge and insulation thickness. The heating anticipator is a wire-wound adjustable heater, which
is energized during the "ON" cycle to help prevent overheating
S-3 CHECKING THERMOSTAT, WIRING, AND of the conditioned space.
ANTICIPATOR The anticipator is a part of the thermostat and if it should fail for
S-3A THERMOSTAT AND WIRING any reason, the thermostat must be replaced. See the follow-
ing for recommended heater anticipator setting.
To determine the proper setting, use an amp meter to measure
WARNING the amperage on the "W" wire going to the thermostat.
Use an amprobe as shown below. Wrap 10 turns of thermostat
LINE VOLTAGE NOW PRESENT.
wire around the stationary jaw of the amprobe and divide the
With power ON and thermostat calling for cooling. reading by 10.
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S-4 CHECKING TRANSFORMER AND S-8 CHECKING CONTACTOR CONTACTS
CONTROL CIRCUIT
A step-down transformer (208/240 volt primary to 24 volt sec-
ondary) is provided with each package unit. This allows ample WARNING
capacity for use with resistance heaters.
DISCONNECT POWER SUPPLY BEFORE SERVICING.
WARNING T2 T1
LINE VOLTAGE NOW PRESENT.
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T3 T2 T1 5. Using a VOM, check for line voltage from the purple wire at
the transformer (terminal 3 on 240 volt units, terminal 2 on
208 volt units) to the COM terminal on the EBTDR. Should
CC read line voltage. If not as above, replace EBTDR.
VOLT/OHM PSC equipped, single phase model coolers and heat pumps
METER have an isolation relay with a 240 volt holding coil in addition to
L3 L2 L1 the EBTDR.
WARNING
DISCONNECT POWER SUPPLY BEFORE SERVICING.
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S-15 CHECKING CAPACITOR
WARNING CAPACITOR, RUN
A run capacitor is wired across the auxiliary and main wind-
DISCONNECT POWER SUPPLY BEFORE SERVICING. ings of a single phase permanent split capacitor motor. The
capacitors primary function is to reduce the line current while
Turn power off.
greatly improving the torque characteristics of a motor. This is
Testing relay holding coil accomplished by using the 90° phase relationship between
1. Remove the leads from the holding coil. the capacitor current and voltage in conjunction with the motor
windings so that the motor will give two phase operation when
2. Using an ohmmeter, test across the coil terminals 1 and 3. connected to a single phase circuit. The capacitor also re-
If the coil does not test continuous, replace the relay. duces the line current to the motor by improving the power
Testing relay contacts factor.
CAPACITOR, START
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S-15A RESISTANCE CHECK Using a hookup as shown below, take the amperage and volt-
age readings and use them in the formula:
Volt / Ohm
Meter
15 AMP FUSE
1. Discharge capacitor and remove wire leads.
WARNING AMMETER
WARNING
C
C L G N
or turned off prior to servicing a system.
If the following test indicates shorted, grounded or open wind-
ings, see procedure S-19 for the next steps to be taken.
WARNING
HERMETIC COMPRESSOR ELECTRICAL TERMINAL
VENTING CAN BE DANGEROUS. WHEN INSULATING
1. Remove the leads from the compressor terminals.
MATERIAL WHICH SUPPORTS A HERMETIC COM-
PRESSOR OR ELECTRICAL TERMINAL SUDDENLY
DISINTEGRATES DUE TO PHYSICAL ABUSE OR AS A
RESULT OF AN ELECTRICAL SHORT BETWEEN THE WARNING
TERMINAL AND THE COMPRESSOR HOUSING, THE
TERMINAL MAY BE EXPELLED, VENTING THE SEE WARNINGS S-17 BEFORE REMOVING COMPRES-
VAPOR AND LIQUID CONTENTS OF THE COMPRES- SOR TERMINAL COVER.
SOR HOUSING AND SYSTEM.
2. Using an ohmmeter, test continuity between terminals S-
If the compressor terminal PROTECTIVE COVER and gasket R, C-R, and C-S, on single phase units or terminals T1, T2
(if required) is not properly in place and secured, there is a and T3, on 3 phase units.
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.
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SERVICING
3. If a ground is indicated, then carefully remove the compres-
sor terminal protective cover and inspect for loose leads or
insulation breaks in the lead wires.
C
4. If no visual problems indicated, carefully remove the leads
OHMMETER S R at the compressor terminals.
COMP Carefully retest for ground, directly between compressor
terminals and ground.
TESTING COMPRESSOR WINDINGS 5. If ground is indicated, replace the compressor.
If either winding does not test continuous, replace the com- S-17D OPERATION TEST
pressor.
If the voltage, capacitor, overload and motor winding test fail to
NOTE: If an open compressor is indicated allow ample time show the cause for failure:
for the internal overload to reset before replacing compressor.
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1. Disassemble and remove the heating element(s). S-101 LEAK TESTING
2. Visually inspect the heater assembly for any breaks in the Refrigerant leaks are best detected with a halide or electronic
wire or broken insulators. leak detector.
3. Using an ohmmeter, test the element for continuity - no However, on outdoor installed systems, provisions must be
reading indicates the element is open. Replace as neces- made to shield the copper element of an halide torch from the
sary. sun and wind conditions in order to be able to see the element
S-100 REFRIGERATION REPAIR PRACTICE properly.
NOTE: The flame of the halide detector will glow green in the
presence of R-22 refrigerant.
DANGER For a system that contains a refrigerant charge and is sus-
pected of having a leak, stop the operation and hold the explor-
ALWAYS REMOVE THE REFRIGERANT CHARGE IN ing tube of the detector as close to the tube as possible, check
A PROPER MANNER BEFORE APPLYING HEAT TO all piping and fittings. If a leak is detected, do not attempt to
THE SYSTEM. apply more brazing to the joint. Remove and capture the charge,
unbraze the joint, clean and rebraze.
These models use the FasTest Access Fitting System, with a For a system that has been newly repaired and does not con-
saddle that is either soldered to the suction and liquid lines or tain a charge, connect a cylinder of refrigerant, through a gauge
is fastened with a locking nut to the access fitting box (core) manifold, to the liquid and suction line dill valves and/or liquid
and then screwed into the saddle. Do not remove the core line dill valve and compressor process tube.
from the saddle until the refrigerant charge has been
removed. Failure to do so could result in property dam- NOTE: Refrigerant hoses must be equipped with dill valve de-
age or personal injury. pressors or special adaptor used. Open the valve on the cylin-
der and manifold and allow the pressure to build up within the
When installing a new core or reinstalling the core after re- system. Check for and handle leaks, as described above.
moval, it is very important to note that before inserting the core After the test has been completed, remove and capture the
into the saddle, the core and saddle must be free of debris and leak test refrigerant.
the “O” Ring must have a thin coating of refrigerant oil applied
to it. The oil is to prevent the “O” Ring from being deformed S-102 EVACUATION
when the core is tightened completely. The core should be This is the most important part of the entire service procedure.
torqued to 8 ft. lb. The life and efficiency of the equipment is dependent upon the
When repairing the refrigeration system: thoroughness exercised by the serviceman when evacuating
1. Never open a system that is under vacuum. Air and mois- air (non-condensable) and moisture from the system.
ture will be drawn in. Air in a system causes high condensing temperature and pres-
2. Plug or cap all openings. sure, resulting in increased power input and reduced perfor-
mance.
3. Remove all burrs and clean the brazing surfaces of the
tubing with sand cloth or paper. Brazing materials do not Moisture chemically reacts with the refrigerant and oil to form
flow well on oxidized or oily surfaces. corrosive hydrofluoric and hydrochloric acids. These attack
motor windings and parts, causing breakdown.
4. Clean the inside of all new tubing to remove oils and pipe
chips. The equipment required to thoroughly evacuate the system is
a high vacuum pump, capable of producing a vacuum equiva-
5. When brazing, sweep the tubing with dry nitrogen to pre- lent to 25 microns absolute and a thermocouple vacuum gauge
vent the formation of oxides on the inside surfaces. to give a true reading of the vacuum in the system
6. Complete any repair by replacing the liquid line drier in the NOTE: Never use the system compressor as a vacuum pump
system, evacuate and charge. or run when under a high vacuum. Motor damage could occur.
At any time the system has been open for repair, the factory
installed liquid line filter drier must be replaced.
BRAZING MATERIALS
Copper to Copper Joints - Sil-Fos used without flux (alloy of
15% silver, 80% copper, and 5% phosphorous). Recommended
heat 1400°F.
Copper to Steel Joints - Silver Solder used without a flux
(alloy of 30% silver, 38% copper, 32% zinc). Recommended
heat - 1200°F.
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5. Evacuate the system to at least 29 inches gauge before
opening valve to thermocouple vacuum gauge.
WARNING 6. Continue to evacuate to a minimum of 250 microns. Close
SCROLL COMPRESSORS valve to vacuum pump and watch rate of rise. If vacuum
DO NOT FRONT SEAT THE SERVICE VALVE(S) WITH does not rise above 1500 microns in three to five minutes,
THE COMPRESSOR OPERATING IN AN ATTEMPT TO system can be considered properly evacuated.
SAVE REFRIGERANT. WITH THE SUCTION LINE OF 7. If thermocouple vacuum gauge continues to rise and levels
THE COMPRESSOR CLOSED OR SEVERLY RESTRICT- off at about 5000 microns, moisture and non-condensables
ED, THE SCROLL COMPRESSOR WILL DRAW A DEEP are still present. If gauge continues to rise a leak is present.
VACUUM VERY QUICKLY. THIS VACUUM CAN CAUSE Repair and re-evacuate.
INTERNAL ARCING OF THE FUSITE RESULTING IN A
DAMAGED OR FAILED COMPRESSOR. 8. Close valve to thermocouple vacuum gauge and vacuum
pump. Shut off pump and prepare to charge.
S-103 CHARGING
R-22
MANIFOLD Charge the system with the exact amount of refrigerant.
Refer to the specification section or check the unit nameplates
LOW SIDE HIGH SIDE for the correct refrigerant charge.
GAUGE GAUGE
AND VALVE AND VALVE After completing airflow measurements and adjustments, the
unit’s refrigerant charge must be checked. The unit comes
factory charged, but this charge is based on 400 CFM per ton
800 PSI
RATED at minimum ESP per ARI test conditions (generally between
HOSES .15 - .25 ESP). When air quantity or ESP is different than
above, charge must be adjusted to the proper amount.
CHARGING
CYLINDER All package units are charged to the superheat method at the
AND SCALE
compressor suction line (these are fixed orifice devices).
For charging in the warmer months, 100F superheat at the com-
{
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5. With the system still running, reseat the suction valve core, To obtain the degrees temperature of superheat subtract 50.0
remove hose and reinstall both valve core caps. from 63.0°F.
6. Check system for leaks. The difference is 13° Superheat.
Units having flow control restrictors can be checked against For charging in the warmer months, 10°F superheat at the
the Desired Superheat vs. Outdoor Temperature Chart in this compressor is required at conditions: 95°F outdoor ambient
section. (dry bulb temperature), 80°F dry bulb / 67°F wet bulb indoor
ambient, approximately 50 % humidity. This superheat varies
S-104 CHECKING COMPRESSOR when conditions vary from the conditions described.
EFFICIENCY A superheat charge chart is provided below for other operating
The reason for compressor inefficiency is broken or damaged conditions. Use it to provide the correct superheat at the
suction and/or discharge valves, or scroll flanks on Scroll com- conditions the unit is being charged at.
pressors, reducing the ability of the compressor to pump re- After superheat is adjusted it is recommended to check unit
frigerant vapor. sub-cooling at the condenser coil liquid line out.
The condition of the valves or scroll flanks is checked in the
following manner.
Ambient Condenser Return Air Temp. (°F Drybulb)
1. Attach gauges to the high and low side of the system. Inlet Temp (°F
65 70 75 80 85
2. Start the system and run a Cooling Performance Test. Drybulb)
If the test shows- 100 - - - 10 10
95 - - 10 10 10
⇒ Below normal high side pressure.
90 - - 12 15 18
⇒ Above normal low side pressure. 85 - 10 13 17 20
⇒ Low temperature difference across coil. 80 - 10 15 21 26
75 10 13 17 25 29
⇒ Low amp draw at compressor.
70 10 17 20 28 32
-and the charge is correct. The compressor is faulty - replace 65 13 19 26 32 35
the compressor. 60 17 25 30 33 37
S-108 SUPERHEAT Superheat
CHECKING SUPERHEAT
Refrigerant gas is considered superheated whenever its tem- Saturated Suction
perature is higher than the saturation temperature correspond- Suction Pressure Temperature (°F)
ing to its pressure. The degree of superheat equals the de- 50 26
grees of temperature increase above the saturation tempera- 53 28
ture at existing pressure. See Temperature - Pressure Chart. 55 30
1. Attach an accurate thermometer or preferably a thermo- 58 32
couple type temperature tester to the suction line at a point 61 34
at least 6" from the compressor. 63 36
2. Install a low side pressure gauge on the suction line ser- 66 38
vice valve at the outdoor unit. 69 40
72 42
3. Record the gauge pressure and the temperature of the line. 75 44
4. Convert the suction pressure gauge reading to temperature 78 46
by finding the gauge reading in Temperature - Pressure 81 48
Chart and reading to the left, find the temperature in the °F. 84 50
Column. 87 52
5. The difference between the thermometer reading and pres- TABLE 5
sure to temperature conversion is the amount of super- Suction Pressure Temperature (R-22)
heat.
S-109 CHECKING SUBCOOLING
EXAMPLE: Refrigerant liquid is considered subcooled whenever its tem-
a. Suction Pressure = 84 perature is lower than the saturation temperature correspond-
b. Corresponding Temp. °F. = 50 ing to its pressure. The degree of subcooling equals the de-
grees of temperature decrease below the saturation tempera-
c. Thermometer on Suction Line = 63°F. ture at the existing pressure.
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1. Attach an accurate thermometer or preferably a thermo- Temp. Gauge Pressure Temp. Gauge Pressure
couple type temperature tester to the liquid line as it leaves °F. (PSIG) Freon-22 °F. (PSIG) Freon-22
the condensing unit. -40 0.61 60 102.5
2. Install a high side pressure gauge on the high side service -38 1.42 62 106.3
valve. -36 2.27 64 110.2
-34 3.15 65 114.2
3. Record the gauge pressure and the temperature of the line. -32 4.07 68 118.3
4. Convert the discharge pressure gauge reading to tempera- -30 5.02 70 122.5
-28 6.01 72 126.8
ture by finding the gauge reading in Temperature - Pres- -26 7.03 74 131.2
sure Chart and reading to the left, find the temperature in -24 8.09 76 135.7
the °F. Column. -22 9.18 78 140.5
5. The difference between the thermometer reading and pres- -20 10.31 80 145.0
-18 11.48 82 149.5
sure to temperature conversion is the amount of subcool-
-16 12.61 84 154.7
ing. -14 13.94 86 159.8
-12 15.24 88 164.9
EXAMPLE:
-10 16.59 90 170.1
a. Discharge Pressure = 260 -8 17.99 92 175.4
b. Corresponding Temp. °F. = 120° -6 19.44 94 180.9
-4 20.94 96 186.5
c. Thermometer on Liquid line = 109°F. -2 22.49 96 192.1
0 24.09 100 197.9
To obtain the amount of subcooling subtract 109°F from 120°F.
2 25.73 102 203.8
The difference is 11° subcooling. The normal subcooling range 4 27.44 104 209.9
is 10° - 15°. 6 29.21 106 216.0
8 31.04 108 222.3
10 32.93 110 228.7
12 34.88 112 235.2
14 36.89 114 241.9
INDOOR LIQUID SUCTION 16 38.96 116 248.7
OUTDOOR 18 41.09 118 255.6
TEMP. °F PRESSURE PRESSURE
TEMP. °F 20 43.28 120 262.6
DB WB PSIG PSIG 22 45.53 122 269.7
63 301 - 332 73 - 83 24 47.85 124 276.9
115 75 67 306 - 335 77 - 78 26 50.24 126 284.1
71 311 - 342 82 - 92 28 52.70 128 291.4
63 268 - 299 72 - 82 30 55.23 130 298.8
32 57.83 132 306.3
105 75 67 273 - 304 77 - 87
34 60.51 134 314.0
71 278 - 309 80 - 90 36 63.27 136 321.9
63 233 - 264 67 - 77 38 66.11 136 329.9
95 75 67 238 - 269 72 - 82 40 69.02 140 338.0
71 243 - 274 77 - 87 42 71.99 142 346.3
44 75.04 144 355.0
63 198 - 229 62 - 72
46 78.18 146 364.3
85 75 67 203 - 234 67 - 77 48 81.40 158 374.1
71 208 - 239 71 - 81 50 84.70 150 384.3
63 172 - 203 57 - 67 52 88.10 152 392.3
75 75 67 175 - 206 61 - 71 54 91.5 154 401.3
71 180 - 211 66 - 76 156 411.3
56 95.1
158 421.8
63 144 - 175 52 - 62 58 98.8
160 433.3
65 75 67 149 - 180 56 - 66
TEMPERATURE-PRESSURE (R-22)
71 155 - 186 60 - 70
Operating Pressures
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S-111 FIXED ORIFICE RESTRICTION S-113 REFRIGERANT OVERCHARGE
DEVICES An overcharge of refrigerant is normally indicated by exces-
The fixed orifice restriction device (flowrator) used in conjunc- sively high head pressure and/or liquid return to the compres-
tion with the indoor coil is a predetermined bore (I.D.). sor.
It is designed to control the rate of liquid refrigerant flow into an Evaporator coils with a fixed orifice metering device could
evaporator coil. allow refrigerant to return to the compressor under extreme
overcharge conditions.
The amount of refrigerant that flows through the fixed orifice
restriction device is regulated by the pressure difference be- If high head pressure is not indicated, an overcharge or a sys-
tween the high and low sides of the system. tem containing non-condensables could be the problem.
In the cooling cycle when the outdoor air temperature rises, If overcharging is indicated:
the high side condensing pressure rises. At the same time, 1. Start the system.
the cooling load on the indoor coil increases, causing the low
2. Remove small quantities of gas from the suction line dill
side pressure to rise, but at a slower rate.
valve until the head pressure is reduced to normal.
Since the high side pressure rises faster when the tempera-
3. Observe the system while running a cooling performance
ture increases, more refrigerant flows to the evaporator, increas-
test, if a shortage of refrigerant is indicated, then the sys-
ing the cooling capacity of the system.
tem contains non-condensables. See S-114 Non-
When the outdoor temperature falls, the reverse takes place. Condensables.
The condensing pressure falls, and the cooling loads on the
indoor coil decreases, causing less refrigerant flow. S-114 NON-CONDENSABLES
If a restriction should become evident, proceed as follows: Check for non-condensables.
1. Recover refrigerant charge. 1. Shut down the system and allow the pressures to equalize
2. Remove the orifice assembly and clean or replace. for a minimum of 15 minutes.
2. Take a pressure reading.
3. Replace liquid line drier, evacuate and recharge.
3. Compare this pressure to the temperature of the coldest
CHECKING EQUALIZATION TIME coil since this is where most of the refrigerant will be. If the
During the "OFF" cycle, the high side pressure bleeds to the pressure indicates a higher temperature than that of the
low side through the fixed orifice restriction device. Check coil temperature, non-condensables are present.
equalization time as follows:
To remove the non-condensables.
1. Attach a gauge manifold to the suction and liquid line dill
1. Remove the refrigerant charge.
valves
2. Replace and/or install liquid line drier
2. Start the system and allow the pressures to stabilize.
3. Evacuate and recharge.
3. Stop the system and check the time it takes for the high
and low pressure gauge readings to equalize. S-115 COMPRESSOR BURNOUT
If it takes more than seven (7) minutes to equalize, the restric- When a compressor burns out, high temperature develops caus-
tion device is inoperative. Replace, install a liquid line drier, ing the refrigerant, oil and motor insulation to decompose form-
evacuate and recharge. ing acids and sludge.
S-112 CHECKING RESTRICTED LIQUID LINE If a compressor is suspected of being burned-out, attach a
refrigerant hose to the liquid line dill valve and properly remove
When the system is operating, the liquid line is warm to the
and dispose of the refrigerant.
touch. If the liquid line is restricted, a definite temperature
drop will be noticed at the point of restriction. In severe cases, Now determine if a burn out has actually occurred. Confirm by
frost will form at the restriction and extend down the line in the analyzing an oil sample using a Sporlan Acid Test Kit, AK-3 or
direction of the flow. its equivalent.
Discharge and suction pressures will be low, giving the ap- Remove the compressor and obtain an oil sample from the
pearance of an undercharged unit. However, the unit will have suction stub. If the oil is not acidic, either a burnout has not
normal to high subcooling. occurred or the burnout is so mild that a complete cleanup is
not necessary.
If a restriction is located, replace the restricted part, replace
drier, evacuate and recharge. If acid level is unacceptable the system must be cleaned by
using the drier cleanup method.
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Wrap the reversing valve with a large rag saturated with water.
CAUTION "Re-wet" the rag and thoroughly cool the valve after each braz-
ing operation of the four joints involved. The wet rag around the
DO NOT ALLOW THE SLUDGE OR OIL TO CONTACT reversing valve will eliminate conduction of heat to the valve
THE SKIN, SEVERE BURNS MAY RESULT. body when brazing the line connection.
The use of a wet rag sometimes can be a nuisance. There are
Suction Line Drier Clean-up Method commercial grades of heat absorbing paste that may be sub-
Discard at least twelve (12) inches of the suction line immedi- stituted.
ately out of the compressor stub due to burned residue and After the valve has been installed, leak test, evacuate and re-
contaminates. charge.
1. Remove compressor discharge line strainer, liquid line S-200 CHECKING EXTERNAL STATIC
strainer and/or drier and capillary tubes from indoor and
outdoor coils. PRESSURE
2. Units with an expansion valve coil, remove the liquid line The minimum and maximum allowable duct static pressure is
drier and expansion valve. found in the Technical Information Manual.
3. Purge all remaining components with dry nitrogen or car- Too great of an external static pressure will result in insuffi-
bon dioxide until clean. cient air that can cause icing of the coil, whereas too much air
4. Install new components including liquid liner drier. can cause poor humidity control, and condensate to be pulled
off the evaporator coil causing condensate leakage. Too much
5. Install suction line drier.
air can cause motor overloading and in many cases this con-
6. Braze all joints, leak test, evacuate, and recharge system. stitutes a poorly designed system. To determine proper air
7. Start up the unit and record the pressure drop across the movement, proceed as follows:
cleanup drier. 1. Using a draft gauge (inclined manometer) measure the static
8. Continue to run the system for a minimum of twelve (12) pressure of the return duct at the inlet of the unit, (Negative
hours and recheck the pressure drop across the drier. Pres- Pressure).
sure drop should not exceed 6 - 8 PSIG.
9. Continue to run the system for several days repeatedly
checking pressure drop across the suction line drier. If the
pressure drop never exceeds the 6 - 8 PSIG, the drier must
be adequate and is trapping the contaminants and it is
permissible to leave it in the system.
10. If the pressure drop becomes greater, then it must be re-
placed and steps 5 through 9 repeated until it does not
exceed 6 - 8 PSIG.
NOTE: The cause for burnout MUST be determined and cor-
rected BEFORE the new compressor is started.
39
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SERVICING
2. Measure the static pressure of the supply duct, (Positive 1. Take entering and leaving air temperatures.
Pressure). 2. Select the proper speed tap from the unit's blower perfor-
3. Add the two readings together. mance data in the Technical Manual for the specific unit.
NOTE: Both readings may be taken simultaneously and read 3. Take motor amperage draw to determine that the motor is
directly on the manometer as shown in the illustration above, if not overloaded during adjustments.
so desired.
4. Consult proper table for quantity of air.
If the external static pressure exceeds the minimum or maxi-
mum allowable statics, check for closed dampers, dirty filters,
undersized or poorly laid out ductwork.
40
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WIRING DIAGRAMS
PACKAGE SYSTEM WIRING DIAGRAM - 1 STAGE ELECTRIC HEAT
TYPICAL HP
SEE NOTE 1 ROOM THERMOSTAT
#18 GAUGE 7 WIRE
REQUIRED FOR PACKAGE UNIT
HEAT PUMPS Y O C W1 G R E LOW VOLTAGE
JUNCTION BOX
R R RED
Y Y YELLOW
G G GREEN
O O ORANGE
BR W WHITE
R
BL BL BLUE
DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS
UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO
BL
2 1
OUTDOOR THERMOSTAT
CLOSE ON TEMPERATURE FALL
TYPICAL HP
SEE NOTE 1 ROOM THERMOSTAT
#18 GAUGE 8 WIRE PACKAGE UNIT
FOR HEAT PUMPS
W2 Y O C W1 G R E LOW VOLTAGE
JUNCTION BOX
R R RED
Y YELLOW
HIGH VOLTAGE!
G G GREEN
O O ORANGE
SEE NOTE 2
BR W WHITE
W
R BR BROWN
BL BL BLUE
2 1
OUTDOOR THERMOSTAT
CLOSE ON TEMPERATURE FALL
W2 Y O C W1 G R E
PACKAGE HEAT PUMP
R R RED
Y Y YELLOW
O O ORANGE
UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO
BR W WHITE
R W
BL
2 1
BR BROWN
Y
3
BL BL BL BLUE
2 1
OUTDOOR THERMOSTAT #1 LOW VOLTAGE
CLOSE ON TEMPERATURE FALL JUNCTION BOX
HIGH VOLTAGE!
COLOR CODES
R --RED
Y --YELLOW
BL-BLUE
BR-BROWN
O --ORANGE
W -WHITE
G --GREEN
42
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WIRING DIAGRAMS GPC/GPH13**M21*
FL
FL
HTR2 TL
HTR1 TL FL
PLM HTR1 TL
R
BK BK 1 PLM
BK BK 1
2
R
PU 2
3 R
BK BL PU 3
M1 4 BK BL
R R M1 M3 4
M2 5
R
M2 M4 5
W 6
W 6
BK 7 R
BK
BK 7
R 8 BK
R 8
DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
9
DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS
9
UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO
L1 L2
ONE (1) ELEMENT ROWS L1 L2 TWO (2) ELEMENT ROWS
5 KW 10 KW
FL
FL BK
HTR1 TL
FL
HTR1 TL BK
FL HTR2 TL R
FL
TL R
FL HTR2 HTR3 TL Y
PLM FL
HTR3 TL PLM
BK 1 HTR4TL BL
BK
1
HIGH VOLTAGE!
R Y 2
Y BK PU PU 2
BL 3 BL BK R
M1 M3 M1
R BL 3
BL 4 R
R M4 M2 Y M1 M3 M5 M7
M2 BL 4
R M2 M4 M6 M8
R1 R2
BR 5
BK R1 R2 BR 5
BK R W 6 BK BK
R W 6
7
Y 7
8 Y
BK BL 8
R BK
9
R 9
15 KW 20 KW
43
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44
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.
FL HTR3 TL
2
WIRING DIAGRAMS
4
FL HTR1 TL
7
RS
M1 M3 8
M2 M4
CIRCUIT 2
3 PH. 208-240V B17579-19
GPC/GPH13[36-60]M23*
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.
FL HTR3 TL
WIRING DIAGRAMS
FL HTR2 TL
3
4
FL HTR1 TL
7
RS
M1 M3 8
CIRCUIT 2
3 PH. 460V HKR4-15
WIRE CODE
COMPONENT CODE
HTR HEAT ELEMENT BK BLACK OR ORANGE
RS RELAY/SEQUENCER BL BLUE PK PINK
TL THERMAL LIMIT BR BROWN PU PURPLE
0140K00147 Rev. A GR GREEN
GPH13[36-60]M24*
45
46
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.
FL HTR3 TL
2
FL HTR2 TL
3
WIRING DIAGRAMS
7
RS
M1 M3 8
M2 M4
9
WHITE
47