Service Instructions

SSX & ASX Condensing Units and SSZ & ASZ Split System Heat Pumps with R-410A Refrigerant Blowers, Coils, & Accessories

This manual is to be used by qualified, professionally trained HVAC technicians only. Goodman does not assume any responsibility for property damage or personal injury due to improper service procedures or services performed by an unqualified person.

RS6200006 November 2006

Copyright 2006 Goodman Manufacturing Company, L.P.

IMPORTANT INFORMATION
IMPORTANT INFORMATION ..................................... 2 - 3 PRODUCT IDENTIFICATION ...................................... 4 - 8 ACCESSORIES ........................................................ 9 - 16 PRODUCT DESIGN ................................................ 17 - 18 SYSTEM OPERATION ........................................... 19 - 23
Pride and workmanship go into every product to provide our customers with quality products. It is possible, however, that during its lifetime a product may require service. Products should be serviced only by a qualified service technician who is familiar with the safety procedures required in the repair and who is equipped with the proper tools, parts, testing instruments and the appropriate service manual. REVIEW ALL SERVICE INFORMATION IN THE APPROPRIATE SERVICE MANUAL BEFORE BEGINNING REPAIRS.

TROUBLESHOOTING CHART ....................................... 24 SERVICE TABLE OF CONTENTS ................................. 25 SERVICING ............................................................ 26 - 61 ACCESSORIES WIRING DIAGRAMS .................... 62 - 66

IMPORTANT NOTICES FOR CONSUMERS AND SERVICERS

RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS

WARNING
THIS UNIT SHOULD NOT BE CONNECTED TO. OR USED IN CONJUNCTION WITH, ANY DEVICES THAT ARE NOT DESIGN CERTIFIED FOR USE WITH THIS UNIT OR HAVE NOT BEEN TESTED AND APPROVED BY GOODMAN. SERIOUS PROPERTY DAMAGE OR PERSONAL INJURY, REDUCED UNIT PERFORMANCE AND/OR HAZARDOUS CONDITIONS MAY RESULT FROM THE USE OF DEVICES THAT HAVE NOT BEEN APPROVED OR CERTIFED BY GOODMAN.

WARNING
TO PREVENT THE RISK OF PROPERTY DAMAGE, PERSONAL
INJURY, OR DEATH,

DO NOT STORE COMBUSTIBLE MATERIALS OR USE GASOLINE OR OTHER FLAMMABLE LIQUIDS OR VAPORS IN THE VICINITY OF THIS APPLIANCE.

W ARNING
G OODMAN W ILL NOT BE R ESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES. I F YOU INSTALL OR PERFORM SERVICE ON THIS UNIT, YOU ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMA GE WHICH MAY RESULT. M ANY JU RISDICTIONS REQU IRE A LICENSE TO INSTALL OR SERVICE HEATING AN D AIR CONDITIONING EQUIPMENT.

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

CONSUMER INFORMATION LINE

GOODMAN BRAND PRODUCTS TOLL FREE 1-877-254-4729 (U.S. only) email us at: customerservice@goodmanmfg.com fax us at: (731) 856-1821
(Not a technical assistance line for dealers.)

AMANA BRAND PRODUCTS TOLL FREE 1-877-254-4729 (U.S. only) email us at: hac.consumer.affairs@amanahvac.com fax us at: (931) 438- 4362
(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.

Outside the U.S., call 1-931-433-6101.

(Not a technical assistance line for dealers.) Your telephone company will bill you for the call.

IMPORTANT INFORMATION
SAFE REFRIGERANT HANDLING
While these items will not cover every conceivable situation, they should serve as a useful guide.
WARNING
REFRIGERANTS ARE HEAVIER THAN AIR. THEY CAN "PUSH OUT" THE TO AVOID BY

WARNING
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.

OXYGEN IN YOUR LUNGS OR IN ANY ENCLOSED SPACE. POSSIBLE DIFFICULTY IN BREATHING OR DEATH:

NEVER PURGE REFRIGERANT INTO AN ENCLOSED ROOM OR SPACE. 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.

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-410 A TO AN R-410A CYLINDER. THE SERVICE EQUIPMENT USED MUST
BE LISTED OR CERTIFIED FOR THE TYPE OF REFRIGERANT USED.

TO AVOID POSSIBLE FROST

BITE 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

STORE

CYLINDERS IN A COOL, DRY PLACE.

NEVER

USE A CYLINDER

AS A PLATFORM OR A ROLLER.

EPA REGULATIONS. NEVER BURN REFRIGERANT,

AS POISONOUS GAS WILL BE PRODUCED.

WARNING
TO AVOID POSSIBLE EXPLOSION, USE ONLY RETURNABLE (NOT DISPOSABLE)
SERVICE CYLINDERS WHEN REMOVING REFRIGERANT 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
TO
AVOID POSSIBLE INJURY, EXPLOSION OR DEATH, PRACTICE SAFE HANDLING OF REFRIGERANTS.

WARNING
SYSTEM CONTAMINANTS, IMPROPER SERVICE PROCEDURE AND/OR PHYSICAL
ABUSE AFFECTING HERMETIC COMPRESSOR ELECTRICAL TERMINALS MAY CAUSE DANGEROUS SYSTEM VENTING.

In either of these instances, an electrical short between the terminal and the compressor housing may result in the loss of integrity between the terminal and its dielectric embedment. This loss may cause the terminals to be expelled, thereby venting the vaporous and liquid contents of the compressor housing and system. A venting compressor terminal normally presents no danger to anyone, providing the terminal protective cover is properly in place. If, however, the terminal protective cover is not properly in place, 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 in the vicinity. Death or serious bodily injury could occur. Under no circumstances is a hermetic compressor to be electrically energized and/or operated without having the terminal protective cover properly in place. See Service Section S-17 for proper servicing.

The successful development of hermetically sealed refrigeration compressors has completely sealed the compressor's moving parts and electric motor inside a common housing, minimizing refrigerant leaks and the hazards sometimes associated with moving belts, pulleys or couplings. Fundamental to the design of hermetic compressors is a method whereby electrical current is transmitted to the compressor motor through terminal conductors which pass through the compressor housing wall. These terminals are sealed in a dielectric material which insulates them from the housing and maintains the pressure tight integrity of the hermetic compressor. The terminals and their dielectric embedment are strongly constructed, but are vulnerable to careless compressor installation or maintenance procedures and equally vulnerable to internal electrical short circuits caused by excessive system contaminants.

PRODUCT IDENTIFICATION

S
Brand Name S: Goodman
(High Feature Set Models)

14

036

A
Minor Revision A: Initial Release

A: Amana Deluxe

Major Revision A: Initial Release

Product Family S: Split System Electrical Product Type X: Condenser R-410A Z: Heat Pump R-410A 1: 208/230V/60Hz/1ph 3: 208/230V/60Hz/3ph 4: 460V/60Hz/3ph

Nominal Capacity 018: 024: 036: 042: 048: 060: 090: 120: 1.5 tons 2 tons 3 tons 3.5 tons 4 tons 5 tons 7.5 tons 10 tons

SEER SEER Rating

PRODUCT IDENTIFICATION

MB
Design Series MB: Modular Blower Motor Types

00

1
Voltage/Hz/Phase 1: 208-230/60/1

E: Variable-speed R: Constant-speed Air Flow Delivered 08: 800 CFM 12: 1,200 CFM 16: 1,600 CFM 20: 2,000 CFM

Design Series A: First Series Circuit Breaker 2: 208/230-60-1 Factory-installed Electric Heat 00: No Heat
MODEL MBE1200 MBE1600 MBE2000 MFG. # MBE1200 MBE1600 MBE2000

MODEL MBR0800 MBR1200 MBR1600 MBR2000

MFG. # MBR0800 MBR1200 MBR1600 MBR2000

CA
Product Type CA: A Coil, Upflow/Downflow CH: Horizontal A Coil, Cased System Type

18

A
Revision A: First Revision B: Second Revision C: Third Revision

Refrigerant 4: R-410A

U: Uncased Coil P: Painted Case Coil Expansion Device F: Flowrator Coil Nominal Capacity 18: 18,000 BTUH 24: 24,000 BTUH 25: 25,000 BTUH 30: 30,000 BTUH 32: 32,000 BTUH 36: 36,000 BTUH 37: 37,000 BTUH 48: 48,000 BTUH 49: 49,000 BTUH 60: 60,000 BTUH 61: 61,000 BTUH 62: 62,000 BTUH

Cabinet Description CA Models A: 14" B: 17 1/2" C: 21" D: 24 1/2"

Cabinet Description CH Models (Cabinet Height) A: 14" B: 17 1/2" C: 21" D: 24 1/2"

MODEL CA*F030B4* CA*F036B4* CA*F042C4* CA*F048C4* CA*F057D4* CA*F060D4*

MFG. # CA*F030B4* CA*F036B4* CA*F042C4* CA*F048C4* CA*F057D4* CA*F060D4*

MODEL CHPF030A4* CHPF036B4* CHPF042A4* CHPF048D4* CHPF060D4* CH36FCB CH48FCB CH60FCB

MFG. # CHPF030A4* CHPF036B4* CHPF042A4* CHPF048D4* CHPF060D4* CH36FCB CH48FCB CH60FCB

PRODUCT IDENTIFICATION

C
Product Type C: Indoor Coil

1824

A
Revision A: Revision

Applicaton A: Upflow/Downflow Coil H: Horizontal A Coil S: Horizontal Slab Coil Refrigerant 6: R-22 or R-41A 4: R-410A

Cabinet Finish U: Unpainted P: Painted C: Unpainted Case Expansion Device F: Flowrator Nominal Width for Gas Furnace A: B: C: D: N: Fits 14" Furnace Cabinet Fits 17 1/2" Furnace Cabinet Fits 21" Furnace Cabinet Fits 24 1/2" Furnace Cabinet Does Not Apply (Horizontal Slab Coils)

Nominal Capacity Range @ 13 SEER 1824: 3030: 3642: 1 1/2 - 2 Tons 2 1/2 Tons 3 - 3 1/2 Tons

PRODUCT IDENTIFICATION
THIS NOMENCLATURE IS TO BE USED AFTER JULY 2006

A
Product Type A: Single Piece Air Handler

3642

A
Minor Revision

Application C: Ceiling Mount PSC Motor D: Downflow PSC Motor E: Multi-Position Variable Speed Motor R: Multi-Position PSC Motor W:Wall Mount PSC Motor Cabinet Finish U: Unpainted P: Painted N: Uncased Expansion Device F: Flowrator Refrigerant

Electrical Supply 1: 208-230V/60Hz/1ph

Multi-Position & Downflow Applications Nominal Capacity Range @ 13 SEER 3642: 1830: 1729: 3 - 3 1/2 Tons 1 1/2 - 3 1/2 Tons 1 1/2 - 2 1/2 Tons (For Export Systems)

Nominal Capacity Range @ 10 SEER

Ceiling Mount & Wall Mount Applications Nominal Cooling Capacity/Electric Heat kw 1805: 2405: 3608: 1 1/2 Tons Cooling/5kw Electric Heat 2 Tons Cooling/5kw Electric Heat 3 Tons Cooling/8kw Electric Heat

PRODUCT IDENTIFICATION
Model No.
SSX14****1* ASX14****1* SSZ14****1* ASZ14****1* MBE****AA1 MBR****AA1 CAUF****4* CAUX****4* CAPF****4* CAPX****4* CHPF****4* CHPX****4* CH**FCB CAUF****6* CAPF****6* CHPF****6* CSPF****6*

Description
{S} Goodman - High feature set model {S} Split System {X} Condenser R-410A {**} SEER {****} Nominal Capacity {1} Voltage {*} Revision {A} Amana Brand Deluxel {S} Split System {X} Condenser R-410A {**} SEER {****} Nominal Capacity {1} Voltage {*} Revision {S} Goodman - High feature set model {S} Split System {X} Heat Pump R-410A {**} SEER {****} Nominal Capacity {1} Voltage {*} Revision {A} Amana Brand Deluxel {S} Split System {X} Heat Pump R-410A {**} SEER {****} Nominal Capacity {1} Voltage {*} Revision {MB} Modular Blower {E} Varialble Spd. {**} Airflow {**} Heat {A} Circuit Breaker {A} Series {1} Voltage {MB} Modular Blower {R} Constant Spd. {**} Airflow {**} Heat {A} Circuit Breaker {A} Series {1} Voltage {CA} A Coil {U} Uncased {F} Flowrator {***} BTU {*} Cabinet Size {4} Ultron {*} Revision {CA} A Coil {U} Uncased {X} TXV {***} BTU {*} Cabinet Size {4} Ultron {*} Revision {CA} A Coil {P} Painted {F} Flowrator {***} BTU {*} Cabinet Size {4} Ultron {*} Revision {CA} A Coil {P} Painted {X} TXV {***} BTU {*} Cabinet Size {4} Ultron {*} Revision {CH} Horizontal {P} Painted {F} Flowrator {***} BTU {*} Cabinet Size {4} Ultron {*} Revision {CH} Horizontal {P} Painted {X} TXV {***} BTU {*} Cabinet Size {4} Ultron {*} Revision {CH} Horizontal {**} Capacity {F} Flowrator {C} Cased Coil {B} Series {CA} A Coil {U} Uncased {F} Flowrator {***} BTU {*} Cabinet Size {6} Ultron or R-22 {*} Revision {CA} A Coil {P} Painted {F} Flowrator {***} BTU {*} Cabinet Size {6} Ultron or R-22 {*} Revision {CH} Horizontal {P} Painted {F} Flowrator {***} BTU {*} Cabinet Size {6} Ultron or R-22 {*} Revision {CH} Horizontal {P} Painted {F} Flowrator {***} BTU {*} Cabinet Size {6} Ultron or R-22 {*} Revision

ACCESSORIES
SSX14
Model ASC01 CSR-U-1 CSR-U-2 CSR-U-3 FSK01A TX3N4 TX5N4
1 2

Description Anti-Short Cycle Kit Hard-start Kit Hard-start Kit Hard-start Kit Freeze Protection Kit TXV Kit TXV Kit TXV Kit

SSX14 018 X X

SSX14 024 X X

SSX14 030 X X

SSX14 036 X X X

SSX14 042 X X X

SSX14 048 X X X X

SSX14 060 X X X X

X X

X X

X X

X X

TX2N4
2 2

Installed on indoor coil

Required for heat pump applications where ambient temperatures fall below 0F with 50% or higher relative humidy. Field-installed, non-bleed, expansion valve kit Condensing units and heat pumps with reciprocating compressors require the use of start-assist components when used in conjunction with an indoor coil using a non-bleed thermal expansion valve refrigerant metering device.

ASX14
Model ASC01 CSR-U-1 CSR-U-2 CSR-U-3 FSK01A
1

Description Anti-Short Cycle Kit Hard-start Kit Hard-start Kit Hard-start Kit Freeze Protection Kit TXV Kit TXV Kit TXV Kit

ASX14 018 X X

ASX14 024 X X

ASX14 030 X X

ASX14 036 X X X

ASX14 042 X X X

ASX14 048 X X X X

ASX14 060 X X x X

X X

X X

X X

X X

TX2N4 TX3N4 TX5N4

1 2

Installed on indoor coil

Required for heat pump applications where ambient temperatures fall below 0F with 50% or higher relative humidy. Field-installed, non-bleed, expansion valve kit Condensing units and heat pumps with reciprocating compressors require the use of start-assist components when used in conjunction with an indoor coil using a non-bleed thermal expansion valve refrigerant metering device.

ACCESSORIES
SSX16
Model ASC01 CSR-U-1 CSR-U-2 CSR-U-3 FSK01A
1

Description Anti-Short Cycle Kit Hard-start Kit Hard-start Kit Hard-start Kit Freeze Protection Kit TXV Kit TXV Kit TXV Kit

SSX16 024 X X

SSX16 030 X X

SSX16 036 X X X

SSX16 042 X X X

SSX16 048 X X X X

SSX16 060 X X X X

X X

X X

X X

TX2N4 TX3N4 TX5N4

1 2

Installed on indoor coil

Required for heat pump applications where ambient temperatures fall below 0F with 50% or higher relative humidy. Field-installed, non-bleed, expansion valve kit Condensing units and heat pumps with reciprocating compressors require the use of start-assist components when used in conjunction with an indoor coil using a non-bleed thermal expansion valve refrigerant metering device.

ASX16
Model ASC01 CSR-U-1 CSR-U-2 CSR-U-3 FSK01A1 TX2N4 TX3N4 TX5N4
1 2

Description Anti-Short Cycle Kit Hard-start Kit Hard-start Kit Hard-start Kit Freeze Protection Kit TXV Kit TXV Kit TXV Kit

ASX16 024 X X

ASX16 030 X X

ASX16 036 X X X

ASX16 042 X X X

ASX16 048 X X X X

ASX16 060 X X X X

X X

X X

X X

Installed on indoor coil

Required for heat pump applications where ambient temperatures fall below 0F with 50% or higher relative humidy. Field-installed, non-bleed, expansion valve kit Condensing units and heat pumps with reciprocating compressors require the use of start-assist components when used in conjunction with an indoor coil using a non-bleed thermal expansion valve refrigerant metering device.

10

ACCESSORIES
SSZ14
Model AFE18-60A ASC01 CSR-U-1 CSR-U-2 CSR-U-3 FSK01A
1

Description All-Fuel Kit Anti-Short Cycle Kit Hard-start Kit Hard-start Kit Hard-start Kit Freeze Protection Kit Emergency Heat Relay kit Outdoor Thermostat w/ Lockout Stat TXV Kit TXV Kit TXV Kit

SSZ14 018 X X X

SSZ14 024 X X X

SSZ14 030 X X X

SSZ14 036 X X X X

SSZ14 042 X X X X X X

SSZ14 048 X X X X X X X

SSZ14 060 X X X X X X X

X X X X

X X X X

X X X X

X X X X

OT/EHR18-60 OT18-60A TX2N4 TX3N4 TX5N4

1 2 3

Installed on indoor coil Required for heat pump applications where ambient temperatures fall below 0F with 50% or higher relative humidy. Condensing units and heatp pumps with reciprocating compressors require the use of start-assist components when used in conjunction with an indoor coil using a non-bleed expansion valve refrigerant metering device.

ASZ14
Model AFE18-60A ASC01 CSR-U-1 CSR-U-2 CSR-U-3 FSK01A
1 2

Description All-Fuel Kit Anti-Short Cycle Kit Hard-start Kit Hard-start Kit Hard-start Kit Freeze Protection Kit Outdoor Thermostat Emergency Heat Relat Kit TXV Kit TXV Kit TXV Kit

ASZ14 018 X X X

ASZ14 024 X X X

ASZ14 030 X X X

ASZ14 036 X X X X

ASZ14 042 X X X X X X

ASZ14 048 X X X X X X X

ASZ14 060 X X X X X X X

X X X X

X X X X

X X X X

X X X X

OT18-60A TX2N4 TX3N4

OY-EHR18-60

TX5N4
1 2 3

Installed on indoor coil Required for heat pump applications where ambient temperatures fall below 0F with 50% or higher relative humidy. Condensing units and heatp pumps with reciprocating compressors require the use of start-assist components when used in conjunction with an indoor coil using a non-bleed expansion valve refrigerant metering device.

11

ACCESSORIES
SSZ16
Model AFE18-60A ASC01 CSR-U-1 CSR-U-2 CSR-U-3 FSK01A
1

Description All-Fuel Kit Anti-Short Cycle Kit Hard-start Kit Hard-start Kit Hard-start Kit Freeze Protection Kit Emergency Heat Relay Kit Emergency Heat Relay Kit Outdoor Thermostat w/ Lockout Stat TXV Kit TXV Kit TXV Kit

SSZ16 024 X X X

SSZ16 030 X X X

SSZ16 036 X X X X

SSZ16 042 X X X X X X X

SSZ16 048 X X X X X X X X

SSZ16 060 X X X X X X X X

X X X X X

X X X X X

X X X X X

OT/EHR18-60 OY/EH R18-60 OT18-60A TX2N4 TX3N4 TX5N4

1 2 3

Installed on indoor coil Required for heat pump applications where ambient temperatures fall below 0F with 50% or higher relative humidy. Field-installed, non-bleed, expansion valve kit Condensing units and heat pumps with reciprocating compressors require the use of start-assist components when used in conjunction with an indoor coil using a non-bleed thermal expansion valve refrigerant metering device.

ASZ16
Model AFE18-60A ASC01 CSR-U-1 CSR-U-2 CSR-U-3 FSK01A
1

Description All-Fuel Kit Anti-Short Cycle Kit Hard-start Kit Hard-start Kit Hard-start Kit Freeze Protection Kit Emergency Heat Relay Kit Emergency Heat Relay Kit Outdoor Thermostat w/ Lockout Stat TXV Kit TXV Kit TXV Kit

ASZ16 024 X X X

ASZ16 030 X X X

ASZ16 036 X X X X

ASZ16 042 X X X X X X X

ASZ16 048 X X X X X X X X

ASZ16 060 X X X X X X X X

X X X X X

X X X X X

X X X X X

OT/EHR18-60 OY/EH R18-60 OT18-60A TX2N4 TX3N4 TX5N4

1 2 3

Installed on indoor coil Required for heat pump applications where ambient temperatures fall below 0F with 50% or higher relative humidy. Field-installed, non-bleed, expansion valve kit Condensing units and heat pumps with reciprocating compressors require the use of start-assist components when used in conjunction with an indoor coil using a non-bleed thermal expansion valve refrigerant metering device.

12

ACCESSORIES
EXPANSION VALVE KITS
For Applications requiring
1/4 FLARE CONNECTION BULB TO BE LOCATED AT 10 OR 2 O'CLOCK

a field installed access fitting

SUCTION LINE EVAPORATOR COIL

BULB

SEAL SUPPLIED W/ KIT SEAL SUPPLIED W/ KIT EXPANSION VALVE

PISTON DISTRIBUTOR BODY SEAL

TAILPIECE

REMOVE BEFORE INSTALLING EXPANSION VALVE

3/8"SWEAT

7/8" NUT

1/4' FLARE CONNECTION

For Applications not requiring a field installed access fitting

BULB TO BE LOCATED AT 10 OR 2 O'CLOCK

BULB

SUCTION LINE

PISTON
EXPANSION VALVE EVAPORATOR COIL

TAILPIECE

DISTRIBUTOR BODY

SEAL

3/8"SWEAT

SEAL SUPPLIED W/ KIT

REMOVE BEFORE INSTALLING EXPANSION VALVE

SEAL SUPPLIED W/ KIT

7/8" NUT

OT/EHR18-60 OUTDOOR THERMOSTAT & EMERGENCY HEAT RELAY

OT18-60
Thermostat Dial

315

DEAD DIAL

COLD WARM 45

(Turn Clockwise) (Turn Counterclockwise)

Set Point Adjustment Screw

Set Point Indicator Mark (Shown @ O F)

13

ACCESSORIES
FSK01A FREEZE THERMOSTAT KIT
Wire Nut Y
Bl ac

Y
k ac Bl

Wire Nut Install Line Thermostat Here Wire Nut

Bla ck
Bla ck Wire Nut

Install Line Thermostat Here

Y Y

ASC01A ANTI-SHORT -CYCLE CONTROL KIT

SHORT CYCLE PROTECTOR

Y1 R1 Y2 R2

YELLOW 1 CONTACTOR T2 T1 BLACK 1 L2 L1 C BLACK 1 UNIT TERMINAL BOARD Y THERMOSTAT WIRE

14

ACCESSORIES
COIL ACCESSORIES
COIL MODEL CA*F030B4* CA*F036B4* CA*F042C4* CA*F048C4* CA*F057D4* CA*F060D4* CHPF030A4* CHPF036B4* CHPF042A4* CHPF048D4* CHPF060D4* CH36FCB CH48FCB CH60FCB CA*F18246* CA*F30306* CA*F36426* CHPF18246* CHPF30306* CHPF36426* CSCF1824N6* CSCF303N6* CSCF3642N6* X X X X X X X X X X X X X X X X X X X X TX2N4 TXV KIT TX3N4 TXV KIT X X X X X X TX5N4 TXV KIT FSK01A FREEZE PROTECTION KIT X X X X X X X X X X X X X X X X X X X X X X X

HKR SERIES ELECTRIC HEAT KITS

ELECTRIC HEAT KIT APPLICATIONS - MBR & MBE
ELECTRIC HEAT KIT BLOWER HKR-03A MBR0800AA-1 MBR1200AA-1 MBR1600AA-1 MBR2000AA-1 MBE1200AA-1 MBE1600AA-1 MBE2000AA-1 X X X X HKR-05(C)A X X X X HKR-06A X X X X HKR-08(C)A HKR-10(C)A HKR-15(C)A HKR-20(C)A HKR-21(C)A X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X HKR3-15A HKR3-20A

X = Allowable combinations

- = Indicate restricted combinations

ELECTRIC HEAT KIT APPLICATIONS - ARPF

HKR-03* HKR-05*, HKR-05C* HKR-06* HKR-08*, HKR-08C* HKR-10*, HKR-10C* HKR-15C* HKR-20C* HKR-21C* ^ HKR3-15* ^ HKR3-20* ARPF1824 1/16 X X X X1 X1 X2 ARPF1931 1/16 X X X X1 X1 X2 ARPF3030 1/16 X X X X X1 X2 X2 X2 X2 X2 ARPF3642 1/16 X X X X X X3 X3 X3 X3 X3 ARPF3743 1/16 X X X X X X3 X3 X3 X3 X3 ARPF4860 1/16 X X X X X X X X X X

* Revision level that may or may not be designated C Circuit breaker option ^ Heat kit requires three-phase power supply

Air handler must either be on medium or high speed Air handler must be on high speed For static pressure of 0.6 or higher, air handler must be on medium or high speed

15

ACCESSORIES
ELECTRIC HEAT KIT APPLICATIONS - ARUF
ARUF1729 1/16 HKR-03* HKR-05*, HKR-05C* HKR-06* HKR-08*, HKR-08C* HKR-10*, HKR-10C* HKR-15C* HKR-20C* HKR-21C* ^ HKR3-15* ^ HKR3-20* X X X X1 X1 X2 ARUF1824 1/16 X X X X1 X1 X2 ARUF1931 1/16 X X X X1 X1 X2 ARUF3030 1/16 X X X X X1 X2 X2 X2 X2 X2 ARUF3642 1/16 X X X X X X3 X3 X3 X3 X3 ARUF3743 1/16 X X X X X X3 X3 X3 X3 X3 ARUF4860 1/16 X X X X X X X X X X

* Revision level that may or may not be designated C Circuit breaker option ^ Heat kit requires three-phase power supply 1 Air handler must either be on medium or high speed 2 Air handler must be on high speed 3 For static pressure of 0.6 or higher, air handler must be on medium or high speed

ARUF02400A1A HKR-03* HKR-05*, HKR-05C* HKR-06* HKR-08*, HKR-08C* HKR-10*, HKR-10C* HKR-15C* HKR-20C* HKR-21C* ^ HKR3-15* ^ HKR3-20* X X X X X1

ARUF03200A1B X X X X1 X1 X2

ARUF04200A1B X X X X X1 X2 X2 X2 X2 X2

ARUF04900A1B X X X X X X3 X3 X3 X3 X3

ARUF06100A1B X X X X X X X X X X

* Revision level that may or may not be designated C Circuit breaker option ^ Heat kit requires three-phase power supply 1 Air handler must either be on medium or high speed 2 Air handler must be on high speed 3 For static pressure of 0.6 or higher, air handler must be on medium or high speed

16

PRODUCT DESIGN
This section gives a basic description of cooling unit operation, its various components and their basic operation. Ensure your system is properly sized for heat gain and loss according to methods of the Air Conditioning Contractors Association (ACCA) or equivalent.

COILS AND BLOWER COILS

MBR/MBE blower cabinets are designed to be used as a twopiece blower and coil combination. MBR/MBE blower sections can be attached to cased evaporator coil. This twopiece arrangement allows for a variety of mix-matching possibilities providing greater flexibility. The MBE blower cabinet uses a variable speed motor that maintains a constant airflow with a higher duct static. It is approved for applications with cooling coils of up to 0.8 inches W.C. external static pressure and includes a feature that allows airflow to be changed by +15%. The MBR blower cabinet uses a PSC motor. It is approved for applications with cooling coils of up to 0.5 inches W.C. external static pressure. The MBR/MBE blower cabinets with proper coil matches can be positioned for upflow, counterflow, horizontal right or horizontal left operation. All units are constructed with R-4.2 insulation. In areas of extreme humidity (greater than 80% consistently), insulate the exterior of the blower with insulation having a vapor barrier equivalent to ductwork insulation, providing local codes permit. The CAPX/CHPX coils are equipped with a thermostatic expansion valve that has a built-in internal check valve for refrigerant metering. The CACF/CAPF/CHPF coils are equipped with a fixed restrictor orifice. The coils are designed for upflow, counterflow or horizontal application, using two-speed direct drive motors on the CACF/CAPF/CHPX models and BPM (Brushless Permanent Magnet) or ECM motors on the MBE models.

CONDENSING UNIT
The condenser air is pulled through the condenser coil by a direct drive propeller fan. This condenser air is then discharged out of the top of the cabinet. These units are designed for free air discharge, so no additional resistance, like duct work, shall be attached. The suction and liquid line connections on present models are of the sweat type for field piping with refrigerant type copper. Front seating valves are factory installed to accept the field run copper. The total refrigerant charge for a normal installation is factory installed in the condensing unit. ASX, SSX, ASZ and SSZ models are available in 1 1/2 through 5 ton sizes and use R-410A refrigerant. They are designed for 208/230 volt single phase applications. ASX and ASZ R-410A model units use the Copeland Scroll "Ultratech" Series compressors which are specifically designed for R-410A refrigerant. These units also have Copeland ComfortAlert diagnostics. SSX and SSZ R-410A model units use the Copeland Scroll "Ultratech" Series compressors which are specifically designed for R-410A refrigerant. There are a number of design characteristics which are different from the traditional reciprocating and/or scroll compressors. "Ultractech" Series scroll compressors will not have a discharge thermostat. Some of the early model scroll compressors required discharge thermostat. "Ultratech" Series scroll compressors use "POE" or polyolester oil which is NOT compatible with mineral oil based lubricants like 3GS. "POE" oil must be used if additional oil is required.

17

PRODUCT DESIGN
The ASX [16 & 18] and ASZ [16 & 18] series split system units use a two-stage scroll compressor. The two-step modulator has an internal unloading mechanism that opens a bypass port in the first compression pocket, effectively reducing the displacement of the scroll. The opening and closing of the bypass port is controlled by an internal electrically operated solenoid.

As this motion occurs, the pockets between the two forms are slowly pushed to the center of the two scrolls while simultaneously being reduced in volume. When the pocket reaches the center of the scroll form, the gas, which is now at a high pressure, is discharged out of a port located at the center. During compression, several pockets are being compressed simultaneously, resulting in a very smooth process. Both the suction process (outer portion of the scroll members) and the discharge process (inner portion) are continuous. The ZPS/ZRS two-step modulated scroll uses a single step of unloading to go from full capacity to approximately 67% capacity. A single speed, high efficiency motor continues to run while the scroll modulates between the two capacity steps. Some design characteristics of the Compliant Scroll compressor are: Compliant Scroll compressors are more tolerant of liquid refrigerant. NOTE: Even though the compressor section of a Scroll compressor is more tolerant of liquid refrigerant, continued floodback or flooded start conditions may wash oil from the bearing surfaces causing premature bearing failure. Compliant Scroll compressors use white oil which is compatible with 3GS. 3GS oil may be used if additional oil is required. Compliant scroll compressors perform "quiet" shutdowns that allow the compressor to restart immediately without the need for a time delay. This compressor will restart even if the system has not equalized. NOTE: Operating pressures and amp draws may differ from standard reciprocating compressors. This information can be found in the unit's Technical Information Manual.

A scroll is an involute spiral which, when matched with a mating scroll form as shown, generates a series of crescent shaped gas pockets between the two members. During compression, one scroll remains stationary (fixed scroll) while the other form (orbiting scroll) is allowed to orbit (but not rotate) around the first form.

18

SYSTEM OPERATION
COOLING The refrigerant used in the system is R-410A. It is a clear, colorless, non-toxic and non-irritating liquid. R-410A is a 50:50 blend of R-32 and R-125. The boiling point at atmospheric pressure is -62.9F. A few of the important principles that make the refrigeration cycle possible are: heat always flows from a warmer to a cooler body. Under lower pressure, a refrigerant will absorb heat and vaporize at a low temperature. The vapors may be drawn off and condensed at a higher pressure and temperature to be used again. The indoor evaporator coil functions to cool and dehumidify the air conditioned spaces through the evaporative process taking place within the coil tubes. NOTE: The pressures and temperatures shown in the refrigerant cycle illustrations on the following pages are for demonstration purposes only. Actual temperatures and pressures are to be obtained from the "Expanded Performance Chart". Liquid refrigerant at condensing pressure and temperatures, (270 psig and 122F), leaves the outdoor condensing coil through the drier and is metered into the indoor coil through the metering device. As the cool, low pressure, saturated refrigerant enters the tubes of the indoor coil, a portion of the liquid immediately vaporizes. It continues to soak up heat and vaporizes as it proceeds through the coil, cooling the indoor coil down to about 48F. Heat is continually being transferred to the cool fins and tubes of the indoor evaporator coil by the warm system air. This warming process causes the refrigerant to boil. The heat removed from the air is carried off by the vapor. As the vapor passes through the last tubes of the coil, it becomes superheated. That is, it absorbs more heat than is necessary to vaporize it. This is assurance that only dry gas will reach the compressor. Liquid reaching the compressor can weaken or break compressor valves. The compressor increases the pressure of the gas, thus adding more heat, and discharges hot, high pressure superheated gas into the outdoor condenser coil. In the condenser coil, the hot refrigerant gas, being warmer than the outdoor air, first loses its superheat by heat transferred from the gas through the tubes and fins of the coil. The refrigerant now becomes saturated, part liquid, part vapor and then continues to give up heat until it condenses to a liquid alone. Once the vapor is fully liquefied, it continues to give up heat which subcools the liquid, and it is ready to repeat the cycle.

HEATING
The heating portion of the refrigeration cycle is similar to the cooling cycle. By energizing the reversing valve solenoid coil, the flow of the refrigerant is reversed. The indoor coil now becomes the condenser coil, and the outdoor coil becomes the evaporator coil. The check valve at the indoor coil will open by the flow of refrigerant letting the now condensed liquid refrigerant bypass the indoor expansion device. The check valve at the outdoor coil will be forced closed by the refrigerant flow, thereby utilizing the outdoor expansion device. The restrictor orifice used with the CA*F, CHPF and CH**FCB coils will be forced onto a seat when running in the cooling cycle, only allowing liquid refrigerant to pass through the orifice opening. In the heating cycle, it will be forced off the seat allowing liquid to flow around the restrictor. A check valve is not required in this circuit. COOLING CYCLE When the contacts of the room thermostat close making terminals R to Y & G, the low voltage circuit of the transformer is completed. Current now flows through the magnetic holding coils of the compressor contactor (CC) and fan relay (RFC). This draws in the normally open contact CC, starting the compressor and condenser fan motors. At the same time, contacts RFC close, starting the indoor fan motor. When the thermostat is satisfied, it opens its contacts, breaking the low voltage circuit, causing the compressor contactor and indoor fan relay to open, shutting down the system. If the room thermostat fan selector switch should be set on the "on" position, then the indoor blower would run continuous rather than cycling with the compressor. ASZ and SSZ models energize the reversing valve thorough the "O" circuit in the room thermostat. Therefore, the reversing valve remains energized as long as the thermostat subbase is in the cooling position. The only exception to this is during defrost.

19

SYSTEM OPERATION
DEFROST CYCLE The defrosting of the outdoor coil is jointly controlled by the defrost control board and the defrost thermostat. Solid State Defrost Control During operation the power to the circuit board is controlled by a temperature sensor, which is clamped to a feeder tube entering the outdoor coil. Defrost timing periods of 30, 60, or 90 minutes may be selected by connecting the circuit board jumper to 30, 60, or 90 respectively. Accumulation of time for the timing period selected starts when the sensor closes (approximately 31 F), and when the room thermostat calls for heat. At the end of the timing period, the units defrost cycle will be initiated provided the sensor remains closed. When the sensor opens (approximately 75 F), the defrost cycle is terminated and the timing period is reset. If the defrost cycle is not terminated due to the sensor temperature, a ten minute override interrupts the units defrost period.
DF2 TEST JUMPER WIRE

HEATING CYCLE The ASZ and SSZ model heat pumps use a different control circuit than preceding heat pump models. These models do not use a reversing relay to energize the reversing valve. Also, many previous models energized the reversing valve off the "B" terminal on the thermostat, and all previous models energized the reversing valve in the heating cycle. The reversing valve on the SSZ and ASZ models is energized in the cooling cycle through the "O" terminal on the room thermostat. These models have a 24 volt reversing valve coil. When the thermostat selector switch is set in the cooling position, the "O" terminal on the thermostat is energized all the time. Care must be taken when selecting a room thermostat. Refer to the installation instructions shipped with the product for approved thermostats.

90 60 30

DF1

W2 R

R DFT

20

SYSTEM OPERATION
COOLING CYCLE

Reversing Valve (Energized) Indoor Coil Accumulator Outdoor Coil

Thermostatic Expansion Valve

Bi-Flow Filter Dryer Check Valve

HEATING CYCLE

Reversing Valve (De-Energized) Indoor Coil Accumulator Outdoor Coil

Thermostatic Expansion Valve

Bi-Flow Filter Dryer Check Valve

21

SYSTEM OPERATION

EXPANSION VALVE/CHECK VALVE ASSEMBLY IN COOLING OPERATION

EXPANSION VALVE/CHECK VALVE ASSEMBLY IN HEATING OPERATION

Most expansion valves used in current Amana Brand Heat Pump products use an internally checked expansion valve. This type of expansion valve does not require an external check valve as shown above. However, the principle of operation is the same. RESTRICTOR ORIFICE ASSEMBLY IN COOLING OPERATION RESTRICTOR ORIFICE ASSEMBLY IN HEATING OPERATION

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

In the heating mode, the orifice moves back off its seat, allowing refrigerant to flow unmetered around the outside of the orifice.

22

SYSTEM OPERATION
AFE18-60A CONTROL BOARD
DESCRIPTION The AFE18 control is designed for use in heat pump applications where the indoor coil is located above/downstream of a gas or fossil fuel furnace. It will operate with single and two stage heat pumps and single and two stage furnaces. The AFE18 control will turn the heat pump unit off when the furnace is turned on. An anti-short cycle feature is also incorporated which initiates a 3 minute timed off delay when the compressor goes off. On initial power up or loss and restoration of power, this 3 minute timed off delay will be initiated. The compressor wont be allowed to restart until the 3 minute off delay has expired. Also included is a 5 second de-bounce feature on the Y, E, W1 and O thermostat inputs. These thermostat inputs must be present for 5 seconds before the AFE18 control will respond to it. An optional outdoor thermostat, OT18-60A, can be used with the AFE18 to switch from heat pump operation to furnace operation below a specific ambient temperature setting, i.e. break even temperature during heating. When used in this manner, the Y heat demand is switched to the W1 input to the furnace by the outdoor thermostat and the furnace is used to satisfy the first stage Y heat demand. On some controls, if the outdoor thermostat fails closed in this position during the heating season, it will turn on the furnace during the cooling season on a Y cooling demand. In this situation, the furnace produces heat and increases the indoor temperature thereby never satisfying the cooling demand. The furnace will continue to operate and can only be stopped by switching the thermostat to the off position or removing power to the unit and then replacing the outdoor thermostat. When the AFE18 receives a Y and O input from the indoor thermostat, it recognizes this as a cooling demand in the cooling mode. If the outdoor thermostat is stuck in the closed position switching the Y demand to the W1 furnace input during the cooling mode as described above, the AFE18 wont allow the furnace to operate. The outdoor thermostat will have to be replaced to restore the unit to normal operation.

HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

23

TROUBLESHOOTING CHART
COOLING/H P ANALYSIS CHART
Com plaint No Cooling Uns atis factor y Cooling/He ating Sys te m Ope r ating Pr e s s ur e s

System runs continuously - little cooling/htg

Compressor runs - goes off on overload

Certain areas too cool, others too warm

Compressor cycles on overload

SYMPTOM

Not cool enough on warm days

P OS SIBLE CAUSE DOTS IN ANALYSIS GUIDE INDICATE "P OS SIBLE CAUSE"

System runs - blows cold air in heating

Compressor will not start - fan runs

Comp. and Cond. Fan will not start

Unit will not terminate defrost

Too cool and then too warm

Evaporator fan will not start

Condenser fan will not start

High suction pressure

Te st Me thod Re m e dy
High head pressure

Low suction pressure

Compressor is noisy

System will not start

Pow er Failure Blow n Fus e Unbalanced Pow er, 3PH Loose Connec tion Shorted or Broken Wires Open Fan Ov erload Faulty Thermos tat Faulty Transf ormer Shorted or Open Capacitor Internal Compres s or Overload Open Shorted or Grounded Compress or Compress or Stuc k Faulty Compress or Contactor Faulty Fan Relay Open Control Circ uit Low V oltage Faulty Evap. Fan Motor Shorted or Grounded Fan Motor Improper Cooling A ntic ipator Shortage of Ref rigerant Res tric ted Liquid Line Open Element or Limit on Elec . Heater Dirty A ir Filter Dirty Indoor Coil Not enough air ac ros s Indoor Coil Too much air across Indoor Coil Ov erc harge of Ref rigerant Dirty Outdoor Coil Noncondensibles Rec irc ulation of Condens ing A ir Inf iltration of Outdoor A ir Improperly Loc ated Thermos tat A ir Flow Unbalanc ed Sy s tem Unders iz ed Broken Internal Parts Broken V alves Inef f ic ient Compress or Wrong Ty pe Ex pans ion V alv e Ex pans ion Dev ice Res tric ted Ov ers iz ed Ex pans ion V alve Unders ized Ex pansion V alv e Ex pans ion V alve Bulb Loos e Inoperativ e Ex pansion V alve Loose Hold-dow n Bolts Faulty Rev ers ing V alv e Faulty Def ros t Control Faulty Def ros t Thermostat Flow rator Not Seating Properly

Low head pressure

Unit will not defrost

Cooling or He ating Cycle (He at Pum p)

He ating Cycle Only (He at Pum p)

Test V oltage S-1 Ins pec t Fuse Siz e & Ty pe S-1 Test V oltage S-1 Ins pec t Connec tion - Tighten S-2, S-3 Test Circ uits With Ohmmeter S-2, S-3 Test Continuity of Ov erload S-17A Test Continuity of Thermos tat & Wiring S-3 Chec k Control Circuit w ith V oltmeter S-4 Test Capacitor S-15 Test Continuity of Ov erload S-17A Test Motor Windings S-17B Us e Test Cord S-17D Test Continuity of Coil & Contac ts S-7, S-8 Test Continuity of Coil A nd Contac ts S-7 Test Control Circ uit w ith V oltmeter S-4 Test V oltage S-1 Repair or Replac e S-16 Test Motor Windings S-16 Chec k Resis tanc e of A ntic ipator S-3B Test For Leaks, A dd Ref rigerant S-101,103 Remov e Res tric tion, Replac e Restricted Part S-112 Test Heater Element and Controls S-26,S-27 Ins pec t Filter-Clean or Replace Ins pec t Coil - Clean Chec k Blow er Speed, Duc t Static Pres s, Filter S-200 Reduc e Blow er Speed S-200 Recov er Part of Charge S-113 Ins pec t Coil - Clean Recov er Charge, Ev ac uate, Recharge S-114 Remov e Obs truc tion to A ir Flow Chec k Window s , Doors , V ent Fans , Etc. Reloc ate Thermostat Readjust A ir V olume Dampers Ref igure Cooling Load Replac e Compres sor S-115 Test Compres sor Ef f icienc y S-104 Test Compres sor Ef f icienc y S-104 Replac e V alv e S-110 Remov e Res tric tion or Replace Ex pans ion Devic e S-110 Replac e V alv e Replac e V alv e Tighten Bulb Brac ket S-105 Chec k V alve Operation S-110 Tighten Bolts Replac e V alv e or Solenoid S-21, 122 Test Control S-24 Test Def rost Thermostat S-25 Chec k Flow rator & Seat or Replac e Flow rator S-111

24

See Service Procedure Ref.

SERVICING
Table of Contents
S-1 S-2 S-3 S-3A S-3B S-3C S-3D S-4 S-5 S-6 S-7 S-8 S-9 S-12 S-13 S-15 S-15A S-15B S-16A S-16B S-16C S-16D S-16E S-17 S-17A S-17B S-17C S-17D S-18 S-21 S-24 Checking Voltage .......................................... 26 Checking Wiring ............................................ 26 Checking Thermostat, Wiring & Anticipator .. 26 Thermostat & Wiring ..................................... 26 Cooling Anticipator ........................................ 27 Heating Anticipator ........................................ 27 Checking Encoded Thermostats ................... 27 Checking Transformer & Control Circuit ....... 28 Checking Cycle Protector ............................. 28 Checking Time Delay Relay .......................... 28 Checking Contactor and/or Relays ................ 29 Checking Contactor Contacts ....................... 29 Checking Fan Relay Contact ........................ 29 Checking High Pressure Control ................... 30 Checking Low Pressure Control .................... 30 Checking Capacitor ....................................... 30 Resistance Check ......................................... 31 Capacitance Check ....................................... 32 Checking Fan & Blower Motor Windings (PSC Motors) ............................... 32 Checking Fan & Blower Motor (ECM Motors) 32 Checking ECM Motor Windings .................... 32 ECM CFM Adjustments ................................ 36 Blower Performance Data .............................. 36 Checking Compressor Windings ................... 38 Resistance Test ............................................ 38 Ground Test .................................................. 38 Unloader Test ................................................ 39 Operation Test .............................................. 39 Testing Crankcase Heater (optional item) ..... 40 Checking Reversing Valve and Solenoid ........ 40 Testing Defrost Control .................................. 40 S-25 S-26 S-27 S-40 S-41 S-60 S-61A S-61B S-62 S-100 S-101 S-102 S-103 S-104 S-105A S-105B S-106 S-107 S-108 S-109 S-109A S-109B S-110 S-111 S-112 S-113 S-114 S-115 S-120 S-202 S-203 S-204 Testing Defrost Thermostat ........................... 40 Checking Heater Limit Control(s) .................. 41 Checking Heater Elements ........................... 41 MBR/ARUF Electronic Blower Time Delay .... 41 MBE/AEPF With SSX and ASX units ........... 43 Electric Heater (optional item) ....................... 47 Checking Heater Limit Control(S) .................. 48 Checking Heater Fuse Line ........................... 49 Checking Heater Elements ........................... 49 Refrigeration Repair Practice ......................... 49 Leak Testing ................................................. 50 Evacuation .................................................... 50 Charging ........................................................ 50 Checking Compressor Efficiency .................. 51 Piston Chart for SSX14 and ASX14 Units ...... 51 Thermostatic Expansion Valve ...................... 51 Overfeeding ................................................... 52 Underfeeding ................................................. 52 Superheat ..................................................... 52 Checking Subcooling .................................... 55 Two Speed Application .................................. 55 Heat Pump Heating Mode ............................. 56 Checking Expansion Valve Operation ........... 56 Fixed Orifice Restriction Devices .................. 56 Checking Restricted Liquid Line .................... 57 Refrigerant Overcharge .................................. 57 Non-condensables ........................................ 57 Compressor Burnout ..................................... 57 Refrigerant Piping .......................................... 58 Duct Static Pressure & Static Pressure Drop Across Coils ............ 60 Air Handler External Static ........................... 60 Coil Static Pressure Drop ............................. 61

HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

25

SERVICING
S-1 CHECKING VOLTAGE
1. Remove outer case, control panel cover, etc., from unit being tested. With power ON:

S-2 CHECKING WIRING

WARNING
Line Voltage now present.
2. Using a voltmeter, measure the voltage across terminals L1 and L2 of the contactor for the condensing unit or at the field connections for the air handler or heaters. 3. No reading - indicates open wiring, open fuse(s) no power or etc., from unit to fused disconnect service. Repair as needed. 4. With ample voltage at line voltage connectors, energize the unit. 5. Measure the voltage with the unit starting and operating, and determine the unit Locked Rotor Voltage. NOTE: If checking heaters, be sure all heating elements are energized. Locked Rotor Voltage is the actual voltage available at the compressor during starting, locked rotor, or a stalled condition. Measured voltage should be above minimum listed in chart below. To measure Locked Rotor Voltage attach a voltmeter to the run "R" and common "C" terminals of the compressor, or to the T1 and T2 terminals of the contactor. Start the unit and allow the compressor to run for several seconds, then shut down the unit. Immediately attempt to restart the unit while measuring the Locked Rotor Voltage. 6. Lock rotor voltage should read within the voltage tabulation as shown. If the voltage falls below the minimum voltage, check the line wire size. Long runs of undersized wire can cause low voltage. If wire size is adequate, notify the local power company in regard to either low or high voltage.
UNIT SUPPLY VOLTAGE VOLTAGE 460 208/230 MIN. 437 198 MAX. 506 253

HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.
1. Check wiring visually for signs of overheating, damaged insulation and loose connections. 2. Use an ohmmeter to check continuity of any suspected open wires. 3. If any wires must be replaced, replace with comparable gauge and insulation thickness.

S-3 CHECKING THERMOSTAT, WIRING, AND ANTICIPATOR

THERMOSTAT WIRE SIZING CHART LENGTH OF RUN 25 feet 50 feet 75 feet 100 feet 125 feet 150 feet MIN. COPPER WIRE GAUGE (AWG) 18 16 14 14 12 12

S-3A THERMOSTAT AND WIRING

WARNING
Line Voltage now present.
With power ON, thermostat calling for cooling 1. Use a voltmeter to check for 24 volts at thermostat wires C and Y in the condensing unit control panel. 2. No voltage indicates trouble in the thermostat, wiring or external transformer source. 3. Check the continuity of the thermostat and wiring. Repair or replace as necessary. Indoor Blower Motor With power ON:

NOTE: When operating electric heaters on voltages other than 240 volts, refer to the System Operation section on electric heaters to calculate temperature rise and air flow. Low voltage may cause insufficient heating.

WARNING
Line Voltage now present.
1. Set fan selector switch at thermostat to "ON" position. 2. With voltmeter, check for 24 volts at wires C and G. 3. No voltage indicates the trouble is in the thermostat or wiring.

26

SERVICING
4. Check the continuity of the thermostat and wiring. Repair or replace as necessary. Resistance Heaters 1. Set room thermostat to a higher setting than room temperature so both stages call for heat. 2. With voltmeter, check for 24 volts at each heater relay. Note: BBA/BBC heater relays are DC voltage. 3. No voltage indicates the trouble is in the thermostat or wiring. 4. Check the continuity of the thermostat and wiring. Repair or replace as necessary. NOTE: Consideration must be given to how the heaters are wired (O.D.T. and etc.). Also safety devices must be checked for continuity. element helping the thermostat call for the next cooling cycle. This prevents the room temperature from rising too high before the system is restarted. A properly sized anticipator should maintain room temperature within 1 1/2 to 2 degree range. The anticipator is supplied in the thermostat and is not to be replaced. If the anticipator should fail for any reason, the thermostat must be changed.

S-3C HEATING ANTICIPATOR

The heating anticipator is a wire wound adjustable heater which is energized during the "ON" cycle to help prevent overheating of the conditioned space. The anticipator is a part of the thermostat and if it should fail for any reason, the thermostat must be replaced. See the following tables for recommended heater anticipator setting in accordance to the number of electric heaters installed.

S-3B COOLING ANTICIPATOR

The cooling anticipator is a small heater (resistor) in the thermostat. During the "off" cycle, it heats the bimetal

S-3D TROUBLESHOOTING ENCODED TWO STAGE COOLING THERMOSTATS OPTIONS

Troubleshooting Encoded Two Stage Cooling Thermostats Options

T E S T

TEST INDICATION S1 + * S1 - * S1 + S2 + INPUT FROM THERMOSTAT S2 -

FUNCTION LOW SPEED COOL * LO SPEED COOL * HI SPEED COOL LO SPEED HEAT O

SIGNAL OUT YCON + * YCON - * YCON + W1 HEATER ED ( FUTURE USE )

SIGNAL FAN Y1 * Y / Y2 HI * Y / Y2 W / W1 O SEE NOTE 3 * ERROR CONDITION ( DIODE ON THERMOSTAT BACKWARDS )

S2 + -

LO SPEED HEAT HI SPEED HEAT

W1 HEATER W2 HEATER NONE N/A N/A R TO T'STAT COM TO T'STAT

W / W1 EM / W2 G N/A N/A R C1 , C2

SEE NOTE 3

S3 + * S3 - * * S3 + - * POWER TO THERMOSTAT R+COM

G N/A N/A 24 VAC GND

* ERROR CONDITION ( S3 CAN ONLY READ + ) * ERROR CONDITION ( S3 CAN ONLY READ + )

NOTES: 1.) THE TEST SPADE CAN BE CONNECTED TO ANY OTHER TEST SPADE ON EITHER BOARD. 2.) THE + LED WILL BE RED AND WILL LIGHT TO INDICATE + HALF CYCLES. THE - LED WILL BE GREEN AND WILL LIGHT TO INDICATE - HALF CYCLES. BOTH RED AND GREEN ILLUMINATED WILL INDICATE FULL CYCLES DENOTED BY + - . 3.) SIGNAL OUT CONDITION FOR W1 , W2 HEATER WILL BE AFFECTED BY OT1 PJ4 AND OT2 PJ2 JUMPERS AND OUTDOOR THERMOSTATS ATTACHED. THE TABLE ABOVE ASSUMES OT1 PJ4 IS REMOVED AND OT2 PJ2 IS MADE WITH NO OUTDOOR THERMOSTATS ATTACHED.

The chart above provides troubleshooting for either version of the encoded thermostat option. This provides diagnostic information for the GMC CHET18-60 or a conventional two cool / two stage heat thermostat with IN4005 diodes added as called out in the above section. A test lead or jumper wire can be added from the test terminal to any terminal on the B13682-74 or B13682-71 variable speed terminal board and provide information through the use of the LED lights on the B13682-71 VSTB control. Using this chart, a technician can determine if the proper input signal is being received by the encoded VSTB control and diagnose any problems that may be relayed to the output response of the B13682-74 VSTM control.

27

SERVICING
S-4 CHECKING TRANSFORMER AND CONTROL CIRCUIT
With power ON:

WARNING
Line Voltage now present.
1. Apply 24 VAC to terminals R1 and R2. 2. Should read 24 VAC at terminals Y1 and Y2. 3. Remove 24 VAC at terminals R1 and R2. 4. Should read 0 VAC at Y1 and Y2. 5. Reapply 24 VAC to R1 and R2 - within approximately three (3) to four (4) minutes should read 24 VAC at Y1 and Y 2. If not as above - replace relay.

HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

A step-down transformer (208/240 volt primary to 24 volt secondary) is provided with each indoor unit. This allows ample capacity for use with resistance heaters. The outdoor sections do not contain a transformer.

S-6 CHECKING TIME DELAY RELAY

Time delay relays are used in some of the blower cabinets to improve efficiency by delaying the blower off time. Time delays are also used in electric heaters to sequence in multiple electric heaters.

WARNING
Disconnect ALL power before servicing.

1. Remove control panel cover, or etc., to gain access to transformer. With power ON:

WARNING
Disconnect ALL power before servicing.

WARNING
Line Voltage now present.
2. Using a voltmeter, check voltage across secondary voltage side of transformer (R to C). 3. No voltage indicates faulty transformer, bad wiring, or bad splices. 4. Check transformer primary voltage at incoming line voltage connections and/or splices. 5 If line voltage available at primary voltage side of transformer and wiring and splices good, transformer is inoperative. Replace.

1. Tag and disconnect all wires from male spade connections of relay. 2. Using an ohmmeter, measure the resistance across terminals H1 and H2. Should read approximately 150 ohms. 3. Using an ohmmeter, check for continuity across terminals 3 and 1, and 4 and 5. 4. Apply 24 volts to terminals H1 and H2. Check for continuity across other terminals - should test continuous. If not as above - replace. NOTE: The time delay for the contacts to make will be approximately 20 to 50 seconds and to open after the coil is de-energized is approximately 40 to 90 seconds.

S-5 CHECKING CYCLE PROTECTOR

Some models feature a solid state, delay-on make after break time delay relay installed in the low voltage circuit. This control is used to prevent short cycling of the compressor under certain operating conditions. The component is normally closed (R1 to Y1). A power interruption will break circuit (R1 to Y1) for approximately three minutes before resetting. 1. Remove wire from Y1 terminal. 2. Wait for approximately four (4) minutes if machine was running.

OHMMETER

TESTING COIL CIRCUIT

28

SERVICING
S-7 CHECKING CONTACTOR AND/OR RELAYS
T2 T1

HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

CC

VOLT/OHM METER
L2 L1

The compressor contactor and other relay holding coils are wired into the low or line voltage circuits. When the control circuit is energized, the coil pulls in the normally open contacts or opens the normally closed contacts. When the coil is de-energized, springs return the contacts to their normal position. NOTE: Most single phase contactors break only one side of the line (L1), leaving 115 volts to ground present at most internal components. 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 contactor.

Ohmmeter for testing holding coil Voltmeter for testing contacts

TESTING COMPRESSOR CONTACTOR (Single Phase) THREE PHASE Using a voltmeter, test across terminals: A. L1-L2, L1-L3, and L2-L3 - If voltage is present, proceed to B. If voltage is not present, check breaker or fuses on main power supply.. T1-T2, T1-T3, and T2-T3 - If voltage readings are not the same as in "A", replace contactor.
T3 T2 T1

B.

S-8 CHECKING CONTACTOR CONTACTS

CC

WARNING
Disconnect ALL power before servicing.

VOLT/OHM METER
L3 L2 L1

SINGLE PHASE: 1. Disconnect the wire leads from the terminal (T) side of the contactor. 2. With power ON, energize the contactor.
Ohmmeter for testing holding coil Voltmeter for testing contacts

TESTING COMPRESSOR CONTACTOR (Three-phase)

WARNING
Line Voltage now present.
3. Using a voltmeter, test across terminals. A. L2 - T1 - No voltage indicates CC1 contacts open. If a no voltage reading is obtained - replace the contactor.

S-9 CHECKING FAN RELAY CONTACTS

HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

1. Disconnect wires leads from terminals 2 and 4 of Fan Relay Cooling and 2 and 4, 5 and 6 of Fan Relay Heating. 2. Using an ohmmeter, test between 2 and 4 - should read open. Test between 5 and 6 - should read continuous. 3. With power ON, energize the relays.

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WARNING
Line Voltage now present.

OHMMETER 2 5

TESTING FAN RELAY 4. Using an ohmmeter, test between 2 and 4 - should read continuous . Test between 5 and 6 - should read open. 5. If not as above, replace the relay. If it cuts-out at 610 PSIG 10 PSIG, it is operating normally (See causes for high head pressure in Service Problem Analysis Guide). If it cuts out below this pressure range, replace the control.

S-12 CHECKING HIGH PRESSURE CONTROL

S-13 CHECKING LOW PRESSURE CONTROL

HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

The low pressure control senses the pressure in the suction line and will open its contacts on a drop in pressure. The low pressure control will automatically reset itself with a rise in pressure. The low pressure control is designed to cut-out (open) at approximately 50 PSIG. It will automatically cut-in (close) at approximately 85 PSIG. Test for continuity using a VOM and if not as above, replace the control.

The high pressure control capillary senses the pressure in the compressor discharge line. If abnormally high condensing pressures develop, the contacts of the control open, breaking the control circuit before the compressor motor overloads. This control is automatically reset.

S-15 CHECKING CAPACITOR

CAPACITOR, RUN A run capacitor is wired across the auxiliary and main windings of a single phase permanent split capacitor motor. The capacitors primary function is to reduce the line current while greatly improving the torque characteristics of a motor. This is accomplished by using the 90 phase relationship between the capacitor current and voltage in conjunction with the motor windings, so that the motor will give two phase operation when connected to a single phase circuit. The capacitor also reduces the line current to the motor by improving the power factor. The line side of this capacitor is marked with "COM" and is wired to the line side of the circuit. CAPACITOR, START

1. Using an ohmmeter, check across terminals of high pressure control, with wire removed. If not continuous, the contacts are open. 3. Attach a gauge to the dill valve port on the base valve. With power ON:

WARNING
Line Voltage now present.
4. Start the system and place a piece of cardboard in front of the condenser coil, raising the condensing pressure. 5. Check pressure at which the high pressure control cutsout.

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SCROLL COMPRESSOR MODELS In most cases hard start components are not required on Scroll compressor equipped units due to a non-replaceable check valve located in the discharge line of the compressor. However, in installations that encounter low lock rotor voltage, a hard start kit can improve starting characteristics and reduce light dimming within the home. Only hard start kits approved by Amana brand or Copeland should be used. "Kick Start" and/or "Super Boost" kits are not approved start assist devices. The discharge check valve closes off high side pressure to the compressor after shut down allowing equalization through the scroll flanks. Equalization requires only about second. To prevent the compressor from short cycling, a Time Delay Relay (Cycle Protector) has been added to the low voltage circuit. RELAY, START A potential or voltage type relay is used to take the start capacitor out of the circuit once the motor comes up to speed. This type of relay is position sensitive. The normally closed contacts are wired in series with the start capacitor and the relay holding coil is wired parallel with the start winding. As the motor starts and comes up to speed, the increase in voltage across the start winding will energize the start relay holding coil and open the contacts to the start capacitor. Two quick ways to test a capacitor are a resistance and a capacitance check.
START CAPACITOR

S-15A RESISTANCE CHECK

WARNING
HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

1. Discharge capacitor and remove wire leads.

WARNING
Discharge capacitor through a 20 to 30 OHM resistor before handling.

OHMMETER

CAPACITOR

TESTING CAPACITOR RESISTANCE 2. Set an ohmmeter on its highest ohm scale and connect the leads to the capacitor A. Good Condition - indicator swings to zero and slowly returns to infinity. (Start capacitor with bleed resistor will not return to infinity. It will still read the resistance of the resistor). B. Shorted - indicator swings to zero and stops there replace. C. Open - no reading - replace. (Start capacitor would read resistor resistance.)

RED 10 VIOLET 20 YELLOW 12

START RELAY

ORANGE 5
COM HERM FAN

T2 T1 L2 L1 CONTACTOR

RUN CAPACITOR

HARD START KIT WIRING

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S-15B CAPACITANCE CHECK
Using a hookup as shown below, take the amperage and voltage readings and use them in the formula: 1. Remove the motor leads from its respective connection points and capacitor (if applicable). 2. Check the continuity between each of the motor leads. 3. Touch one probe of the ohmmeter to the motor frame (ground) and the other probe in turn to each lead. If the windings do not test continuous or a reading is obtained from lead to ground, replace the motor.
VOLTMETER

S-16B CHECKING FAN AND BLOWER MOTOR (ECM MOTORS)

15 AMP FUSE

AMMETER

CAPACITOR

An ECM is an Electronically Commutated Motor which offers many significant advantages over PSC motors. The ECM has near zero rotor loss, synchronous machine operation, variable speed, low noise, and programmable air flow. Because of the sophisticated electronics within the ECM motor, some technicians are intimated by the ECM motor; however, these fears are unfounded. GE offers two ECM motor testers, and with a VOM meter, one can easily perform basic troubleshooting on ECM motors. An ECM motor requires power (line voltage) and a signal (24 volts) to operate. The ECM motor stator contains permanent magnet. As a result, the shaft feels "rough" when turned by hand. This is a characteristic of the motor, not an indication of defective bearings.

TESTING CAPACITANCE

WARNING
Line Voltage now present.
1. Disconnect the 5-pin connector from the motor. 2. Using a volt meter, check for line voltage at terminals #4 & #5 at the power connector. If no voltage is present:

WARNING
Discharge capacitor through a 20 to 30 OHM resistor before handling.

Capacitance (MFD) = 2650 X Amperage Voltage

3. Check the unit for incoming power See section S-1. 4. Check the control board, See section S-40. 5. If line voltage is present, reinsert the 5-pin connector and remove the 16-pin connector. 6. Check for signal (24 volts) at the transformer. 7. Check for signal (24 volts) from the thermostat to the "G" terminal at the 16-pin connector. 8. Using an ohmmeter, check for continuity from the #1 & #3 (common pins) to the transformer neutral or "C" thermostat terminal. If you do not have continuity, the motor may function erratically. Trace the common circuits, locate and repair the open neutral. 9. Set the thermostat to "Fan-On". Using a voltmeter, check for 24 volts between pin # 15 (G) and common.

S-16A CHECKING FAN AND BLOWER MOTOR WINDINGS (PSC MOTORS)

The auto reset fan motor overload is designed to protect the motor against high temperature and high amperage conditions by breaking the common circuit within the motor, similar to the compressor internal overload. However, heat generated within the motor is faster to dissipate than the compressor, allow at least 45 minutes for the overload to reset, then retest.

HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

10. Disconnect power to compressor. Set thermostat to call for cooling. Using a voltmeter, check for 24 volts at pin # 6 and/or #14. 11. Set the thermostat to a call for heating. Using a voltmeter, check for 24 volts at pin #2 and/or #11.

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1 2 3 4 5

Lines 1 and 2 will be connected for 12OVAC Power Connector applications only

Gnd AC Line Connection AC Line Connection

OUT ADJUST +/Y1 COOL DELAY COMMON2 W/W1 COMMON1

16

OUT + G (FAN) Y/Y2 EM Ht/W2 24 Vac (R) HEAT BK/PWM (SPEED) O (REV VALVE)

15

14

13

12

11

10

16-PIN ECM HARNESS CONNECTOR

If you do not read voltage and continuity as described, the problem is in the control or interface board, but not the motor. If you register voltage as described , the ECM power head is defective and must be replaced.

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34
Troubleshooting Chart for ECM Variable Speed Air Circulator Blower Motors
Possible Causes ---------Corrective Action Cautions and Notes - Manual disconnect switch off or door switch open. - Blown fuse or circuit breaker. - 24 Vac wires miswired. - Unseated pins in wiring harness connectors. - Bad motor/control module. - Moisture present in motor or control module. - Check 230 Vac power at motor. - Check low voltage (24 Vac R to C) at motor. - Check low voltage connections (G, Y, W, R, C) at motor. - Check for unseated pins in connectors on motor harness. - Test with a temporary jumper between R - G. - Check m - Turn power OFF prior to repair. Wait 5 minutes after disconnecting power before opening motor. - Handle electronic motor/control with care. - Loose motor mount. - Blower wheel not tight on motor shaft. - Bad motor/control module. - Check for loose motor mount. - Make sure blower wheel is tight on shaft. - Perform motor/control replacement check, ECM motors only. - Turn power OFF prior to repair. Wait 5 minutes after disconnecting power before opening motor. - Handle electronic motor/control with care. ---------- Variation in 230 Vac to motor. - Unseated pins in wiring harness connectors. - Erratic CFM command from "BK" terminal. - Improper thermostat connection or setting. - Moisture present in motor/control module. - Check line voltage for variation or "sag". - Check low voltage connections (G, Y, W, R, C) at motor, unseated pins in motor harness connectors. - Check-out system controls - Thermostat. - Perform Moisture Check.* - Turn power OFF prior to repair. - Incorrect or dirty filter(s). - Incorrect supply or return ductwork. - Incorrect blower speed setting. - Does removing panel or filter reduce "puffing"? - Check/replace filter. - Check/correct duct restrictions. - Adjust to correct blower speed setting. - Turn power OFF prior to repair.

Symptom

Fault Description(s)

- Motor rocks slightly when starting.

- This is normal start-up for variable speed motor.

- No movement.

- Motor won't start.

- Motor rocks, but won't start.

- Motor oscillates up & down while being tested off of blower.

- It is normal for motor to oscillate with no load on shaft.

- Varies up and down or intermittent.

- Motor starts, but runs erratically.

- "Hunts" or "puffs" at high CFM (speed).

*Moisture Check - Connectors are oriented "down" (or as recommended by equipment manufacturer). - Arrange harnesses with "drip loop" under motor. - Check for low airflow (too much latent capacity). - Is condensate drain plugged? - Check and plug leaks in return ducts, cabinet. - Check for undercharged condition. Note: You must use the correct replacement control/motor module since they are factory programmed for specific operating modes. Even though they look alike, different modules may have completely different functionality. The ECM variable speed motors are c Important Note: Using the wrong motor/control module voids all product warranties and may produce unexpected results.

CHART CONTINUED ON NEXT PAGE

CHART CONTINUED FROM PREVIOUS PAGE.

Troubleshooting Chart for ECM Variable Speed Air Circulator Blower Motors
Possible Causes Corrective Action Cautions and Notes

SERVICING

Symptom

Fault Description(s)

- Stays at low CFM despite system call for cool or heat CFM.

- 24 Vac wires miswired or loose. - "R" missing/not connected at motor. - Fan in delay mode.

- Check low voltage (Thermostat) wires and connections. - Verify fan is not in delay mode wait until delay complete. - Perform motor/control replacement check, ECM motors only.

- Turn power OFF prior to repair. Wait 5 minutes after disconnecting power before opening motor. - Handle electronic motor/control with care.

- Motor starts, but runs erratically. - "R" missing/not connected at motor. - Fan in delay mode. - Is fan in delay mode? - wait until delay time complete. - Perform motor/control replacement check, ECM motors only.

- Stays at high CFM.

- Turn power OFF prior to repair. Wait 5 minutes after disconnecting power before opening motor. - Handle electronic motor/control with care.

- Blower won't shut off.

- Current leakage from controls into G, Y, or W.

- Check for Triac switched t'stat or solid state relay.

- Turn power OFF prior to repair.

- Air noise.

- High static creating high blower speed. - Incorrect supply or return ductwork. - Incorrect or dirty filter(s). - Incorrect blower speed setting.

- Check/replace filter. - Check/correct duct restrictions. - Adjust to correct blower speed setting.

- Turn power OFF prior to repair.

- Excessive noise.

- Noisy blower or cabinet.

- Loose blower housing, panels, etc. - High static creating high blower speed. - Air leaks in ductwork, cabinets, or panels.

- Check for loose blower housing, panels, etc. - Check for air whistling thru seams in ducts, cabinets or panels. - Check for cabinet/duct deformation.

- Turn power OFF prior to repair.

- "Hunts" or "puffs" at high CFM (speed).

- High static creating high blower speed. - Incorrect or dirty filter(s). - Incorrect supply or return ductwork. - Incorrect blower speed setting.

- Does removing panel or filter reduce "puffing"? - Check/replace filter. - Check/correct duct restrictions. - Adjust to correct blower speed setting.

- Turn power OFF prior to repair.

- Evidence of Moisture.

- Motor failure or malfunction has occurred and moisture is present.

- Moisture in motor/control module.

- Replace motor and perform Moisture Check.*

- Turn power OFF prior to repair. Wait 5 minutes after disconnecting power before opening motor. - Handle electronic motor/control with care.

35

*Moisture Check - Connectors are oriented "down" (or as recommended by equipment manufacturer). - Arrange harnesses with "drip loop" under motor. - Check for low airflow (too much latent capacity). - Is condensate drain plugged? - Check and plug leaks in return ducts, cabinet. - Check for undercharged condition. Note: You must use the correct replacement control/motor module since they are factory programmed for specific operating modes. Even though they look alike, different modules may have completely different functionality. The ECM variable speed motors are c Important Note: Using the wrong motor/control module voids all product warranties and may produce unexpected results.

SERVICING
S-16C CHECKING ECM MOTOR WINDINGS
MOTOR SPEED ADJUSTMENT

HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

Each ECM blower motor has been preprogrammed for operation at 4 distinct airflow levels when operating in Cooling/Heat Pump mode or Electric Heat mode. These 4 distinct levels may also be adjusted slightly lower or higher if desired. The adjustment between levels and the trim adjustments are made by changing the dipswitch(s) either to an "OFF" or "ON" position.
DIPSWITCH FUNCTIONS

1. Disconnect the 5-pin and the 16-pin connectors from the ECM power head. 2. Remove the 2 screws securing the ECM power head and separate it from the motor. 3. Disconnect the 3-pin motor connector from the power head and lay it aside. 4. Using an ohmmeter, check the motor windings for continuity to ground (pins to motor shell). If the ohmmeter indicates continuity to ground, the motor is defective and must be replaced. 5. Using an ohmmeter, check the windings for continuity (pin to pin). If no continuity is indicated, the thermal limit (over load) device may be open. Allow motor to cool and retest.
3-pin motor connector

The MBE / AEPF air handler motors have an electronic control that contains an eight (8) position dip switch. The function of these dipswitches are shown in Table 1.
Dipsw itch Num ber 1 2 3 4 5 6 7 8 Function Electric Heat N/A Indoor Therm ostat Cooling & Heat Pum p CFM CFM Trim Adjust

Table 1
CFM DELIVERY

Tables 2, 3, 5 and 6 show the CFM output for dipswitch combinations 1-2, and 5-6.
Electric Heat Operation
Model Switch 1 OFF ON OFF ON OFF MBE1600 ON OFF ON OFF ON OFF ON Switch 2 OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON CFM

MBE1200
16-pin connector

5-pin connector

MBE2000

S-16D ECM CFM ADJUSTMENTS MBE / AEPF

MBE MOTOR

1,200 1,000 800 600 1,600 1,400 1,200 1,000 2,000 1,800 1,600 1,200

This section references the operation characteristics of the MBE/AEPF models motor only. The ECM control board is factory set with the dipswitch #4 in the ON position and all other dipswitches are factory set in the OFF position. When MBE/AEPF are used with 2-stage cooling units, dipswitch #4 should be in the "OFF" position. For most applications, the settings are to be changed according to the electric heat size and the outdoor unit selection. The MBE/AEPF products use a General Electric ECMTM motor. This motor provides many features not available on the traditional PSC motor. These features include: Improved Efficiency Constant CFM Soft Start and Stop Improved Humidity Control

Table 2
Cooling/Heat Pump Operation
Model Switch 5 OFF MBE1200 ON OFF ON OFF MBE1600 ON OFF ON OFF ON OFF ON Switch 6 OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON CFM

MBE2000

1,200 1,000 800 600 1,600 1,400 1,200 1,000 2,000 1,800 1,600 1,200

Table 3

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THERMOSTAT FAN ONLY MODE AEPF DIPSWITCH FUNCTIONS
Model Switch 1 OFF AEPF1830 ON OFF OFF ON AEPF3036/4260 OFF ON ON Switch 2 OFF1 OFF ON OFF OFF ON ON ON EMERGENCY BACKUP CFM 1100 850 700 2050 1750 1600 1200 1020 EMERGENCY BACKUP CFM 1100 850 700 1800 1580 1480 1200 1020 HEAT PUMP CFM WITH BACKUP 1210 935 770 2150 1835 1680 1260 1020 HEAT PUMP CFM WITH BACKUP 1100 850 600 1800 1580 1480 1200 1020

During Fan Only Operations, the CFM output is 30% of the cooling setting.
CFM TRIM ADJUST

Minor adjustments can be made through the dip switch combination of 7-8. Table 4 shows the switch position for this feature. NOTE: The airflow will not make the decreasing adjustment in Electric Heat mode.

C FM +10% -1 5 %

S w itc h 7 ON OFF

S w itc h 8 OFF ON

Table 5
Model Switch 5 OFF AEPF1830 ON OFF OFF ON AEPF3036/4260 OFF ON ON
1

Switch 6 OFF OFF ON OFF OFF ON ON ON

Table 4
HUMIDITY CONTROL

When using a Humidstat (normally closed), cut jumper PJ6 on the control board. The Humidstat will only affect cooling airflow by adjusting the Airflow to 85%.
TWO STAGE HEATING

Table 6

7 - 8 shall be OFF-ON for 2.5 ton applications

When using staged electric heat, cut jumper PJ4 on the control board.

S-16E BLOWER PERFORMANCE DATA

MBR800**-* SCFM 1,240 1,170 1,120 1,060 980 900 900 850 790 740 680 605 650 590 540 500 430 330 MBR1200**-* SCFM 1,500 1,460 1,360 1,280 1,200 1,110 1,380 1,320 1,270 1,200 1,140 1,040 1,170 1,130 1,080 1,020 950 830 MBR1600**-* SCFM 1,800 1,740 1,680 1,610 1,520 1,430 1,540 1,490 1,450 1,400 13,560 1,280 1,130 1,100 1,070 1,030 990 930 MBR2000**-* SCFM 2,160 2,080 1,990 1,890 1,790 1,690 1,730 1,670 1,590 1,520 1,420 1,320 1,520 1,450 1,360 1,290 1,200 1,090

SPEED

STATIC 0.1 0.2 0.3 0.4 0.5 0.6 0.1 0.2 0.3 0.4 0.5 0.6 0.1 0.2 0.3 0.4 0.5 0.6

HIGH

MEDIUM

LOW

NOTE: External static is for blower @ 230 Volts. It does not include Coil, Air Filter or Electric Heaters.

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S-17 CHECKING COMPRESSOR

WARNING
Hermetic compressor electrical terminal venting can be dangerous. When insulating material which supports a hermetic compressor or electrical terminal suddenly disintegrates due to physical abuse or as a result of an electrical short between the terminal and the compressor housing, the terminal may be expelled, venting the vapor and liquid contents of the compressor housing and system.

HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

1. Remove the leads from the compressor terminals.

If the compressor terminal PROTECTIVE COVER and gasket (if required) are not properly in place and secured, there is a remote possibility if a terminal vents, that the vaporous and liquid discharge can be ignited, spouting flames several feet, causing potentially severe or fatal injury to anyone in its path. This discharge can be ignited external to the compressor if the terminal cover is not properly in place and if the discharge impinges on a sufficient heat source. Ignition of the discharge can also occur at the venting terminal or inside the compressor, if there is sufficient contaminant air present in the system and an electrical arc occurs as the terminal vents. Ignition cannot occur at the venting terminal without the presence of contaminant air, and cannot occur externally from the venting terminal without the presence of an external ignition source. Therefore, proper evacuation of a hermetic system is essential 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 extinguished or turned off prior to servicing a system. If the following test indicates shorted, grounded or open windings, see procedures S-19 for the next steps to be taken.

See warnings S-17 before removing compressor terminal cover.

2. Using an ohmmeter, test continuity between terminals S-R, C-R, and C-S, on single phase units or terminals T2, T2 and T3, on 3 phase units.

OHMMETER

S COMP

TESTING COMPRESSOR WINDINGS If either winding does not test continuous, replace the compressor. NOTE: If an open compressor is indicated, allow ample time for the internal overload to reset before replacing compressor.

S-17B GROUND TEST

If fuse, circuit breaker, ground fault protective device, etc., has tripped, this is a strong indication that an electrical problem exists and must be found and corrected. The circuit protective device rating must be checked, and its maximum rating should coincide with that marked on the equipment nameplate. With the terminal protective cover in place, it is acceptable to replace the fuse or reset the circuit breaker ONE TIME ONLY to see if it was just a nuisance opening. If it opens again, DO NOT continue to reset. Disconnect all power to unit, making sure that all power legs are open. 1. DO NOT remove protective terminal cover. Disconnect the three leads going to the compressor terminals at the nearest point to the compressor.

S-17A RESISTANCE TEST

Each compressor is equipped with an internal overload. The line break internal overload senses both motor amperage and winding temperature. High motor temperature or amperage heats the disc causing it to open, breaking the common circuit within the compressor on single phase units. Heat generated within the compressor shell, usually due to recycling of the motor, high amperage or insufficient gas to cool the motor, is slow to dissipate. Allow at least three to four hours for it to cool and reset, then retest. Fuse, circuit breaker, ground fault protective device, etc. has not tripped -

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2. Identify the leads and using a Megger, Hi-Potential Ground Tester, or other suitable instrument which puts out a voltage between 300 and 1500 volts, check for a ground separately between each of the three leads and ground (such as an unpainted tube on the compressor). Do not use a low voltage output instrument such as a voltohmmeter. Unloader Test Procedure If it is suspected that the unloader is not working, the following methods may be used to verify operation. 1. Operate the system and measure compressor current. Cycle the unloader ON and OFF at 10 second intervals. The compressor amperage should go up or down at least 25 percent. 2. If step one does not give the expected results, shut unit off. Apply 18 to 28 volt ac to the unloader molded plug leads and listen for a click as the solenoid pulls in. Remove power and listen for another click as the unloader returns to its original position. 3. If clicks cant be heard, shut off power and remove the control circuit molded plug from the compressor and measure the unloader coil resistance. The resistance should be 32 to 60 ohms, depending on compressor temperature. 4. Next check the molded plug. A. Voltage check: Apply control voltage to the plug wires (18 to 28 volt ac). The measured dc voltage at the female connectors in the plug should be around 15 to 27 vdc. Resistance check: Measure the resistance from the end of one molded plug lead to either of the two female connectors in the plug. One of the connectors should read close to zero ohms while the other should read infinity. Repeat with other wire. The same female connector as before should read zero while the other connector again reads infinity. Reverse polarity on the ohmmeter leads and repeat. The female connector that read infinity previously should now read close to zero ohms. Replace plug if either of these test methods doesnt show the desired results.

HI-POT

COMPRESSOR GROUND TEST 3. If a ground is indicated, then carefully remove the compressor terminal protective cover and inspect for loose leads or insulation breaks in the lead wires. 4. If no visual problems indicated, carefully remove the leads at the compressor terminals.

WARNING
Damage can occur to the glass embedded terminals if the leads are not properly removed. This can result in terminal and hot oil discharging.
Carefully retest for ground, directly between compressor terminals and ground. 5. If ground is indicated, replace the compressor.

B.

S-17C UNLOADER TEST PROCEDURE

A nominal 24-volt direct current coil activates the internal unloader solenoid. The input control circuit voltage must be 18 to 28 volt ac. The coil power requirement is 20 VA. The external electrical connection is made with a molded plug assembly. This plug contains a full wave rectifier to supply direct current to the unloader coil.

C.

S-17D OPERATION TEST

If the voltage, capacitor, overload and motor winding test fail to show the cause for failure:

HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

1. Remove unit wiring from disconnect switch and wire a test cord to the disconnect switch. NOTE: The wire size of the test cord must equal the line wire size and the fuse must be of the proper size and type.

UNLOADER SOLENOID (Molded Plug)

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SERVICING
2. With the protective terminal cover in place, use the three leads to the compressor terminals that were disconnected at the nearest point to the compressor and connect the common, start and run clips to the respective leads. 3. Connect good capacitors of the right MFD and voltage rating into the circuit as shown. 4. With power ON, close the switch. When stuck in the mid-position, part of the discharge gas from the compressor is directed back to the suction side, resulting in excessively high suction pressure. An increase in the suction line temperature through the reversing valve can also be measured. Check operation of the valve by starting the system and switching the operation from COOLING to HEATING cycle. If the valve fails to change its position, test the voltage (24V) at the valve coil terminals, while the system is on the COOLING cycle. If no voltage is registered at the coil terminals, check the operation of the thermostat and the continuity of the connecting wiring from the "O" terminal of the thermostat to the unit. If voltage is registered at the coil, tap the valve body lightly while switching the system from HEATING to COOLING, etc. If this fails to cause the valve to switch positions, remove the coil connector cap and test the continuity of the reversing valve solenoid coil. If the coil does not test continuous replace it. If the coil test continuous and 24 volts is present at the coil terminals, the valve is inoperative - replace it.

WARNING
Line Voltage now present.
A. If the compressor starts and continues to run, the cause for failure is somewhere else in the system. B. If the compressor fails to start - replace.

COPELAND COMPRESSOR 03
YEAR

A
MONTH

12345
SER IAL NUMBER

L
PLANT

S-24 TESTING DEFROST CONTROL

To check the defrost control for proper sequencing, proceed as follows: 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 (208230 VAC) indicating the relay is open in the defrost mode. 7. Using VOM check for voltage across "W2 & C" terminals on the board. You should read 24 volts. 8. If not as above, replace control board. 9. Set thermostat to off position and disconnect power before removing any jumpers or wires. NOTE: Remove jumper across defrost thermostat before returning system to service.

S-18 TESTING CRANKCASE HEATER (OPTIONAL ITEM)

The crankcase heater must be energized a minimum of four (4) hours before the condensing unit is operated. Crankcase heaters are used to prevent migration or accumulation of refrigerant in the compressor crankcase during the off cycles and prevents liquid slugging or oil pumping on start up. A crankcase heater will not prevent compressor damage due to a floodback or over charge condition.

WARNING
Disconnect ALL power before servicing.

1. Disconnect the heater lead in wires. 2. Using an ohmmeter, check heater continuity - should test continuous. If not, replace. NOTE: The positive temperature coefficient crankcase heater is a 40 watt 265 voltage heater. The cool resistance of the heater will be approximately 1800 ohms. The resistance will become greater as the temperature of the compressor shell increases.

S-25 TESTING DEFROST THERMOSTAT

1. Install a thermocouple type temperature test lead on the tube adjacent to the defrost control. Insulate the lead point of contact. 2. Check the temperature at which the control closes its contacts by lowering the temperature of the control. Part # 0130M00009P which is used on 2 and 2.5 ton units should close at 34F 5F. Part # 0130M00001P which is used on 3 thru 5 ton units should close at 31F 3F.

S-21 CHECKING REVERSING VALVE AND SOLENOID

Occasionally the reversing valve may stick in the heating or cooling position or in the mid-position.

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3. Check the temperature at which the control opens its contacts by raising the temperature of the control. Part # 0130M00009P which is used on 2 and 2.5 ton units should open at 60F 5F. Part # 0130M00001P which is used on 3 thru 5 ton units should open at 75F 6F. 4. If not as above, replace control. During a cooling or heat pump heating demand, 24Vac is supplied to terminal G of the EBTDR to turn on the blower motor. The EBTDR initiates a 7 second delay on and then energizes its onboard relay. The relay on the EBTDR board closes its normally open contacts and supplies power to the blower motor. When the G input is removed, the EBTDR initiates a 65 second delay off. When the 65 seconds delay expires the onboard relay is de-energized and its contacts open and remove power from the blower motor. During an electric heat only demand, W1 is energized but G is not. The blower motor is connected to the normally closed contacts of the relay on the EBTDR board. The other side of this set of contacts is connected to the heat sequencer on the heater assembly that provides power to the first heater element. When W1 is energized, the sequencer will close its contacts within 10 to 20 seconds to supply power to the first heater element and to the blower motor through the normally closed contacts on the relay on the EBTDR. When the W1 demand is removed, the sequencer opens it contacts within 30 to 70 seconds and removes power from the heater element and the blower motor. The EBTDR also contains a speedup terminal to reduce the delays during troubleshooting of the unit. When this terminal is shorted to the common terminal, C, on the EBTDR board, the delay ON time is reduced to 3 seconds and the delay OFF time is reduced to 5 second. Two additional terminals, M1 and M2, are on the EBTDR board. These terminals are used to connect the unused leads from the blower motor and have no affect on the boards operation.

S-26 CHECKING HEATER LIMIT CONTROL(S)

(OPTIONAL ELECTRIC HEATERS) Each individual heater element is protected with an automatic rest limit control connected in series with each element to prevent overheating of components in case of low airflow. This limit control will open its circuit at approximately 150F. to 160F and close at approximately 110F.

WARNING
DISCONNECT 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 before testing. IF FOUND OPEN - REPLACE - DO NOT WIRE AROUND.

S-27 CHECKING HEATER ELEMENTS

Optional electric heaters may be added, in the quantities shown in the spec sheet for each model unit, to provide electric resistance heating. Under no condition shall more heaters than the quantity shown be installed.

SEQUENCE OF OPERATION
This document covers the basic sequence of operation for a typical application with a mercury bulb thermostat. When a digital/electronic thermostat is used, the on/off staging of the auxiliary heat will vary. Refer to the installation instructions and wiring diagrams provided with the MBR/AR*F for specific wiring connections and system configuration.

HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

MBR/AR*F WITH SINGLE STAGE CONDENSERS

1. Disassemble and remove the heating element(s). 2. Visually inspect the heater assembly for any breaks in the wire or broken insulators. 3. Using an ohmmeter, test the element for continuity - no reading indicates the element is open. Replace as necessary. 1.0 Cooling Operation 1.1 On a demand for cooling, the room thermostat energizes G and Y and 24Vac is supplied to Y at the condensing unit and the G terminal on the EBTDR board. 1.2 The compressor and condenser fan are turned on and after a 7 second on delay, the relay on the EBTDR board is energized and the blower motor starts. 1.3 When the cooling demand Y is satisfied, the room thermostat removes the 24Vac from G and Y. 1.4 The compressor and condenser fan are turned off and after a 65 second delay off, the relay on the EBTDR board is de-energized and the blower is turned off.

S-40 MBR/AR*F ELECTRONIC BLOWER TIME DELAY RELAY

The MBR/AR*F contains an Electronic Blower Time Delay Relay board, B1370735. This board provides on/off time delays for the blower motor in cooling and heat pump heating demands when G is energized.

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2.0 Heating Operation 2.1 On a demand for heat, the room thermostat energizes W1 and 24Vac is supplied to heat sequencer, HR1, on the heater assembly. 2.2 The contacts M1 and M2 will close within 10 to 20 seconds and turn on heater element #1. The normally closed contacts on the EBTDR are also connected to terminal M1. When M1 and M2 close, the blower motor will be energized thru the normally closed contacts on the EBTDR board. At the same time, if the heater assembly contains a second heater element, HR1 will contain a second set of contacts, M3 and M4, which will close to turn on heater element #2. Note: If more than two heater elements are on the heater assembly, it will contain a second heat sequencer, HR2, which will control the 3rd and 4th heater elements if available. If the first stage heat demand, W1 cannot be satisfied by the heat pump, the temperature indoors will continue to drop. The room thermostat will then energize W2 and 24Vac will be supplied to HR2 on the heater assembly. When the W2 demand is satisfied, the room thermostat will remove the 24Vac from HR2. The contacts on HR2 will open between 30 to 70 seconds and heater elements #3 and #4 will be turned off. On most digital/electronic thermostats, W2 will remain energized until the first stage demand W1 is satisfied and then the W1 and W2 demands will be removed. 2.3 When the W1 heat demand is satisfied, the room thermostat will remove the 24Vac from HR1. Both set of contacts on the relay opens within 30 to 70 seconds and turn off the heater element(s) and the blower motor. On heat pump units, when the room thermostat set to the heating mode, the reversing valve is not energized. As long as the thermostat is set for heating, the reversing valve will be in the de-energized position for heating except during a defrost cycle. Some installations may use one or more outdoor thermostats to restrict the amount of electric heat that is available above a preset ambient temperature. Use of optional controls such as these can change the operation of the electric heaters during the heating mode. This sequence of operation does not cover those applications. 4.1 On a demand for first stage heat with heat pump units, the room thermostat energizes G and Y and 24Vac is supplied to Y at the heat pump unit and the G terminal on the EBTDR board. The heat pump is turned on in the heating mode and the blower motor starts after a 7 second on delay. 4.2 If the first stage heat demand cannot be satisfied by the heat pump, the temperature indoors will continue to drop. The room thermostat will then energize terminal W2 for second stage heat and 24Vac will be supplied to heat sequencer HR1 on the heater assembly. 4.3 HR1 contacts M1 and M2 will close will close within 10 to 20 seconds and turn on heater element #1. At the same time, if the heater assembly contains a second heater element, HR1 will contain a second set of contacts, M3 and M4, which will close and turn on heater element #2. The blower motor is already on as a result of terminal G on the EBTDR board being energized for the first stage heat demand. Note: If more than two heater elements are on the heater assembly, it will contain a second heat sequencer, HR2, which will control the 3rd and 4th heater elements if available. If the second stage heat demand, W2 cannot be satisfied by the heat pump, the temperature indoors will continue to drop. The room thermostat will then energize W3 and 24Vac will be supplied to HR2 on the heater assembly. When the W3 demand is satisfied, the room thermostat will remove the 24Vac from HR2. The contacts on HR2 will open between 30 to 70 seconds and heater elements #3 and #4 will be turned off. On most digital/electronic thermostats, W3 will remain energized until the first stage heat demand Y is satisfied and then the G, Y, W2 and W3 demands will be removed. 4.4 As the temperature indoors increase, it will reach a point where the second stage heat demand, W2, is satisfied. When this happens, the room thermostat will remove the 24Vac from the coil of HR1. The contacts on HR1 will open between 30 to 70 seconds and turn off both heater element(s). The heat pump remains on along with the blower motor because the Y demand for first stage heat will still be present. 4.5 When the first stage heat demand Y is satisfied, the room thermostat will remove the 24Vac from G and Y. The heat pump is turned off and the blower motor turns off after a 65 second off delay.

MBR/AR*F WITH SINGLE STAGE HEAT PUMPS

3.0 Cooling Operation On heat pump units, when the room thermostat set to the cooling mode, 24Vac is supplied to O which energizes the reversing valve. As long as the thermostat is set for cooling, the reversing valve will be in the energized position for cooling. 3.1 On a demand for cooling, the room thermostat energizes G and Y and 24Vac is supplied to Y at the heat pump and the G terminal on the EBTDR board. 3.2 The heat pump turned on in the cooling mode and after a 7 second on delay, the relay on the EBTDR board is energized and the blower motor starts. 3.3 When the cooling demand is satisfied, the room thermostat removes the 24Vac from G and Y. 3.4 The heat pump is turned off and after a 65 second delay off, the relay on the EBTDR board is de-energized and the blower motor is turned off. 4.0 Heating Operation

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5.0 Defrost Operation On heat pump units, when the room thermostat is set to the heating mode, the reversing valve is not energized. As long as the thermostat is set for heating, the reversing valve will be in the de-energized position for heating except during a defrost cycle. 5.1 The heat pump will be on and operating in the heating mode as described the Heating Operation in section 4. 5.2 The defrost control in the heat pump unit checks to see if a defrost is needed every 30, 60 or 90 minutes of heat pump operation depending on the selectable setting by monitoring the state of the defrost thermostat attached to the outdoor coil. 5.3 If the temperature of the outdoor coil is low enough to cause the defrost thermostat to be closed when the defrost board checks it, the board will initiate a defrost cycle. 5.4 When a defrost cycle is initiated, the contacts of the HVDR relay on the defrost board open and turns off the outdoor fan. The contacts of the LVDR relay on the defrost board closes and supplies 24Vac to O and W2. The reversing valve is energized and the contacts on HR1 close and turns on the electric heater(s). The unit will continue to run in this mode until the defrost cycle is completed. 5.5 When the temperature of the outdoor coil rises high enough to causes the defrost thermostat to open, the defrost cycle will be terminated. If at the end of the programmed 10 minute override time the defrost thermostat is still closed, the defrost board will automatically terminate the defrost cycle. 5.6 When the defrost cycle is terminated, the contacts of the HVDR relay will close to start the outdoor fan and the contacts of the LVDR relay will open and turn off the reversing valve and electric heater(s). The unit will now be back in a normal heating mode with a heat pump demand for heating as described in the Heating Operation in section 4. MBE/AEPF WITH SINGLE STAGE ASX AND SSX CONDENSERS When used with a single stage SSX and ASX condensers, dip switch #4 must be set to the on position on the VSTB inside the MBE/AEPF. The Y output from the indoor thermostat must be connected to the yellow wire labeled Y/ Y2 inside the wire bundle marked Thermostat and the yellow wire labeled Y/Y2 inside the wire bundle marked Outdoor Unit must be connected to Y at the condenser. The orange jumper wire from terminal Y1 to terminal O on the VSTB inside the MBE/AEPF must remain connected. 1.0 Cooling Operation 1.1 On a demand for cooling, the room thermostat energizes G and Y and 24Vac is supplied to G and Y/Y2 of the MBE/AEPF unit. The VSTB inside the MBE/AEPF will turn on the blower motor and the motor will ramp up to the speed programmed in the motor based on the settings for dip switch 5 and 6. The VSTB will supply 24Vac to Y at the condenser and the compressor and condenser are turned on. 1.2 When the cooling demand is satisfied, the room thermostat removes the 24Vac from G and Y. The MBE/ AEPF removes the 24Vac from Y at the condenser and the compressor and condenser fan are turned off. The blower motor will ramp down to a complete stop based on the time and rate programmed in the motor. 2.0 Heating Operation 2.1 On a demand for heat, the room thermostat energizes W1 and 24Vac is supplied to terminal E/W1 of the VSTB inside the MBE/AEPF unit. The VSTB will turn on the blower motor and the motor will ramp up to the speed programmed in the motor based on the settings for dip switch 1 and 2. The VSTB will supply 24Vac to heat sequencer HR1 on the electric heater assembly. 2.2 HR1 contacts M1 and M2 will close within 10 to 20 seconds and turn on heater element #1. At the same time, if the heater assembly contains a second heater element, HR1 will contain a second set of contacts, M3 and M4, which will close and turn on heater element #2. Note: If more than two heater elements are on the heater assembly, it will contain a second heat sequencer, HR2, which will control the 3rd and 4th heater elements if available. For the 3rd and 4th heater elements to operate on a second stage heat demand, the PJ4 jumper on the VSTB inside the MBE/AEPF must be cut. With the PJ4 jumper cut, the VSTB will run the blower motor on low speed on a W1 only demand. If the first stage heat demand, W1 cannot be satisfied by the heat pump, the temperature indoors will continue to drop. The room thermostat will then energize W2 and 24Vac will be supplied to HR2 on the heater assembly and the blower motor will change to high speed. When the W2 demand is satisfied, the room

S-41 MBE/AEPF WITH SSX AND ASX

MBE ELECTRONIC BLOWER TIME DELAY RELAY AEPF AIR HANDLER

SEQUENCE OF OPERATION
This document covers the basic sequence of operation for a typical application with a mercury bulb thermostat. When a digital/electronic thermostat is used, the on/off staging of the auxiliary heat will vary. Refer to the installation instructions and wiring diagrams provided with the MBE/AEPF for specific wiring connections, dip switch settings and system configuration.

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thermostat will remove the 24Vac from W2 and the VSTB will remove the 24Vac from HR2. The contacts on HR2 will open between 30 to 70 seconds and heater elements #3 and #4 will be turned off and the blower motor will change to low speed. On most digital/electronic thermostats, W2 will remain energized until the first stage demand W1 is satisfied and then the W1 and W2 demands will be removed. 2.3 When the W1 heat demand is satisfied, the room thermostat will remove the 24Vac from E/W1 and the VSTB removes the 24Vac from HR1. The contacts on HR1 will open between 30 to 70 seconds and turn off the heater element(s) and the blower motor ramps down to a complete stop. MBE/AEPF WITH SINGLE STAGE SSZ & ASZ HEAT PUMPS When used with a single stage SSZ or ASZ heat pumps, dip switch #4 must be set to the ON position on the VSTB inside the MBE. The Y output from the indoor thermostat must be connected to the yellow wire labeled Y/Y2 inside the wire bundle marked Thermostat and the yellow wire labeled Y/ Y2 inside the wire bundle marked Outdoor Unit must be connected to Y at the heat pump. The orange jumper wire from terminal Y1 to terminal O on the VSTB inside the MBE/AEPF must be removed. 3.0 COOLING OPERATION On heat pump units, when the room thermostat is set to the cooling mode, 24Vac is supplied to terminal O of the VSTB inside the MBE/AEPF unit. The VSTB will supply 24Vac to O at the heat pump to energize the reversing valve. As long as the thermostat is set for cooling, the reversing valve will be in the energized position for cooling. 3.1 On a demand for cooling, the room thermostat energizes G and Y and 24Vac is supplied to terminals G and Y/Y2 of the MBE/AEPF unit. The VSTB will turn on the blower motor and the motor will ramp up to the speed programmed in the motor based on the settings of dip switch 5 and 6. The VSTB will supply 24Vac to Y at the heat pump. 3.2 The heat pump is turned on in the cooling mode. 3.3 When the cooling demand is satisfied, the room thermostat removes the 24Vac from G and Y/Y2 of the MBE/ AEPF and the VSTB removes the 24Vac from Y at the heat pump. The heat pump is turned off and the blower motor will ramp down to a complete stop based on the time and rate programmed in the motor. 4.0 HEATING OPERATION On heat pump units, when the room thermostat is set to the heating mode, the reversing valve is not energized. As long as the thermostat is set for heating, the reversing valve will be in the de-energized position for heating except during a defrost cycle. Some installations may use one or more outdoor thermostats to restrict the amount of electric heat that is available above a preset ambient temperature. Use of optional controls such as these can change the operation of the electric heaters during the heating mode. This sequence of operation does not cover those applications. 4.1 On a demand for first stage heat with heat pump units, the room thermostat energizes Y and G and 24Vac is supplied to G and Y/Y2 of the MBE/AEPF. The VSTB will turn on the blower motor and the motor will ramp up to the speed programmed in the motor based on the settings of dip switch 1 and 2. The VSTB will supply 24Vac to Y at the heat pump and the heat pump is turned on in the heating mode. 4.2 If the first stage heat demand cannot be satisfied by the heat pump, the temperature indoors will continue to drop. The room thermostat will then energize terminal W2 for second stage heat and 24Vac will be supplied to E/W1 of the MBE/AEPF. The VSTB will supply 24Vac to heat sequencer, HR1, on the electric heater assembly. 4.3 HR1 contacts M1 and M2 will close within 10 to 20 seconds and turn on heater element #1. At the same time, if the heater assembly contains a second heater element, HR1 will contain a second set of contacts, M3 and M4, which will close to turn on heater element #2. Note: If more than two heater elements are on the heater assembly, it will contain a second heat sequencer, HR2, which will control the 3rd and 4th heater elements if available. For the 3rd and 4th heater elements to operate on a third stage heat demand, the PJ4 jumper on the VSTB inside the MBE/AEPF must be cut. If the second stage heat demand, W2, cannot be satisfied by the heat pump, the temperature indoors will continue to drop. The room thermostat will then energize W3 and 24Vac will be supplied to W/W2 of the MBE/AEPF. The VSTB will supply 24Vac to HR2 on the electric heater assembly. When the W3 demand is satisfied, the room thermostat will remove the 24Vac from W/W2 of the MBE/AEPF. The contacts on HR2 will open between 30 to 70 seconds and heater elements #3 and #4 will be turned off. On most digital/ electronic thermostats, W3 will remain energized until the first stage demand Y is satisfied and then the G, Y, W2 and W3 demands will be removed. 4.4 As the temperature indoors increase, it will reach a point where the second stage heat demand, W2, is satisfied. When this happens, the room thermostat will remove the 24Vac from E/W1 of the MBE/AEPF. The contacts on HR1 will open between 30 to 70 seconds and turn off both heater element(s). The heat pump remains on along with the blower motor because the Y demand for first stage heat will still be present. 4.5 When the first stage heat demand Y is satisfied, the room thermostat will remove the 24Vac from G and Y/ Y2 of the MBE/AEPF. The VSTB removes the 24Vac from Y at the heat pump and the heat pump is turned off. The blower motor will ramp down to a complete stop based on the time and rate programmed in the motor control.

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5.0 DEFROST OPERATION

MBE/AEPF WITH TWO STAGE ASX CONDENSERS

1.0 COOLING OPERATION

On heat pump units, when the room thermostat is set to the heating mode, the reversing valve is not energized. As long as the thermostat is set for heating, the reversing valve will be in the de-energized position for heating except during a defrost cycle. 5.1 The heat pump will be on and operating in the heating mode as described the Heating Operation in section 4. 5.2 The defrost control in the heat pump unit checks to see if a defrost is needed every 30, 60 or 90 minutes of heat pump operation depending on the selectable setting by monitoring the state of the defrost thermostat attached to the outdoor coil. 5.3 If the temperature of the outdoor coil is low enough to cause the defrost thermostat to be closed when the defrost board checks it, the board will initiate a defrost cycle. 5.4 When a defrost cycle is initiated, the contacts of the HVDR relay on the defrost board open and turns off the outdoor fan. The contacts of the LVDR relay on the defrost board closes and supplies 24Vac to O and W2. The reversing valve is energized and the contacts on HR1 close and turns on the electric heater(s). The unit will continue to run in this mode until the defrost cycle is completed. 5.5 When the temperature of the outdoor coil rises high enough to causes the defrost thermostat to open, the defrost cycle will be terminated. If at the end of the programmed 10 minute override time the defrost thermostat is still closed, the defrost board will automatically terminate the defrost cycle. 5.6 When the defrost cycle is terminated, the contacts of the HVDR relay on the defrost board will close to start the outdoor fan and the contacts of the LVDR relay will open and turn off the reversing valve and electric heater(s). The unit will now be back in a normal heating mode with a heat pump demand for heating as described in the Heating Operation in section 4. SEQUENCE OF OPERATION This document covers the basic sequence of operation for a typical application with a mercury bulb thermostat. When a digital/electronic thermostat is used, the on/off staging of the outdoor unit and auxiliary heat will vary. Refer to the installation instructions and wiring diagrams provided with the MBE for specific wiring connections, dip switch settings and system configuration.

When used with the ASX two stage condensers, dip switch #4 must be set to the OFF position on the VSTB inside the MBE/AEPF. The Y1 output from the indoor thermostat must be connected to the purple wire labeled Ylow/Y1 inside the wire bundle marked Thermostat and the purple wire labeled Ylow/Y1 inside the wire bundle marked Outdoor Unit must be connected to Ylow/Y1 at the condenser. The Y2 output from the indoor thermostat must be connected to the yellow wire labeled Y/Y2 inside the wire bundle marked Thermostat and the yellow wire labeled Y/Y2 inside the wire bundle marked Outdoor Unit must be connected to Y/Y2 at the condenser. The orange jumper wire from terminal Y1 to terminal O on the VSTB inside the MBE/AEPF must remain connected. 1.1 On a demand for cooling, the room thermostat energizes G and Y1 and 24Vac is supplied to G and Ylow/Y1 of the MBE/AEPF unit. The VSTB inside the MBE/ AEPF will turn on the blower motor and the motor will ramp up to 60% of the speed programmed in the motor based on the settings for dip switch 5 and 6. The VSTB will supply 24Vac to Ylow/Y1 at the condenser and the compressor and condenser fan starts in low speed operation. 1.2 If first stage cooling cannot satisfy the demand, the room thermostat will energize Y2 and supply 24Vac to the MBE/AEPF unit. The blower motor will change to the cfm for high speed operation and the VSTB will supply 24Vac to Y/Y2 at the condenser and the compressor and condenser fan will change to high speed operation. When the Y2 demand is satisfied, the thermostat will remove the Y2 demand and the VSTB will remove the 24Vac from Y/Y2 at the condenser. The blower will drop to 60% of the programmed cfm and the compressor and condenser fan will change to low speed. On most digital/electronic thermostats, Y2 will remain energized until the first stage cooling demand Y1 is satisfied and then the G, Y1 and Y2 demands will be removed. 1.3 When the first stage cooling demand, Y1, is satisfied, the room thermostat removes the 24Vac from G and Y1. The MBE/AEPF removes the 24Vac from Ylow/ Y1 at the condenser and the compressor and condenser fan are turned off. The blower motor will ramp down to a complete stop based on the time and rate programmed in the motor. 2.0 Heating Operation 2.1 On a demand for heat, the room thermostat energizes W1 and 24Vac is supplied to terminal E/W1 of the VSTB inside the MBE/AEPF unit. The VSTB will turn on the blower motor and the motor will ramp up to the speed programmed in the motor based on the settings for dip switch 1 and 2. The VSTB will supply 24Vac to heat sequencer HR1 on the electric heater assembly.

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2.2 HR1 contacts M1 and M2 will close within 10 to 20 seconds and turn on heater element #1. At the same time, if the heater assembly contains a second heater element, HR1 will contain a second set of contacts, M3 and M4, which will close and turn on heater element #2. Note: If more than two heater elements are on the heater assembly, it will contain a second heat sequencer, HR2, which will control the 3rd and 4th heater elements if available. For the 3rd and 4th heater elements to operate on a second stage heat demand, the PJ4 jumper on the VSTB inside the MBE/AEPF must be cut. With the PJ4 jumper cut, the VSTB will run the blower motor on low speed on a W1 only demand. If the first stage heat demand, W1 cannot be satisfied by the heat pump, the temperature indoors will continue to drop. The room thermostat will then energize W2 and 24Vac will be supplied to HR2 on the heater assembly and the blower motor will change to high speed. When the W2 demand is satisfied, the room thermostat will remove the 24Vac from W2 and the VSTB will remove the 24Vac from HR2. The contacts on HR2 will open between 30 to 70 seconds and heater elements #3 and #4 will be turned off and the blower motor will change to low speed. On most digital/electronic thermostats, W2 will remain energized until the first stage demand W1 is satisfied and then the W1 and W2 demands will be removed. 2.3 When the W1 heat demand is satisfied, the room thermostat will remove the 24Vac from E/W1 and the VSTB removes the 24Vac from HR1. The contacts on HR1 will open between 30 to 70 seconds and turn off the heater element(s) and the blower motor ramps down to a complete stop.
MBE/AEPF WITH TWO STAGE ASZ HEAT PUMP UNITS

3.1 On a demand for cooling, the room thermostat energizes G and Y1 and 24Vac is supplied to G and Ylow/Y1 of the MBE unit. The VSTB inside the MBE will turn on the blower motor and the motor will ramp up to 60% of the speed programmed in the motor based on the settings for dip switch 5 and 6. The VSTB will supply 24Vac to Y at the heat pump and the compressor and outdoor fan starts in low speed operation. 3.2 If first stage cooling cannot satisfy the demand, the room thermostat will energize Y2 and supply 24Vac to Y/ Y2of the MBE unit. The blower motor will change to the cfm for high speed operation and the VSTB will supply 24Vac to Y2 at the heat pump. The compressor and outdoor fan will change to high speed operation. When the Y2 demand is satisfied, the thermostat will remove the Y2 demand and the VSTB will remove the 24Vac from Y2 at the heat pump. The blower will drop to 60% of the programmed cfm and the compressor and outdoor fan will change to low speed operation. On most digital/ electronic thermostats, Y2 will remain energized until the first stage cooling demand Y1 is satisfied and then the G, Y1 and Y2 demands will be removed. 3.3 When the first stage cooling demand, Y1, is satisfied, the room thermostat removes the 24Vac from G and Y1. The VSTB removes the 24Vac from Y at the heat pump and the compressor and outdoor fan are turned off. The blower motor will ramp down to a complete stop based on the time and rate programmed in the motor. 4.0 Heating Operation On heat pump units, when the room thermostat is set to the heating mode, the reversing valve is not energized. As long as the thermostat is set for heating, the reversing valve will be in the de-energized position for heating except during a defrost cycle. Some installations may use one or more outdoor thermostats to restrict the amount of electric heat that is available above a preset ambient temperature. Use of optional controls such as these can change the operation of the electric heaters during the heating mode. This sequence of operation does not cover those applications. 4.1 On a demand for first stage heat with heat pump units, the room thermostat energizes G and Y1 and 24Vac is supplied to G and Ylo/Y1 of the MBE/AEPF. The VSTB will turn on the blower motor and the motor will ramp up to 60% of the speed programmed in the motor based on the settings of dip switch 1 and 2. The VSTB will supply 24Vac to Y at the heat pump. The compressor will start on high speed and outdoor fan will start on low speed on a Y1 heating demand but the blower motor will deliver only 60% of the programmed cfm for high speed heating operation.

3.0 Cooling Operation When used with the ASZ two stage heat pump, dip switch #4 must be set to the OFF position on the VSTB inside the MBE/AEPF. The Y1 output from the indoor thermostat must be connected to the purple wire labeled Ylow/Y1 inside the wire bundle marked Thermostat and the purple wire labeled Ylow/Y1 inside the wire bundle marked Outdoor Unit must be connected to Y at the heat pump. The Y2 output from the indoor thermostat must be connected to the yellow wire labeled Y/Y2 inside the wire bundle marked Thermostat and the yellow wire labeled Y/Y2 inside the wire bundle marked Outdoor Unit must be connected to Y/Y2 at the heat pump. The orange jumper wire from terminal Y1 to terminal O on the VSTB inside the MBE/AEPF must be removed. On heat pump units, when the room thermostat is set to the cooling mode, 24Vac is supplied to terminal O of the VSTB inside the MBE unit. The VSTB will supply 24Vac to O at the heat pump to energize the reversing valve. As long as the thermostat is set for cooling, the reversing valve will be in the energized position for cooling.

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4.2 If a thermostat that provides a Y2 demand in heating is used and first stage heating cannot satisfy the demand, the room thermostat will energize Y2 and supply 24Vac to Y/Y2 of the MBE unit. The blower motor will change to the cfm for high speed heating operation and the VSTB will supply 24Vac to Y/Y2 at the heat pump. The outdoor fan will change to high speed operation. If the Y2 demand is present and becomes satisfied, the thermostat will remove the Y2 demand and the VSTB will remove the 24Vac from Y/Y2 at the heat pump. The blower will drop to 60% of the programmed cfm and the outdoor fan will change to low speed. On most digital/ electronic thermostats, Y2 will remain energized until the first stage heating demand Y1 is satisfied and then the G, Y1 and Y2 demands will be removed. 4.3 If the heat pump operation cannot satisfy the demand, the room thermostat energizes W2/W3 and 24Vac is supplied to terminal E/W1 of the VSTB inside the MBE/ AEPF unit. The VSTB will supply 24Vac to heat sequencer HR1 on the electric heater assembly. 4.4 HR1 contacts M1 and M2 will close within 10 to 20 seconds and turn on heater element #1. At the same time, if the heater assembly contains a second heater element, HR1 will contain a second set of contacts, M3 and M4, which will close and turn on heater element #2. Note: If more than two heater elements are on the heater assembly, it will contain a second heat sequencer, HR2, which will control the 3rd and 4th heater elements if available. For the 3rd and 4th heater elements to operate on a second stage auxiliary heat demand, the PJ4 jumper on the VSTB inside the MBE/AEPF must be cut. If the W2/ W3 demand cannot be satisfied by the heat pump, the temperature indoors will continue to drop. The room thermostat will then energize W3/W4 and 24Vac will be supplied to W/W2 of the MBE. The VSTB will supply 24Vac to HR2 on the electric heater assembly. When the W3/W4 demand is satisfied, the room thermostat will remove the 24Vac from W/ W2 of the MBE/AEPF. The contacts on HR2 will open between 30 to 70 seconds and heater elements #3 and #4 will be turned off. On most digital/electronic thermostats, W3/W4 will remain energized until the first stage demand Y1 is satisfied and then the G, Y1, Y2 W2/W3 and W3/W4 demands will be removed. 4.5 As the temperature indoors increase, it will reach a point where the W2/W3 demand is satisfied. When this happens, the room thermostat will remove the 24Vac from E/W1 of the MBE/AEPF. The contacts on HR1 will open between 30 to 70 seconds and turn off the 1st and 2nd heater elements. If the Y2 demand is present and becomes satisfied the room thermostat will remove the 24Vac from Y/Y2 of the MBE and the blower motor will change to 60% of the programmed cfm. The VSTB will remove the 24Vac from Y/Y2 at the heat pump and the outdoor fan will change to low speed operation. The heat pump remains on along with the blower motor because the Y1 demand for first stage heat will still be present. 4.6 When the first stage heat demand Y1 is satisfied, the room thermostat will remove the 24Vac from G and Ylo/Y1 of the MBE/AEPF. The VSTB removes the 24Vac from Ylo/Y1 at the heat pump and the compressor and outdoor fan are turned off. The blower motor will ramp down to a complete stop based on the time and rate programmed in the motor control. 5.0 Defrost Operation On heat pump units, when the room thermostat is set to the heating mode, the reversing valve is not energized. As long as the thermostat is set for heating, the reversing valve will be in the de-energized position for heating except during a defrost cycle. 5.1 The heat pump will be on and operating in the heating mode as described the Heating Operation in section 4. 5.2 The defrost control in the heat pump unit checks to see if a defrost is needed every 30, 60 or 90 minutes of heat pump operation depending on the selectable setting by monitoring the state of the defrost thermostat attached to the outdoor coil. 5.3 If the temperature of the outdoor coil is low enough to cause the defrost thermostat to be closed when the defrost board checks it, the board will initiate a defrost cycle. 5.4 When a defrost cycle is initiated, the contacts of the HVDR relay on the defrost board open and turns off the outdoor fan. The contacts of the LVDR relay on the defrost board closes and supplies 24Vac to O and W2. The reversing valve is energized and the contacts on HR1 close and turns on the electric heater(s). The unit will continue to run in this mode until the defrost cycle is completed. 5.5 When the temperature of the outdoor coil rises high enough to causes the defrost thermostat to open, the defrost cycle will be terminated. If at the end of the programmed 10 minute override time the defrost thermostat is still closed, the defrost board will automatically terminate the defrost cycle. 5.6 When the defrost cycle is terminated, the contacts of the HVDR relay on the defrost board will close to start the outdoor fan and the contacts of the LVDR relay will open and turn off the reversing valve and electric heater(s). The unit will now be back in a normal heating mode with a heat pump demand for heating as described in the Heating Operation in section 4.

S-60 ELECTRIC HEATER (OPTIONAL ITEM)

Optional electric heaters may be added, in the quantities shown in the specifications section, to provide electric resistance heating. Under no condition shall more heaters than the quantity shown be installed. The low voltage circuit in the air handler is factory wired and terminates at the location provided for the electric heater(s). A minimum of field wiring is required to complete the installation.

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Other components such as a Heating/Cooling Thermostat and Outdoor Thermostats are available to complete the installation. The system CFM can be determined by measuring the static pressure external to the unit. The installation manual supplied with the blower coil, or the blower performance table in the service manual, shows the CFM for the static measured. Alternately, the system CFM can be determined by operating the electric heaters and indoor blower WITHOUT having the compressor in operation. Measure the temperature rise as close to the blower inlet and outlet as possible. If other than a 240V power supply is used, refer to the BTUH CAPACITY CORRECTION FACTOR chart below.
BTUH CAPACITY CORRECTION FACTOR SUPPLY VOLTAGE MULTIPLICATION FACTOR 250 1.08 230 .92 220 .84 208 .75
ELECTRIC HEATER CAPACITY BTUH
HTR KW 3.0 KW 4.7 KW 6.0 KW 7.0 KW 9.5 KW 14.2 KW 19.5 KW 21.0 KW

BTUH 10200 16200 20400 23800 32400 48600 66500 71600

FORMULAS: Heating Output = KW x 3413 x Corr. Factor Actual CFM = CFM (from table) x Corr. Factor BTUH = KW x 3413 BTUH = CFM x 1.08 x Temperature Rise (T) CFM = KW x 3413 1.08 x T T = BTUH CFM x 1.08

EXAMPLE: Five (5) heaters provide 24.0 KW at the rated 240V. Our actual measured voltage is 220V, and our measured temperature rise is 42F. Find the actual CFM: Answer: 24.0KW, 42F Rise, 240 V = 1800 CFM from the TEMPERATURE RISE chart on the right. Heating output at 220 V = 24.0KW x 3.413 x .84 = 68.8 MBH. Actual CFM = 1800 x .84 Corr. Factor = 1400 CFM. NOTE: The temperature rise table is for sea level installations. The temperature rise at a particular KW and CFM will be greater at high altitudes, while the external static pressure at a particular CFM will be less.
TEMPERATURE RISE (F) @ 240V CFM 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 4.8 KW 25 22 19 17 15 14 13 12 11 10 9 9 8 8 8 7 7 7 7.2 KW 38 33 29 26 23 21 19 18 16 15 14 14 13 12 12 11 11 10 9.6 KW 51 43 38 34 30 27 25 23 22 20 19 18 17 16 15 14 14 13 14.4 KW 57 51 46 41 38 35 32 30 28 27 25 24 23 22 21 20 19.2 KW 55 50 46 43 40 38 36 34 32 30 29 27 26 24.0 KW 54 50 47 44 42 40 38 36 34 33 28.8 KW 65 60 57 53 50 48 45 43 41 39

S-61A CHECKING HEATER LIMIT CONTROL(S)

Each individual heater element is protected with a limit control device connected in series with each element to prevent overheating of components in case of low airflow. This limit control will open its circuit at approximately 150F.

HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

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. IF FOUND OPEN - REPLACE - DO NOT WIRE AROUND.

S-61B CHECKING HEATER FUSE LINK (OPTIONAL ELECTRIC HEATERS)

Each individual heater element is protected with a one time fuse link which is connected in series with the element. The fuse link will open at approximately 333.

WARNING
Disconnect ALL power before servicing.
1. Remove heater element assembly so as to expose fuse link.

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2. Using an ohmmeter, test across the fuse link for continuity - no reading indicates the link is open. Replace as necessary. NOTE: The link is designed to open at approximately 333F. DO NOT WIRE AROUND - determine reason for failure. BRAZING MATERIALS Copper to Copper Joints - Sil-Fos used without flux (alloy of 15% silver, 80% copper, and 5% phosphorous). Recommended heat 1400F. Copper to Steel Joints - Silver Solder used without a flux (alloy of 30% silver, 38% copper, 32% zinc). Recommended heat - 1200F.

S-62 CHECKING HEATER ELEMENTS

WARNING
Disconnect ALL power before servicing.
1. Disassemble and remove the heating element. 2. Visually inspect the heater assembly for any breaks in the wire or broken insulators. 3. Using an ohmmeter, test the element for continuity - no reading indicates the element is open. Replace as necessary.

S-101 LEAK TESTING (NITROGEN OR NITROGEN-TRACED)

WARNING
To avoid the risk of fire or explosion, never use oxygen, high pressure air or flammable gases for leak testing of a refrigeration system.

S-100 REFRIGERATION REPAIR PRACTICE

WARNING
To avoid possible explosion, the line from the nitrogen cylinder must include a pressure regulator and a pressure relief valve. The pressure relief valve must be set to open at no more than 150 psig.
Pressure test the system using dry nitrogen and soapy water to locate leaks. If you wish to use a leak detector, charge the system to 10 psi using the appropriate refrigerant then use nitrogen to finish charging the system to working pressure, then apply the detector to suspect areas. If leaks are found, repair them. After repair, repeat the pressure test. If no leaks exist, proceed to system evacuation.

DANGER
Always remove the refrigerant charge in a proper manner before applying heat to the system.
When repairing the refrigeration system:

HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

S-102 EVACUATION

1. Never open a system that is under vacuum. Air and moisture 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 not flow well on oxidized or oily surfaces. 4. Clean the inside of all new tubing to remove oils and pipe chips. 5. When brazing, sweep the tubing with dry nitrogen to prevent the formation of oxides on the inside surfaces. 6. Complete any repair by replacing the liquid line drier in the system, evacuate and charge.

WARNING
REFRIGERANT UNDER PRESSURE! Failure to follow proper procedures may cause property damage, personal injury or death.
This is the most important part of the entire service procedure. The life and efficiency of the equipment is dependent upon the thoroughness exercised by the serviceman when evacuating air (non-condensables) and moisture from the system. Air in a system causes high condensing temperature and pressure, resulting in increased power input and reduced performance. Moisture chemically reacts with the refrigerant oil to form corrosive acids. These acids attack motor windings and parts, causing breakdown.

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The equipment required to thoroughly evacuate the system is a high vacuum pump, capable of producing a vacuum equivalent to 25 microns absolute and a thermocouple vacuum gauge to give a true reading of the vacuum in the system NOTE: Never use the system compressor as a vacuum pump or run when under a high vacuum. Motor damage could occur. 4. Evacuate the system to at least 29 inches gauge before opening valve to thermocouple vacuum gauge. 5. Continue to evacuate to a maximum of 250 microns. Close valve to vacuum pump and watch rate of rise. If vacuum does not rise above 1500 microns in three to five minutes, system can be considered properly evacuated. 6. If thermocouple vacuum gauge continues to rise and levels off at about 5000 microns, moisture and noncondensables are still present. If gauge continues to rise a leak is present. Repair and re-evacuate. 7. Close valve to thermocouple vacuum gauge and vacuum pump. Shut off pump and prepare to charge.

WARNING
Do not front seat the service valve(s) with the compressor open, with the suction line of the comprssor closed or severely restricted.
1. Connect the vacuum pump, vacuum tight manifold set with high vacuum hoses, thermocouple vacuum gauge and charging cylinder as shown. 2. Start the vacuum pump and open the shut off valve to the high vacuum gauge manifold only. After the compound gauge (low side) has dropped to approximately 29 inches of vacuum, open the valve to the vacuum thermocouple gauge. See that the vacuum pump will blank-off to a maximum of 25 microns. A high vacuum pump can only produce a good vacuum if its oil is non-contaminated.

S-103 CHARGING

WARNING
REFRIGERANT UNDER PRESSURE! * Do not overcharge system with refrigerant. * Do not operate unit in a vacuum or at negative pressure. Failure to follow proper procedures may cause property damage, personal injury or death.

R-22 MANIFOLD
LOW SIDE GAUGE AND VALVE HIGH SIDE GAUGE AND VALVE

CAUTION
Use refrigerant certified to ARI standards. Used refrigerant may cause compressor damage and will void the warranty. Most portable machines cannot clean used refrigerant to meet ARI standards.

800 PSI RATED HOSES CHARGING CYLINDER AND SCALE

CAUTION
Operating the compressor with the suction valve closed will void the warranty and cause serious compressor damage.
Charge the system with the exact amount of refrigerant.
VACUUM PUMP ADAPTER

TO UNIT SERVICE VALVE PORTS

Refer to the specification section or check the unit nameplates for the correct refrigerant charge. An inaccurately charged system will cause future problems.

VACUUM PUMP

1. When using an ambient compensated calibrated charging cylinder, 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.

EVACUATION 3. If the vacuum pump is working properly, close the valve to the vacuum thermocouple gauge and open the high and low side valves to the high vacuum manifold set. With the valve on the charging cylinder closed, open the manifold valve to the cylinder.

3. Start the system and charge the balance of the refrigerant through the low side.

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NOTE: R410A should be drawn out of the storage container or drum in liquid form due to its fractionation properties, but should be "Flashed" to its gas state before entering the system. There are commercially available restriction devices that fit into the system charging hose set to accomplish this. DO NOT charge liquid R410A into the compressor. 4. With the system still running, close the valve on the charging cylinder. At this time, you may still have some liquid refrigerant in the charging cylinder hose and will definitely have liquid in the liquid hose. Reseat the liquid line core. Slowly open the high side manifold valve and transfer the liquid refrigerant from the liquid line hose and charging cylinder hose into the suction service valve port. CAREFUL: Watch so that liquid refrigerant does not enter the compressor. Final Charge Adjustment The outdoor temperature must be 60F or higher. Set the room thermostat to COOL, fan switch to AUTO, and set the temperature control well below room temperature. After system has stabilized per startup instructions, compare the operating pressures and outdoor unit amp draw to the numbers listed on the performance label on the outdoor unit. If pressures and amp draw are too low, add charge. If pressures and amp draw are too high, remove charge. Check subcooling and superheat as detailed in the following section. 5. With the system still running, remove hose and reinstall both valve caps. 6. Check system for leaks. Do not charge a remote condensing unit with a non-matching evaporator coil, or a system where the charge quantity is unknown. Do not install or charge R410A condensers matched with coils having capillary tubes or flow control restrictors. ARI rated Coil combinations with thermostatic expansion valves (TEV's) should be charged by subcooling. See "Checking Subcooling and Superheat" sections in this manual. Subcooling values for "Ultron" system are found in the Technical Information manuals for "Ultron" outdoor units. Due to their design, Scroll compressors are inherently more tolerant of liquid refrigerant. NOTE: Even though the compressor section of a Scroll compressor is more tolerant of liquid refrigerant, continued floodback or flooded start conditions may wash oil from the bearing surfaces causing premature bearing failure. If the test shows: a. Below normal high side pressure. b. Above normal low side pressure. c. Low temperature difference across coil. d. Low amp draw at compressor. And the charge is correct. The compressor is faulty - replace the compressor.

S-105A PISTON CHART FOR SSX14 & ASX14 UNITS

Remote Condenser SSX140181 SSX140241 SSX140301 SSX140361 SSX140421 SSX140481 SSX140601 ASX140181A ASX140241A ASX140301A ASX140361A ASX140421A ASX140481A ASX140601A

Orifice Size 0.049 0.057 0.063 0.067 0.074 0.079 0.088 0.049 0.057 0.063 0.067 0.074 0.079 0.088

S-105B THERMOSTATIC EXPANSION VALVE

The expansion valve is designed to control the rate of liquid refrigerant flow into an evaporator coil in exact proportion to the rate of evaporation of the refrigerant in the coil. The amount of refrigerant entering the coil is regulated since the valve responds to temperature of the refrigerant gas leaving the coil (feeler bulb contact) and the pressure of the refrigerant in the coil. This regulation of the flow prevents the return of liquid refrigerant to the compressor. The illustration below shows typical heatpump TXV/check valve operation in the heating and cooling modes.

S-104 CHECKING COMPRESSOR EFFICIENCY

The reason for compressor inefficiency is broken or damaged scroll flanks on Scroll compressors, reducing the ability of the compressor to pump refrigerant vapor. The condition of the scroll flanks is checked in the following manner. 1. Attach gauges to the high and low side of the system. 2. Start the system and run a "Cooling Performance Test.

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S-107 UNDERFEEDING
Underfeeding by the expansion valve results in low system capacity and low suction pressures. If these symptoms are observed:

COOLING

HEATING

TXV VALVES Some TXV valves contain an internal check valve thus eliminating the need for an external check valve and bypass loop. The three forces which govern the operation of the valve are: (1) the pressure created in the power assembly by the feeler bulb, (2) evaporator pressure, and (3) the equivalent pressure of the superheat spring in the valve. 0% bleed type expansion valves are used on indoor and outdoor coils. The 0% bleed valve will not allow the system pressures (High and Low side) to equalize during the shut down period. The valve will shut off completely at approximately 100 PSIG. 30% bleed valves used on some other models will continue to allow some equalization even though the valve has shut-off completely because of the bleed holes within the valve. This type of valve should not be used as a replacement for a 0% bleed valve, due to the resulting drop in performance. The bulb must be securely fastened with two straps to a clean straight section of the suction line. Application of the bulb to a horizontal run of line is preferred. If a vertical installation cannot be avoided, the bulb must be mounted so that the capillary tubing comes out at the top. THE VALVES PROVIDED BY GOODMAN ARE DESIGNED TO MEET THE SPECIFICATION REQUIREMENTS FOR OPTIMUM PRODUCT OPERATION. DO NOT USE SUBSTITUTES.

1. Check for a restricted liquid line or drier. A restriction will be indicated by a temperature drop across the drier. 2. Check the operation of the power element of the valve as described in S-110 Checking Expansion Valve Operation.

S-108 SUPERHEAT
The expansion valves are factory adjusted to maintain 8 to 12 degrees superheat of the suction gas. Before checking the superheat or replacing the valve, perform all the procedures outlined under Air Flow, Refrigerant Charge, Expansion Valve - Overfeeding, Underfeeding. These are the most common causes for evaporator malfunction. CHECKING SUPERHEAT Refrigerant gas is considered superheated when its temperature is higher than the saturation temperature corresponding to its pressure. The degree of superheat equals the degrees of temperature increase above the saturation temperature at existing pressure. See Temperature - Pressure Chart on following pages.

S-106 OVERFEEDING
Overfeeding by the expansion valve results in high suction pressure, cold suction line, and possible liquid slugging of the compressor. If these symptoms are observed: 1. Check for an overcharged unit by referring to the cooling performance charts in the servicing section. 2. Check the operation of the power element in the valve as explained in S-110 Checking Expansion Valve Operation. 3. Check for restricted or plugged equalizer tube.

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Pressure vs. Temperature Chart R-410A
PSIG 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 F -37.7 -34.7 -32.0 -29.4 -36.9 -24.5 -22.2 -20.0 -17.9 -15.8 -13.8 -11.9 -10.1 -8.3 -6.5 -4.5 -3.2 -1.6 0.0 1.5 3.0 4.5 5.9 7.3 8.6 10.0 11.3 12.6 13.8 15.1 16.3 17.5 18.7 19.8 21.0 22.1 23.2 24.3 25.4 26.4 27.4 28.5 29.5 30.5 31.2 32.2 33.2 34.1 35.1 35.5 36.9 PSIG 114.0 116.0 118.0 120.0 122.0 124.0 126.0 128.0 130.0 132.0 134.0 136.0 138.0 140.0 142.0 144.0 146.0 148.0 150.0 152.0 154.0 156.0 158.0 160.0 162.0 164.0 166.0 168.0 170.0 172.0 174.0 176.0 178.0 180.0 182.0 184.0 186.0 188.0 190.0 192.0 194.0 196.0 198.0 200.0 202.0 204.0 206.0 208.0 210.0 212.0 214.0 F 37.8 38.7 39.5 40.5 41.3 42.2 43.0 43.8 44.7 45.5 46.3 47.1 47.9 48.7 49.5 50.3 51.1 51.8 52.5 53.3 54.0 54.8 55.5 56.2 57.0 57.7 58.4 59.0 59.8 60.5 61.1 61.8 62.5 63.1 63.8 64.5 65.1 65.8 66.4 67.0 67.7 68.3 68.9 69.5 70.1 70.7 71.4 72.0 72.6 73.2 73.8 PSIG 216.0 218.0 220.0 222.0 224.0 226.0 228.0 230.0 232.0 234.0 236.0 238.0 240.0 242.0 244.0 246.0 248.0 250.0 252.0 254.0 256.0 258.0 260.0 262.0 264.0 266.0 268.0 270.0 272.0 274.0 276.0 278.0 280.0 282.0 284.0 286.0 288.0 290.0 292.0 294.0 296.0 298.0 300.0 302.0 304.0 306.0 308.0 310.0 312.0 314.0 316.0 F 74.3 74.9 75.5 76.1 76.7 77.2 77.8 78.4 78.9 79.5 80.0 80.6 81.1 81.6 82.2 82.7 83.3 83.8 84.3 84.8 85.4 85.9 86.4 86.9 87.4 87.9 88.4 88.9 89.4 89.9 90.4 90.9 91.4 91.9 92.4 92.8 93.3 93.8 94.3 94.8 95.2 95.7 96.2 96.6 97.1 97.5 98.0 98.4 98.9 99.3 99.7 PSIG 318.0 320.0 322.0 324.0 326.0 328.0 330.0 332.0 334.0 336.0 338.0 340.0 342.0 344.0 346.0 348.0 350.0 352.0 354.0 356.0 358.0 360.0 362.0 364.0 366.0 368.0 370.0 372.0 374.0 376.0 378.0 380.0 382.0 384.0 386.0 388.0 390.0 392.0 394.0 396.0 398.0 400.0 402.0 404.0 406.0 408.0 410.0 412.0 414.0 416.0 418.0 F 100.2 100.7 101.1 101.6 102.0 102.4 102.9 103.3 103.7 104.2 104.6 105.1 105.4 105.8 106.3 106.6 107.1 107.5 107.9 108.3 108.8 109.2 109.6 110.0 110.4 110.8 111.2 111.6 112.0 112.4 112.6 113.1 113.5 113.9 114.3 114.7 115.0 115.5 115.8 116.2 116.6 117.0 117.3 117.7 118.1 118.5 118.8 119.2 119.6 119.9 120.3 PSIG 420.0 422.0 424.0 426.0 428.0 430.0 432.0 434.0 436.0 438.0 440.0 442.0 444.0 446.0 448.0 450.0 452.0 454.0 456.0 458.0 460.0 462.0 464.0 466.0 468.0 470.0 472.0 474.0 476.0 478.0 480.0 482.0 484.0 486.0 488.0 490.0 492.0 494.0 496.0 498.0 500.0 502.0 504.0 506.0 508.0 510.0 512.0 514.0 516.0 518.0 520.0 F 120.7 121.0 121.4 121.7 122.1 122.5 122.8 123.2 123.5 123.9 124.2 124.6 124.9 125.3 125.6 126.0 126.3 126.6 127.0 127.3 127.7 128.0 128.3 128.7 129.0 129.3 129.7 130.0 130.3 130.7 131.0 131.3 131.6 132.0 132.3 132.6 132.9 133.3 133.6 133.9 134.0 134.5 134.8 135.2 135.5 135.8 136.1 136.4 136.7 137.0 137.3 PSIG 522.0 524.0 526.0 528.0 530.0 532.0 534.0 536.0 538.0 540.0 544.0 548.0 552.0 556.0 560.0 564.0 568.0 572.0 576.0 580.0 584.0 588.0 592.0 596.0 600.0 604.0 608.0 612.0 616.0 620.0 624.0 628.0 632.0 636.0 640.0 644.0 648.0 652.0 656.0 660.0 664.0 668.0 672.0 676.0 680.0 684.0 688.0 692.0 696.0 F 137.6 137.9 138.3 138.6 138.9 139.2 139.5 139.8 140.1 140.4 141.0 141.6 142.1 142.7 143.3 143.9 144.5 145.0 145.6 146.2 146.7 147.3 147.9 148.4 149.0 149.5 150.1 150.6 151.2 151.7 152.3 152.8 153.4 153.9 154.5 155.0 155.5 156.1 156.6 157.1 157.7 158.2 158.7 159.2 159.8 160.3 160.8 161.3 161.8

*Based on ALLIED SIGNAL Data

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SERVICING REQUIRED LIQUID LINE TEMPERATURE

LIQUID PRESSURE AT SERVICE VALVE (PSIG) 189 195 202 208 215 222 229 236 243 251 259 266 274 283 291 299 308 317 326 335 345 354 364 374 384 395 406 416 427 439 450 462 474 486 499 511 8 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 122 124 126 128 REQUIRED SUBCOOLING TEMPERATURE (F) 10 12 14 16 56 54 52 50 58 56 54 52 60 58 56 54 62 60 58 56 64 62 60 58 66 64 62 60 68 66 64 62 70 68 66 64 72 70 68 66 74 72 70 68 76 74 72 70 78 76 74 72 80 78 76 74 82 80 78 76 84 82 80 78 86 84 82 80 88 86 84 82 90 88 86 84 92 90 88 86 94 92 90 88 96 94 92 90 98 96 94 92 100 98 96 94 102 100 98 96 104 102 100 98 106 104 102 100 108 106 104 102 110 108 106 104 112 110 108 106 114 112 110 108 116 114 112 110 118 116 114 112 120 118 116 114 122 120 118 116 124 122 120 118 126 124 122 120 18 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118

CAUTION
To prevent personal injury, carefully connect and disconnect manifold gauge hoses. Escaping liquid refrigerant can cause burns. Do not vent refrigerant to atmosphere. Recover during system repair or final unit disposal.
1. Run system at least 10 minutes to allow pressure to stabilize.

2. Temporarily install thermometer on suction (large) line near suction line service valve with adequate contact and insulate for best possible reading. 3. Refer to the superheat table provided for proper system superheat. Add charge to lower superheat or recover charge to raise superheat.

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Superheat Formula = Suct. Line Temp. - Sat. Suct. Temp.

EXAMPLE: a. Suction Pressure = 143 b. Corresponding Temp. F. = 50 c. Thermometer on Suction Line = 61F. To obtain the degrees temperature of superheat, subtract 50.0 from 61.0F. The difference is 11 Superheat. The 11 Superheat would fall in the range of allowable superheat. SUPERHEAT AND SUBCOOLING ADJUSTMENT ON TXV APPLICATIONS 1. Run system at least 10 minutes to allow pressure to stabilize. 2. Temporarily install thermometer on liquid (small) line near liquid line service valve with adequate contact and insulate for best possible reading. 3. Check subcooling and superheat. Systems with TXV application should have a subcooling and superheat of 7 2F. a. b. If subcooling and superheat are low, adjust TXV to 7 - 9F then check subcooling. If subcooling is low and superheat is high, add charge to raise subcooling to 7 2F then check superheat. If subcooling and superheat are high, adjust TXV valve to 7 9F then check subcooling. If subcooling is high and superheat is low, adjust TXV valve to 7 to 9F superheat and remove charge to lower the subcooling to 7 2F.

4. Review the technical information manual or specification sheet for the model being serviced to obtain the design subcooling. 5. Compare the hi-pressure reading to the "Required Liquid Line Temperature" chart (page 43). Find the hi-pressure value on the left column. Follow that line right to the column under the design subcooling value. Where the two intersect is the required liquid line temperature. Alternately you can convert the liquid line pressure gauge reading to temperature by finding the gauge reading in Temperature - Pressure Chart and reading to the left, find the temperature in the F. Column. 6. The difference between the thermometer reading and pressure to temperature conversion is the amount of subcooling. Add charge to raise subcooling. Recover charge to lower subcooling. Subcooling Formula = Sat. Liquid Temp. - Liquid Line Temp. EXAMPLE: a. Liquid Line Pressure = 417 b. Corresponding Temp. F. = 120 c. Thermometer on Liquid line = 109F. To obtain the amount of subcooling subtract 109F from 120F. The difference is 11 subcooling. See the specification sheet or technical information manual for the design subcooling range for your unit.

c. d.

S-109A TWO SPEED APPLICATION

Run the remote on low stage cooling for 10 minutes until refrigerant pressures stabilize. Follow the guidelines and methods below to check unit operation and ensure that the refrigerant charge is within limits. Charge the unit on low stage. 1. Purge gauge lines. Connect service gauge manifold to base-valve service ports. Run system at least 10 minutes to allow pressure to stabilize. 2. Temporarily install thermometer on liquid (small) line near liquid line service valve with adequate contact and insulate for best possible reading. 3. Check subcooling and superheat. Systems with TXV application should have a subcooling of 5 to 7 F and superheat of 7 to 9 F. a. If subcooling and superheat are low, adjust TXV to 7 to 9 F superheat, then check subcooling. NOTE: To adjust superheat, turn the valve stem clockwise to increase and counter clockwise to decrease.

The TXV should NOT be adjusted at light load conditions 55 to 60F, under such conditions only the subcooling can be evaluated. This is because suction pressure is dependent on the indoor coil match, indoor airflow, and wet bulb temperature. NOTE: Do NOT adjust charge based on suction pressure unless there is a gross undercharge. 4. Disconnect manifold set. Installation is complete.

S-109 CHECKING SUBCOOLING

Refrigerant liquid is considered subcooled when its temperature is lower than the saturation temperature corresponding to its pressure. The degree of subcooling equals the degrees of temperature decrease below the saturation temperature at the existing pressure. 1. Attach an accurate thermometer or preferably a thermocouple type temperature tester to the liquid line as it leaves the condensing unit. 2. Install a high side pressure gauge on the high side (liquid) service valve at the front of the unit. 3. Record the gauge pressure and the temperature of the line.

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SERVICING
b. If subcooling is low and superheat is high, add charge to raise subcooling to 5 to 7 F then check superheat. If subcooling and superheat are high, adjust TXV valve to 7 to 9 F superheat, then check subcooling. If subcooling is high and superheat is low, adjust TXV valve to 7 to 9 F superheat and remove charge to lower the subcooling to 5 to 7 F. c. d. 4. If a temperature or pressure change is noticed, the expansion valve is operating. If no change is noticed, the valve is restricted, the power element is faulty, or the equalizer tube is plugged. 5. Capture the charge, replace the valve and drier, evacuate and recharge.

S-111 FIXED ORIFICE RESTRICTOR DEVICES

The fixed orifice restrictor device (flowrator) used in conjunction with the indoor coil is a predetermined bore (I.D.). It is designed to control the rate of liquid refrigerant flow into an evaporator coil. The amount of refrigerant that flows through the fixed orifice restrictor device is regulated by the pressure difference between 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 low side pressure to rise, but at a slower rate. Since the high side pressure rises faster when the temperature increases, more refrigerant flows to the evaporator, increasing the cooling capacity of the system. When the outdoor temperature falls, the reverse takes place. The condensing pressure falls, and the cooling loads on the indoor coil decreases, causing less refrigerant flow. A strainer is placed on the entering side of the tube to prevent any foreign material from becoming lodged inside the fixed orifice restriction device. If a restriction should become evident, proceed as follows: 1. Recover refrigerant charge. 2. Remove the orifice or tube strainer assembly and replace. 3. Replace liquid line drier, evacuate and recharge. CHECKING EQUALIZATION TIME During the "OFF" cycle, the high side pressure bleeds to the low side through the fixed orifice restriction device. Check equalization time as follows: 1. Attach a gauge manifold to the suction and liquid line dill valves. 2. 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 restrictor device is inoperative. Replace, install a liquid line drier, evacuate and recharge.

NOTE: Do NOT adjust the charge based on suction pressure unless there is a gross undercharge. 4. Disconnect manifold set, installation is complete.
Subcooling Formula = Sat. Liquid Temp. - Liquid Line Temp.

S-109B HEAT PUMP HEATING MODE

Hot Gas Method System charge can be checked in the heating mode by measuring the hot discharge gas at the compressor. 1. Allow the system to operate at least 20 minutes. 2. Attach and insulate an electronic thermometer probe to the vapor service valve (large line) at the base valve. 3. Operate the system for 10 minutes. 4. Using an accurate electronic thermometer, measure the temperature of the discharge gas at the probe and the outdoor ambient temperature. 5. The temperature measured on the vapor service valve line should be equal to the outdoor ambient temperature plus 110F ( 4). For example, if the outdoor ambient temperature is 45F, then the temperature measured by the thermometer probe at the vapor service valve line should be 155F for a system that is properly charged. If the temperature measured by the thermometer probe is higher than the outdoor ambient plus 110F, the system charge should be adjusted by adding refrigerant to lower the temperature. If the temperature measured is lower than the outdoor ambient plus 110F, the system charge should be adjusted by recovering charge to raise the temperature NOTE: When adjusting the charge in this manner, allow the system to operate for at least 10 minutes before taking the next temperature reading.

S-110 CHECKING EXPANSION VALVE OPERATION

1. Remove the remote bulb of the expansion valve from the suction line. 2. Start the system and cool the bulb in a container of ice water, closing the valve. As you cool the bulb, the suction pressure should fall and the suction temperature will rise. 3. Next warm the bulb in your hand. As you warm the bulb, the suction pressure should rise and the suction temperature will fall.

56

SERVICING
S-112 CHECKING RESTRICTED LIQUID LINE
When the system is operating, the liquid line is warm to the touch. If the liquid line is restricted, a definite temperature drop will be noticed at the point of restriction. In severe cases, frost will form at the restriction and extend down the line in the direction of the flow. Discharge and suction pressures will be low, giving the appearance of an undercharged unit. However, the unit will have normal to high subcooling. Locate the restriction, replace the restricted part, replace drier, evacuate and recharge.

S-115 COMPRESSOR BURNOUT

When a compressor burns out, high temperature develops causing the refrigerant, oil and motor insulation to decompose forming acids and sludge. If a compressor is suspected of being burned-out, attach a refrigerant hose to the liquid line dill valve and properly remove and dispose of the refrigerant.

NOTICE
Violation of EPA regulations may result in fines or other penalties.
Now determine if a burn out has actually occurred. Confirm by analyzing an oil sample using a Sporlan Acid Test Kit, AK3 or its equivalent. Remove the compressor and obtain an oil sample from the suction stub. If the oil is not acidic, either a burnout has not occurred or the burnout is so mild that a complete clean-up is not necessary. If acid level is unacceptable, the system must be cleaned by using the clean-up drier method.

S-113 OVERCHARGE OF REFRIGERANT

An overcharge of refrigerant is normally indicated by an excessively high head pressure. An evaporator coil, using an expansion valve metering device, will basically modulate and control a flooded evaporator and prevent liquid return to the compressor. An evaporator coil, using a capillary tube metering device, could allow refrigerant to return to the compressor under extreme overcharge conditions. Also with a capillary tube metering device, extreme cases of insufficient indoor air can cause icing of the indoor coil and liquid return to the compressor, but the head pressure would be lower. There are other causes for high head pressure which may be found in the "Service Problem Analysis Guide." If other causes check out normal, an overcharge or a system containing non-condensables would be indicated. If this system is observed: 1. Start the system. 2. Remove and capture 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 system contains non-condensables.

CAUTION
Do not allow the sludge or oil to contact the skin. Severe burns may result.
NOTE: The Flushing Method using R-11 refrigerant is no longer approved by Amana Heating-Cooling. Suction Line Drier Clean-Up Method The POE oils used with R410A refrigerant is an excellent solvent. In the case of a burnout, the POE oils will remove any burnout residue left in the system. If not captured by the refrigerant filter, they will collect in the compressor or other system components, causing a failure of the replacement compressor and/or spread contaminants throughout the system, damaging additional components. Use AMANA brand part number RF000127 suction line filter drier kit. This drier should be installed as close to the compressor suction fitting as possible. The filter must be accessible and be rechecked for a pressure drop after the system has operated for a time. It may be necessary to use new tubing and form as required. NOTE: At least twelve (12) inches of the suction line immediately out of the compressor stub must be discarded due to burned residue and contaminates. 1. Remove compressor discharge line strainer. 2. Remove the liquid line drier and expansion valve. 3 Purge all remaining components with dry nitrogen or carbon dioxide until clean.

S-114 NON-CONDENSABLES
If non-condensables are suspected, shut down the system and allow the pressures to equalize. Wait at least 15 minutes. Compare the pressure to the temperature of the coldest coil since this is where most of the refrigerant will be. If the pressure indicates a higher temperature than that of the coil temperature, non-condensables are present. Non-condensables are removed from the system by first removing the refrigerant charge, replacing and/or installing liquid line drier, evacuating and recharging.

4. Install new components including liquid line drier.

57

SERVICING
5. Braze all joints, leak test, evacuate, and recharge system. 6. Start up the unit and record the pressure drop across the drier. 7. Continue to run the system for a minimum of twelve (12) hours and recheck the pressure drop across the drier. Pressure drop should not exceed 6 PSIG. 8. Continue to run the system for several days, repeatedly checking pressure drop across the suction line drier. If the pressure drop never exceeds the 6 PSIG, the drier has trapped the contaminants. Remove the suction line drier from the system. 9. If the pressure drop becomes greater, then it must be replaced and steps 5 through 9 repeated until it does not exceed 6 PSIG. NOTICE: Regardless, the cause for burnout must be determined and corrected before the new compressor is started. 2. TXV Requirement: All line set applications over 50 ft will require a TXV. 3. Hard Start Assist- increased charge level in long line applications can require extra work from the compressor at start-up. A hard start assist device may be required to overcome this. 4. Liquid Line Solenoid - A long line set application can critically increase the charge level needed for a system. As a result, the system is very prone to refrigerant migration during its off-cycle and a liquid line solenoid will help minimize this. A liquid line solenoid is recommended for any long line application on straight cooling units. Tube Sizing: 1. In long line applications, the equivalent line length is the sum of the straight length portions of the suction line plus losses (in equivalent length) from 45 and 90 degree bends. Select the proper suction tube size based on equivalent length of the suction line (see Tables 4 & 5) and recalculated system capacity. Equivalent length = Length horizontal + Length vertical + Losses from bends (see Tables 4 & 5) 2. For any residential split system installed with a long line set, the liquid line size must never exceed 3/8". Limiting the liquid line size to 3/8" is critical since an increased refrigerant charge level from having a larger liquid line could possibly shorten a compressors lifespan. 3. Single Stage Condensing Unit: The maximum length of tubing must not exceed 150 feet. 50 feet is the maximum recommended vertical difference between the condenser and evaporator when the evaporator is above the condenser. Equivalent length is not to exceed 150 feet. The vertical difference between the condenser and evaporator when the evaporator is below the condenser can approach 150 feet, as long as the equivalent length does not exceed 150 feet. The distance between the condenser and evaporator in a completely horizontal installation in which the indoor and outdoor unit do not differ more than 10 feet in vertical distance from each other can approach 150 feet, as long as the equivalent length does not exceed 150 feet.

S-120 REFRIGERANT PIPING

The piping of a refrigeration system is very important in relation to system capacity, proper oil return to compressor, pumping rate of compressor and cooling performance of the evaporator. POE oils maintain a consistent viscosity over a large temperature range which aids in the oil return to the compressor; however, there will be some installations which require oil return traps. These installations should be avoided whenever possible, as adding oil traps to the refrigerant lines also increases the opportunity for debris and moisture to be introduced into the system. Avoid long running traps in horizontal suction line. LONG LINE SET APPLICATION R-410A This long line set application guideline applies to all ARI listed R-410A air conditioner and heat pump split system matches of nominal capacity 18,000 to 60,000 Btuh. This guideline will cover installation requirements and additional accessories needed for split system installations where the line set exceeds 50 feet in actual length. Additional Accessories: 1. Crankcase Heater- a long line set application can critically increase the charge level needed for a system. As a result, the system is very prone to refrigerant migration during its off-cycle and a crankcase heater will help minimize this risk. A crankcase heater is recommended for any long line application (50 watt minimum).

58

SERVICING
4. Two-Stage Condensing Unit: The maximum length of tubing must not exceed 75 feet where indoor coil is located above the outdoor unit. NOTE: When the outdoor unit is located above the indoor coil, the maximum vertical rise must not exceed 25 feet. If the maximum vertical rise exceeds 25 feet, premature compressor failure will occur due to inadequate oil return. 5. Vibration and Noise: In long line applications, refrigerant tubing is highly prone to transmit noise and vibration to the structure it is fastened to. Use adequate vibrationisolating hardware when mounting line set to adjacent structure. Most refrigerant tubing kits are supplied with 3/8"-thick insulation on the vapor line. For long line installations over 50 feet, especially if the line set passes through a high ambient temperature, -thick suction line insulation is recommended to reduce loss of capacity. The liquid line should be insulated if passing through an area of 120F or greater. Do not attach the liquid line to any non-insulated portion of the suction line. Table 4 lists multiplier values to recalculate system-cooling capacity as a function of a systems equivalent line length (as calculated from the suction line) and the selected suction tube size. Table 5 lists the equivalent length gained from adding bends to the suction line. Properly size the suction line to minimize capacity loss. TABLE 4. CAPACITY MULTIPLIERS AS A FUNCTION OF SUCTION LINE SIZE & EQUIVALENT LENGTH
Nominal capacity Btuh 18,000 24,000 30,000 36,000 42,000 Vapor line diameter (in.) 3/4 3/4 3/4 3/4 7/8 3/4 7/8 1-1/8 3/4 7/8 1-1/8 7/8 1-1/8 EQUIVALENT LINE LENGTH (FT) 50 .99 1 .98 .93 .98 .93 .97 1 .90 .96 1 .93 .99 75 .97 .99 .97 .90 .96 .90 .96 1 .86 .94 1 .91 .98 100 .96 .99 .96 .86 .94 .87 .94 .99 .82 .93 .99 .89 .98 125 .95 .98 .95 .83 .92 .83 .93 .99 .78 .91 .99 .86 .97 150 .95 .97 .94 .79 .90 .80 .92 .98 N/R .89 .98 .84 .97

TABLE 5. LOSSES FROM SUCTION LINE ELBOWS (EQUIVALENT LENGTH, FT.)

Type of elbow fitting 90 short radius 90 long radius 45 I.D. (in.) 7/8 2 1.7 0.8

3/4 1.7 1.5 0.7

1-1/8 2.3 1.6 1

Installation Requirements 1. In a completely horizontal installation with a long line set where the evaporator is at the same altitude as (or slightly below) the condenser, the line set should be sloped towards the evaporator. This helps reduce refrigerant migration to the condenser during a systems off-cycle. 2. For a system installation where the evaporator is above the condenser, an inverted vapor line trap should be installed on the suction line just before the inlet to the evaporator (see Fig 6). The top of the inverted loop must be slightly above the top of the evaporator coil and can be created simply by brazing two 90 long radius elbows together, if a bending tool is unavailable. Properly support and secure the inverted loop to the nearest point on the indoor unit or adjacent structure.

Fig 6. Evaporator unit with inverted vapor loop

48,000 60,000

NOTE: For a condenser with a liquid valve tube connection less than 3/8" diameter, use 3/8" liquid line tubing for a line set greater than 25 feet.

3. An oil trap is required at the evaporator only if the condenser is above the evaporator. Preformed oil traps are available at most HVAC supply houses, or oil traps may be created by brazing tubing elbows together (see diagram below). Remember to add the equivalent length from oil traps to the equivalent length calculation of the suction line. For example, if you construct an oil trap using two 45 elbows, one short and one long 90 elbow in a diameter suction line, the additional equivalent length would be 0.7+ 0.7+1.7+1.5, which equals 4.6 feet (refer to table 2).

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SERVICING
Oil Trap Construction

S-202 DUCT STATIC PRESSURES AND/OR STATIC PRESSURE DROP ACROSS COILS
This minimum and maximum allowable duct static pressure for the indoor sections are found in the specifications section. Tables are also provided for each coil, listing quantity of air (CFM) versus static pressure drop across the coil. Too great an external static pressure will result in insufficient air that can cause icing of the coil. Too much air can cause poor humidity control and condensate to be pulled off the evaporator coil causing condensate leakage. Too much air can also cause motor overloading and in many cases this constitutes a poorly designed system.

Long Radius Street Ell 45 Ell

45 Street Ell Short Radius Street Ell

S-203 AIR HANDLER EXTERNAL STATIC

Fig 7. Oil Trap

To determine proper air movement, proceed as follows: 1. Using a draft gauge (inclined manometer), measure the static pressure of the return duct at the inlet of the unit, (Negative Pressure). 2. Measure the static pressure of the supply duct, (Positive Pressure). 3. Add the two readings together.

4. Low voltage wiring. Verify low voltage wiring size is adequate for the length used since it will be increased in a long line application. System Charging R-410A condensers are factory charged for 15 feet of line set. To calculate the amount of extra refrigerant (in ounces) needed for a line set over 15 feet, multiply the additional length of line set by 0.6 ounces. Note for the following formula, the linear feet of line set is the actual length of liquid line (or suction line, since both should be equal) used, not the equivalent length calculated for the suction line. Extra refrigerant needed = (Linear feet of line set 15 ft.) x X oz./ft. Where X = 0.6 for 3/8" liquid tubing Remember, for condensers with a liquid valve connection less than 3/8" diameter, 3/8" liquid tubing is required for a line set longer than 25 feet. Follow the charging procedures in the outdoor unit I/O manual to ensure proper superheat and sub-cooling levels, especially on a system with a TXV installed in the indoor unit. Heat pumps should be checked in both heating and cooling mode for proper charge level. This guideline is meant to provide installation instructions based on most common long line set applications. Installation variables may affect system operation. NO ADDITIONAL COMPRESSOR OIL IS NEEDED FOR LONG LINE SET APPLICATIONS ON RESIDENTIAL SPLIT SYSTEMS.

TOTAL EXTERNAL STATIC NOTE: Both readings may be taken simultaneously and read directly on the manometer if so desired. 4. Consult proper table for quantity of air. If external static pressure is being measured on a furnace to determine airflow, supply static must be taken between the "A" coil and the furnace.

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SERVICING

Air Flow

STATIC PRESSURE DROP If the total external static pressure and/or static pressure drop exceeds the maximum or minimum allowable statics, check for closed dampers, dirty filters, undersized or poorly laid out duct work.

TOTAL EXTERNAL STATIC

S-204 COIL STATIC PRESSURE DROP

1. Using a draft gauge (inclined manometer), connect the positive probe underneath the coil and the negative probe above the coil. 2. A direct reading can be taken of the static pressure drop across the coil. 3. Consult proper table for quantity of air.

61

ACCESSORIES WIRING DIAGRAMS

HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

ALL FUEL SYSTEM AFE18-60A CONTROL BOARD

24VAC F1 3A +VD C

POWER SUPPLY INPUT FURNACE DEMAND OUTPUT BLOWER FAN DEMAND OUTPUT POWER SUPPLY INPUT (COMMON) SECOND STAGE FURNACE DEMAND OUTPUT COMPRESSOR OUTPUT SECOND STAGE COMPRESSOR OUTPUT REVERSING VALVE OUTPUT POWER SUPPLY OUT TO THERMOSTAT CALL FOR REVERSING VALVE CALL FOR COMPRESSOR CALL FOR EMERGENCY HEAT CALL FOR BLOWER FAN CALL FOR FURNACE HEAT POWER SUPPLY COMMON OUT TO THERMOSTAT CALL FOR 2ND STAGE FURNACE HEAT CALL FOR 2ND STAGE COMPRESSOR POWER SUPPLY OUT TO HP CONTROL HP CALL FOR FURNACE (DURING DEFROST) REVERSING VALVE OUTPUT COMPRESSOR CONTACTOR OUTPUT POWER SUPPLY COMMON OUT TO HP CONTROL ODT (OUTDOOR THERMOSTAT)

P1-8

R
P1-7

F U R N A C E

W1
P1-4

POWER SUPPLY

+5VDC

W1-FURN W2-HP
+VD C 24VAC

G
P1-6 C K1 P1-5

C W2
P1-2

G-STAT G-FURN

Y
P1-3 K2

Y2
P1-1 +VD C

Y2-HP Y2-STAT Y2-FURN

K4 Q1 P2-1

O
24VAC P2-2

T H E R M O S T A T

R O
P2-7

Y-STAT Y-FURN Y-HP

K3

Y
P2-8

E
P2-5

G
P2-9

+5VDC

Q2

W1
P2-3

C
P2-4

E/W1
1.0K

W2
P2-6

Y2
24VAC P3-9

O
6.8K

MICROPROCESSOR

R
P3-8

H E A T P U M P

W2
P3-7

O
P3-2

Y
6.8K P3-6 C

Y C
P3-3

OT-NO
P3-1

OT-NC
P3-4

2ND STAGE COMPRESSOR DEMAND OUTPUT

OT-C
P3-5

Y2
2

BREAK FOR ODT

1

ALL FUEL CONTROL BOARD - AFE18-60A This wiring diagram is for reference only. Not all wiring is as shown above. Refer to the appropriate wiring diagram for the unit being serviced. (For use with Heat Pumps in conjunction with 80% or 90% Single-Stage or Two-Stage Furnaces)

62

ACCESSORIES WIRING DIAGRAMS

HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

10kw and Below, One Stage Electric Heat

From Air Handler
N U E IT E W H BL RE D RE E G

C
BLUE

W2

R C

WHITE

G W2

BROWN

BLACK RED

EMERGENCY HEAT RELAY

THERMOSTAT

E R

OT/EHR18-60

O Y

C
U BL E

R
D RE

W2
W E IT H

O
O NG RA E

Y
L YE LO W

From Outdoor Unit

15kw and Above, Two Stage Electric Heat

From Air Handler
EE N H IT E E BR O W N BL U G R W

SEE NOTE
R C
R ED

W2

W3

BLUE

WHITE

G W2

Indoor Thermostat

BROWN

BLACK RED

EMERGENCY HEAT RELAY

THERMOSTAT

E R

OT/EHR18-60

O Y

R
ED R

W2
W H E IT

O
O G AN R E

Y
YE O LL W

Note: When using a Thermostat with only one stage for electric heat (W2), tie white and brown wires from air handler together.

From Outdoor Unit

Typical Wiring Schematics for OT/EHR18-60 (Outdoor Thermostat & Emergency Heat Relay). This wiring diagram is for reference only. Not all wiring is as shown above. Refer to the appropriate wiring diagram for the unit being serviced.

Indoor Thermostat

E U BL

63

ACCESSORIES WIRING DIAGRAMS

HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

15kw and Above with Two OT/EHR18-60's, Two Stage Electric Heat and Two Stage Thermostat
From Air Handler
G RE EN W H

OT/EHR18-60 #1
BLUE

BL UE

IT E

O W

W2

W3

R C

RE D

BR

WHITE

G W2 W3 E R

BROWN

BLACK RED

EMERGENCY HEAT RELAY

THERMOSTAT

OT/EHR18-60 #2
BLUE

O Y

WHITE

BROWN

BLACK RED

EMERGENCY HEAT RELAY

THERMOSTAT

C
UE BL

R
D RE

W2
H W E IT

O
R O E G AN

Y
W O LL YE

From Outdoor Unit

Typical Wiring Schematics for OT/EHR18-60 (Outdoor Thermostat & Emergency Heat Relay). This wiring diagram is for reference only. Not all wiring is as shown above. Refer to the appropriate wiring diagram for the unit being serviced.

64

Indoor Thermostat

ACCESSORIES WIRING DIAGRAMS

HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

R R 1
HTR2

TR 4 24V 2 3 5 BL PU

208/240 BK

FL

HTR3

Y
TL

BL

BK
FL HTR4 TL

BL BK

PC
1

BL
2

EBTDR R PU BL BR BL R

G
BL R Y
M5 M6 M7 RS2 M8 3

R
K1

R XFMR-R XFMR-C

NO COM NC

BL

K1

C
BR W
5

SPEEDUP
6

M1

Y BL BK R
9 8

W BR G PK BL L1 L2 L1 L2 SR EQUIPMENT GROUND USE COPPER OR ALUMINUM WIRE

Typical Wiring Schematic MBR/AR*F Air Handler with Electric Heat. This wiring diagram is for reference only. Not all wiring is as shown above. Refer to the appropriate wiring diagram for the unit being serviced.

65

ACCESSORIES WIRING DIAGRAMS

HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

BL

24V

BL

L1

L2

TR

240 1

R BK BK R W 4 2 6 BR

208 2

3 COM

BK

R
R BK 1

PU R

BK

BK

PL 1

R HTR2 TL

C Y1 Y/Y2 W1 YCON O O R G R C W2 W2

HTR1

TL

TO THERMOSTAT

PK

PL2

BR

BL

BK

BL

TO CONDENSER

BL

BR

HKR Heat Kit

BR

BR

BL

O BR

BL

E\W1

OTC

THERMOSTATS OT1 OT2 C

Y1

PK

HUMIDISTAT HUM

W/W2

OUTDOOR

Y/Y2

O
HEATER 24 VAC Y1

CONDENSER HEATPUMP

OT2 HUM
PN. B1368270 REV. A J1

PJ2 PJ6

VSTB

Blower Section

Typical Wiring Schematic MBE/AEPF with Electric Heat. This wiring diagram is for reference only. Not all wiring is as shown above. Refer to the appropriate wiring diagram for the unit being serviced.

66

DS1 J2 J3

OT1

PJ4

BR

W1

W2

BL

R YCON COM O

W2

ED

W1

W2

R BL BR W

EM

BL