(Goodman) Service Instructions-RS6300006 (41 Pages)

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ServiceInstructionsGPH PACKAGE HEAT PUMPSGPC PACKAGE COOLING

Model numbers listed onpage 6

This manual is to be used by qualified, professional HVAC technicians only. Goodman does not assumeany responsibility for property damage or personal injury for improper service procedures or servicesperformed by an unqualified person.

RS6300006 Rev1June 2006

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INDEXIMPORTANT INFORMATION .......................................................................................................... 4PRODUCT IDENTIFICATION .......................................................................................................... 6ACCESSORIES ............................................................................................................................... 8

PCCP101-103 ROOF CURB ...................................................................................................................................... 8PCP101-103 DOWNFLOW PLENUM ........................................................................................................................ 8PCEF101-103 ELBOW AND FLASHING KIT ............................................................................................................. 9PCE101-103 ECONOMIZER....................................................................................................................................... 9PCMD101-103 DOWNFLOW MANUAL DAMPER ................................................................................................... 10GPHMD101-103 HORIZONTAL MOTORIZED DAMPER WITH DUCT FLANGE....................................................... 10SQRPC SQUARE TO ROUND CONVERTER .......................................................................................................... 11SQRPCH SQUARE TO ROUND CONVERTER ........................................................................................................ 11PCFR101-103 HORIZONTAL FILTER KIT ............................................................................................................... 12

PRODUCT DESIGN ...................................................................................................................... 13ELECTRICAL WIRING ............................................................................................................................................ 14LINE VOLTAGE WIRING......................................................................................................................................... 15

SYSTEM OPERATION .................................................................................................................. 16COOLING ................................................................................................................................................................ 16COOLING CYCLE ................................................................................................................................................... 16HEATING CYCLE .................................................................................................................................................... 16DEFROST CYCLE ................................................................................................................................................... 17FAN OPERATION .................................................................................................................................................... 18

SCHEDULED MAINTENANCE..................................................................................................... 21ONCE A MONTH ..................................................................................................................................................... 21ONCE A YEAR ........................................................................................................................................................ 21TEST EQUIPMENT ................................................................................................................................................. 21

SERVICING ................................................................................................................................... 22COOLING /HEAT PUMP- SERVICE ANALYSIS GUIDE .......................................................................................... 22S-1 CHECKING VOLTAGE ...................................................................................................................................... 23S-2 CHECKING WIRING ......................................................................................................................................... 24S-3 CHECKING THERMOSTAT, WIRING, AND ANTICIPATOR ............................................................................... 24S-3A Thermostat and Wiring ................................................................................................................................ 24S-3B Cooling Anticipator ...................................................................................................................................... 24S-3C Heating Anticipator ...................................................................................................................................... 24S-4 CHECKING TRANSFORMER AND CONTROL CIRCUIT .................................................................................. 24S-7 CHECKING CONTACTOR AND/OR RELAYS ................................................................................................... 25S-8 CHECKING CONTACTOR CONTACTS ............................................................................................................. 25S-9 CHECKING FAN RELAY CONTACTS ................................................................................................................ 26S-11 CHECKING LOSS OF CHARGE PROTECTOR .............................................................................................. 27S-15 CHECKING CAPACITOR ................................................................................................................................ 27S-15A Resistance Check ....................................................................................................................................... 27S-15B Capacitance Check .................................................................................................................................... 28S-16 CHECKING MOTORS ..................................................................................................................................... 28S-16A CHECKING FAN AND BLOWER MOTOR WINDINGS (PSC MOTORS) ....................................................... 28S-16D CHECKING GE X13TM MOTORS ................................................................................................................ 28

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S-17 CHECKING COMPRESSOR WINDINGS ........................................................................................................ 29S-17A Resistance Test ........................................................................................................................................... 29S-17B Ground Test ................................................................................................................................................. 29S-17D Operation Test ............................................................................................................................................ 30S-18 TESTING CRANKCASE HEATER ................................................................................................................... 30S-21 CHECKING REVERSING VALVE AND SOLENOID ......................................................................................... 30S-24 TESTING DEFROST CONTROL ..................................................................................................................... 31S-25 TESTING DEFROST THERMOSTAT............................................................................................................... 31S-26 CHECKING HEATER LIMIT CONTROL(S) ...................................................................................................... 31S-27 CHECKING HEATER ELEMENTS ................................................................................................................... 31S-100 REFRIGERATION REPAIR PRACTICE.......................................................................................................... 31S-101 LEAK TESTING ............................................................................................................................................ 32S-102 EVACUATION................................................................................................................................................ 32S-103 CHARGING ................................................................................................................................................... 33S-104 CHECKING COMPRESSOR EFFICIENCY .................................................................................................... 33S-108 SUPERHEAT ................................................................................................................................................. 33S-109 CHECKING SUBCOOLING ........................................................................................................................... 34S-111 FIXED ORIFICE RESTRICTION DEVICES .................................................................................................... 35S-112 CHECKING RESTRICTED LIQUID LINE ....................................................................................................... 35S-113 REFRIGERANT OVERCHARGE .................................................................................................................... 35S-114 NON-CONDENSABLES ................................................................................................................................. 36S-115 COMPRESSOR BURNOUT ........................................................................................................................... 36S-122 REVERSING VALVE REPLACEMENT ........................................................................................................... 36S-200 CHECKING EXTERNAL STATIC PRESSURE ............................................................................................... 37S-201 CHECKING TEMPERATURE RISE ................................................................................................................ 37

WIRING DIAGRAMS ...................................................................................................................... 38OT18-60A OUTDOOR THERMOSTAT ..................................................................................................................... 38OT18-60A OUTDOOR THERMOSTAT ..................................................................................................................... 39HKR** HEAT KIT ..................................................................................................................................................... 40PCE* ECONOMIZER................................................................................................................................................ 41

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IMPORTANT INFORMATIONPride 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 technicianwho is familiar with the safety procedures required in the repair and who is equipped with the proper tools, parts, testinginstruments and the appropriate service manual. REVIEW ALL SERVICE INFORMATION IN THE APPROPRIATESERVICE MANUAL BEFORE BEGINNING REPAIRS.

IMPORTANT NOTICES FOR CONSUMERS AND SERVICERSRECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS

To locate an authorized servicer, please consult your telephone book or the dealer from whom youpurchased this product. For further assistance, please contact:

CONSUMER INFORMATION LINEGOODMAN MANUFACTURING COMPANY, L.P. TOLL FREE

1-877-254-4729 (U.S. only)email us at: [email protected]

fax us at: (731) 856-1821(Not a technical assistance line for dealers.)

Outside the U.S., call 1-713-861-2500. (Not a technical assistance line for dealers.)Your telephone company will bill you for the call.

ONLY individuals meeting the requirements of an“Entry Level Technician” as specified by the AirConditioning and Refrigeration Institute (ARI) may usethis information. Attempting to install or repair thisunit without such background may result in productdamage, personal injury, or death.

WARNING

WARNINGTo prevent the risk of property damage, personalinjury, or death, do not store combustible materials oruse gasoline or other flammable liquids or vaporsin the vicinity of this appliance.

WARNINGHazards or unsafe practices which could result inproperty damage, product damage, personal injuryor death.

WARNINGGoodman will not be responsible for any injury or property damage arising from improper service or serviceprocedures. If you install or perform service on this unit, you assume responsibility for any personal injury or propertydamage which may result. Many jurisdictions require a license to install or service heating and air conditioningequipment.

WARNINGThe United States Environmental Protection Agency ("EPA") has issued various regulations regarding the introductionand disposal of refrigerants introduced into this unit. Failure to follow these regulations may harm the environmentand can lead to the imposition of substantial fines. These regulations may vary by jurisdiction. A certified technicianmust perform the installation and service of this product. Should questions arise, contact your local EPA office.Violations of EPA regulations may result in fines or penalties.

Do not connect to or use any device that is not designcertified by Goodman for use with this unit. Seriousproperty damage, personal injury, reduced unitperformance and/or hazardous conditions may resultfrom the use of such non-approved devices.

WARNING

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IMPORTANT INFORMATION

The successful development of hermetically sealed refrig-eration compressors has completely sealed the compressor'smoving parts and electric motor inside a common housing,minimizing refrigerant leaks and the hazards sometimesassociated with moving belts, pulleys or couplings.Fundamental to the design of hermetic compressors is amethod whereby electrical current is transmitted to the com-pressor motor through terminal conductors which passthrough the compressor housing wall. These terminals aresealed in a dielectric material which insulates them from thehousing and maintains the pressure tight integrity of the her-metic compressor. The terminals and their dielectric em-bedment are strongly constructed, but are vulnerable to care-less compressor installation or maintenance procedures andequally vulnerable to internal electrical short circuits causedby excessive system contaminants.

WARNINGSystem contaminants, improper service procedureand/or physical abuse affecting hermetic compressorelectrical terminals may cause dangerous systemventing.

SAFE REFRIGERANT HANDLINGWhile these items will not cover every conceivable situation, they should serve as a useful guide.

In either of these instances, an electrical short between theterminal and the compressor housing may result in the lossof integrity between the terminal and its dielectric embed-ment. This loss may cause the terminals to be expelled,thereby venting the vaporous and liquid contents of the com-pressor housing and system.A venting compressor terminal normally presents no dangerto anyone, providing the terminal protective cover is properlyin place.If, however, the terminal protective cover is not properly inplace, a venting terminal may discharge a combination of

(a) hot lubricating oil and refrigerant(b) flammable mixture (if system is contaminated

with air)in a stream of spray which may be dangerous to anyone inthe vicinity. Death or serious bodily injury could occur.Under no circumstances is a hermetic compressor to be elec-trically energized and/or operated without having the terminalprotective cover properly in place.See Service Section S-17 for proper servicing.

WARNINGTo avoid possible injury, explosion or death, practicesafe handling of refrigerants.

To avoid possible explosion: • Never apply flame or steam to a refrigerant cylinder. If you must heat a cylinder for faster charging, partially immerse it in warm water.• Never fill a cylinder more than 80% full of liquid refrigerant.• Never add anything other than R-22 to an R-22 cylinder or R-410A to an R-410A cylinder. The service equipment used must be listed or certified for the type of refrigerant used.• Store cylinders in a cool, dry place. Never use a cylinder as a platform or a roller.

WARNING

To avoid possible explosion, use only returnable (notdisposable) service cylinders when removing refrig-erant from a system. • Ensure the cylinder is free of damage which could lead to a leak or explosion.• Ensure the hydrostatic test date does not exceed 5 years.• Ensure the pressure rating meets or exceeds 400 lbs.When in doubt, do not use cylinder.

WARNING

Refrigerants are heavier than air. They can "push out"the oxygen in your lungs or in any enclosed space.Toavoid possible difficulty in breathing or death:• Never purge refrigerant into an enclosed room or space. By law, all refrigerants must be reclaimed.• If an indoor leak is suspected, thoroughly ventilate the area before beginning work.• Liquid refrigerant can be very cold. To avoid possible frostbite or blindness, avoid contact with refrigerant and wear gloves and goggles. If liquid refrigerant does contact your skin or eyes, seek medical help immediately.• Always follow EPA regulations. Never burn refrigerant, as poisonous gas will be produced.

WARNING

WARNINGHIGH VOLTAGE!Disconnect ALL power before servicing or installingthis unit. Multiple power sources may be present.Failure to do so may cause property damage, personalinjury or death.

PRODUCT IDENTIFICATION

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G P C 13 24 H 2 1 * *

Product Series

13: 13 SEER Rating

Refrigerant

2: R-224: R-410A

Product TypePackageCooling/Heating

Product FamilyC: CoolingH: Heat Pump

Configuration

H: HorizontalM: Multi-Position

Voltage

1: 208-230V/1ph/60Hz3: 208-230V/3ph/60Hz4: 460V/3ph/60Hz

Major Revision

Nominal Capacity

24: 24,000 BTUH30: 30,000 BTUH36: 36,000 BTUH42: 42,000 BTUH48: 48,000 BTUH60: 60,000 BTUH

Minor Revision

BrandG: Goodman or Distinctions

PRODUCT IDENTIFICATION

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Part Number Description Fits ModelsPCCP101-103 Roof Curb AllPCE101-103 Downflow Economizer AllPCMD101-103 Downflow Manual 25% Fresh Air Damper AllPCP101-103 Downflow Plenum Kit AllPCEF101-103 Elbow and Flashing Kit AllGPHMDM101-103 Horizontal Motorized 25% Fresh Air Damper AllPCFR101-103 Horizontal Filter Kit with Duct Flange AllSQRPCH101SQRPCH102-103

Horizontal Square to Round AdapterHorizontal Square to Round Adapter

Small ChassisMed/Large Chassis

SQRPC101*SQRPC102-103*

Downflow Square to Round AdapterDownflow Square to Round Adapter


CDK1-2CDK3

Concentric Duct KitConcentric Duct Kit


OT18-60AOutdoor Thermostat (Required for heat pumps with 0o outdoor ambient and 50% or higher relative humidity)

All

OT/EHR-60A Outdoor Thermostat with Emergency Heat Relay All

ACCESSORIES

* - SQRPC101 and SQRPC102-103 must be used with PCP101-103 Downflow Plenum kit and PCCP101-103 Roof Curb

MODEL # DESCRIPTION

GPC13****1** Goodman or Distinctions Package Cooling - 13 Seer 208-230/1/60 Single-Phase Electric Cooling Unit.

GPH13****1** Goodman or Distinctions Package Heat Pump - 13 Seer 208-230/1/60 Single-Phase Heat Pump.

1213401 White Manual Changeover 5 + 2 Programming Digital 1 Heat - 1 Cool1213402 White Manual Changeover Nonprogrammable Digital 1 Heat - 1 Cool1213403 White Manual Changeover 7 Day Programming Digital 2 Heat - 1 Cool1213404 White Manual Changeover Nonprogrammable Digital 2 Heat - 1 Cool1213406 Beige Manual/Auto Changeover 5 + 2 Programming Digital 3 Heat - 2 Cool1213407 White Manual Changeover 5 + 2 Programming Digital 2 Heat - 2 Cool1213408 White Manual/Auto Changeover 7 Day Programming Digital 1 Heat - 1 Cool1213410 White Manual Changeover 5 + 2 Programming Digital 2 Heat - 1 Cool1213411 White Manual Changeover Nonprogrammable Digital 2 Heat - 2 Cool1213412 White Manual/Auto Changeover 7 Day Programming Digital 3 Heat - 2 Cool1213431 White Manual/Auto Changeover 7 Day Programming Digital 3 Heat - 2 Cool

AMANA® THERMOSTATS

CH70TG Manual Changeover Digital, Nonprogrammable 1 Heat - 1 CoolCHSATG Manual Changeover Mechanical, Nonprogrammable 1 Heat - 1 CoolCHT18-60 Manual Changeover Mechanical, Nonprogrammable 1 Heat - 1 CoolCHT90-120 Manual Changeover Mechanical, Nonprogrammable 2 Heat - 2 Cool

CHTP18-60HD Manual Changeover Digital, Nonprogrammable 2 Heat - 1 CoolCT18-60 Manual Changeover Mechanical, Nonprogrammable Cool Only

GOODMAN THERMOSTATS

Chassis ModelsSmall 2 - 2.5 Ton

Medium 3 - 3.5 TonLarge 4 - 5 Ton

GPHChassis ModelsSmall 2 - 3 Ton

Medium 3.5 TonLarge 4 - 5 Ton

GPC

ACCESSORIES

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PCCP101-103 ROOF CURB

PCP101-103 DOWNFLOW PLENUM(Use with PCCP Roof Curb)

64"

33"

26"

33"

59"

14" RoofCurb

31"

29 3/4"

29 3/8"

13"

13"

28 3/4"

37"

25 1/2"33"

1" Flange

ACCESSORIES

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PCE101-103 ECONOMIZER(DOWNFLOW APPLICATIONS )

31 1/4"

3"

5"

17 3/4"

20" x 17 1/2"Filter

17 3/4"

20 3/8"

27 3/4"

16 1/2"

PCEF101-103 ELBOW AND FLASHING KIT

25"8"

4"

4"

3"

33"

25"

28"35"

ACCESSORIES

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PCMD101-103 DOWNFLOW MANUAL DAMPER(USED WITH PCP101-103 DOWNFLOW PLENUM)

GPHMD101-103 HORIZONTAL MOTORIZED DAMPER WITH DUCT FLANGE

18"

29 3/4"

6"10"

12 1/8"

6"2"

12"

25 1

/4" 17"

17 1

/4"

18"8 1/4"

ACCESSORIES

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SQRPC SQUARE TO ROUND CONVERTER(DOWNFLOW APPLICATIONS)

SQRPCH SQUARE TO ROUND CONVERTER(HORIZONTAL APPLICATIONS)

OUTER FLANGE

STARTER FLANGE

BEAD

SQUARE TO ROUNDDUCT CONVERTER PANEL

1 1/2"

29 1/2" 29 1/4"

RA

SA

1" FLANGES

SQRPC101 SQRP102-103SA 16" 18"RA 16" 18"

SQRPCH-101 SQRPCH-102 SQRPCH-103 SQRPCH102-14 SQRPCH103-14A 15" 17" 17" 15" 15"B 15" 17" 17" 15" 15"C 17" 17" 19" 15" 15"D 22 1/2" 24 1/2" 24 1/2" 24 1/2" 24 1/2"

SUPPLY 14" 16" 16" 14" 14"RETURN 16" 16" 18" 14" 14"

A

B

2" SUPPLY

RETURN

C

D

2"

ACCESSORIES

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14"

24"

4"

15"

25"

14" x 25" x 2" FILTER

PCFR101-103 HORIZONTAL FILTER KIT(HORIZONTAL APPLICATIONS)

PRODUCT DESIGN

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In installations where the unit is installed above ground leveland not serviceable from the ground (Example: Roof Top in-stallations) the installer must provide a service platform for theservice person with rails or guards in accordance with localcodes or ordinances.

NOTE: Roof overhang should be no more than 36" andprovisions made to deflect the warm discharge air out from theoverhang.

Minimum clearances are required to avoid air recirculation andkeep the unit operating at peak efficiency. A minimum 10 inchclearance is required from the wall to the condenser coil.

WARNINGTO PREVENT POSSIBLE DAMAGE, THE UNIT SHOULDREMAIN IN AN UPRIGHT POSITION DURING ALLRIGGING AND MOVING OPERATIONS. TO FACILITATELIFTING AND MOVING IF A CRANE IS USED, PLACETHE UNIT IN AN ADEQUATE CABLE SLIDE.

Refer to Roof curb Installation Instructions for proper curb in-stallation. Curbing must be installed in compliance with theNational Roofing Contractors Association Manual.

Lower unit carefully onto roof mounting curb. While riggingunit, center of gravity will cause condenser end to be lowerthan supply air end.

Downflow Plenum

Roof Curb and Platform

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 connectedfor horizontal discharge airflow. In the down discharge applica-tions, a matching Platform/Roof Curb (PCCP101-103) andDownflow Plenum (PCP101-103) is recommended.A return air filter must be installed behind the return air grille(s)or provision must be made for a filter in an accessible locationwithin the return air duct. The minimum filter area should notbe less than those sizes listed in the Specification Section.Under no circumstances should the unit be operated withoutreturn air filters.A 3/4" - 14 NPT drain connector is provided for removal of con-densate water from the indoor coil. In order to provide propercondensate flow, do not reduce the drain line size.Refrigerant flow control is achieved by use of restrictororifices.The GPH and GPC model package heat pumps usethe FasTest Access Fitting System. The FasTest AccessSystem consists of a saddle that is fastened with a locking nutto the access fitting box. The access fitting (core) is thenscrewed into the saddle. Do not remove the core from thesaddle until the refrigerant charge has been removed.Failure to do so could result in property damage or per-sonal injury.The single phase units use permanent split capacitors (PSC)design compressors. Starting components are therefore notrequired. A low MFD run capacitor assists the compressor tostart and remains in the circuit during operation.

PRODUCT DESIGN

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The outdoor fan motor and the indoor blower motor are singlephase capacitor type motors.Air for condensing (cooling) is drawn through the outdoor coilby a propeller fan, and is discharged vertically out the top ofthe unit. The outdoor coil is designed for .0 static. No addi-tional restriction (ductwork) shall be applied.Conditioned air is drawn through the filter(s), field installed,across the evaporator coil and back into the conditioned spaceby the indoor blower.

COMPRESSORSSome GPC/GPH series package units use the Compliant Scrollcompressor, instead of traditional reciprocating compressors.Still other models use reciprocating compressors.A scroll is an involute spiral which, when matched with a mat-ing scroll form as shown, generates a series of crescent shapedgas pockets between the two members.During compression, one scroll remains stationary (fixed scroll)while the other form (orbiting scroll) is allowed to orbit (but notrotate) around the first form.

As this motion occurs, the pockets between the two forms areslowly pushed to the center of the two scrolls while simulta-neously being reduced in volume. When the pocket reachesthe center of the scroll form, the gas, which is now at a highpressure, is discharged out of a port located at the center.During compression, several pockets are being compressedsimultaneously, resulting in a very smooth process. Both thesuction process (outer portion of the scroll members) and thedischarge 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 Scrollcompressor is more tolerant of liquid refrigerant, continuedfloodback or flooded start conditions may wash oil from thebearing 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 isrequired.

• Compliant scroll compressors perform "quiet" shutdownsthat allow the compressor to restart immediately withoutthe need for a time delay. This compressor will restart evenif the system has not equalized.NOTE: Operating pressures and amp draws may differ fromstandard reciprocating compressors. This information canbe found in the unit's Technical Information Manual.

INDOOR BLOWER MOTORSome GPC/GPH model package units use a GE X13TM blowermotor while others use the standard PSC type blower motor.The GE X13TM motor is a 3 Phase brushless DC (single phaseAC input), ball bearing construction motor with an integral con-trol module with an internal FCC B EMI filter.The GE X13TM motor is continuously powered with line voltage.The switched 24 volt control signal is controlled by the thermo-stat in the cooling and heat pump mode and the blower relay inthe electric heat mode.

GE X13TM Motor

ELECTRICAL WIRINGThe units are designed for operation at the voltages and hertzas shown on the rating plate. All internal wiring is complete.Ensure the power supply to the compressor contactor is broughtto the unit as shown on the supplied unit wiring diagram. The24V wiring must be connected between the unit control paneland the room thermostat.

WARNINGTO AVOID PERSONAL INJURY OR DEATH DUE TOELECTRIC SHOCK, WIRING TO THE UNIT MUST BEPROPERLY POLARIZED AND GROUNDED.

WARNINGTO AVOID PERSONAL INJURY OR DEATH DUE TOELECTRIC SHOCK, DISCONNECT ELECTRICALPOWER BEFORE CHANGING ANY ELECTRICALWIRING.

PRODUCT DESIGN

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WARNINGTO AVOID THE RISK OF PROPERTY DAMAGE,PERSONAL INJURY OR FIRE, USE ONLY COPPERCONDUCTORS.

LINE VOLTAGE WIRINGPower supply to the unit must be N.E.C. Class 1, and mustcomply with all applicable codes. The unit must be electricallygrounded in accordance with the local codes or, in their ab-sence, with the latest edition of the National Electrical Code,ANSI/NFPA No. 70, or in Canada, Canadian Electrical Code,C22.1, Part 1. A fused disconnected must be provided andsized in accordance with the unit minimum circuit ampacity.The best protection for the wiring is the smallest fuse or breakerwhich will hold the equipment on line during normal operationwithout nuisance trips. Such a device will provide maximumcircuit protection.

WARNINGDO NOT EXCEED THE MAXIMUM OVERCURRENTDEVICE SIZE SHOWN ON THE UNIT DATA PLATE.

All line voltage connections must be made through weatherproof fittings. All exterior power supply and ground wiring mustbe in approved weather proof conduit. Low voltage wiring fromthe unit control panel to the thermostat requires coded cable.The unit transformer is connected for 230V operation. If theunit is to operate on 208V, reconnect the transformer primarylead as shown on the unit wiring diagram.If it is necessary for the installer to supply additional line volt-age wiring to the inside of the package unit, the wiring mustcomply with all local codes. This wiring must have a minimumtemperature rating of 105°C. All line voltage splices must bemade inside the unit or heat kit control box.

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SYSTEM OPERATIONWhen the thermostat is satisfied, breaking the circuit be-tween R to Y and R to G, the compressor and outdoor fanmotor will stop. The indoor blower will stop after the fan offdelay.If the room thermostat fan selector switch should be set tothe "on" position then the indoor blower would run continu-ous rather than cycling with the compressor.

Heat Pump ModelsAny time the room thermostat is switched to cool, the Oterminal is energized. This energizes the 24 volt coil on thereversing valve and switches it to the cooling position.When the contacts of the room thermostat close, this closesthe circuit from R to Y and R to G in the unit.This energizes the compressor contactor and will energizethe indoor blower following the EBTDR 7 second fan on delayon 2 thru 4 ton units, and instantly on 5 ton units with the GEX13TM motor.When the thermostat is satisfied, it opens its contacts break-ing the low voltage circuit causing the compressor contactorto open and indoor fan to stop after the EBTDR 65 seconddelay on 2 thru 4 ton units, and after the programmed 60second off delay on 5 ton units with the GE X13TM motor.If the room thermostat fan selector switch should be set tothe "on" position then the indoor blower would run continu-ous rather than cycling with the compressor.

HEATING CYCLECooling Only Units

NOTE: The following only applies if the cooling only unit hasan approved electric heat kit installed for heating. If auxiliaryelectric heaters should be used, they may be controlled byoutdoor thermostats (OT18-60A or OT/EHR18-60A).

GPC 2 thru 4 ton units: (A Revision Models)With the thermostat set to the heat position and a call forheat, R to W will be energized. This will energize the electricheat sequencers. When the normally open contacts of theheat sequencers close, this will energize the electric resis-tance heat and also the indoor blower motor through the nor-mally closed contacts of the EBTDR.

GPC 2 thru 4 ton units: (AB Revision Models)With the thermostat set to the heat position and a call forheat, R to W will be energized. This will energize the electricheat sequencers. When the normally open contacts of theheat sequencers close, this will energize the electric resis-tance heat and also the 240 volt coil on the isolation relay inthe control panel. The normally open contacts of the isola-tion relay will close energizing the indoor blower motor throughthe normally closed contacts of the EBTDR.

COOLINGThe refrigerant used in the system is R-22. It is clear, color-less, non-toxic, non-irritating, and non-explosive liquid. Thechemical formula is CHCLF2. The boiling point, at atmosphericpressure is -41.4°F.A few of the important principles that make the refrigerationcycle possible are: heat always flows from a warmer to acooler body, under lower pressure a refrigerant will absorbheat and vaporize at a low temperature, the vapors may bedrawn off and condensed at a higher pressure and tempera-ture to be used again.The indoor evaporator coil functions to cool and dehumidifythe air conditioned spaces through the evaporative processtaking place within the coil tubes.

NOTE: Actual temperatures and pressures are to be obtainedfrom the expanded ratings in the Technical InformationManual.

High temperature, high pressure vapor leaves the compres-sor through the discharge line and enters the condenser coil.Air drawn through the condenser coil by the condenser fancauses the refrigerant to condense into a liquid by removingheat from the refrigerant. As the refrigerant is cooled belowits condensing temperature it becomes subcooled.The subcooled high pressure liquid refrigerant now leaves thecondenser coil via the liquid line until it reaches the indoorexpansion device.As the refrigerant passes through the expansion device andinto the evaporator coil a pressure drop is experienced caus-ing the refrigerant to become a low pressure liquid. Low pres-sure saturated refrigerant enters the evaporator coil whereheat is absorbed from the warm air drawn across the coil bythe evaporator blower. As the refrigerant passes through thelast tubes of the evaporator coil it becomes superheated,that is, it absorbs more heat than is necessary for the refrig-erant to vaporize. Maintaining proper superheat assures thatliquid refrigerant is not returning to the compressor whichcan lead to early compressor failure.Low pressure superheated vapor leaves the evaporator coiland returns through the suction line to the compressor wherethe cycle begins again.

COOLING CYCLECooling Only ModelsWhen the thermostat is switched to cool, this closes thecircuit between R and O in the unit. This energizes the re-versing valve solenoid coil, shifting the reversing valve to thecool position.When the contacts of the room thermostat close, makingterminals R to Y and R to G, the low voltage circuit to thecontactor is completed starting the compressor and outdoorfan motor. This also energizes the indoor blower through thenormally open contacts of the EBTDR on 2 thru 4 ton units,and through the blower relay on the 5 ton units.

SYSTEM OPERATION

SYSTEM OPERATION

17

GPC 5 ton units: (A and AA Revision Models)With the thermostat set to the heat position and a call forheat, R to W will be energized. This will energize the electricheat sequencers and the blower relay. The electric heat willbe energized through the normally open contacts of the elec-tric heat sequencers. The indoor blower will be energizedthrough the normally open contacts of the blower relay.When the thermostat is satisfied, this breaks the circuit fromR to W. This will turn off the electric heaters, and the indoorblower after the programmed 60 second off delay on 5 tonunits with the GE X13TM motor.

GPC 5 ton units: (AB Revision Models)With the thermostat set to the heat position and a call forheat, R to W will be energized. This will energize the electricheat sequencers and the GE X13TM motor. The electric heatwill be energized through the normally open contacts of theelectric heat sequencers. The indoor blower will be energizedthrough W from the thermostat.When the thermostat is satisfied, this breaks the circuit fromR to W. This will turn off the electric heaters, and the indoorblower after the programmed 60 second off delay on 5 tonunits with the GE X13TM motor.

Heat Pump UnitsOn a call for first stage heat, the contacts of the room ther-mostat close. This energizes terminals R to Y and R to G,the low voltage circuit to the contactor is completed startingthe compressor and outdoor fan motor. This also energizesthe indoor blower through the normally open contacts of theEBTDR after a 7 second on delay on 2 thru 4 ton units, andinstantly on 5 ton units with the GE X13TM motor.When the thermostat is satisfied, breaking the circuit be-tween R to Y and R to G, the compressor and outdoor fanmotor will stop. The indoor blower will stop after the EBTDR65 second off delay on 2 thru 4 ton units, and after the pro-grammed 60 second off delay on 5 ton units with the GEX13TM motor. .When auxiliary electric heaters are used, a two stage heat-ing single stage cooling thermostat would be installed.Should the second stage heating contacts in the room ther-mostat close, which would be wired to W1 at the unit lowvoltage connections, this would energize the coil(s) of theelectric heat relay(s). Contacts within the relay(s) will close,bringing on the electric resistance heaters.If auxiliary electric heaters should be used, they may be con-trolled by outdoor thermostats (OT18-60A or OT/EHR18-60A).

Emergency Heat Mode (Heat Pumps)

NOTE: The following only applies if the unit has an approvedelectric heat kit installed for auxiliary heating.

GPC 2 thru 4 ton units: (A Revision Models)With the thermostat set to the emergency heat position anda call for 2nd stage heat, R to W1 will be energized. This willenergize the electric heat sequencers. When the normallyopen contacts of the heat sequencers close, this will ener-

gize the electric resistance heat and also the indoor blowermotor through the normally closed contacts of the EBTDR.

GPH 2 thru 4 ton units: (AB Revision Models)With the thermostat set to the emergency heat position anda call for 2nd stage heat, R to W1 will be energized. This willenergize the electric heat sequencers. When the normallyopen contacts of the heat sequencers close, this will ener-gize the electric resistance heat and also the 240 volt coil onthe isolation isolation relay in the control panel. The normallyopen contacts of the isolation relay will close energizing theindoor blower motor through the normally closed contacts ofthe EBTDR.

GPH 5 ton units: (A and AA Revision Models)With the thermostat set to the emergency heat position anda call for 2nd stage heat, R to W1 will be energized. This willenergize the electric heat sequencers and the blower relay.The electric heat will be energized through the normally opencontacts of the electric heat sequencers. The indoor blowerwill be energized through the normally open contacts of theblower relay.

GPH 5 ton units: (AB Revision Models)With the thermostat set to the emergency heat position anda call for 2nd stage heat, R to W1 will be energized. This willenergize the electric heat sequencers and the GE X13TM

motor. The electric heat will be energized through the nor-mally open contacts of the electric heat sequencers. Theindoor blower will be energized through W from the thermo-stat.

DEFROST CYCLEPackage Heat PumpsThe defrosting of the outdoor coil is jointly controlled by thedefrost control board and the defrost thermostat.

Solid State Defrost ControlDuring operation the power to the circuit board is controlledby a temperature sensor, which is clamped to a feeder tubeentering the outdoor coil. Defrost timing periods of 30, 60, or90 minutes may be selected by connecting the circuit boardjumper to 30, 60, or 90 respectively. Accumulation of time forthe timing period selected starts when the sensor closes(approximately 31° F), and when the room thermostat callsfor heat. At the end of the timing period, the unit’s defrostcycle will be initiated provided the sensor remains closed.When the sensor opens (approximately 75° F), the defrostcycle is terminated and the timing period is reset. If the de-frost cycle is not terminated due to the sensor temperature,a ten minute override interrupts the unit’s defrost period.

C Y W2 R R DFT

TEST

DF1

DF2

JUMPER WIRE

906030

A

18

SYSTEM OPERATIONFAN OPERATIONContinuous Fan Mode(A, AB Revision 2 - 4 Ton and A, AA Revision 5 Ton)If the thermostat calls for continuous fan, the indoor blowerwill be energized from the normally open contacts of theEBTDR after a 7 second delay on 2 thru 4 ton units, or fromthe G terminal of the thermostat to the X13 blower motor on 5ton units.Anytime there is a call for continuous fan, the indoor blowerwill be energized through the normally open contacts of theEBTDR on 2 thru 4 ton units and from the G terminal of thethermostat to the GE X13TM motor on 5 ton units, regardlessof a call for heat or cool.If the thermostat is not calling for heat or cool, and the fanswitch on the thermostat is returned to the automatic posi-tion, the fan will stop after a 65 second delay on 2 thru 4 tonunits, and after the programmed 60 second off delay on 5 tonunits with the GE X13TM motor.

Continuous Fan Mode (AB Revision 5 Ton Only)If the thermostat calls for continuous fan, the indoor blowerwill be energized from the G terminal of the thermostat to theX13 blower motor.If a call for heat or cool occurs during a continuous fan call,the GE X13TM motor will always recognize the call for thehighest speed and ignore the lower speed call.If the thermostat is not calling for heat or cool, and the fanswitch on the thermostat is returned to the automatic posi-tion, the fan will stop after the programmed 60 second offdelay on units with the GE X13TM motor.

SYSTEM OPERATION

19

Typical Package Cooling

Restrictor Orifice Assembly in Cooling Operation

In the cooling mode the orifice is pushed into its seat forcing refrigerant to flow through the metered hole in the center of theorifice.

IndoorCoil

OutdoorCoil

ChatleffOrificeAssy

20

SYSTEM OPERATION

IndoorCoil

Accumulator

OutdoorCoil

Reversing Valve(Energized)

IndoorCoil

Accumulator

OutdoorCoil

Reversing Valve(De-Energized)

Typical Heat Pump System in Heating

Typical Heat Pump System in Cooling

SCHEDULED MAINTENANCE

21

The owner should be made aware of the fact, that, as with anymechanical equipment the remote air conditioner requires regu-larly scheduled maintenance to preserve high performance stan-dards, prolong the service life of the equipment, and lessen thechances of costly failure.In many instances the owner may be able to perform some ofthe maintenance; however, the advantage of a service con-tract, which places all maintenance in the hands of a trainedserviceman, should be pointed out to the owner.

WARNINGHIGH VOLTAGE!DISCONNECT ALL POWER BEFORE SERVICING ORINSTALLING THIS UNIT. MULTIPLE POWER SOURCESMAY BE PRESENT. FAILURE TO DO SO MAY CAUSEPROPERTY DAMAGE, PERSONAL INJURY, OR DEATH.

ONCE A MONTH1. Inspect the return filters of the evaporator unit and clean or

change if necessary.

NOTE: Depending on operation conditions, it may be necessaryto clean the filters more often. If permanent type filters areused, they should be washed with warm water, dried andsprayed with an adhesive according to manufacturersrecommendations.

2. When operating on the cooling cycle, inspect the conden-sate line piping from the evaporator coil. Make sure thepiping is clear for proper condensate flow.

ONCE A YEARQualified Service Personnel Only1. Clean the indoor and outdoor coils.2. Clean the casing of the outdoor unit inside and out .3. Motors are permanently lubricated and do not require oil-

ing. TO AVOID PREMATURE MOTOR FAILURE, DO NOTOIL.

4. Manually rotate the outdoor fan and indoor blower to besure they run freely.

5. Inspect the control panel wiring, compressor connections,

and all other component wiring to be sure all connectionsare tight. Inspect wire insulation to be certain that it isgood.

6. Check the contacts of the compressor contactor. If theyare burned or pitted, replace the contactor.

7. Using a halide or electronic leak detector, check all pipingand etc. for refrigerant leaks.

8. Check the combustion chamber (Heat Exchanger) for soot,scale, etc. Inspect all burners for lint and proper position-ing.

9. Start the system, using the proper instrumentation checkgas inlet and manifold pressures, burner flame and microampsignal. Adjust if necessary.

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 possiblecause.

TEST EQUIPMENTProper test equipment for accurate diagnosis is as essentialas regular hand tools.The following is a must for every service technician and serviceshop:1. Thermocouple type temperature meter - measure dry bulb

temperature.2. Sling psychrometer- measure relative humidity and wet bulb

temperature.3. Amprobe - measure amperage and voltage.4. Volt-Ohm Meter - testing continuity, capacitors, and motor

windings.5. Accurate Leak Detector - testing for refrigerant leaks.6. High Vacuum Pump - evacuation.7. Electric Vacuum Gauge, Manifold Gauges and high vacuum

hoses - to measure and obtain proper vacuum.8. Accurate Electronic Scale - measure proper refrigerant

charge.9. Inclined Manometer - measure static pressure and pres-

sure drop across coils.Other recording type instruments can be essential in solvingabnormal problems, however, in many instances they may berented from local sources.Proper equipment promotes faster, more efficient service, andaccurate repairs with less call backs.

SERVICING

22

Com plaintSystem

Operating Pressures

POSSIBLE CAUSE

DOTS IN ANALYSISGUIDE INDICATE

"POSSIBLE CAUSE"

SYM

PTO

MSy

stem

will

not s

tart

Com

pres

sor w

ill no

t sta

rt - f

an ru

ns

Com

p. a

nd C

ond.

Fan

will

not s

tart

Evap

orat

or fa

n w

ill no

t sta

rt

Con

dens

er fa

n w

ill no

t sta

rt

Com

pres

sor r

uns

- goe

s of

f on

over

load

Com

pres

sor c

ycle

s on

ove

rload

Syst

em ru

ns c

ontin

uous

ly -

little

coo

ling/

htg

Too

cool

and

then

too

war

m

Not

coo

l eno

ugh

on w

arm

day

s

Cer

tain

are

as to

o co

ol, o

ther

s to

o w

arm

Com

pres

sor i

s no

isy

Syst

em ru

ns -

blow

s co

ld a

ir in

hea

ting

Uni

t will

not t

erm

inat

e de

frost

Uni

t will

not d

efro

st

Low

suc

tion

pres

sure

Low

hea

d pr

essu

re

Hig

h su

ctio

n pr

essu

re

Hig

h he

ad p

ress

ure

Test MethodRemedy

See

Ser

vice

Pro

cedu

re R

ef.

Pow er Failure • Test Voltage S-1Blow n Fuse • • • Inspect Fuse Size & Type S-1Unbalanced Pow er, 3PH • • • Test Voltage S-1Loose Connection • • • Inspect Connection - Tighten S-2, S-3Shorted or Broken Wires • • • • • • Test Circuits With Ohmmeter S-2, S-3Open Fan Overload • • Test Continuity of Overload S-17AFaulty Thermostat • • • • Test continuity of Thermostat & Wiring S-3Faulty Transformer • • Check control circuit w ith voltmeter S-4Shorted or Open Capacitor • • • • • Test Capacitor S-15Internal Compressor Overload Open • ♦ Test Continuity of Overload S-17AShorted or Grounded Compressor • • Test Motor Windings S-17BCompressor Stuck • • • ♦ Use Test Cord S-17DFaulty Compressor Contactor • • • Test continuity of Coil & Contacts S-7, S-8Faulty Fan Control • Test continuity of Coil And Contacts S-7, S-9Open Control Circuit • Test Control Circuit w ith Voltmeter S-4Low Voltage • • • Test Voltage S-1Faulty Evap. Fan Motor • • ♦ Repair or Replace S-16Shorted or Grounded Fan Motor • • Test Motor Windings S-16A,DImproper Cooling Anticipator • • Check resistance of Anticipator S-3BShortage of Ref rigerant • • ♦ • • Test For Leaks, Add Ref rigerant S-101,103Restricted Liquid Line • • • • • Remove Restriction, Replace Restricted Part S-112Open Element or Limit on Elec. Heater ♦ ♦ Test Heater Element and Controls S-26,S-27Dirty Air Filter • • • • ♦ Inspect Filter-Clean or ReplaceDirty Indoor Coil • • • • ♦ Inspect Coil - CleanNot enough air across Indoor Coil • • • • ♦ Check Blow er Speed, Duct Static Press, Filter S-200Too much air across Indoor Coil • ♦ • Reduce Blow er Speed S-200Overcharge of Refrigerant • • • ♦ • • Recover Part of Charge S-113Dirty Outdoor Coil • • • ♦ • Inspect Coil - CleanNoncondensibles • • ♦ • Recover Charge, Evacuate, Recharge S-114Recirculation of Condensing Air • • • Remove Obstruction to Air FlowInf iltration of Outdoor Air • • • Check Window s, Doors, Vent Fans, Etc.Improperly Located Thermostat • • Relocate ThermostatAir Flow Unbalanced • • Readjust Air Volume DampersSystem Undersized • • Ref igure Cooling LoadBroken Internal Parts • ♦ Replace Compressor S-115Broken Valves • • • • Test Compressor Ef f iciency S-104Inef f icient Compressor • ♦ • • Test Compressor Ef f iciency S-104Loose Hold-dow n Bolts • Tighten BoltsFaulty Reversing Valve • ♦ ♦ ♦ ♦ ♦ ♦ Replace Valve or Solenoid S-21, 122Faulty Def rost Control • ♦ ♦ ♦ ♦ ♦ ♦ Test Control S-24Faulty Def rost Thermostat ♦ ♦ ♦ ♦ ♦ ♦ ♦ Test Def rost Thermostat S-25Flow rator Not Seating Properly • • • Check Flow rator & Seat or Replace Flow rator S-111

• ♦

No CoolingUnsatisfactory

Cooling/Heating

Cooling or Heating Cycle (Heat Pum p) Heating Cycle Only (Heat Pum p)

COOLING /HEAT PUMP- SERVICE ANALYSIS GUIDESERVICING

SERVICING

23

S-1 CHECKING VOLTAGE


1. Remove doors, control panel cover, etc. from unit beingtested.

With power ON:

WARNINGLINE VOLTAGE NOW PRESENT.

2. Using a voltmeter, measure the voltage across terminalsL1 and L2 of the contactor for single phase units, and L3,for 3 phase units.

3. No reading - indicates open wiring, open fuse(s) no poweror etc. from unit to fused disconnect service. Repair asneeded.

4. With ample voltage at line voltage connectors, energizethe unit.

5. Measure the voltage with the unit starting and operating,and determine the unit Locked Rotor Voltage.Locked Rotor Voltage is the actual voltage available atthe compressor during starting, locked rotor, or a stalledcondition. Measured voltage should be above minimumlisted in chart below.To measure Locked Rotor Voltage attach a voltmeter tothe run "R" and common "C" terminals of the compres-sor, or to the T1 and T2 terminals of the contactor. Startthe unit and allow the compressor to run for several sec-onds, then shut down the unit. Immediately attempt torestart the unit while measuring the Locked Rotor Volt-age.

6. Should read within the voltage tabulation as shown. Ifthe voltage falls below the minimum voltage, check theline wire size. Long runs of undersized wire can causelow voltage. If wire size is adequate, notify the localpower company in regards to either low or high voltage.

Voltage Min. Max.460 437 506

208/230 198 253

Unit Supply Voltage

Three phase units require a balanced 3 phase power supply tooperate. If the percentage of voltage imbalance exceeds 3%the unit must not be operated until the voltage condition iscorrected.

Max. Voltage Deviation% Voltage = From Average Voltage X 100Imbalance Average VoltageTo find the percentage of imbalance, measure the incomingpower supply.

L1 - L2 = 240VL1 - L3 = 232V Avg. V = 710 = 236.7L2 - L3 = 238V 3Total 710V

To find Max. deviation: 240 - 236.7 = +3.3232 - 236.7 = -4.7238 - 236.7 = +1.3

Max deviation was 4.7V% Voltage Imbalance = 4.7 = 1.99%

236.7If the percentage of imbalance had exceeded 3%, it must bedetermined if the imbalance is in the incoming power supply orthe equipment. To do this rotate the legs of the incomingpower and retest voltage as shown below.

L1 L2 L3

L3L2L1By the voltage readings we see that the imbalance rotated ortraveled with the switching of the incoming legs. Therefore thepower lies within the incoming power supply.If the imbalance had not changed then the problem would liewithin the equipment. Check for current leakage, shorted mo-tors, etc.

L1 - L2 = 240VL1 - L3 = 227VL2 - L3 = 238V

Rotate all 3 incominglegs as shown.

L1 - L2 = 227VL1 - L3 = 238VL2 - L3 = 240V

SERVICING

24

S-2 CHECKING WIRING


1. Check wiring visually for signs of overheating, damagedinsulation and loose connections.

2. Use an ohmmeter to check continuity of any suspectedopen wires.

3. If any wires must be replaced, replace with comparablegauge and insulation thickness.

S-3 CHECKING THERMOSTAT, WIRING, ANDANTICIPATOR

S-3A THERMOSTAT AND WIRING


With power ON and thermostat calling for cooling.1. Use a voltmeter to verify 24 volts present at thermostat

wires C and R.2. If no voltage present, check transformer and transformer

wiring. If 24 volts present, proceed to step 3.3. Use a voltmeter to check for 24 volts at thermostat wires C

and Y.4. No voltage indicates trouble in the thermostat, wiring or

external transformer source.5. Check the continuity of the thermostat and wiring. Repair

or replace as necessary.

Indoor Blower MotorWith power ON:


1. Use a voltmeter to verify 24 volts present at thermostatwires C and R.

2. If no voltage present, check transformer and transformerwiring. If 24 volts present, proceed to step 3.

3. Set fan selector switch at thermostat to "ON" position.4. With voltmeter, check for 24 volts at wires C and G.

5. No voltage, indicates the trouble is in the thermostat orwiring.

6. Check the continuity of the thermostat and wiring. Repairor replace as necessary.

S-3B COOLING ANTICIPATORThe cooling anticipator is a small heater (resistor) in the ther-mostat. During the "off" cycle it heats the bimetal elementhelping the thermostat call for the next cooling cycle. Thisprevents the room temperature from rising too high before thesystem is restarted. A properly sized anticipator should main-tain room temperature within 1 1/2 to 2 degree range.The anticipator is supplied in the thermostat and is not to bereplaced. If the anticipator should fail for any reason, the ther-mostat must be changed.

S-3C HEATING ANTICIPATORThe heating anticipator is a wire-wound adjustable heater, whichis energized during the "ON" cycle to help prevent overheatingof the conditioned space.The anticipator is a part of the thermostat and if it should fail forany 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 measurethe amperage on the "W" wire going to the thermostat.Use an amprobe as shown below. Wrap 10 turns of thermostatwire around the stationary jaw of the amprobe and divide thereading by 10.

10 TURNS OFTHERMOSTAT WIRE(From "W" on thermostat)

STATIONARY JAWOF AMPROBE

READS 4 AMPSCURRENT DRAWWOULD BE .4 AMPS

Checking Heat Anticipator Amp Draw

SERVICING

25

S-4 CHECKING TRANSFORMER ANDCONTROL CIRCUITA step-down transformer (208/240 volt primary to 24 volt sec-ondary) is provided with each package unit. This allows amplecapacity for use with resistance heaters.


1. Remove control panel cover or etc. to gain access to trans-former.

With power ON:


2. Using a voltmeter, check voltage across secondary voltageside of transformer (R to C).

3. No voltage indicates faulty transformer, bad wiring, or badsplices.

4. Check transformer primary voltage at incoming line voltageconnections and/or splices.

5 If line voltage is present at the primary voltage side of thetransformer and 24 volts is not present on the secondaryside, then the transformer is inoperative. Replace.

S-7 CHECKING CONTACTOR AND/ORRELAYSThe compressor contactor and other relay holding coils arewired into the low or line voltage circuits. When the controlcircuit is energized the coil pulls in the normally open contactsor opens the normally closed contacts. When the coil is de-energized, springs return the contacts to their normal position.

WARNINGDISCONNECT POWER SUPPLY BEFORE SERVICING.

1. Remove the leads from the holding coil.2. Using an ohmmeter, test across the coil terminals.If the coil does not test continuous, replace the relay or con-tactor.

S-8 CHECKING CONTACTOR CONTACTS


SINGLE PHASE1. Disconnect the wire leads from the terminal (T) side of the

contactor.2. With power ON, energize the contactor.


VOLT/OHMMETER

T1T2

L1L2

CC

Ohmmeter for testing holding coilVoltmeter for testing contacts

TESTING COMPRESSOR CONTACTOR(Single Phase)

3. Using a voltmeter, test across terminals.A. L1 to L2 - No voltage. Check breaker or fuses on main

power supply. If voltage present, proceed to step B.B. T1 to T2 - Meter should read the same as L1 to L2 in

step A. If voltage readings are not the same as step A,replace contactor.

THREE PHASEUsing a voltmeter, test across terminals:

A. L1-L2, L1-L3, and L2-L3 - If voltage is present, pro-ceed to B. If voltage is not present, check breaker orfuses on main power supply..

B. T1-T2, T1-T3, and T2-T3 - If voltage readings are notthe same as in "A", replace contactor.

SERVICING

26

VOLT/OHMMETER

CC

Ohmmeter for testing holding coilVoltmeter for testing contacts

T1

L1

T3

L3

T2

L2

TESTING COMPRESSOR CONTACTOR(Three-phase)

S-9 CHECKING FAN RELAY CONTACTS2 Thru 4 Ton UnitsThe Electronic Blower Time Delay Relay is used on the 2 thru4 ton units.


Checking EBTDR High Voltage Contacts1. With power off, remove wires from terminals NC, COM, and

NO.2. Using a VOM, check for resistance from NO to COM. Should

read open. Next, check for resistance from NC to COM.Should read closed.

3. If not as above, replace EBTDR.

Checking EBTDR Contact OperationWith power on:


1. Set the thermostat to the fan "on" position.2. Check for 24 volts at the C and G terminals of the EBTDR.3. If no voltage present, check fan circuit from thermostat. If

24 volts present, proceed to step 4.4. Using a VOM, check for line voltage from the purple wire at

the transformer (terminal 3 on 240 volt units, terminal 2 on208 volt units) to terminal NO on the EBTDR. Should readline voltage. If no voltage present, check line voltage wiringin unit. If line voltage present, proceed to step 5.

5. Using a VOM, check for line voltage from the purple wire atthe transformer (terminal 3 on 240 volt units, terminal 2 on208 volt units) to the COM terminal on the EBTDR. Shouldread line voltage. If not as above, replace EBTDR.

2 Thru 4 Ton Units (AB Revision)The 2 thru 4 ton AB revision model coolers and heat pumpshave an isolation relay with a 240 volt holding coil in addition tothe EBTDR.


Turn power off.

Testing relay holding coil1. Remove the leads from the holding coil terminals 1 and 3.2. Using an ohmmeter, test across the coil terminals 1 and 3.

If the coil does not test continuous, replace the relay.

Testing relay contacts


Turn power off.1. Using a VOM, test resistance across relay terminals 2 and

4. Should read open.2. Turn power on.


3. Apply 240 volts to coil terminals 1 and 3.4. Using a VOM, check for 240 volts from terminals 3 and 1 of

relay. Should read 240 volts. In no voltage, check wiringfrom heater kit to relay. If voltage present, proceed to step5.

5. Using a VOM, check for 240 volts from L1 at contactor toterminal 4 of relay. Should read 240 volts. Next check fromL1 at contactor to terminal 2 of relay. Should read 240volts.

If not as above, replace relay.

SERVICING

27

5 Ton Units (A and AA Revision)

NOTE: The 5 Ton AB revision models do not have a relay.

On the A and AA revision 5 ton units with the GE X13TM motor,a standard fan relay is used.


Turn power off.

Testing relay holding coil1. Remove the leads from the holding coil.2. Using an ohmmeter, test across the coil terminals 1 and 3.

If the coil does not test continuous, replace the relay.

Testing relay contacts


Turn power off.1. Using a VOM, test resistance across relay terminals 2 and

4. Should read open.2. Turn power on.


3. Apply 24 volts to coil terminals 1 and 3.4. Using a VOM, check for 24 volts from terminals 3 and 2 of

relay. Should read 24 volts. If no voltage, check low voltagewiring from transformer to relay. If voltage present, proceedto step 5.

5. Using a VOM, check for 24 volts from terminals 3 and 4 ofrelay. Should read 24 volts.

If not as above, replace relay.

S-11 CHECKING LOSS OF CHARGEPROTECTOR(Heat Pump Models)The loss of charge protector senses the pressure in the liquidline and will open its contacts on a drop in pressure. The lowpressure control will automatically reset itself with a rise inpressure.The low pressure control is designed to cut-out (open) at ap-proximately 7 PSIG. It will automatically cut-in (close) at ap-proximately 25 PSIG.Test for continuity using a VOM and if not as above, replacethe control.

S-15 CHECKING CAPACITORCAPACITOR, RUNA run capacitor is wired across the auxiliary and main wind-ings of a single phase permanent split capacitor motor. Thecapacitors primary function is to reduce the line current whilegreatly improving the torque characteristics of a motor. This isaccomplished by using the 90° phase relationship betweenthe capacitor current and voltage in conjunction with the motorwindings so that the motor will give two phase operation whenconnected to a single phase circuit. The capacitor also re-duces the line current to the motor by improving the powerfactor.

CAPACITOR, STARTSCROLL COMPRESSOR MODELSHard start components are not required on Scroll compressorequipped units due to a non-replaceable check valve located inthe discharge line of the compressor. However hard start kitsare available and may improve low voltage starting characteris-tics.This check valve closes off high side pressure to the compres-sor after shut down allowing equalization through the scrollflanks. Equalization requires only about one or two secondsduring which time the compressor may turn backwards.Your unit comes with a 180-second anti-short cycle to preventthe compressor from starting and running backwards.

MODELS EQUIPPED WITH A HARD START DEVICEA start capacitor is wired in parallel with the run capacitor toincrease the starting torque. The start capacitor is of the elec-trolytic type, rather than metallized polypropylene as used inthe run capacitor.A switching device must be wired in series with the capacitorto remove it from the electrical circuit after the compressorstarts to run. Not removing the start capacitor will overheat thecapacitor and burn out the compressor windings.These capacitors have a 15,000 ohm, 2 watt resistor wiredacross its terminals. The object of the resistor is to dischargethe capacitor under certain operating conditions, rather thanhaving it discharge across the closing of the contacts withinthe switching device such as the Start Relay, and to reducethe chance of shock to the servicer. See the Servicing Sectionfor specific information concerning capacitors.

RELAY, STARTA potential or voltage type relay is used to take the start ca-pacitor out of the circuit once the motor comes up to speed.This type of relay is position sensitive. The normally closedcontacts are wired in series with the start capacitor and therelay holding coil is wired parallel with the start winding. Asthe motor starts and comes up to speed, the increase in volt-age across the start winding will energize the start relay hold-ing coil and open the contacts to the start capacitor.Two quick ways to test a capacitor are a resistance and acapacitance check.

SERVICING

28

S-15A RESISTANCE CHECK


1. Discharge capacitor and remove wire leads.

WARNINGDISCHARGE CAPACITOR THROUGH A 20 TO 30 OHMRESISTOR BEFORE HANDLING.

Capac

itor

Volt / Ohm Meter

TESTING CAPACITOR RESISTANCE2. Set an ohmmeter on its highest ohm scale and connect

the leads to the capacitor -A. Good Condition - indicator swings to zero and slowlyreturns to infinity. (Start capacitor will bleed resistor willnot return to infinity. It will still read the resistance of theresistor).B. Shorted - indicator swings to zero and stops there -replace.C. Open - no reading - replace. (Start capacitor would readresistor resistance).

S-15B CAPACITANCE CHECK

WARNINGDISCHARGE CAPACITOR THROUGH A 20 TO 30 OHMRESISTOR BEFORE HANDLING.

Using a hookup as shown below, take the amperage and volt-age readings and use them in the formula:

Capacitance (MFD) = 2650 X AmperageVoltage

15 AMP FUSE

Volt / Ohm Meter

AMMETER

TESTING CAPACITANCE

S-16 CHECKING MOTORS

S-16A CHECKING FAN AND BLOWER MOTORWINDINGS (PSC MOTORS)The auto reset fan motor overload is designed to protect themotor against high temperature and high amperage conditionsby breaking the common circuit within the motor, similar to thecompressor internal overload. However, heat generated withinthe motor is faster to dissipate than the compressor, allow atleast 45 minutes for the overload to reset, then retest.


1. Remove the motor leads from its respective connectionpoints and capacitor (if applicable).

2. Check the continuity between each of the motor leads.3. Touch one probe of the ohmmeter to an unpainted end of

the motor frame (ground) and the other probe in turn toeach lead.

If the windings do not test continuous or a reading is obtainedfrom any lead to ground, replace the motor.

S-16D CHECKING GE X13TM MOTORSThe GE X13TM Motor is a one piece, fully encapsulated, 3 phasebrushless DC (single phase AC input) motor with ball bearingconstruction. Unlike the ECM 2.3/2.5 motors, the GE X13TM

features an integral control module.

Note: The GE TECMate will not currently operate the GE X13TM

motor.

1. Using a voltmeter, check for 230 volts to the motor connec-tions L and N. If 230 volts is present, proceed to step 2. If230 volts is not present, check the line voltage circuit tothe motor.

SERVICING

29

2. Using a voltmeter, check for 24 volts from terminal C toeither terminal 1(Low), 2 (Medium), or 3 (High), dependingon which tap is being used, at the motor. If voltage present,proceed to step 3. If no voltage, check 24 volt circuit tomotor.

3. If voltage was present in steps 1 and 2, the motor has failedand will need to be replaced.

Note: When replacing motor, ensure the belly band is betweenthe vents on the motor and the wiring has the proper drip loopto prevent condensate from entering the motor.

C L G N

1 2 3 4 5

High VoltageConnections

3/16"

Low Voltage Connections1/4”

GE X13TM MOTOR CONNECTIONS

S-17 CHECKING COMPRESSOR WINDINGS

WARNINGHERMETIC COMPRESSOR ELECTRICAL TERMINALVENTING CAN BE DANGEROUS. WHEN INSULATINGMATERIAL WHICH SUPPORTS A HERMETIC COM-PRESSOR OR ELECTRICAL TERMINAL SUDDENLYDISINTEGRATES DUE TO PHYSICAL ABUSE OR AS ARESULT OF AN ELECTRICAL SHORT BETWEEN THETERMINAL AND THE COMPRESSOR HOUSING, THETERMINAL MAY BE EXPELLED, VENTING THE VAPOR AND LIQUID CONTENTS OF THE COMPRES-SOR HOUSING AND SYSTEM.

If the compressor terminal PROTECTIVE COVER and gasket(if required) is not properly in place and secured, there is aremote 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.This discharge can be ignited external to the compressor if theterminal cover is not properly in place and if the dischargeimpinges on a sufficient heat source.Ignition of the discharge can also occur at the venting terminalor inside the compressor, if there is sufficient contaminant airpresent in the system and an electrical arc occurs as the ter-minal vents.Ignition cannot occur at the venting terminal without the pres-ence of contaminant air, and cannot occur externally from theventing terminal without the presence of an external ignitionsource.Therefore, proper evacuation of a hermetic system is essen-tial at the time of manufacture and during servicing.To reduce the possibility of external ignition, all open flame,electrical power, and other heat sources should be extinguishedor 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.

S-17A RESISTANCE TESTEach compressor is equipped with an internal overload.The line break internal overload senses both motor amperageand winding temperature. High motor temperature or amper-age heats the disc causing it to open, breaking the commoncircuit within the compressor on single phase units. The threephase internal overload will open all three legs.Heat generated within the compressor shell, usually due torecycling of the motor, high amperage or insufficient gas tocool the motor, is slow to dissipate, allow at least three to fourhours for it to cool and reset, then retest.


1. Remove the leads from the compressor terminals.

WARNINGSEE WARNINGS S-17 BEFORE REMOVING COMPRES-SOR TERMINAL COVER.

2. Using an ohmmeter, test continuity between terminals S-R, C-R, and C-S, on single phase units or terminals T1, T2and T3, on 3 phase units.

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30

S R

C

COMP

OHMMETER

TESTING COMPRESSOR WINDINGSIf either winding does not test continuous, replace the com-pressor.NOTE: If an open compressor is indicated allow ample timefor the internal overload to reset before replacing compressor.

S-17B GROUND TESTIf fuse, circuit breaker, ground fault protective device, etc., hastripped, this is a strong indication that an electrical problemexists and must be found and corrected. The circuit protectivedevice rating must be checked and its maximum rating shouldcoincide with that marked on the equipment nameplate.With the terminal protective cover in place, it is acceptable toreplace the fuse or reset the circuit breaker ONE TIME ONLYto see if it was just a nuisance opening. If it opens again, DONOT continue to reset.Disconnect all power to unit, making sure that all power legsare open.1. DO NOT remove protective terminal cover. Disconnect the

three leads going to the compressor terminals at the near-est point to the compressor.

WARNINGDAMAGE CAN OCCUR TO THE GLASS EMBEDDEDTERMINALS IF THE LEADS ARE NOT PROPERLYREMOVED. THIS CAN RESULT IN TERMINAL ANDHOT OIL DISCHARGING.

HI-POT

COMPRESSOR GROUND TEST2. Identify the leads and using a Megger, Hi-Potential Ground

Tester, or other suitable instrument which puts out a volt-age between 300 and 1500 volts, check for a ground sepa-rately between each of the three leads and ground (suchas an unpainted tube on the compressor). Do not use alow voltage output instrument such as a volt-ohmmeter.

3. If a ground is indicated, then carefully remove the compres-sor terminal protective cover and inspect for loose leads orinsulation breaks in the lead wires.

4. If no visual problems indicated, carefully remove the leadsat the compressor terminals.Carefully retest for ground, directly between compressorterminals and ground.

5. If ground is indicated, replace the compressor.

S-17D OPERATION TESTIf the voltage, capacitor, overload and motor winding test fail toshow the cause for failure:


1. Remove unit wiring from disconnect switch and wire a testcord to the disconnect switch.

NOTE: The wire size of the test cord must equal the line wiresize and the fuse must be of the proper size and type.2. With the protective terminal cover in place, use the three

leads to the compressor terminals that were disconnectedat the nearest point to the compressor and connect thecommon, start and run clips to the respective leads.

3. Connect good capacitors of the right MFD and voltage rat-ing into the circuit.

4. With power ON, close the switch.


A. If the compressor starts and continues to run, thecause for failure is somewhere else in the system.

B. If the compressor fails to start - replace.

S-18 TESTING CRANKCASE HEATER

Note: Not all compressors use crankcase heaters.

The crankcase heater must be energized a minimum of four(4) hours before the compressor is operated.Crankcase heaters are used to prevent migration or accumula-tion of refrigerant in the compressor crankcase during the offcycles and prevents liquid slugging or oil pumping on start up.Scroll Compressors are not equipped with a crankcase heat-ers.A crankcase heater will not prevent compressor damage dueto a floodback or over charge condition.

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1. Disconnect the heater lead wires.2. Using an ohmmeter, check heater continuity - should test

continuous, if not, replace.

S-21 CHECKING REVERSING VALVE ANDSOLENOIDOccasionally the reversing valve may stick in the heating orcooling position or in the mid-position.When stuck in the mid-position, part of the discharge gas fromthe compressor is directed back to the suction side, resultingin excessively high suction pressure. An increase in the suc-tion line temperature through the reversing valve can also bemeasured. Check operation of the valve by starting the sys-tem and switching the operation from COOLING to HEATINGcycle.If the valve fails to change its position, test the voltage (24V) atthe valve coil terminals, while the system is on the COOLINGcycle.If no voltage is registered at the coil terminals, check the op-eration of the thermostat and the continuity of the connectingwiring from the "O" terminal of the thermostat to the unit.If voltage is registered at the coil, tap the valve body lightlywhile switching the system from HEATING to COOLING, etc.If this fails to cause the valve to switch positions, remove thecoil connector cap and test the continuity of the reversing valvesolenoid coil. If the coil does not test continuous - replace it.If the coil test continuous and 24 volts is present at the coilterminals, the valve is inoperative - replace it.

S-24 TESTING DEFROST CONTROLTo check the defrost control for proper sequencing, proceed asfollows: With power ON; unit not running.1. Jumper defrost thermostat by placing a jumper wire across

the terminals "DFT" and "R" at defrost control board.2. Connect jumper across test pins on defrost control board.3. Set thermostat to call for heating. System should go into

defrost within 21 seconds.4. Immediately remove jumper from test pins.5. Using VOM check for voltage across terminals "C & O".

Meter should read 24 volts.6. Using VOM check for voltage across fan terminals DF1

and DF2 on the board. You should read line voltage (208-230 VAC) indicating the relay is open in the defrost mode.

7. Using VOM check for voltage across "W2 & C" terminalson 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 before re-turning system to service.

S-25 TESTING DEFROST THERMOSTAT1. Install a thermocouple type temperature test lead on the

tube adjacent to the defrost control. Insulate the lead pointof contact.

2. Check the temperature at which the control closes its con-tacts by lowering the temperature of the control. Part #0130M00009P which is used on 2 and 2.5 ton units shouldclose at 34°F ± 5°F. Part # 0130M00001P which is usedon 3 thru 5 ton units should close at 31°F ± 3°F.

3. Check the temperature at which the control opens its con-tacts by raising the temperature of the control. Part #0130M00009P which is used on 2 and 2.5 ton units shouldopen at 60°F ± 5°F. Part # 0130M00001P which is usedon 3 thru 5 ton units should open at 75°F ± 6°F.

4. If not as above, replace control.

S-26 CHECKING HEATER LIMIT CONTROL(S)(OPTIONAL ELECTRIC HEATERS)Each individual heater element is protected with an automaticrest limit control connected in series with each element toprevent overheating of components in case of low airflow. Thislimit control will open its circuit at approximately 150°F. to160°F and close at approximately 110°F.

WARNINGDISCONNECT ELECTRICAL POWER SUPPLY.

1. Remove the wiring from the control terminals.2. Using an ohmmeter test for continuity across the normally

closed contacts. No reading indicates the control is open- replace if necessary. Make sure the limits are cool beforetesting.

IF FOUND OPEN - REPLACE - DO NOT WIRE AROUND.

S-27 CHECKING HEATER ELEMENTSOptional electric heaters may be added, in the quantities shownin the spec sheet for each model unit, to provide electric resis-tance heating. Under no condition shall more heaters than thequantity shown be installed.


1. Disassemble and remove the heating element(s).

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32

2. Visually inspect the heater assembly for any breaks in thewire or broken insulators.

3. Using an ohmmeter, test the element for continuity - noreading indicates the element is open. Replace as neces-sary.

S-100 REFRIGERATION REPAIR PRACTICE

DANGERALWAYS REMOVE THE REFRIGERANT CHARGE INA PROPER MANNER BEFORE APPLYING HEAT TOTHE SYSTEM.

The GPH and GPC model package heat pumps use the FasTestAccess Fitting System. The FasTest Access System con-sists of a saddle that is fastened with a locking nut to theaccess fitting box. The access fitting (core) is then screwedinto the saddle. Do not remove the core from the saddleuntil the refrigerant charge has been removed. Failureto do so could result in property damage or personal in-jury.When installing a new core or reinstalling the core after re-moval, it is very important to note that before inserting the coreinto the saddle, the core and saddle must be free of debris andthe “O” Ring must have a thin coating of refrigerant oil appliedto it. The oil is to prevent the “O” Ring from being deformedwhen the core is tightened completely. The core should betorqued to 8 ft. lb.When repairing the refrigeration system:1. Never open a system that is under vacuum. Air and mois-

ture will be drawn in.2. Plug or cap all openings.3. Remove all burrs and clean the brazing surfaces of the

tubing with sand cloth or paper. Brazing materials do notflow well on oxidized or oily surfaces.

4. Clean the inside of all new tubing to remove oils and pipechips.

5. When brazing, sweep the tubing with dry nitrogen to pre-vent the formation of oxides on the inside surfaces.

6. Complete any repair by replacing the liquid line drier in thesystem, evacuate and charge.

At any time the system has been open for repair, the factoryinstalled liquid line filter drier must be replaced.

BRAZING MATERIALSCopper to Copper Joints - Sil-Fos used without flux (alloy of15% silver, 80% copper, and 5% phosphorous). Recommendedheat 1400°F.Copper to Steel Joints - Silver Solder used without a flux(alloy of 30% silver, 38% copper, 32% zinc). Recommendedheat - 1200°F.

S-101 LEAK TESTINGRefrigerant leaks are best detected with a halide or electronicleak detector.However, on outdoor installed systems, provisions must bemade to shield the copper element of an halide torch from thesun and wind conditions in order to be able to see the elementproperly.NOTE: The flame of the halide detector will glow green in thepresence of R-22 refrigerant.For a system that contains a refrigerant charge and is sus-pected of having a leak, stop the operation and hold the explor-ing tube of the detector as close to the tube as possible, checkall piping and fittings. If a leak is detected, do not attempt toapply more brazing to the joint. Remove and capture the charge,unbraze the joint, clean and rebraze.For a system that has been newly repaired and does not con-tain a charge, connect a cylinder of refrigerant, through a gaugemanifold, to the liquid and suction line dill valves and/or liquidline dill valve and compressor process tube.NOTE: Refrigerant hoses must be equipped with dill valve de-pressors or special adaptor used. Open the valve on the cylin-der and manifold and allow the pressure to build up within thesystem. Check for and handle leaks, as described above.After the test has been completed, remove and capture theleak test refrigerant.

S-102 EVACUATIONThis is the most important part of the entire service procedure.The life and efficiency of the equipment is dependent upon thethoroughness exercised by the serviceman when evacuatingair (non-condensable) and moisture from the system.Air in a system causes high condensing temperature and pres-sure, resulting in increased power input and reduced perfor-mance.Moisture chemically reacts with the refrigerant and oil to formcorrosive hydrofluoric and hydrochloric acids. These attackmotor windings and parts, causing breakdown.The equipment required to thoroughly evacuate the system isa high vacuum pump, capable of producing a vacuum equiva-lent to 25 microns absolute and a thermocouple vacuum gaugeto give a true reading of the vacuum in the systemNOTE: Never use the system compressor as a vacuum pumpor run when under a high vacuum. Motor damage could occur.

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WARNINGSCROLL COMPRESSORSDO NOT FRONT SEAT THE SERVICE VALVE(S) WITHTHE COMPRESSOR OPERATING IN AN ATTEMPT TOSAVE REFRIGERANT. WITH THE SUCTION LINE OFTHE COMPRESSOR CLOSED OR SEVERLY RESTRICT-ED, THE SCROLL COMPRESSOR WILL DRAW A DEEPVACUUM VERY QUICKLY. THIS VACUUM CAN CAUSEINTERNAL ARCING OF THE FUSITE RESULTING IN ADAMAGED OR FAILED COMPRESSOR.

LOW SIDEGAUGE

AND VALVE

HIGH SIDEGAUGE

AND VALVE

TO UNIT SERVICEVALVE PORTS

VACUUM PUMP

VACUUM PUMPADAPTER

800 PSIRATEDHOSES

CHARGINGCYLINDER

AND SCALE

{

R-22MANIFOLD

1. Connect the vacuum pump, vacuum tight manifold set withhigh vacuum hoses, thermocouple vacuum gauge and charg-ing cylinder as shown.

2. If the service dill valves are to be used for evacuation, it isrecommended that a core remover be used to lift the corefor greater efficiency.

3. Start the vacuum pump and open the shut off valve to thehigh vacuum gauge manifold only. After the compoundgauge (low side) has dropped to approximately 29 inchesof vacuum, open the valve to the vacuum thermocouplegauge. See that the vacuum pump will blank-off to a maxi-mum of 25 microns. A high vacuum pump can only pro-duce a good vacuum if its oil is non-contaminated.

4. If the vacuum pump is working properly, close the valve tothe vacuum thermocouple gauge and open the high andlow side valves to the high vacuum manifold set. With thevalve on the charging cylinder closed, open the manifoldvalve to the cylinder.

5. Evacuate the system to at least 29 inches gauge beforeopening valve to thermocouple vacuum gauge.

6. Continue to evacuate to a minimum of 250 microns. Closevalve to vacuum pump and watch rate of rise. If vacuumdoes not rise above 1500 microns in three to five minutes,system can be considered properly evacuated.

7. If thermocouple vacuum gauge continues to rise and levelsoff at about 5000 microns, moisture and non-condensablesare still present. If gauge continues to rise a leak is present.Repair and re-evacuate.

8. Close valve to thermocouple vacuum gauge and vacuumpump. Shut off pump and prepare to charge.

S-103 CHARGINGCharge the system with the exact amount of refrigerant.Refer to the specification section or check the unit nameplatesfor the correct refrigerant charge.After completing airflow measurements and adjustments, theunit’s refrigerant charge must be checked. The unit comesfactory charged, but this charge is based on 400 CFM per tonat minimum ESP per ARI test conditions (generally between.15 - .25 ESP). When air quantity or ESP is different thanabove, charge must be adjusted to the proper amount.All package units are charged to the superheat method at thecompressor suction line (these are fixed orifice devices).For charging in the warmer months, 100F superheat at the com-pressor is required at conditions: 950F outdoor ambient (drybulb temperature), 800F dry bulb / 670F wet bulb indoor ambi-ent, approximately 50% humidity. This superheat varies whenconditions vary from the conditions described.A superheat charge chart is available for other operating condi-tions. Use it to provide the correct superheat at the conditionsthe unit is being charged at.After superheat is adjusted it is recommended to check unitsub-cooling at the condenser coil liquid line out. In most oper-ating conditions 10 - 150F of sub-cooling is adequate.An inaccurately charged system will cause future problems.1. Using a charging scale, allow liquid refrigerant only to enter

the high side.2. After the system will take all it will take, close the valve on

the high side of the charging manifold.3. Start the system and charge the balance of the refrigerant

through the low side. DO NOT charge in a liquid form.4. With the system still running, close the valve on the charg-

ing manifold. At this time, you may still have some liquidrefrigerant in the charging manifold and will definitely haveliquid in the liquid hose. Reseat the liquid line core. Slowlyopen the high side manifold valve and transfer the liquidrefrigerant from the liquid line hose and charging manifoldinto the suction service valve port. CAREFUL: Watch sothat liquid refrigerant does not enter the compressor.

5. With the system still running, reseat the suction valve core,remove hose and reinstall both valve core caps.

6. Check system for leaks.

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34

Units having flow control restrictors can be checked againstthe Desired Superheat vs. Outdoor Temperature Chart in thissection.

S-104 CHECKING COMPRESSOREFFICIENCYThe reason for compressor inefficiency is broken or damagedsuction and/or discharge valves, or scroll flanks on Scroll com-pressors, reducing the ability of the compressor to pump re-frigerant vapor.The condition of the valves or scroll flanks is checked in thefollowing manner.1. Attach gauges to the high and low side of the system.2. Start the system and run a Cooling Performance Test.If the test shows-⇒ Below normal high side pressure.⇒ Above normal low side pressure.⇒ Low temperature difference across coil.⇒ Low amp draw at compressor.-and the charge is correct. The compressor is faulty - replacethe compressor.

S-108 SUPERHEATCHECKING SUPERHEATRefrigerant gas is considered superheated whenever its tem-perature is higher than the saturation temperature correspond-ing to its pressure. The degree of superheat equals the de-grees of temperature increase above the saturation tempera-ture at existing pressure. See Temperature - Pressure Chart.1. Attach an accurate thermometer or preferably a thermo-

couple type temperature tester to the suction line at a pointat least 6" from the compressor.

2. Install a low side pressure gauge on the suction line ser-vice valve at the outdoor unit.

3. Record the gauge pressure and the temperature of the line.4. Convert the suction pressure gauge reading to temperature

by finding the gauge reading in Temperature - PressureChart and reading to the left, find the temperature in the °F.Column.

5. The difference between the thermometer reading and pres-sure to temperature conversion is the amount of super-heat.

EXAMPLE:a. Suction Pressure = 84b. Corresponding Temp. °F. = 50c. Thermometer on Suction Line = 63°F.

To obtain the degrees temperature of superheat subtract 50.0from 63.0°F.The difference is 13° Superheat.

For charging in the warmer months, 10°F superheat at thecompressor is required at conditions: 95°F outdoor ambient(dry bulb temperature), 80°F dry bulb / 67°F wet bulb indoorambient, approximately 50 % humidity. This superheat varieswhen conditions vary from the conditions described.A superheat charge chart is provided below for other operatingconditions. Use it to provide the correct superheat at theconditions the unit is being charged at.After superheat is adjusted it is recommended to check unitsub-cooling at the condenser coil liquid line out.

100 - - - 10 1095 - - 10 10 1090 - - 12 15 1885 - 10 13 17 2080 - 10 15 21 2675 10 13 17 25 2970 10 17 20 28 3265 13 19 26 32 3560 17 25 30 33 37

Ambient Condenser Inlet Temp (°F

Drybulb) 65 70 75

Return Air Temp. (°F Drybulb)

80 85

Superheat

Suction Pressure Saturated Suction Temperature (°F)

50 2653 2855 3058 3261 3463 3666 3869 4072 4275 4478 4681 4884 5087 52

TABLE 5 Suction Pressure Temperature (R-22)

S-109 CHECKING SUBCOOLINGRefrigerant liquid is considered subcooled whenever its tem-perature is lower than the saturation temperature correspond-ing to its pressure. The degree of subcooling equals the de-grees of temperature decrease below the saturation tempera-ture at the existing pressure.1. Attach an accurate thermometer or preferably a thermo-

couple type temperature tester to the liquid line as it leavesthe condensing unit.

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35

2. Install a high side pressure gauge on the high side servicevalve.

3. Record the gauge pressure and the temperature of the line.4. Convert the discharge pressure gauge reading to tempera-

ture by finding the gauge reading in Temperature - Pres-sure Chart and reading to the left, find the temperature inthe °F. Column.

5. The difference between the thermometer reading and pres-sure to temperature conversion is the amount of subcool-ing.

EXAMPLE:a. Discharge Pressure = 260b. Corresponding Temp. °F. = 120°c. Thermometer on Liquid line = 109°F.

To obtain the amount of subcooling subtract 109°F from 120°F.The difference is 11° subcooling. The normal subcooling rangeis 10° - 15°.

DB WB63 301 - 332 73 - 83 67 306 - 335 77 - 78 71 311 - 342 82 - 92 63 268 - 299 72 - 82 67 273 - 304 77 - 87 71 278 - 309 80 - 90 63 233 - 264 67 - 77 67 238 - 269 72 - 82 71 243 - 274 77 - 87 63 198 - 229 62 - 72 67 203 - 234 67 - 77 71 208 - 239 71 - 81 63 172 - 203 57 - 67 67 175 - 206 61 - 71 71 180 - 211 66 - 76 63 144 - 175 52 - 62 67 149 - 180 56 - 66 71 155 - 186 60 - 70

75

75

75

SUCTION PRESSURE

PSIG

75

75

7595

85

75

65

LIQUID PRESSURE

PSIG

INDOOR TEMP. °F

115

105

OUTDOOR TEMP. °F

Operating Pressures

Temp.°F.

Gauge Pressure(PSIG) Freon-22

Temp.°F.

Gauge Pressure(PSIG) Freon-22

-40-38-36-34

0.611.422.273.15

60626465

102.5106.3110.2114.2

-32-30-28-26

4.075.026.017.03

68707274

118.3122.5126.8131.2

-24-22-20-18

8.099.1810.3111.48

76788082

135.7140.5145.0149.5

-16-14-12-10

12.6113.9415.2416.59

84868890

154.7159.8164.9170.1

-8-6-4-2

17.9919.4420.9422.49

92949696

175.4180.9186.5192.1

0246

24.0925.7327.4429.21

100102104106

197.9203.8209.9216.0

8101214

31.0432.9334.8836.89

108110112114

222.3228.7235.2241.9

16182022

38.9641.0943.2845.53

116118120122

248.7255.6262.6269.7

24262830

47.8550.2452.7055.23

124126128130

276.9284.1291.4298.8

32343638

57.8360.5163.2766.11

132134136136

306.3314.0321.9329.9

40424446

69.0271.9975.0478.18

140142144146

338.0346.3355.0364.3

48505254

81.4084.7088.1091.5

158150152154

374.1384.3392.3401.3

5658

95.198.8

156158160

411.3421.8433.3

TEMPERATURE-PRESSURE (R-22)

S-111 FIXED ORIFICE RESTRICTIONDEVICESThe fixed orifice restriction device (flowrator) used in conjunc-tion with the indoor coil is a predetermined bore (I.D.).It is designed to control the rate of liquid refrigerant flow into anevaporator coil.

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The amount of refrigerant that flows through the fixed orificerestriction device is regulated by the pressure difference be-tween the high and low sides of the system.In the cooling cycle when the outdoor air temperature rises,the high side condensing pressure rises. At the same time,the cooling load on the indoor coil increases, causing the lowside pressure to rise, but at a slower rate.Since the high side pressure rises faster when the tempera-ture increases, more refrigerant flows to the evaporator, increas-ing the cooling capacity of the system.When the outdoor temperature falls, the reverse takes place.The condensing pressure falls, and the cooling loads on theindoor coil decreases, causing less refrigerant flow.If a restriction should become evident, proceed as follows:1. Recover refrigerant charge.2. Remove the orifice assembly and clean or replace.3. Replace liquid line drier, evacuate and recharge.

CHECKING EQUALIZATION TIMEDuring the "OFF" cycle, the high side pressure bleeds to thelow side through the fixed orifice restriction device. Checkequalization time as follows:1. Attach a gauge manifold to the suction and liquid line dill

valves2. Start the system and allow the pressures to stabilize.3. Stop the system and check the time it takes for the high

and low pressure gauge readings to equalize.If it takes more than seven (7) minutes to equalize, the restric-tion device is inoperative. Replace, install a liquid line drier,evacuate and recharge.

S-112 CHECKING RESTRICTED LIQUID LINEWhen the system is operating, the liquid line is warm to thetouch. If the liquid line is restricted, a definite temperaturedrop will be noticed at the point of restriction. In severe cases,frost will form at the restriction and extend down the line in thedirection of the flow.Discharge and suction pressures will be low, giving the ap-pearance of an undercharged unit. However, the unit will havenormal to high subcooling.If a restriction is located, replace the restricted part, replacedrier, evacuate and recharge.

S-113 REFRIGERANT OVERCHARGEAn overcharge of refrigerant is normally indicated by exces-sively high head pressure and/or liquid return to the compres-sor.Evaporator coils with a fixed orifice metering device couldallow refrigerant to return to the compressor under extremeovercharge conditions.

If high head pressure is not indicated, an overcharge or a sys-tem containing non-condensables could be the problem.If overcharging is indicated:1. Start the system.2. Remove small quantities of gas from the suction line dill

valve until the head pressure is reduced to normal.3. Observe the system while running a cooling performance

test, if a shortage of refrigerant is indicated, then the sys-tem contains non-condensables. See S-114 Non-Condensables.

S-114 NON-CONDENSABLESCheck for non-condensables.1. Shut down the system and allow the pressures to equalize

for a minimum of 15 minutes.2. Take a pressure reading.3. Compare this pressure to the temperature of the coldest

coil since this is where most of the refrigerant will be. If thepressure indicates a higher temperature than that of thecoil temperature, non-condensables are present.

To remove the non-condensables.1. Remove the refrigerant charge.2. Replace and/or install liquid line drier3. Evacuate and recharge.

S-115 COMPRESSOR BURNOUTWhen a compressor burns out, high temperature develops caus-ing the refrigerant, oil and motor insulation to decompose form-ing acids and sludge.If a compressor is suspected of being burned-out, attach arefrigerant hose to the liquid line dill valve and properly removeand dispose of the refrigerant.Now determine if a burn out has actually occurred. Confirm byanalyzing an oil sample using a Sporlan Acid Test Kit, AK-3 orits equivalent.Remove the compressor and obtain an oil sample from thesuction stub. If the oil is not acidic, either a burnout has notoccurred or the burnout is so mild that a complete cleanup isnot necessary.If acid level is unacceptable the system must be cleaned byusing the drier cleanup method.

CAUTIONDO NOT ALLOW THE SLUDGE OR OIL TO CONTACTTHE SKIN, SEVERE BURNS MAY RESULT.

Suction Line Drier Clean-up MethodDiscard at least twelve (12) inches of the suction line immedi-ately out of the compressor stub due to burned residue andcontaminates.

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1. Remove compressor discharge line strainer, liquid linestrainer and/or drier and capillary tubes from indoor andoutdoor coils.

2. Units with an expansion valve coil, remove the liquid linedrier and expansion valve.

3. Purge all remaining components with dry nitrogen or car-bon dioxide until clean.

4. Install new components including liquid liner drier.5. Install suction line drier.6. Braze all joints, leak test, evacuate, and recharge system.7. Start up the unit and record the pressure drop across the

cleanup drier.8. Continue to run the system for a minimum of twelve (12)

hours and recheck the pressure drop across the drier. Pres-sure drop should not exceed 6 - 8 PSIG.

9. Continue to run the system for several days repeatedlychecking pressure drop across the suction line drier. If thepressure drop never exceeds the 6 - 8 PSIG, the drier mustbe adequate and is trapping the contaminants and it ispermissible 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 notexceed 6 - 8 PSIG.

NOTE: The cause for burnout MUST be determined and cor-rected BEFORE the new compressor is started.

S-122 REVERSING VALVE REPLACEMENTRemove the refrigerant charge from the system.When brazing a reversing valve into the system, it is of ex-treme importance that the temperature of the valve does notexceed 250°F. at any time.Wrap the reversing valve with a large rag saturated with water."Re-wet" the rag and thoroughly cool the valve after each braz-ing operation of the four joints involved. The wet rag around thereversing valve will eliminate conduction of heat to the valvebody when brazing the line connection.The use of a wet rag sometimes can be a nuisance. There arecommercial grades of heat absorbing paste that may be sub-stituted.After the valve has been installed, leak test, evacuate and re-charge.

S-200 CHECKING EXTERNAL STATICPRESSUREThe minimum and maximum allowable duct static pressure isfound in the Technical Information Manual.Too great of an external static pressure will result in insuffi-cient air that can cause icing of the coil, whereas too much aircan cause poor humidity control, and condensate to be pulledoff the evaporator coil causing condensate leakage. Too muchair can cause motor overloading and in many cases this con-stitutes a poorly designed system. To determine proper airmovement, proceed as follows:

1. Using a draft gauge (inclined manometer) measure the staticpressure of the return duct at the inlet of the unit, (NegativePressure).

Supply

Return

Total External Static2. Measure the static pressure of the supply duct, (Positive

Pressure).3. Add the two readings together.NOTE: Both readings may be taken simultaneously and readdirectly on the manometer as shown in the illustration above, ifso 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.

S-201 CHECKING TEMPERATURE RISETemperature rise is related to the BTUH output of the unit andthe amount of air (CFM) circulated over the indoor coil.All units are designed for a given range of temperature increase.This is the temperature of the air leaving the unit minus thetemperature of the air entering the unit.The more air (CFM) being delivered through a given unit theless the rise will be; so the less air (CFM) being delivered, thegreater the rise. The temperature rise should be adjusted inaccordance to a given unit specifications and its external staticpressure.1. Take entering and leaving air temperatures.2. Select the proper speed tap from the unit's blower perfor-

mance data in the Technical Manual for the specific unit.3. Take motor amperage draw to determine that the motor is

not overloaded during adjustments.

38

WIRING DIAGRAMSTO

AV

OID

PO

SS

IBLE

ELE

CTR

ICA

L S

HO

CK

, PE

RS

ON

AL

INJU

RY

,O

R D

EA

TH, D

ISC

ON

NE

CT

THE

PO

WE

R B

EFO

RE

SE

RV

ICIN

G.

WA

RN

ING

!

OT18-60A OUTDOOR THERMOSTAT

BLUE

WHITE

ORANGEGREEN

YELLOW

RED

SEE NOTE 1#18 GAUGE 7 WIRE

REQUIRED FOR HEAT PUMPS

PACKAGE SYSTEM WIRING DIAGRAM - 1 STAGE ELECTRIC HEAT

TYPICAL HPROOM THERMOSTAT

OUTDOOR THERMOSTATCLOSE ON TEMPERATURE FALL

12

Y O C W1 G R E

R

YY

R

GOO

G

WBR

BLBL

R

PACKAGE UNITLOW VOLTAGE JUNCTION BOX

BL

W2 C RY O W1 G E

TYPICAL HPROOM THERMOSTAT

12OUTDOOR THERMOSTAT

CLOSE ON TEMPERATURE FALL

PACKAGE UNITLOW VOLTAGE JUNCTION BOX

BLUE

BROWN

WHITE

ORANGE

GREEN

YELLOW

RED

SEE NOTE 1#18 GAUGE 8 WIREFOR HEAT PUMPS

PACKAGE SYSTEM WIRING DIAGRAM - 2 STAGE ELECTRIC HEATABOVE 10 KW

SEE NOTE 2

R

Y

G

OO

Y

G

R

BLBL

BRR

WBRW

NOTES:

1) "O" and "E" used on heat pumps only.2) Connect wire from terminal #1 on outdoor thermostat to the white wire on package units if single stage indoor thermostat is used.

Color CodesR - RedY - YellowBL - BlueBR - BrownO - OrangeW - WhiteG - Green

WIRING DIAGRAMS

39

WIRING DIAGRAMS

TO A

VO

ID P

OS

SIB

LE E

LEC

TRIC

AL

SH

OC

K, P

ER

SO

NA

L IN

JUR

Y,

OR

DE

ATH

, DIS

CO

NN

EC

T TH

E P

OW

ER

BE

FOR

E S

ER

VIC

ING

.W

AR

NIN

G!

OT18-60A OUTDOOR THERMOSTAT

R

W2 C RY O W1 G E

TYPICAL H/PROOM THERMOSTAT

12

PACKAGE HEAT PUMP

LOW VOLTAGE JUNCTION BOX

BLUE

BROWN

WHITE

ORANGE

GREEN

YELLOW

RED

#18 GAUGE 8 WIRE

R

Y

G

OO

Y

G

R

BLBL

BR

WBRW

3BL

Y

PACKAGE SYSTEM WIRING DIAGRAM - HEAT PUMPS ONLY! TWO-STAGE ELECTRIC HEAT ABOVE 10 kW

For outdoor temperatures below 0° F with 50% or higher relative humidity,set outdoor thermostat at 0° FNOTE 1: OT18 #2 CAN BE CONNECTED BETWEEN W2 OF THERMOSTAT AND BROWN WIRE IF DESIRED.

COLOR CODESR --REDY --YELLOW

BR-BROWNO --ORANGEW -WHITEG --GREEN

BL-BLUE

OUTDOOR THERMOSTAT #1CLOSE ON TEMPERATURE FALL

BL12

OUTDOOR THERMOSTAT #2(IF USED, SEE NOTE 1)

40

WIRING DIAGRAMSTO

AV

OID

PO

SS

IBLE

ELE

CTR

ICA

L S

HO

CK

, PE

RS

ON

AL

INJU

RY

,O

R D

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TH, D

ISC

ON

NE

CT

THE

PO

WE

R B

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RE

SE

RV

ICIN

G.

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ING

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HKR** HEAT KIT

BK

BL

BK

L1 L2

BK

BK

HTR1TLHTR2

R

9

8

7

R

W

BLPU

TL

BK

5

6

3

4

PLM

BK

R

1

2

W

BK

L2L1

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R

R

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R

HTR1 TL

6

8

9

7

2R

PU

4

5

3

BK

R

1PLM

ONE (1) ELEMENT ROWS TWO (2) ELEMENT ROWS

FL

M1

M2

FL

FL

M1

M2

M3

M4

5 KW 10 KW

L1

BK

BK

L2 L1 L2

R

Y

M1

M2

BK

R

Y

R

R1M4

RBK

M3

HTR3 TL

HTR2

HTR1 TL

TL

PU

M2R2

Y

M1BL

WBR

BLR

BK

R

BK

TLHTR1

BK

HTR4

HTR3

HTR2

BK R

9

7

8

L2L1 L1 L2

2

5

6

3

4

PLM

1

RM1Y

BK

M2

BL

W 6

BL

RBK

Y8

9

7

M6

M5M3

R1

M4

RPU

M7

R2

M8

BL

TL

TL

TL

Y

BL

R

BK

RBL

BR4

5

3

2

BKPLM

1

THREE (3) ELEMENT ROWS FOUR (4) ELEMENT ROWS

FL

FL

FL

FL

FL

FL

FL

15 KW 20 KW

41

WIRING DIAGRAMS

TO A

VO

ID P

OS

SIB

LE E

LEC

TRIC

AL

SH

OC

K, P

ER

SO

NA

L IN

JUR

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, DIS

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MP

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TB

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RB

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2

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GO

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MA

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GP

H, G

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sed

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with

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age

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BLA

CK

PCE* ECONOMIZER

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(Goodman) Service Instructions-RS6300006 (41 Pages)

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