Amana A/GPC 14 Guide
Service and Troubleshooting
RS6300013r5
April 2021
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 qualied 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.
TABLE OF CONTENTS
IMPORTANT INFORMATION............................................ 2
PRODUCT IDENTIFICATION ........................................... 3
SYSTEM OPERATION...................................................... 7
SCHEDULED MAINTENANCE ....................................... 10
SERVICING..................................................................... 11
CHECKING VOLTAGE ............................................... 11
CHECKING WIRING ................................................... 11
CHECKING THERMOSTAT AND WIRING ................. 11
CHECKING TRANSFORMER AND
CONTROL CIRCUIT.................................................... 11
CHECKING CONTACTOR AND/OR RELAYS ............ 12
CHECKING CONTACTOR CONTACTS...................... 12
CHECKING LOW PRESSURE CONTROL................. 12
CHECKING HIGH PRESSURE CONTROL ................ 13
CHECKING CAPACITOR............................................ 13
RESISTANCE CHECK ................................................ 14
CAPACITANCE CHECK.............................................. 14
CHECKING FAN AND BLOWER MOTOR WINDINGS
(PSC MOTORS) .......................................................... 14
CHECKING EEM MOTORS ....................................... 14
CHECKING ECM MOTORS........................................ 15
CHECKING ECM MOTOR WINDINGS....................... 16
CHECKING COMPRESSOR....................................... 16
RESISTANCE TEST.................................................... 17
GROUND TEST .......................................................... 17
UNLOADER TEST PROCEDURE ............................. 18
OPERATION TEST...................................................... 18
LOCKED ROTOR TEST ............................................. 18
TESTING CRANKCASE HEATER .............................. 19
CHECKING CRANKCASE HEATER THERMOSTAT.. 19
CHECKING REVERSING VALVE AND SOLENOID ... 19
TESTING DEFROST CONTROL ................................ 19
TESTING DEFROST THERMOSTAT.......................... 20
CHECKING HEATER LIMIT CONTROL(S)................. 20
CHECKING HEATER ELEMENTS.............................. 20
REFRIGERATION REPAIR PRACTICE...................... 20
©2020-2021 Goodman Manufacturing Company, L.P.
Brand®is a registered trademark of Maytag Corporation or its related companies and is used under license. All rights reserved.
IMPORTANT INFORMATION
2
OUTSIDE THE U.S., .
(Not a technical assistance line for dealers.) Your telephone company will bill you for the call.
While these items will not cover every conceivable
situation, they should serve as a useful guide.
•
•
•
•
•
•
•
•
•
•
•
STANDING PRESSURE TEST (RECOMMENDED
BEFORE SYSTEM EVACUATION)............................. 21
LEAK TESTING
(NITROGEN OR NITROGEN-TRACED)..................... 21
SYSTEM EVACUATION.............................................. 21
CHARGING ................................................................. 22
CHECKING COMPRESSOR EFFICIENCY ................ 23
THERMOSTATIC EXPANSION VALVE....................... 23
OVERFEEDING .......................................................... 23
UNDERFEEDING........................................................ 23
SUPERHEAT............................................................... 26
CHECKING SUBCOOLING......................................... 27
CHECKING EXPANSION VALVE OPERATION.......... 28
FIXED ORIFICE RESTRICTION DEVICES ................ 28
CHECKING RESTRICTED LIQUID LINE.................... 28
REFRIGERANT OVERCHARGE ............................... 28
NON-CONDENSABLES.............................................. 28
COMPRESSOR BURNOUT........................................ 28
REVERSING VALVE REPLACEMENT ....................... 29
CHECKING EXTERNAL STATIC PRESSURE............ 30
CHECKING TEMPERATURE RISE ............................ 30
WIRING DIAGRAMS....................................................... 31
PRODUCT IDENTIFICATION
3
The model number is used for positive identication of component parts used in manufacturing. Please use this number
when requesting service or parts information.
PRODUCT IDENTIFICATION
4
The model number is used for positive identication of component parts used in manufacturing. Please use this number
when requesting service or parts information.
PRODUCT IDENTIFICATION
5
Model #
APC14[24-60]M41AA
Amana
®
Brand Package Cooling 14 SEER R410A Multiposition cooling units. Initial release
of single phase models.
GPC14[24-60]M41AA
Goodman
®
Brand Package Cooling 14 SEER R410A Multiposition cooling units. Initial
release of single phase models.
APC14[24-60]M41AB
Amana
®
Brand Package Cooling 14 SEER R410A Multiposition cooling units. Release of
models with access box removed.
GPC14[24-60]M41AB
Goodman
®
Brand Package Cooling 14 SEER R410A Multiposition cooling units. Release of
models with access box removed.
GPC1430M41BA
Goodman
®
Brand Package Cooling 14 SEER R410A Multiposition cooling units. Release of
models with Rechi compressor.
GPC1436M41BA
Goodman
®
Brand Package Cooling 14 SEER R410A Multiposition cooling units. Release of
models with Rechi compressor.
Model #
APH14[24-60]M41AA
Amana
®
Brand Package eat Pump 14 SEER R410A Multiposition heating/cooling units.
Initial release of single phase models.
GPH14[24-60]M41AA
Goodman
®
Brand Package eat Pump 14 SEER R410A Multiposition heating/cooling units.
Initial release of single phase models.
APH14[24-60]M41AB
Amana
®
Brand Package eat Pump 14 SEER R410A Multiposition heating/cooling units.
Release of models with access box removed.
Model #
APH14[24-60]M41AA
Amana
®
Brand Package eat Pump 14 SEER R410A Multiposition heating/cooling units.
Initial release of single phase models.
GPH14[24-60]M41AA
Goodman
®
Brand Package eat Pump 14 SEER R410A Multiposition heating/cooling units.
Initial release of single phase models.
APH14[24-60]M41AB
Amana
®
Brand Package eat Pump 14 SEER R410A Multiposition heating/cooling units.
Release of models with access box removed.
GPH14[24-60]M41AB
Goodman
®
Brand Package eat Pump 14 SEER R410A Multiposition heating/cooling units.
Release of models with access box removed.
PRODUCT IDENTIFICATION
6
Model #
APH16[24-48]M41AA
Amana
®
Brand Package eat Pump up to 16 SEER R410A Multiposition heating/cooling units.
Initial release of single phase models.
GPH16[24-48]M41AA
Goodman
®
Brand Package eat Pump up to 16 SEER R410A Multiposition heating/cooling units.
Initial release of single phase models.
APH16[24-48]M41AB
Amana
®
Brand Package eat Pump up to 16 SEER R410A Multiposition heating/cooling units.
Release of models with access box removed.
GPH16[24-48]M41AB
Goodman
®
Brand Package eat Pump up to 16 SEER R410A Multiposition heating/cooling units.
Release of models with access box removed.
APH1660M41AA
Amana
®
Brand Package eat Pump up to 16 SEER R410A Multiposition heating/cooling units.
Converting light commercial 6 ton unit to 5 ton residential gas pack and heat pump units.
GPH1660M41AA
Goodman
®
Brand Package eat Pump up to 16 SEER R410A Multiposition heating/cooling units.
Converting light commercial 6 ton unit to 5 ton residential gas pack and heat pump units.
APH1660M41BA
Amana
®
Brand Package eat Pump up to 16 SEER R410A Multiposition heating/cooling units.
Release of 5 Ton single phase models with new chassis design.
GPH1660M41BA
Goodman
®
Brand Package eat Pump up to 16 SEER R410A Multiposition heating/cooling units.
Release of 5 Ton single phase models with new chassis design.
SYSTEM OPERATION
7
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 atmo-
spheric pressure is -62.9°F.
A few of the important principles that make the refrigeration
cycle possible are: heat always ows 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 o 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.
Liquid refrigerant at condensing pressure and
temperatures, (270 psig and 122°F), 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 48°F.
Heat is continually being transferred to the cool ns 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 o 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
super-heated gas into the outdoor condenser coil.
In the condenser coil, the hot refrigerant gas, being
warmer than the outdoor air, rst loses its superheat by
heat transferred from the gas through the tubes and ns
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
liqueed, it continues to give up heat which subcools the
liquid, and it is ready to repeat the cycle.
When the contacts of the room thermostat close, making
terminals R to Y and R to G, the low voltage circuit to the
contactor is completed starting the compressor and outdoor
fan motor. The EEM indoor blower motor is energized at
the cool speed when the compressor contactor energizes.
When the thermostat is satised, breaking the circuit
between R to Y and R to G, the compressor and outdoor
fan motor will stop. The indoor blower will stop after the fan
o delay.
If the room thermostat fan selector switch should be set
to the “on” position then the indoor blower would run
continuous rather than cycling with the compressor.
Any time the room thermostat is switched to cool, the O
terminal is energized. This energizes the 24 volt coil on the
reversing valve and switches it to the cooling position.
When the contacts of the room thermostat close, this
closes the circuit from R to Y and R to G in the unit.
This energizes the compressor contactor and will energize
the indoor blower on models equipped with the EEM motor.
When the thermostat is satised, it opens its contacts
breaking the low voltage circuit causing the compressor
contactor to open and indoor fan to stop after the
programmed 60 second o delay on units with the EEM
motor.
If the room thermostat fan selector switch should be set
to the “on” position then the indoor blower would run
continuous rather than cycling with the compressor.
With the thermostat set to the heat position and a call
for heat, R to W will be energized. This will energize the
electric heat contactor(s)/sequencer(s) and the EEM indoor
blower motor. When the normally open contacts of the
heat contactor(s)/sequencer(s) close, this will energize the
electric resistance heat.
SYSTEM OPERATION
8
On a call for rst stage heat, the contacts of the room
thermostat close. This energizes terminals R to Y and R
to G, the low voltage circuit to the contactor is completed
starting the compressor and outdoor fan motor. This also
energizes the indoor blower on models equipped with the
EEM motor.
When the thermostat is satised, breaking the circuit
between R to Y and R to G, the compressor and outdoor
fan motor will stop. The indoor blower will stop after the
programmed 60 second o delay on models equipped with
the EEM motor.
On a call for rst stage heat, the contacts of the room
thermostat close. This energizes terminals R to Y1 and R
to G, the low voltage circuit to the contactor is completed
starting the compressor and outdoor fan motor. This also
energizes the indoor blower motor.
When the thermostat is satised, breaking the circuit
between R to Y1 and R to G, the compressor and outdoor
fan motor will stop. The indoor blower will stop after the
programmed o delay.
During rst stage operation the stat calls for second stage
heat. This energizes terminals R to Y2. This powers voltage
to the compressor solenoid allowing the compressor to
shift to full capacity. When the thermostat is satised,
breaking the circuit between R to Y1, R to Y2 and R to G,
the compressor and outdoor fan motor will stop. The indoor
blower will stop after the programmed o delay on the
motor.
When auxiliary electric heaters are used the Aux stage
heating contacts in the room thermostat close, which
would be wired to W1 at the unit low voltage connections,
this would energize the coil(s) of the electric heat
contactor(s)/sequencer(s). Contacts within the contactor(s)/
Sequencer(s) will close, bringing on the electric resistance
heaters. If auxilary electric heaters should be used, the
may be controlled by outdoor thermostats (OT18-60A or
OT/EHR18-60A).
With the thermostat set to the emergency heat position and
a call for 2nd stage heat, R to W1 will be energized. This
will energize the electric heat contactor(s)/sequencer(s)
and the EEM motor. The electric heat will be energized
through the normally open contacts of the electric heat
contactor(s)/sequencer(s). The indoor blower will be
energized through W from the thermostat.
The defrosting of the outdoor coil is jointly controlled by the
defrost control board and the defrost thermostat.
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 setting the circuit board
jumper to 30, 60, or 90 respectively. Accumulation of time
for the timing period selected starts when the sensor closes
(approximately 30° F), and when the room thermostat
calls for heat. At the end of the timing period, the unit’s
defrost cycle will be initiated provided the sensor remains
closed. When the sensor opens (approximately 60° 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 twelve minute override interrupts the unit’s
defrost period.
If the thermostat calls for continuous fan, the indoor blower
will be energized from the G terminal of the thermostat to
the EEM blower motor.
If a call for heat or cool occurs during a continuous fan call,
the EEM motor will always recognize the call for the highest
speed and ignore the lower speed call.
If the thermostat is not calling for heat or cool, and the
fan switch on the thermostat is returned to the automatic
position, the fan will stop after the programmed 60 second
o delay on units with the EEM motor.
SYSTEM OPERATION
9
Indoor
Coil
Accumulator
Outdoor
Coil
Reversing Valve
(Energized)
Indoor
Coil
Accumulator
Outdoor
Coil
Reversing Valve
(De-Energized)
SCHEDULED MAINTENANCE
10
Package gas units require regularly scheduled
maintenance to preserve high performance standards,
prolong the service life of the equipment, and lessen the
chances of costly failure.
In many instances the owner may be able to perform some
of the maintenance; however, the advantage of a service
contract, which places all maintenance in the hands of a
trained serviceman, should be pointed out to the owner.
1. Inspect the return lters of the evaporator unit and
clean or change if necessary. Depending on
operation conditions, it may be necessary to clean
or replace the lters more often. If permanent type
lters are used, they should be washed with warm
water and dried.
2. When operating on the cooling cycle, inspect the
condensate line piping from the evaporator coil.
Make sure the piping is clear for proper condensate
ow.
1. Clean the indoor and outdoor coils.
2. Clean the cabinet inside and out.
3. Motors are permanently lubricated and do not require
oiling. TO AVOID PREMATURE MOTOR FAILURE,
DO NOT OIL.
4. Manually rotate the outdoor fan and indoor blower to
be sure they run freely.
5. Inspect the control panel wiring, compressor
connections, and all other component wiring to be
sure all connections are tight. Inspect wire insulation
to be certain that it is good.
6. Check the contacts of the compressor contactor. If
they are burned or pitted, replace the contactor.
7. Using a halide or electronic leak detector, check all
piping and etc. for refrigerant leaks.
Proper test equipment for accurate diagnosis is as
essential as regular hand tools.
The following is a must for every service technician and
service shop:
1. Thermocouple type temperature meter - measure dry
bulb temperature.
2. Sling psychrometer - measure relative humidity and
wet bulb temperature.
3. Volt-Ohm Meter - testing continuity, capacitors, motor
windings and voltage.
4. Accurate Leak Detector - testing for refrigerant leaks.
5. High Vacuum Pump - evacuation.
6. Electric Vacuum Gauge, Manifold Gauges and
high vacuum hoses - to measure and obtain proper
vacuum.
7. Accurate Charging Cylinder or Electronic Scale -
measure proper refrigerant charge.
8. Inclined Manometer - measure static pressure and
pressure drop across coils.
Other recording type instruments can be essential in
solving abnormal problems, however, in many instances
they may be rented from local sources.
Proper equipment promotes faster, more ecient service,
and accurate repairs with less call backs.
SERVICING
11
1. Remove doors, control panel cover, etc. from unit
being tested.
With power ON:
2. Using a voltmeter, measure the voltage across
terminals L1 and L2 of the contactor.
3. No reading - indicates open wiring, open fuse(s) no
power or etc. from unit to fused disconnect service.
Repair as needed.
4. If incoming voltage is within the range listed in the
chart below, energize the unit.
5. Using a voltmeter, measure the voltage with the unit
starting and operating to determine if voltage is within
the range listed in the chart below.
6. If the voltage falls below the minimum voltage, check
the line wire size. Long runs of undersized wire can
cause low voltage. If the wire size is adequate, notify
the local power company regarding either low or high
voltage.
208/230 198 253
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.
Thermostat Wiring: The maximum wire length for 18 AWG
thermostat wire is 100 feet.
With power ON, thermostat calling for cooling:
1. Use a voltmeter to verify 24 volts present at
thermostat wires C and R.
2. If no voltage present, check transformer and
transformer wiring. If 24 volts present, proceed to
step 3.
3. Use a voltmeter to check for 24 volts at thermostat
wires C and Y.
4. No voltage indicates trouble in the thermostat, wiring
or external transformer source.
5. Check the continuity of the thermostat and wiring.
Repair or replace as necessary.
With power ON:
1. Use a voltmeter to verify 24 volts present at
thermostat wires C and R.
2. If no voltage present, check transformer and
transformer wiring. If 24 volts present, proceed to
step 3.
3. Set fan selector switch at thermostat to “ON”
position.
4. With voltmeter, check for 24 volts at wires C and G.
5. No voltage, indicates the trouble is in the thermostat
or wiring.
6. Check the continuity of the thermostat and wiring.
Repair or replace as necessary.
A step-down transformer (208/240 volt primary to 24 volt
secondary) is provided with each package unit. This allows
ample capacity for use with resistance heaters.
SERVICING
12
1. Remove control panel cover, or etc., to gain access
to transformer.
With power ON:
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 is present at the primary voltage side
of the transformer and 24 volts is not present on the
secondary side, then the transformer is inoperative.
Replace.
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.
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.
1. Disconnect the wire leads from the terminal (T) side
of the contactor.
2. With power ON, energize the contactor.
3. Using a voltmeter, test across terminals.
A. L1 - L2 - No voltage. Check breaker or fuses on
main power supply. If voltage present, proceed to
step B.
B. T1 to T2 - Meter should read the same as L1 to
L2 in step A. If voltage readings are not the same
as step A, replace contactor.
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 22 PSIG. It will automatically cut-in (close) at
approximately 50 PSIG.
SERVICING
13
Test for continuity using a VOM and if not as above,
replace the control.
The high pressure control capillary senses the pressure in
the liquid or 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.
1. Using an ohmmeter, check across terminals of
high pressure control, with wire removed. If not
continuous, the contacts are open.
2. Attach a gauge to the dill valve port on the base
valve.
With power ON:
3. Start the system and place a piece of cardboard in
front of the condenser coil, raising the condensing
pressure.
4. Check pressure at which the high pressure control
cuts-out.
If it cuts-out at 660 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. The control should reset at 420 PSIG +
25 PSIG.
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.
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 hard start kits are available and may improve low
voltage starting characteristics.
This check valve closes o high side pressure to the
compressor after shut down allowing equalization through
the scroll anks. Equalization requires only about one or
two seconds during which time the compressor may turn
backwards.
Your unit comes with a 180-second anti-short cycle
to prevent the compressor from starting and running
backwards.
A start capacitor is wired in parallel with the run capacitor
to increase the starting torque. The start capacitor is of the
electrolytic type, rather than metallized polypropylene as
used in the run capacitor.
A switching device must be wired in series with the
capacitor to remove it from the electrical circuit after the
compressor starts to run. Not removing the start capacitor
will overheat the capacitor and burn out the compressor
windings.
These capacitors have a 15,000 ohm, 2 watt resistor
wired across its terminals. The object of the resistor
is to discharge the capacitor under certain operating
conditions, rather than having it discharge across the
closing of the contacts within the switching device such as
the Start Relay, and to reduce the chance of shock to the
servicer. See the Servicing Section for specic information
concerning capacitors.
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.
SERVICING
14
1. Discharge capacitor and remove wire leads.
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 innity. (Start capacitor with
bleed resistor will not return to innity. 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.)
Using a hookup as shown below, take the amperage and
voltage readings and use them in the formula:
Capacitance (MFD) = 2650 X Amperage
Voltage
SC
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.
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.
SERVICING
15
If the windings do not test continuous or a reading is
obtained from lead to ground, replace the motor.
The EEM Motor is a one piece, fully encapsulated, 3 phase
brushless DC (single phase AC input) motor with ball
bearing construction. The EEM features an integral control
module.
1. Using a voltmeter, check for 230 volts to the motor
connections L and N. If 230 volts is present, proceed
to step 2. If 230 volts is not present, check the line
voltage circuit to the motor.
2. Using a voltmeter, check for 24 volts from terminal C
to either terminal 1, 2, 3, 4 or 5, depending on which
tap is being used, at the motor. If voltage is present,
proceed to step 3. If no voltage, check 24 volt circuit
to motor.
3. If voltage was present in steps 1 and 2, the motor
has failed and will need to be replaced.
CL G N
1 2 345
/
1/4
An ECM is an Electronically Commutated Motor which
oers many signicant advantages over PSC motors.
The ECM has near zero rotor loss, synchronous machine
operation, variable speed, low noise, and programmable
air ow. Because of the sophisticated electronics within
the ECM motor, some technicians are intimated by the
ECM motor; however, these fears are unfounded. GE/
Regal Beloit oers 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.
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:
3. Check the unit for incoming power.
4. Check the control board.
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.
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.
SERVICING
16
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
}
11
1 9
2
3
4
5
6
7
816
15
14
13
12
10
OUT - OUT +
ADJUST +/- G (FAN)
Y1 Y/Y2
COOL EM Ht/W2
DELAY 24 Vac (R)
COMMON2 HEAT
W/W1 BK/PWM (SPEED)
COMMON1 O (REV VALVE)
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.
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.
16-pin
connector
5-pin
connector
3-pin motor
connector
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
ames 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 sucient heat source.
Ignition of the discharge can also occur at the venting
terminal or inside the compressor, if there is sucient
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.
SERVICING
17
To reduce the possibility of external ignition, all open
ame, electrical power, and other heat sources should be
extinguished or turned o prior to servicing a system.
If the following test indicates shorted, grounded or open
windings, see procedure for the next steps to be taken.
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 insucient gas to
cool the motor, is slow to dissipate. Allow at least three to
four hours for it to cool and reset, then retest.
1. Remove the leads from the compressor terminals.
2. Using an ohmmeter, test continuity between
terminals S-R, C-R, and C-S.
If either winding does not test continuous, replace the
compressor.
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
to see if it was just a nuisance opening. If it opens
again, continue to reset.
all
1. Carefully remove the compressor terminal protective
cover and inspect for loose leads or insulation breaks
in the lead wires.
2. Disconnect the three leads going to the compressor
terminals at the compressor or nearest point to the
compressor.
3. Check for a ground separately between each of the
three terminals and ground (such as an unpainted
tube on the compressor). If there is any reading of
continuity to ground on the meter, the compressor
should be considered defective.
4. If ground is indicated, replace the compressor.
SERVICING
18
A nominal 24-volt direct current coil activates the
compressor internal unloader solenoid. The input control
circuit voltage must be 18 to 28 volt ac. (remove) The
coil power requirement is 5 VA. The external electrical
connection is made with a molded plug assembly. This plug
contains a full wave rectier to supply direct current to the
unloader coil. The measured DC voltage at the connectors
in the plug should be 15 to 27 volt dc.
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
amperage. Cycle the unloader ON and OFF at 10
second intervals. The compressor amperage should
increase when switching from part-load to full-load
and decrease when switching from full-load to part-
load. The percent change depends on the operating
conditions and voltage, but should be at least 25
percent.
2. If step one does not give the expected results, shut
unit o. 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 can’t be heard, shut o power to the unit
and remove the control circuit molded plug from
the compressor and measure the unloader coil
resistance (connections on the compressor).
The solenoid coil should have continuity and not
be grounded or have innite resistance. If the
coil resistance is innite, zero, or grounded, the
compressor must be replaced.
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.
B. 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 innity. Repeat with other
wire. The same female connector as before
should read zero while the other connector again
reads innity. Reverse polarity on the ohmmeter
leads and repeat. The female connector that
read innity previously should now read close to
zero ohms.
C. Replace plug if either of these test methods
doesn’t show the desired results.
If the voltage, capacitor, overload and motor winding test
fail to show the cause for failure:
1. Remove unit wiring from disconnect switch and wire
a test cord to the disconnect switch.
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.
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.
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.
Before checking for locked rotor, the compressor terminals
should be checked for open windings (see Resistance Test)
and the run capacitor and start capacitor (if used) should
be checked thoroughly (see Checking Capacitor).
SERVICING
19
With power ON:
1. Check the serial data plate for the compressor locked
rotor amps (LRA) rating.
2. Using an ampmeter, measure the amperage reading
for the run and common wires to the compressor.
Since the compressor motor overload will likely
trip soon after drawing locked rotor amps, this
measurement should be taken as soon as the
compressor starts.
3. If the amperage reading roughly equals the
compressor LRA rating and all other checks have
been completed, locked rotor amps has been
veried.
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 o cycles and prevents liquid slugging or oil
pumping on start up.
A crankcase heater will not prevent compressor damage
due to a oodback or over charge condition.
1. Disconnect the heater lead in wires.
2. Using an ohmmeter, check heater continuity - should
test continuous. If not, replace.
1. Install a thermocouple type temperature test lead on
the discharge line adjacent to the crankcase heater
thermostat.
2. Check the temperature at which the control closes its
contacts by lowering the temperature of the control.
The crankcase heater thermostat should close at
67°F ± 5°F.
3. Check the temperature at which the control opens
its contacts by raising the temperature of the control.
The crankcase heater thermostat should open at
85°F ± 5°F.
4. If not as above, replace control.
Occasionally the reversing valve may stick in the heating or
cooling position or in the mid-position.
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.
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”/” R-DFT” at
defrost control board.
2. Remove jumper from timer pins and jump across test
pins on defrost control board.
3. Set thermostat to call for heating. System should go
into defrost within 21 seconds.
SERVICING
20
4. Immediately remove jumper from test pins.
5. Using VOM check for voltage across terminals “C &
O”. Meter should read 24 volts.
6. Using VOM check for voltage across fan terminals
DF1 and DF2 on the board. You should read line
voltage (208-230 VAC) indicating the relay is open in
the defrost mode.
7. Using VOM check for voltage across “W”/”W2” & “C”
terminals on the board. You should read 24 volts.
8. If not as above, replace control board.
9. Set thermostat to o position and disconnect power.
Remove jumper from defrost thermostat and replace
timer jumper to the desired defrost time.
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.
The defrost control should close at approximately
30°F.
3. Check the temperature at which the control opens
its contacts by raising the temperature of the control.
The defrost control should open at approximately
60°F.
4. If not as above, replace control.
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 airow. This limit control will open its circuit at
approximately 150°F. to 160°F and close at approximately
110°F.
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.
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.
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.
These models use the FasTest Access Fitting System,
with a saddle that is either soldered to the suction and
liquid lines or is fastened with a locking nut to the access
tting box (core) and then screwed into the saddle.
When installing a new core or reinstalling the core after
removal, it is very important to note that before inserting
the core into the saddle, the core and saddle must be
free of debris and the “O” Ring have a thin coating
of refrigerant oil applied to it. The oil is to prevent the “O”
Ring from being deformed when the core is tightened
completely. The core should be torqued to 8 ft. lb.
When repairing the refrigeration system:
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 ow 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.
This manual suits for next models
2
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