Service Instructions PHB**C, PHD**C PACKAGE HEAT PUMPS PGA**C, PGB**C, PGD**C PACKAGE GAS & PCC**C PACKAGE COOLERS Models listed on Page 6 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. is a trademark of Maytag Corporation and is used under license to Goodman Company, L.P. All rights reserved.
INDEX IMPORTANT INFORMATION ........................................................................................................ 4 PRODUCT IDENTIFICATION ........................................................................................................ 6 ACCESSORIES ............................................................................................................................. 9 LIGHTING INSTRUCTIONS .....................................................................................
INDEX S-106 S-107 S-108 S-109 S-110 S-111 S-112 S-113 S-114 S-115 S-200 S-301 S-302 S-304 S-306 S-307 S-308 S-309 S-310 S-311 S-313 S-314 S-315 OVERFEEDING ......................................................................................................................... 52 UNDERFEEDING ...................................................................................................................... 52 SUPERHEAT .....................................................................................
IMPORTANT INFORMATION Pride and workmanship go into every product to provide our customers with quality products. It is possible, however, that during its lifetime a product may require service. Products should be serviced only by a qualified service technician who is familiar with the safety procedures required in the repair and who is equipped with the proper tools, parts, testing instruments and the appropriate service manual.
IMPORTANT INFORMATION SAFE REFRIGERANT HANDLING While these items will not cover every conceivable situation, they should serve as a useful guide. WARNING WARNING TO AVOID POSSIBLE EXPLOSION: • NEVER APPLY FLAME OR STEAM TO A REFRIGERANT CYLINDER. IF YOU REFRIGERANTS ARE HEAVIER THAN AIR. THEY CAN "PUSH OUT" THE TO AVOID OXYGEN IN YOUR LUNGS OR IN ANY ENCLOSED SPACE.
PRODUCT IDENTIFICATION P G B 24 C 045 2 D Product Type Engineering Revision Single Package Cooling/Heating Voltage 2: 230V/60Hz/1ph Product Family G - Gas/Electric H - Heat Pump C - Cooling Heating Input HEAT PUMPS Product Series 0: No heat installed C: 10 kw heat installed A: 10 SEER Line B: 11 SEER Line C: 12 SEER Line D: 13 SEER Line PACKAGE GAS Nominal Capacity 24: 24000 BTUH 30: 30000 BTUH 36: 36000 BTUH 42: 42000 BTUH 48: 48000 BTUH 60: 60000 BTUH PGA60C0902* PGA60C1152* PGB24C0452*
PRODUCT IDENTIFICATION Gas Units Package Gas Units Model # Manufacturing # Description Package Gas (A) 10 Seer gas/electric units. New chassis design with PGA60C0902D P1217301C-P1217302C smaller footprint. PGA models have stronger blower performance for down PGA60C1152D shot applications. PGA60C0902D PGA60C1152D Package Gas (A) 10 Seer gas/electric units. Changed from 26" fan blade to P1220301C-1220302C 22" fan blade to improve operating sound.
COOLERS HEAT PUMPS PRODUCT IDENTIFICATION 8 Heat Pumps and Coolers Model # Manufacturing # Description PHB**C02D P1214402C-P1214404C Package Heat Pump (B) 11 Seer heat pump units. New chassis design with smaller footprint. PHB**C02E P1204501C-P1214404C Package Heat Pump (B) 11 Seer heat pump units. New chassis design with smaller footprint. Improved heating capacity PHB**C02E P1220101C-P1220106C Package Heat Pump (B) 11 Seer heat pump units.
ACCESSORIES Additional Amana® brand accessories, as described below, can be purchased to fit specific application needs. Accessories can be ordered by the following part numbers and each accessory includes its own separate instructions. ACCESSORY PART NUMBER DESCRIPTION Duct Transition Round RSDK01A (24-60) Converts existing round duct connections to rectangular. Used to install the horizontal duct cover kit on heat pump units.
ACCESSORIES Accessories PHCB**C1 SPK**A P1219401C-P1219406C Package Heat kit with Circuit Breakers. Electric heat kits include breakers P1219408C-P1219412C for electric heat only. Single Point power connection Kit. Kit allows for one circuit to provide P1221701C-P1221706C power supply for package heat pumps (PHB/PHD**C) and coolers P1221708C-P1221712C (PCC**C). Kit includes circuit breaker for compressor. PRC06A1 PRC07A1 PRC07A1 Package Roof Curb Kit.
ACCESSORIES 1" 42-3 /8" " 35 14" SUPPLY 19-3 RETURN /16" 19-3 " 19 /16" PRC06A1 ROOF CURB 12" 42 " 3/8 47" 2" SUPPLY RETURN " 25 14" 25" " 12 2" PRC07A1 ROOF CURB 11
ACCESSORIES 1 14 42 3/8 24 3/8 47 2 RETURN SUPPLY 14 12 14 35 INSULATED PLATFORM UNIT SUPPORT PRC08A ROOF CURB J A H 1.
LIGHTING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions LIRE AVANT DE METTRE EN MARCHELIRE AVERTISSEMENT: Ouiconque ne respcte pas `a la lettre les instructions dans le present manuel risque de declencher un incendie ou une explosion entrainant des dommages materiels, des lesions corporelles ou la perte de vies humaines. exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A.
LIGHTING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions LIRE AVANT DE METTRE EN MARCHELIRE AVERTISSEMENT: Ouiconque ne respcte pas `a la lettre les instructions dans le present manuel risque de declencher un incendie ou une explosion entrainant des dommages materiels, des lesions corporelles ou la perte de vies humaines. exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A.
LIGHTING INSTRUCTIONS LIRE AVANT DE METTRE EN MARCHELIRE AVERTISSEMENT: Quiconque ne respecte pas á FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions explosion may result causing property damage, personal injury or loss of life. la lettre les instructions dans le présent manuel risque de déclecher un incendie ou une explosion entraînant des dammages matériels, des lésions corporelles ou la perte de vies humaines. A. This appliance does not have a pilot.
LIGHTING INSTRUCTIONS IN 2 PSI OFF ON ROBINET A GAZ MANUEL, EN POS "ON/MARCHE" GAS INLET ARRIVEE DU GAZ MANUAL GAS SWITCH SHOWN IN "ON" POS 16
LIGHTING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions explosion may result causing property damage, personal injury or loss of life. LIRE AVANT DE METTRE EN MARCHELIRE AVERTISSEMENT: Quiconque ne respecte pas á la lettre les instructions dans le présent manuel risque de déclecher un incendie ou une explosion entraînant des dammages matériels, des lésions corporelles ou la perte de vies humaines. A. This appliance does not have a pilot.
LIGHTING INSTRUCTIONS ROBINET A GAZ MANUEL, EN POS "ON/MARC HE" ON * ARRIVEE DU GAZ ** * OFF GAS INLET * * MANUAL GAS LEVER SHOWN IN "ON" POS 18 *
PRODUCT DESIGN WARNING TO PREVENT POSSIBLE DAMAGE, THE UNIT SHOULD REMAIN IN AN UPRIGHT POSITION DURING ALL RIGGING AND MOVING OPERATIONS. TO FACILITATE LIFTING AND MOVING IF A CRANE IS USED, PLACE THE UNIT IN AN ADEQUATE 36" Side Clearance for Servicing Recommended 24" Clearance (Condenser End) CABLE SLIDE. 36" Maximum Overhang 48" Minimum Overhang IMPORTANT: If using bottom discharge with roof curb, ductwork should be attached to the curb prior to installing the unit.
PRODUCT DESIGN The single phase units use permanent split capacitors (PSC) design compressors. Starting components are therefore not required. A low MFD run capacitor assists the compressor to start and remains in the circuit during operation. The outdoor fan and indoor blower motors are single phase capacitor type motors. Air for condensing (cooling cycle) or evaporation (heating cycle) is drawn through the outdoor coil by a propeller fan, and is discharged vertically out the top of the unit.
PRODUCT DESIGN The best protection for the wiring is the smallest fuse or breaker which will hold the equipment on line during normal operation without nuisance trips. Such a device will provide maximum circuit protection. DO NOT EXCEED THE MAXIMUM OVERCURRENT DEVICE SIZE SHOWN ON THE UNIT DATA PLATE. All line voltage connections must be made through weather proof fittings. All exterior power supply and ground wiring must be in approved weather proof conduit.
PRODUCT DESIGN 8. The furnace shall be connected to the building piping by one of the following. a. Rigid metallic pipe and fittings. b. Semirigid metallic tubing and metallic fittings. Aluminum alloy tubing shall not be used in exterior locations. c. Listed gas appliance connectors used in accordance with the terms of their listing that are completely in the same room as the equipment. d.
PRODUCT DESIGN TYPICAL PROPANE PIPING Sizing Between Single or Second Stage Regulator and Appliance Maximum Propane Capacities listed are based on 1/2" W.C. Pressure 5 to 15 PSIG (20 PSIG Max.) First Stage Regulator 200 PSIG Maximum Drop at 11" W.C. Setting. Capacities in 1000 BTU/HR Continuous 11" W.C. PIPE OR TUBING TUBING SIZE, O.D.
SYSTEM OPERATION COOLING The refrigerant used in the system is R-22. It is clear, colorless, non-toxic, non-irritating, and non-explosive liquid. The chemical formula is CHCLF2. The boiling point, at atmospheric pressure is -41.4°F.
SYSTEM OPERATION Typical Package Cooling or Package Gas Indoor Coil Outdoor Coil Thermostatic Expansion Valve Either a thermostatic expansion valve or restrictor orifice assy may be used depending on model, refer to the parts catalog for the model being serviced.
SYSTEM OPERATION Typical Heat Pump System in Cooling Reversing Valve (Energized) Indoor Coil Outdoor Coil Accumulator Expansion device may not be as shown. Refer to product parts manual for actual part description. Thermostatic Expansion Valve Check Valve Typical Heat Pump System in Heating Reversing Valve (De-Energized) Indoor Coil Outdoor Coil Accumulator Expansion device may not be as shown. Refer to product parts manual for actual part description.
SYSTEM OPERATION The timing interval can not begin until the outdoor coil temperature reaches approximately 30°F. (initiation temperature) at the defrost (30/60) control point of contact. As long as this point of contact does not reach 60°F. (termination temperature) the defrost timer board will count the number of minutes that the compressor runs. The system may be controlled by most good heating and cooling thermostats with an adjustable heat anticipator.
SYSTEM OPERATION Figure 9 illustrates the pressure control in an off position. NEGATIVE PRESSURE CONNECTOR NORMALLY OPEN TERMINAL OFF COMMON TERMINAL ON Figure 9 With the furnace in the off position the induced draft blower motor will not be running. Atmospheric pressure will therefore be on both sides of the diaphragm and the electrical switch will be open between (C) common and (NO) normally open terminals.
SYSTEM OPERATION ELECTRIC HEATERS Optional electric heaters may be added, in the quantities shown in the specifications section to provide electric resistance heating. Under no condition shall more heaters than the quantity shown be installed. The low voltage circuit in the blower section is factory wired and terminates at the location provided for the electric heater(s). A minimum of field wiring is required to complete the installation.
SCHEDULED MAINTENANCE The owner should be made aware of the fact, that, as with any mechanical equipment the package unit requires regularly scheduled maintenance to preserve high performance standards, prolong the service life of the equipment, and lessen the chances of costly failure. In many instances the owner may be able to perform some of the maintenance; however, the advantage of a service contract, which places all maintenance in the hands of a trained serviceman, should be pointed out to the owner.
SERVICING To find the BTU input, multiply the number of cubic feet of gas consumed per hour by the heating value of the gas being used. (The calorific value of the gas being used is found by contacting your local utility.) Example: It is found by the gas meter, that it takes forty (40) seconds for the hand on the cubic foot dial to make one complete revolution, with all appliances off, except the furnace. Take this information and locate it on the gas rate chart.
SERVICING 1 0 9 2 8 3 7 7 4 6 5 1 Million Quarter 1 1 9 2 8 5 4 100 Thousand 8 2 7 7 3 8 3 3 6 4 5 1 9 9 2 6 6 5 4 1 Thousand 10 Thousand CUBIC FEET One Foot Foot 0 GAS RATE -- CUBIC FEET PER HOUR 32 Seconds for One Revolution 1/4 cu/ft 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 90 82 75 69 64 60 56 53 50 47 45 43 41 39 37 36 34 33 32 31 30 -28 -26 -- Size of Test Dial 1/2 1 2 cu/ft cu/ft cu/ft 5 cu/ft Seconds for One Revol
SERVICING COOLING OR HEAT PUMP - SERVICE ANALYSIS GUIDE Power Failure Blown Fuse Loose Connection Shorted or Broken W ires Open Overload Faulty Thermostat Faulty Transformer Shorted or Open Capacitor Shorted or Grounded Compressor Compressor Stuck Faulty Compressor Contactor Faulty Fan Relay Open Control Circuit Low Voltage Faulty Evap.
SERVICING GAS HEATING - SERVICE ANALYSIS GUIDE Power Failure Blown Fuse Loose Connection Shorted or Broken Wires No Low Voltage Faulty Thermostat Faulty Transformer • • • Improper Heat Anticipator Setting Faulty Limit or Roll Out Switch Faulty Flame Sensor Faulty Ignition Control Gas Valve or Gas Supply Shut Off Faulty Induced Draft Blower Broken or Shorted Ignitor Faulty Combustion Relay Dirty Flame Sensor, Low uA Flame Sensor not in Flame, Low uA Faulty Gas Valve Open Auxillary Limit Improper Air Flow
SERVICING NOTE: When operating electric heaters on voltages other than 240 volts refer to the System Operation section on electric heaters to calculate temperature rise and air flow. Low voltage may cause insufficient heating. S-1 CHECKING VOLTAGE WARNING HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. F AILURE TO DO SO MAY CAUSE PROPERTY Three phase units require a balanced 3 phase power supply to operate.
SERVICING If the imbalance had not changed then the problem would lie within the equipment. Check for current leakage, shorted motors, etc. S-2 CHECKING WIRING WARNING HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. F AILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. 1. Check wiring visually for signs of overheating, damaged insulation and loose connections. 2.
SERVICING 5. If line voltage available at primary voltage side of transformer and wiring and splices good, transformer is inoperative. Replace. 3. Using a voltmeter, test across terminals. A. L2 - T1 - No voltage indicates CC1 contacts open. If a no voltage reading is obtained - replace the contactor. S-6 CHECKING TIME DELAY RELAY Time delay relays are used in Amana® brand Package Units to improve efficiency by delaying the blower off time. This feature is incorporated into the electronic controls.
SERVICING These capacitors have a 15,000 ohm, 2 watt resistor wired across its terminals. The object of the resistor is to discharge the capacitor under certain operating conditions, rather than having it discharge across the closing of the contacts within the switching device such as the Start Relay, and to reduce the chance of shock to the servicer. See the Servicing Section for specific information concerning capacitors.
SERVICING S-16B ECM/ICM Motors ECM/ICM Features Many of the Amana® brand high efficiency package units incorporate the GE© ICM or variable speed blower motors for greater efficiency. ECM/ICM motors vary the motor RPMs to provide a set volume of air over a wide range of conditions. ECM/ICM Control Connections Control functions (G, Y1, Y2) May be Active at less than 1/2 control voltage. (i.e. 12 volts). Relay contacts on control functions must reliably switch low currents (less than 5 MA).
SERVICING OUT - 8 16 OUT + ADJUST +/- 7 15 G (fan) Y1 6 14 Y/Y2 COOL 5 13 EM HT/W2 DELAY 4 12 24VAC (R) COMMON 2 3 11 HEAT W/W1 2 10 BK/Pwm (Speed) COMMON 1 1 9 O (Rev Valve) CONTROL CONNECTOR "Motor Half“ CAUTION HIGH VOLTAGE ON CONTROL PINS WILL DESTROY MOTOR. Replacing ICM Control Module Use the following steps to replace the control module for the GE© variable speed indoor blower motor. 1. You must have the correct replacement module.
SERVICING S-16E Testing Interface Board Fan Only With thermostat set to the “Fan” position, and system switch “Off”: 4. If no voltage present from “C” to “G” and “C” to “Y/Y2”, check low voltage wiring in unit and thermostat and thermostat wiring. 1. Check for 24 volts from “C” to “R2” or “R3”. 5. If 24 volts present from “C” to “G” and “C” to “Y/Y2”, check for 24 volts from pin 1 to pin 6 and from pin 3 to pin 6 in the 16 pin connector at the interface board. 2.
Check for undercharged condition. - Arrange harnesses with "drip loop" under motor. - You must use the correct replacement control motor module since they are factory programmed for specific operating modes. Even though they look alike, different modules may have completely different functionality. The ECM variable speed motors are currently the only motors that can have the motor/control module replaced. - Turn power OFF prior to repair.
Check and plug leaks in return ducts, cabinet. Check for undercharged condition. - Arrange harnesses with "drip loop" under motor. - Check for low airflow (too much latent capacity). You must use the correct replacement control motor module since they are factory programmed for specific operating modes. Even though they look alike, different modules may have completely different functionality. The ECM variable speed motors are currently the only motors that can have the motor/control module replaced.
SERVICING ECM VARIABLE SPEED CIRCULATOR BLOWER MOTORS DO DON'T - Check-out motor, controls, wiring, and connections before replacing motor. - Orient connectors down to prevent water infiltration. - Install "drip loops". - Use authorized motor and control model #'s for replacement. - Automatically assume the motor is bad. - Keep static pressure to a minimum: - Use high pressure drop filters - some have 1/2" H2O drop! - Use restricted returns. - Recommend high efficiency, low static filters.
SERVICING S-17 CHECKING COMPRESSOR WINDINGS WARNING HERMETIC COMPRESSOR ELECTRICAL TERMINAL VENTING CAN BE DANGEROUS. WHEN INSULATING MATERIAL, WHICH SUPPORTS A HERMETIC WARNING 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. COMPRESSOR ELECTRICAL TERMINAL, SUDDENLY DISINTEGRATES DUE TO PHYSICAL ABUSE OR AS A RESULT OF AN ELECTRICAL SHORT BETWEEN 1.
SERVICING WARNING DAMAGE CAN OCCUR TO THE EMBEDDED TERMINALS AT THIS POINT IF THE WARNING L INE VOLTAGE NOW PRESENT. LEADS ARE NOT PROPERLY REMOVED, WHICH CAN RESULT IN THE TERMINAL VENTING AND HOT OIL DISCHARGING. A. If the compressor starts and continues to run, the cause for failure is somewhere else in the system. B. If the compressor fails to start - replace. Compressor Serial Number Identification COPELAND COMPRESSOR HI-POT E COMPRESSOR GROUND TEST 2.
SERVICING NOTE: The positive temperature coefficient crankcase heater is a 40 watt 265 voltage heater. The cool resistance of the heater will be approximately 1800 ohms. The resistance will become greater as the temperature of the compressor shell increases. Normal sequence of operation, Cooling Mode. 1. If the compressor has been off for at least 3 minutes when a call for cool is received, the compressor is immediately energized. The indoor blower is energized at the cooling speed after a 7 second delay.
SERVICING DEFROST CONTROL BOARD NOTE: If the board is powered up with the jumper connected to the test pins, the board will ignore test and default to 90 minute time. If the jumper is left on the test connection for more than ten minutes, the board will ignore test jumper and default to 90 minute time. If jumper is missing, the board will default to 90 minute time. 6. Whenever the (CC) compressor contactor is energized, the solid state timer counts the compressor run time.
SERVICING 7. Using VOM check for voltage across "W & C" terminals on the board. You should read 24 volts. 8. If not as above, replace control board. 9. Set thermostat to off position and disconnect power before removing any jumpers or wires. NOTE: Remove jumper across defrost thermostat and replace jumper to 30, 60, or 90 minute position before returning system to service. S-25 TESTING DEFROST CONTROL (30°/60°) 1.
SERVICING 3. Using an ohmmeter, test the element for continuity - no reading indicates the element is open. Replace as necessary. See "Electric Heater" in the Product Design Section to verify heater amperage and temperature rise. S-53 OUTDOOR TEMPERATURE CONTROL (OPTIONAL ITEM) ATK01 This kit includes an ambient thermostat mounted in a weatherproof box for installation exterior to the unit. This kit is used for ambient control on all Amana® brand package models and remote cooling models.
SERVICING Moisture chemically reacts with the refrigerant and oil to form corrosive hydrofluoric and hydrochloric acids. These attack motor windings and parts, causing breakdown. The equipment required to thoroughly evacuate the system is a high vacuum pump, capable of producing a vacuum equivalent to 25 microns absolute and a thermocouple vacuum gauge to give a true reading of the vacuum in the system NOTE: Never use the system compressor as a vacuum pump or run when under a high vacuum.
SERVICING NOTE: THIS CHARGING PROCEDURE CAN ONLY BE DONE IN THE COOLING MODE OF OPERATION. ALL MODELS WITH COMPRESSOR PROCESS TUBE ACCESS VALVE CAN BE PROCESSED IN HEATING CYCLE IF THIS VALVE IS USED. Units having capillary tubes or flow control restrictors can be checked against the Desired Superheat vs. Outdoor Temperature Chart in this section. Coils with thermostatic expansion valves (TXV's) must be checked by subcooling. See "Checking Subcooling and Superheat" sections in this manual.
SERVICING S-108 SUPERHEAT The expansion valves are factory adjusted to maintain 12 to 18 degrees superheat of the suction gas. Before checking the superheat or replacing the valve, perform all the procedures outlined under Air Flow, Refrigerant Charge, Expansion Valve - Overfeeding, Underfeeding. These are the most common causes for evaporator malfunction.
SERVICING TEMPERATURE - PRESSURE (R-22) Temp. °F. Gauge Pressure (PSIG) Freon-22 Temp. °F. Gauge Pressure (PSIG) Freon-22 -40 -38 -36 -34 -32 -30 -28 -26 -24 -22 -20 -18 -16 -14 -12 -10 -8 -6 -4 -2 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 0.61 1.42 2.27 3.15 4.07 5.02 6.01 7.03 8.09 9.18 10.31 11.48 12.61 13.94 15.24 16.59 17.99 19.44 20.94 22.49 24.09 25.73 27.44 29.21 31.04 32.93 34.88 36.89 38.96 41.09 43.28 45.53 47.85 50.24 52.70 55.23 57.83 60.51 63.27 66.
SERVICING S-111 FIXED ORIFICE RESTRICTION DEVICES S-113 OVERCHARGE OF REFRIGERANT The fixed orifice restriction device (flowrator) used in conjunction with the indoor and outdoor coils are a predetermined bore (I.D.). An overcharge of refrigerant is normally indicated by an excessively high head pressure. It is designed to control the rate of liquid refrigerant flow into an evaporator coil.
SERVICING S-200 CHECKING EXTERNAL STATIC PRESSURE CAUTION D O NOT ALLOW THE SLUDGE OR OIL TO CONTACT THE SKIN. S EVERE BURNS MAY RESULT. NOTE: The Flushing Method using R-11 refrigerant is no longer approved by Goodman Company, L.P. Suction Line Drier Clean-Up Method Use AMANA® brand part number R0157057 Suction Line Drier Clean-Up Kit (41 cubic inches). This drier should be installed as close to the compressor as possible, either in a vertical or horizontal position.
SERVICING AUX. LIMIT THERMODISC (TOD) LIMIT CONTROL Refer to the specification section to determine the proper limit cutout temperature for the model being serviced. In all instances the limit control is wired in series with the ignition control. If the temperature within the furnace should exceed this setting, the control will open, de-energizing the ignition control which in turn will open the electrical circuit to the gas valve.
SERVICING If the rollout control has opened, the circuit between the ignition control and gas valve will be interrupted and the ignition control module will go into lockout. The servicer should reset the ignition control by opening and closing the thermostat circuit. The servicer should look for the ignitor glowing which indicates there is power to the ignition control.
SERVICING 7. The unit will deliver heat to the conditioned space until the thermostat is satisfied. 11. Using a microamp meter verify flame sense. Microamp readings should be 0.3 microamps or greater. 12. Smart Valve will not allow main burner operation until pilot is proven. NOTE: pilot positioning will affect pilot operation and flame sensing characteristics. See S-314 for proper pilot positioning 13. If pilot looses flame sense, valve will shut off main burners and attempt relight.
SERVICING A dent or burr will cause severe deflection of gas stream. 1/2PSI No resizing should be attempted until all factors are taken into consideration such as inlet manifold gas pressure, alignment, and positioning, specific gravity and BTU content of the gas being consumed. OFF IN ON The only time resizing is required is when a reduction in firing rate is required for an increase in altitude.
SERVICING S-308 CHECKING FOR DELAYED IGNITION Delayed ignition is a delay in lighting a combustible mixture of gas and air which has accumulated in the combustion chamber. Gas Line Gas Shutoff Valve When the mixture does ignite, it may explode and/or rollout causing burning in the burner venturi. If delayed ignition should occur, the following should be checked: Gas Line To Furnace Open To Atm ospere Drip Leg Cap With Fitting 1. Improper gas pressure - adjust to proper pressure. (See S-307) 2.
SERVICING Honeywell Smart Valve Sequence of Operation SV9500 Start Power to System Board checks limit circuit Limit(s) open Limits closed Control board applies power to Air circulating blower (ACB) cooling speed. Pilot and Igniter are locked out. Thermostat calls for heat Self Check "Smart Valve" checks Igniter circuit and valve Ignition Igniter Missing or Broken System shuts down.. Igniter and gas valve check OK "Smart Valve" powers Igniter, opens pilot valve.
SERVICING Honeywell Smart Valve Sequence of Operation SV9501 Start Power to System Control board applies power to Air circulating blower (ACB) cooling speed. Pilot and Igniter are locked out. Limit(s) open Board checks limit circuit Limits closed Five minute retry delay Thermostat calls for heat Self Check Flame signal detected Yes No Pilot valve and Igniter remain closed.
YES Turn gas on. Pilot burner lights YES Igniter warms up and glows red. YES NO NO Check gas valve Check pilot assembly Check pilot to burner alignment. Check ingiter Check gas valve Check pressure switch operation Check induced draft blower operation Check primary, Aux.
Smart Valve system OK YES Blower runs after 30 Seconds YES Main valve opens NO NO Verify unit is properly grounded? Check flame proving circuits and gas valve Check control board Replace control board YES Check for output from gas valve to control board. 19.5 volts min. at Blue 34 wire to transformer common. Discard old Igniter/flame sensor Assembly YES Replace Igniter/flame sensor assembly and restart trouble shooting sequence Does main burner light? YES Verify flames sense circuit.
SERVICING If the pressure switch opens before the ignition period, the induced draft blower will remain on and the control will stay in pre-purge until the pressure switch is closed for an entire 15 second pre-purge period. The LED will flash a code of "2" to indicate open pressure switch. If the pressure switch opens after the gas valve has been energized, the control will de-energize the gas valve and run the indoor blower through the heat off delay.
SERVICING Honeywell Smart Valve Ignition Systems Blower Off Delay Settings L2 NORMAL SEQUENCE OF OPERATION (Honeywell Smart Valve System) COOL With Power ON: HEAT L2 L2 UNUSED L1 L1 D1 1 3 2 6 5 4 9 8 7 12 11 10 speed up FS Diagnostic LED Testing Honeywell Smart Valve Systems The ignition control module is a combination electronic and electromechanical device and is not field repairable. Complete unit must be replaced. L2 WARNING L INE VOLTAGE NOW PRESENT.
SERVICING Diagnostics Flash Codes LED Steady On Control is OK in standby, heat, cool, or fan only modes. LED Steady Off Internal control fault or no power. 1 Flash Lockout due to failed ignition or flame dropouts. 2 Flashes Pressure switch is open with induced draft motor energized. 3 Flashes Pressure switch is stuck closed with induced draft motor de-energized. 4 Flashes Limit switch is open (primary, auxiliary, or roll out). 5 Flashes Flame detected with gas valve closed.
SERVICING Honeywell Smart Valve Systems DSI Direct Spark Ignition Systems WARNING WARNING HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. F AILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. 1. The Honeywell "Flame Sense Measurement Kit", Amana® brand part # R9900026, is required to correctly measure the microamp flame proving current. 2.
SERVICING Spark Igniter Flame Sensor DSI Flame Sensor and Spark Ignitor Location S-315 CHECKING HOT SURFACE IGNITER "Smart Valve" systems use a silicone carbide restrictive element ignitor is used for ignition. The normal operating temperature is approximately 2550°F. "DSI" systems use a spark type igniter. 2. Disconnect the ignitor from the Ignition Control Module and line voltage terminal board. 3.
S 1 S R COMP C H E A T 2 3 0 C O M N 2 L2 T2 N0 PS NC C COMB BLOWER 2 0 8 D I 3 1 2 3 4 RL L I M I T A U X L I M I T R 6 N 4 1 S S HEAT FAN DELAY OFF S 2 3 BK 17 60 120 1 Y HUM EAC N N MOTOR LEADS HUM EAC DI UNUSED 4 4 4 4 4 4 2 PGB24C0902D PGB30C0702D PGB30C0902D PGB36C0702D PGB36C0902D PGB42C0902D MOTOR SPEEDS HI HI MED HI HI MED HI HI MED HI LOW SPEED BK-26 BK-26 BU-23 BK-26 BU-23 BK-26 BU-23 YL-27 MOTOR TO "HEAT" * HEATING BLO
C O M S R COMP C C O M N 2 L2 T2 N0 PS NC C COMB BLOWER D I 3 C Y 1 2 1 2 3 4 GAS VALVE 4 4 3 2 1 W RL L I M I T A U X L I M I T R 6 N 4 1 S S HEAT FAN DELA Y O FF S 2 3 BK 17 60 120 1 Y HUM EAC N N MOTOR LEADS HUM EAC DI UNUSED 3 3 3 3 3 PGB48C1152D PGB48C1402D PGB60C0902D PGB60C1152D PGB60C1402D MOTOR SPEEDS HI MED LOW HI MED LOW MED SPEED BK-26 BU-23 RD-24 BK-26 BU-23 RD-24 BU-23 MOTOR TO "HEAT" * HEATING BLOWER SPEED 3 NE
S 1 L P S S R COMP C C O M L2 T2 PS N0 NC C 3 Y 2 4 1 2 3 4 GAS VALVE 1 4 3 2 1 W RL L I M I T A U X L I M I T R 6 N 4 S 3 2 S S 60 120 1 Y HUM EAC N N MOTOR LEADS UNUSED HUM EAC DI SEE DETAIL 1 OR 2 HEAT FA N DELAY OF F 1 BK 17 4 4 4 4 4 4 2 PGD24C0902D PGD30C0702D PGD30C0902D PGD36C0702D PGD36C0902D PGD42C0902D MOTOR SPEEDS HI HI HI HI HI HI MED HI LOW SPEED BK-26 BK-26 BK-26 BK-26 BK-26 BK-26 BU-23 YL-27 MOTOR TO "HEAT"
90 WARNING:DISCONNECT POWER BEFORE SERVICING.
90 FAN CC START RELAY L2 T2 208/230 VAC 1ø WARNING:DISCONNECT POWER BEFORE SERVICING. USE COPPER CONDUCTORS ONLY CAP 5 LOW MED PHB48C02E COOLING BLOWER SPEED TAP PHB42C02E MODEL NUMBER MED LOW MED LOW DOWN HORIZ PHCB07C1 MED LOW MED LOW DOWN HORIZ PHCB10C1 MED LOW MED LOW DOWN HORIZ PHCB15C1 ELECTRIC HEAT BLOWER TAP HI MED HI MED DOWN HORIZ PHCB20C1 ALTERNATE UNIT POWER REFRIGERANT LEADS MAY BE USED WITH ELECTRIC HEATER ACCESSORIES.
FAN CC START RELAY L2 T2 208/230 VAC 1ø WARNING:DISCONNECT POWER BEFORE SERVICING.
FAN HEATER KIT W2 W1 G E CAP 2 5 C START RELAY L2 T2 208/230 VAC 1ø WARNING:DISCONNECT POWER BEFORE SERVICING. USE COPPER CONDUCTORS ONLY CC 1 COMP 5KW 20KW 15KW 10KW KW (HEAT) D C B A 1400 1200 1000 800 CFM (COOL) DETAIL 2 D C B A TEST (-) (+) NORM R BK 19 ADJUST FUSE START S R ALTERNATE UNIT POWER REFRIGERANT LEADS MAY BE USED WITH ELECTRIC HEATER ACCESSORIES. SEE HEATER ACCESSORY INSTALLATION INSTRUCTIONS.
(ACB) CIRCULATION FAN (-) A B A B RD-13 SOLENOID DIAGNOSTICS BOARD OPERATION DIAGNOSTICS HEATCRAFT VT-14 TEST FAN OPTIONAL COMP RD-13 (- ) INTERFACE RD-31 VT-14 FOR PROPER OPERATION ON 208 VOLT THE FOLLOWING CHANGE MUST BE MADE: MOVE RD6 WIRE FROM TRANSFORMER COMMON FAN OD 24V PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 (ACB) CIRCULATION FLASHING FLASHING VT VT RD-27 RD RED CAPACITOR FAN HI VOLTAGE HI VOLTAGE FIELD VT VIOLET GN GREEN VT RD-27
L1 5 STAR T RE LAY L2 T2 R 208/230 VAC 1Ø WARNING:DISCONNECT POWER BEFORE SERVICING.
L1 2 5 START RELAY L2 T2 R 208/230 VA C 1 Ø WA RNING:D ISCO NNECT POWER BEFORE SERVICING.
L1 EM /W2 CAP 1 2 COMP 5 C START RELAY L2 T2 208/230 VAC 1Ø WARNING: DISCONNECT POWER BEF ORE SERVICING. USE COPPER CONDUCTORS ONLY CC START S R O R HERM FAN OD 230/208 24V C T1 G CAP O G R2 A A TEST (-) (+) NORM ADJUST D C B A ( )+ (- ) TEST NO R M ADJUST COOL A B C D BLOWER INTERFACE 1750 1734 1717 1700 CFM ALTERNATE UNIT POWER REFRIGERANT LEADS MAY BE USED WITH ELECTRIC HEATER ACCESSORIES. SEE HEATER ACCESSORY INSTALLATION INSTRUCTIONS.
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. E 2 W2 OFF Y O W AUTO 19 - 21 R SEQ 1 O DF W COOL 6 Y Y 7 AUTO 8 ON G G 9 R R C C 11 12 DT Pressure Switches not used on all models. PS1 B B PS2 A G PHB/PHD using ATK to control 2nd stage (3rd,4th bank) of electric heat.
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. E 2 W2 OFF Y O HEAT W AUTO 19 - 21 R SEQ 1 O DF W COOL 6 Y Y 7 AUTO 8 ON G G 9 R R C C 11 DT Pressure Switches not used on all models. PS1 B B PS2 A G PHB/PHD using ATK to control "W2" thermostat input.
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. E 2 W2 OFF W FSK 7 AUTO 8 ON 9 G G R R C C Pressure Switches not used on all models. B DEFROST CONTROL B PS2 A G PS COOLING RELAY 28 34 30 TEST 11 A DT PS1 PHB/PHD with FSK controling "Y" thermostat input.
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.
