Service Instructions Model numbers listed on page 6 *PH 15 SEER Multi-Position Package Heat Pumps with R-410A Refrigerant & Accessories This manual is to be used by qualified, professionally trained HVAC technicians only. Goodman does not assume any responsibility for property damage or personal injury due to improper service procedures or services performed by an unqualified person. Copyright © 2007 Goodman Manufacturing Company, L.P. RS6300008 Rev.
INDEX IMPORTANT INFORMATION .......................................................................................................... 4 PRODUCT IDENTIFICATION - *PH15**M4*.................................................................................. 6 ACCESSORIES ............................................................................................................................... 7 GPGHFR101-103 ...................................................................................................
INDEX S-11 CHECKING LOSS OF CHARGE PROTECTOR .............................................................................................. 25 S-15 CHECKING CAPACITOR ................................................................................................................................ 25 S-15A Resistance Check ................................................................................................................................. 26 S-15B Capacitance Check .................................
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 G P H 15 36 M 4 1 * * Brand G: Goodman® Brand or Distinctions A: Amana® Brand Minor Revision Major Revision Product Type Voltage Package Cooling/Heating 1: 208-230V/1ph/60Hz 3: 208-230V/3ph/60Hz 4: 460V/3ph/60Hz Product Family C: Cooling H: Heat Pump Refrigerant Product Series 4: R-410A 15: 15 SEER Rating Nominal Capacity Configuration 24: 36: 48: 60: M: Multi-Position 24,000 BTUH 36,000 BTUH 48,000 BTUH 60,000 BTUH Single Phase Multiposition Package Heat Pump
*PH15[24-60]M4* ACCESSORIES ACCESSORIES Part Number Description Fits Models GPH13MED103 Economizer Downflow All PGEH102 Economizer Horizontal Medium Chassis PGEH103 Economizer Horizontal Large Chassis PGMDD102 Downflow Manual 25% Fresh Air Damper Medium Chassis PGMDD103 Downflow Manual 25% Fresh Air Damper Large Chassis PGMDH102 Horizontal Manual 25% Fresh Air Damper Medium Chassis PGMDH103 Horizontal Manual 25% Fresh Air Damper Large Chassis PGMDMH102 Horizontal Motorized 25% Fres
*PH15[24-60]M4* ACCESSORIES EXTERNAL HORIZONTAL FILTER RACK (GPGHFR101-103) 16" 24" 4" 16" x 25" x 2" FILTER 26 1/2" 17 1/4" Filter Size: 16" x 25" x 2" (Requires 1 filter) Measurement in inches DOWNFLOW FILTER RACK (GPH13MFR) PANEL SIDE VIEW DUCT SIDE VIEW FILTER PLATFORM LEFT SIDE RIGHT SIDE DOWNFLOW R/A DUCT OPENING EVAPORATOR COIL Filter Size: 14" x 25" x 2" (Requires 2 filters) - Measurement in inches 8
ACCESSORIES *PH15[24-60]M4* MOTORIZED/MANUAL FRESH AIR DAMPERS (DOWNFLOW APPLICATIONS) B 7 5/8 5 3/4 11 7/8 A B A Manual Fresh Air Dampers MODEL A B PGMDD101/102 16 16 PGMDD103 18 16 Motorized Fresh Air Dampers MODEL A B PGMDMD102 16 16 PGMDMD103 18 16 MOTORIZED/MANUAL FRESH AIR DAMPERS (HORIZONTAL APPLICATIONS) BOTTOM VIEW 12 1/8 10 6 5 3/4 11 7/8 1 PGMDD103 BOTTOM VIEW 12 1/8 10 6 5 3/4 11 7/8 1 PGMDD101/102 Manual Fresh Air Dampers MODEL A B PGMDH102 31 1/2 29 3/4 PGMD
ACCESSORIES *PH15[24-60]M4* SQUARE TO ROUND CONVERTER (DOWNFLOW APPLICATIONS) 12 1/4 14 3/4 C D S 16 ø 22 3/4 16 ø 22 1/4 R A 12 1/4 14 3/4 B 18 ø 22 3/4 18 ø 22 1/4 MODEL A B C D RETURN SUPPLY SQRPG101/102 22 3/4 12 1/4 22 1/4 14 3/4 16 16 SQRPG103 22 3/4 12 1/4 22 1/4 14 3/4 18 18 SQUARE TO ROUND CONVERTER (HORIZONTAL APPLICATIONS) B C M ODEL A B C SQRPGH101/102 16 16 1/2 16 1/2 SQRPGH103 18 18 1/2 18 1/2 A 10 Measurements are in inches.
ACCESSORIES *PH15[24-60]M4* ECONOMIZER GPH13MED103 (DOWNFLOW APPLICATIONS ) Blockoff External Hood Panel Louver Assembly ECONOMIZER PGEH102-103 (HORIZONTAL APPLICATIONS ) B 16 1/8 18 D A E C MODEL A B PGEH102 25 1/4 18 18 PGEH103 35 1/4 18 1/8 C D E FILTER 18 13 3/4 16 1/8 16 X 25 X1 18 18 1/4 16 1/8 16 X 25 X1 Measurements in inches 11
*PH15[24-60]M4* ACCESSORIES ROOF CURBS B S A R C 1 5/8 14 1/2 1 3/8 MODEL A B C RETURN SUPPLY PGC101/102/103 46 1/4* 39 3/8* 14 1/2 12 1/2 x 23* 15 x 22 1/2* *Inside Dimensions 12
PRODUCT DESIGN LOCATION & CLEARANCES In installations where the unit is installed above ground level and not serviceable from the ground (Example: Roof Top installations) the installer must provide a service platform for the service person with rails or guards in accordance with local codes or ordinances. Roof Curb *PH15[24-60]M4* *PH Package Units are designed for outdoor installations only in either residential or light commercial applications.
PRODUCT DESIGN The outdoor fan motors are single phase capacitor type motors. Air for condensing (cooling) is drawn through the outdoor coil by a propeller fan, and is discharged vertically out the top of the unit. The outdoor coil is designed for .0 static. No additional restriction (ductwork) shall be applied. Conditioned air is drawn through the filter(s), field installed, across the evaporator coil and back into the conditioned space by the indoor blower.
PRODUCT DESIGN ELECTRICAL WIRING LINE VOLTAGE 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. Power supply to the unit must be N.E.C. Class 1, and must comply with all applicable codes.
SYSTEM OPERATION COOLING The refrigerant used in the system is R-410A. It is a clear, colorless, non-toxic and non-irritating liquid. R-410A is a 50:50 blend of R-32 and R-125. The boiling point at atmospheric pressure is -62.9°F. A few of the important principles that make the refrigeration cycle possible are: heat always flows from a warmer to a cooler body. Under lower pressure, a refrigerant will absorb heat and vaporize at a low temperature.
*PH15[24-60]M41* SYSTEM OPERATION APH15 M Series ECM equipped models only: With the thermostat set to the emergency heat position and a call for 2nd stage heat, R to W1 will be energized. This will energize the electric heat sequencers and also energize W1 on the Variable Speed Terminal Board to start the indoor blower motor. When the normally open contacts of the heat sequencers close, this will energize the electric resistance heat.
SYSTEM OPERATION Dip Switch Number 1 2 3 4 5 6 7 8 Model Function Electric Heat N/A Indoor Thermostat APH1524 Cooling & Heat Pump CFM APH1536 CFM Trim Adjust Table 1 CFM Delivery APH1548 Tables 2 and 4 show the CFM output for dip switch combinations 1-2 (Electric Heat), and 5-6 (Cooling/Heating). Tables 3 shows the dip switch settings for 1 and 2-stage thermostats.
SYSTEM OPERATION Typical Heat Pump System in Cooling Reversing Valve (Energized) Indoor Coil Outdoor Coil Accumulator Typical Heat Pump System in Heating Reversing Valve (De-Energized) Indoor Coil Outdoor Coil Accumulator 19
SCHEDULED MAINTENANCE Package heat pumps require 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. WARNING 6. Check the contacts of the compressor contactor.
SERVICING COOLING /HEAT PUMP- SERVICE ANALYSIS GUIDE Pow er Failure Blow n Fuse • • Shorted or Broken Wires • • • • Open Fan Overload Faulty Thermostat Faulty Transformer Shorted or Open Capacitor Internal Compressor Overload Open Shorted or Grounded Compressor Compressor Stuck • • • • • • • • • • • • • ♦ • • • • • • ♦ • • • • • Shorted or Grounded Fan Motor • • • Improper Cooling Anticipator Shortage of Refrigerant Restricted Liquid Line Open Element or Limit on Elec.
SERVICING S-1 CHECKING VOLTAGE WARNING 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. Max. Voltage Deviation From Average Voltage X 100 Average Voltage % Voltage = Imbalance To find the percentage of imbalance, measure the incoming power supply. L1 - L2 = 240V L1 - L3 = 232V 1. Remove doors, control panel cover, etc. from unit being tested. With power ON: Avg.
SERVICING S-2 CHECKING WIRING WARNING 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. S-3B COOLING ANTICIPATOR 1. Check wiring visually for signs of overheating, damaged insulation and loose connections. 2. Use an ohmmeter to check continuity of any suspected open wires. 3. If any wires must be replaced, replace with comparable gauge and insulation thickness.
SERVICING S-4 CHECKING TRANSFORMER AND CONTROL CIRCUIT A step-down transformer (208/240 volt primary to 24 volt secondary) is provided with each package unit. This allows ample capacity for use with resistance heaters. WARNING S-8 CHECKING CONTACTOR CONTACTS WARNING DISCONNECT POWER SUPPLY BEFORE SERVICING. SINGLE PHASE 1. Disconnect the wire leads from the terminal (T) side of the contactor. 2. With power ON, energize the contactor. WARNING LINE VOLTAGE NOW PRESENT. 1.
SERVICING T3 T2 T1 4. Start the system and place a piece of cardboard in front of the condenser coil, raising the condensing pressure. 5. Check pressure at which the high pressure control cutsout.
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-16 CHECKING MOTORS S-16B CHECKING FAN AND BLOWER MOTOR (ECM MOTORS) 1 APH15 M Series Only 2 An ECM is an Electronically Commutated Motor which offers many significant advantages over PSC motors. The ECM has near zero rotor loss, synchronous machine operation, variable speed, low noise, and programmable air flow. Because of the sophisticated electronics within the ECM motor, some technicians are intimated by the ECM motor; however, these fears are unfounded.
- Does removing panel or filter reduce "puffing"? - Check/replace filter. - Check/correct duct restrictions. - Adjust to correct blower speed setting. - Incorrect or dirty filter(s). - Incorrect supply or return ductwork. - Incorrect blower speed setting. - Varies up and down or intermittent. - "Hunts" or "puffs" at high CFM (speed). ---- - Check line voltage for variation or "sag". - Check low voltage connections (G, Y, W, R, C) at motor, unseated pins in motor harness connectors.
- Turn power OFF prior to repair. - Check for loose blower housing, panels, etc. - Check for air whistling thru seams in ducts, cabinets or panels. - Check for cabinet/duct deformation. - Does removing panel or filter reduce "puffing"? - Check/replace filter. - Check/correct duct restrictions. - Adjust to correct blower speed setting. - Loose blower housing, panels, etc. - High static creating high blower speed. - Air leaks in ductwork, cabinets, or panels. - High static creating high blower speed.
SERVICING S-16C CHECKING ECM MOTOR WINDINGS APH15 M Series Only WARNING 2. Using a voltmeter, check for 24 volts from terminal C to either terminal 1, 2, 3, 4 or 5, depending on which tap is being used, at the motor. If voltage present, proceed to step 3. If no voltage, check 24 volt circuit to motor. 3. If voltage was present in steps 1 and 2, the motor has failed and will need to be replaced.
SERVICING If the compressor terminal PROTECTIVE COVER and gasket (if required) is not properly in place and secured, there is a remote possibility if a terminal vents, that the vaporous and liquid discharge can be ignited, spouting flames several feet, causing potentially severe or fatal injury to anyone in its path. 2. Using an ohmmeter, test continuity between terminals SR, C-R, and C-S, on single phase units or terminals T1, T2 and T3, on 3 phase units.
SERVICING 2. Identify the leads and using a Megger, Hi-Potential Ground Tester, or other suitable instrument which puts out a voltage between 300 and 1500 volts, check for a ground separately between each of the three leads and ground (such as an unpainted tube on the compressor). Do not use a low voltage output instrument such as a volt-ohmmeter. 3. If a ground is indicated, then carefully remove the compressor terminal protective cover and inspect for loose leads or insulation breaks in the lead wires.
SERVICING S-18 TESTING CRANKCASE HEATER Note: Not all compressors use crankcase heaters. 3. Set thermostat to call for heating. System should go into defrost within 21 seconds. 4. Immediately remove jumper from test pins. The crankcase heater must be energized a minimum of four (4) hours before the compressor is operated. 5. Using VOM check for voltage across terminals "C & O". Meter should read 24 volts.
SERVICING WARNING 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. 1. Disassemble and remove the heating element(s). 2.
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: R410A should be drawn out of the storage container or drum in liquid form due to its fractionation properties, but should be "Flashed" to its gas state before entering the system. There are commercially available restriction devices that fit into the system charging hose set to accomplish this. DO NOT charge liquid R410A into the compressor. 4. With the system still running, close the valve on the charging cylinder.
SERVICING S-106 OVERFEEDING Superheat Formula = Suct. Line Temp. - Sat. Suct. Temp. Overfeeding by the expansion valve results in high suction pressure, cold suction line, and possible liquid slugging of the compressor. EXAMPLE: If these symptoms are observed: 1. Check for an overcharged unit by referring to the cooling performance charts in the servicing section. 2. Check the operation of the power element in the valve as explained in S-110 Checking Expansion Valve Operation. 3.
SERVICING SUBCOOLING = SAT. LIQUID TEMP. - LIQUID LINE TEMP. SATURATED LIQUID PRESSURE TEMPERATURE CHART Liquid Pressure PSIG 200 210 220 225 235 245 255 265 275 285 295 305 325 355 375 405 Saturated Liquid Temperature °F R-410A 70 73 76 78 80 83 85 88 90 92 95 97 101 108 112 118 Two Speed Application (*PH1548**-*PH1560**) Run the unit on low stage cooling for 10 minutes until refrigerant pressures stabilize.
SERVICING Pressure vs. Temperature Chart R-410A PSIG 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 °F -37.7 -34.7 -32.0 -29.4 -36.9 -24.5 -22.2 -20.0 -17.9 -15.8 -13.8 -11.9 -10.1 -8.3 -6.5 -4.5 -3.2 -1.6 0.0 1.5 3.0 4.5 5.9 7.3 8.6 10.0 11.3 12.6 13.8 15.1 16.3 17.5 18.7 19.8 21.0 22.1 23.2 24.3 25.4 26.4 27.4 28.5 29.5 30.5 31.2 32.2 33.2 34.1 35.1 35.5 36.9 PSIG 114.0 116.0 118.0 120.0 122.
SERVICING REQUIRED LIQUID LINE TEMPERATURE LIQUID PRESSURE AT SERVICE VALVE (PSIG) 189 195 202 208 215 222 229 236 243 251 259 266 274 283 291 299 308 317 326 335 345 354 364 374 384 395 406 416 427 439 450 462 474 486 499 511 40 8 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 122 124 126 128 REQUIRED SUBCOOLING TEMPERATURE (°F) 10 12 14 16 56 54 52 50 58 56 54 52 60 58 56 54 62 60 58 56 64 62 60 58 66 64 62 60 68 66 64 62 70 68 66 64 72 70 68
SERVICING S-110 CHECKING EXPANSION VALVE OPERATION S-114 NON-CONDENSABLES 1. Remove the remote bulb of the expansion valve from the suction line. 1. Shut down the system and allow the pressures to equalize for a minimum of 15 minutes. 2. Start the system and cool the bulb in a container of ice water, closing the valve. As you cool the bulb, the suction pressure should fall and the suction temperature will rise. 2. Take a pressure reading. 3. Next warm the bulb in your hand.
SERVICING NOTE: The Flushing Method using R-11 refrigerant is no longer approved by Goodman® Manufacturing Company, L.P. S-122 REVERSING VALVE REPLACEMENT Suction Line Drier Clean-Up Method The POE oils used with R410A refrigerant is an excellent solvent. In the case of a burnout, the POE oils will remove any burnout residue left in the system.
SERVICING S-200 CHECKING EXTERNAL STATIC PRESSURE The minimum and maximum allowable duct static pressure is found in the Technical Information Manual. Too great of an external static pressure will result in insufficient air that can cause icing of the coil, whereas too much air can cause poor humidity control, and condensate to be pulled off the evaporator coil causing condensate leakage. Too much air can cause motor overloading and in many cases this constitutes a poorly designed system.
WIRING DIAGRAMS PACKAGE SYSTEM WIRING DIAGRAM - 1 STAGE ELECTRIC HEAT TYPICAL HP ROOM THERMOSTAT SEE NOTE 1 #18 GAUGE 7 WIRE REQUIRED FOR HEAT PUMPS Y O C W1 G R PACKAGE UNIT LOW VOLTAGE JUNCTION BOX E R R RED Y Y YELLOW G G GREEN O O ORANGE BR W WHITE BL BLUE 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.
WIRING DIAGRAMS PACKAGE SYSTEM WIRING DIAGRAM - HEAT PUMPS ONLY! TWO-STAGE ELECTRIC HEAT ABOVE 10 kW TYPICAL H/P ROOM THERMOSTAT 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.
*PH15**M4* WIRING DIAGRAMS FL FL FL HTR1 TL HTR1 TL PLM BK BK M1 4 M2 5 BK 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.
NOTE: RECOMMEND MULTI-STAGE T'STAT B ORANGE YELLOW GOODMAN MANUFACTURING CO. MODEL GPH13MED ECONOMIZER ROOFTOP UNITS SERIES WIRING DIAGRAM GPC*PH & GPH SERIES WIRING DIAGRAM WHITE 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.