Amana PCC**C Service Instructions Manual Download Page 1 | Manualshive

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RS6300003 Rev. 1

January 2007

PHB**C, PHD**C PACKAGE HEAT PUMPS
PGA**C, PGB**C, PGD**C PACKAGE GAS
& PCC**C PACKAGE COOLERS

Service
Instructions

®

is a trademark of Maytag Corporation and is used under license

to Goodman Company, L.P. All rights reserved.

Copyright © 1999-2007 Goodman Company, L.P.

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.

Models listed on

Page 6

1
2
3
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Summary of Contents for PCC**C

Page 1: ...used under license to Goodman Company L P All rights reserved Copyright 1999 2007 Goodman Company L P This manual is to be used by qualified professionally trained HVAC technicians only Goodman does...

Page 2: ...RELAY CONTACTS 37 S 15 CHECKING CAPACITOR 37 S 15A Resistance Check 38 S 15B Capacitance Check 38 S 16 CHECKING FAN AND BLOWER MOTOR 38 S 16B ECM ICM Motors 39 S 16E Testing Interface Board 41 S 17 CH...

Page 3: ...COMPRESSOR BURNOUT 55 S 200 CHECKING EXTERNAL STATIC PRESSURE 56 S 301 TESTING AUXILIARY LIMIT 57 S 302 CHECKING FLAME ROLLOUT SWITCH 57 S 304 TESTING GAS VALVE 58 S 306 CHECKING ORIFICES 60 S 307 CH...

Page 4: ...LL 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 WARNING GOODMAN WILL NOT BE RESPONSIBLE FOR...

Page 5: ...could occur Under no circumstances is a hermetic compressor to be elec trically energized and or operated without having the terminal protective cover properly in place See Service Section S 17 for pr...

Page 6: ...D42C0902 PGD42C1152 PGD48C0902 PGD48C1152 PGD48C1402 PGD60C0902 PGD60C1152 PGD60C1402 PHD36CC2 PCC24C02 PCC30C02 PCC36C02 PCC42C02 PCC48C02 PCC60C02 Engineering Revision Product Series A 10 SEER Line...

Page 7: ...ller footprint PGB C 2D P1220201C P1220207C P1222201C P1222208C Package Gas B 11 Seer gas electric units Changed from 26 fan blade to 22 fan blade to improve operating sound PGB C 2E P1231701C P123170...

Page 8: ...at Pump B 11 Seer heat pump units Changed from tan to new corporate colors PHB CC2F1 P1239911C P1239913C Package Heat Pump B 11 Seer heat pump units Changed from tan to new corporate colors PHD C02E P...

Page 9: ...ns For use on all Amana brand Package Units 50 F Compressor Lockout LOK501A Prevents mechanical cooling at ambients below 50 F For use on all Amana brand Package Units Ambient Thermostat Kit ATK01 Thi...

Page 10: ...mable 1 Stage Heat 1 Stage Cool 1213403 Electronic non programmable 2 Stage Heat 1 Stage Cool 1213404 Electronic non programmable 2 Stage Heat 1 Stage Cool 1213405 Electronic programmable 2 Stage Heat...

Page 11: ...11 ACCESSORIES 42 3 8 1 35 14 19 19 3 16 19 3 16 SUPPLY RETURN PRC06A1 ROOF CURB SUPPLY RETURN 12 2 47 42 3 8 25 12 2 25 14 PRC07A1 ROOF CURB...

Page 12: ...A BRAND MODEL A DIM B DIM C DIM D DIM E DIM F DIM G DIM H DIM J DIM PDTROU4A 42 26 7 16 12 26 1 4 15 6 7 8 20 11 16 9 16 9 16 PDTROU6A 42 32 12 39 1 2 15 10 20 11 16 1 9 16 PDTROU4A PDTROU6A Duct Tran...

Page 13: ...ult in a fire or explosion D Do not use this appliance if any part has been underwater Immediately call a qualified service technician to inspect the appliance and to replace any part of the control s...

Page 14: ...orce or attempted repair may result in a fire or explosion D Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to...

Page 15: ...pilot It is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand B BEFORE OPERATING smell all around the appliance area for gas Be sure to sme...

Page 16: ...LIGHTING INSTRUCTIONS 16 PSI IN OFF ON 2 GAS INLET ARRIVEE DU GAZ ROBINET A GAZ MANUEL EN POS ON MARCHE MANUAL GAS SWITCH SHOWN IN ON POS PSI IN OFF ON 2...

Page 17: ...not have a pilot It is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand B BEFORE OPERATING smell all around the appliance area for gas Be...

Page 18: ...LIGHTING INSTRUCTIONS 18 OFF ON ROBINET A GAZ MANUEL EN POS ON MARCHE MANUAL GAS LEVER SHOWN IN ON POS GAS INLET ARRIVEE DU GAZ OFF ON...

Page 19: ...d to be lower than supply air end Amana brand Package Units are designed for outdoor in stallations only in either residential or light commercial ap plications The connecting ductwork Supply and Retu...

Page 20: ...n may be found in the Cooling Performance Data section The scroll is a simple compression concept first patented in 1905 A scroll is an involute spiral which when matched with a mating scroll form as...

Page 21: ...ue Shown in the table Above The minimum supply pressure must not be varied downward because this could lead to unreliable ignition In addition gas input to the burners must not exceed the rated input...

Page 22: ...g 3 48 kPa This unit must be isolated from the gas supply system by closing its individual manual shutoff valve during any pres sure testing of the gas supply piping system at test pres sures equal to...

Page 23: ...1100 1800 720 1500 To Convert to Capacities at 15 PSIG Settings Multiply by 1 130 To Convert to Capacities at 5 PSIG Settings Multiply by 0 879 NOMINAL PIPE SIZE SCH 40 Sizing Between Single or Secon...

Page 24: ...non explosive liquid The chemical formula is CHCLF2 The boiling point at atmospheric pressure is 41 4 F A few of the important principles that make the refrigeration cycle possible are heat always flo...

Page 25: ...ana 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 In the cooling mode the orifice is pushed in...

Page 26: ...ator Outdoor Coil Thermostatic Expansion Valve Check Valve Reversing Valve Energized Typical Heat Pump System in Cooling Typical Heat Pump System in Heating Expansion device may not be as shown Refer...

Page 27: ...vides for field adjustment of the blower delay at the end of the heating cycle The range of adjustment is for 60 90 120 or 180 seconds The factory delay setting is 30 seconds delay on 120 seconds dela...

Page 28: ...not force Some Gas valves may have a different off on style switch OFF ON Figure 10 7 Wait five minutes to clear out any gas 8 Smell for gas including near the ground This is impor tant because some...

Page 29: ...V 24 0 x 3 413 x 84 68 8 MBh Actual CFM 1800 x 84 1400 CFM NOTE The temperature rise table is for sea level installa tions The temperature rise at a particular KW and CFM will be greater at high alti...

Page 30: ...Exchanger for soot scale etc Inspect all burners for lint and proper positioning 9 Start the system using the proper instrumentation check gas inlet and manifold pressures burner flame and microamp s...

Page 31: ...input multiply the number of cubic feet of gas consumed per hour by the heating value of the gas being used The calorific value of the gas being used is found by contacting your local utility Example...

Page 32: ...44 41 82 164 409 19 47 95 189 379 947 45 20 40 80 160 400 20 45 90 180 360 900 46 78 157 391 21 43 86 171 343 857 47 19 38 76 153 383 22 41 82 164 327 818 48 75 150 375 23 39 78 157 313 783 49 147 36...

Page 33: ...ance of Anticipator S 3 Shortage or Refrigerant Test For Leaks Add Refrigerant S 103 Restricted Liquid Line Replace Restricted Part S 112 Dirty Air Filter Inspect Filter Clean or Replace Dirty Indoor...

Page 34: ...pply Shut Off Turn Valves to On Position S 304 Faulty Induced Draft Blower Test Blower S 309 Broken or Shorted Ignitor Test Ignitor S 312 Faulty Combustion Relay Test Relay S 20 Dirty Flame Sensor Low...

Page 35: ...ltage 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 com...

Page 36: ...tat and wiring Re pair or replace as necessary NOTE Consideration must be given as to how the heaters are wired O D T and etc Also safety devices must be checked for continuity S 3B Cooling Anticipato...

Page 37: ...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 u...

Page 38: ...lt Ohm Meter 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 Sta...

Page 39: ...connect directly to the Line DO NOT Insert Contactors in Series with the ECM ICM Motor AC line Con trol is powered continuously to Insure reliable start up Plug is polarized verify and reverify corre...

Page 40: ...nce from each motor lead in the motor plug just re moved to the motor shell is greater than 100k ohms Measure resistance to unpainted motor end plate If any motor lead fails this test do not proceed t...

Page 41: ...to R2 or R3 check for 24 volts from C to G and from C to Y Y2 4 If no voltage present from C to G and C to Y Y2 check low voltage wiring in unit and thermostat and ther mostat wiring 5 If 24 volts pre...

Page 42: ...se 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 on...

Page 43: ...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 fi...

Page 44: ...unless an authorized replacement Keep static pressure to a minimum Use high pressure drop filters some have 1 2 H2O drop Recommend high efficiency low static filters Use restricted returns Recommend...

Page 45: ...h an internal overload The line break internal overload senses both motor amper age and winding temperature High motor temperature or amperage heats the disc causing it to open breaking the common cir...

Page 46: ...nd the fuse must be of the proper size and type 2 With the protective terminal cover in place use the three leads to the compressor terminals that were disconnected at the nearest point to the compres...

Page 47: ...BOARD The Defrost Control Board is an electronic device which is not field repairable If a malfunction should occur the com plete board must be replaced The board has anti short cycle protection high...

Page 48: ...R G G Y L 5 S E E D E T A IL 1 T E S T 6 0 D E T A IL 1 H E A T C R A F T A D JU S T A B L E D E F R O S T IN T E R V A L F A C T O R Y S E T T IN G A S S H O W N 3 0 90 D E F R O S T C O N T R O L C...

Page 49: ...ntrol Insulate the lead point of contact 2 Check the temperature at which the control closes its contacts 30 F 5 F 3 Raise the temperature of the control until opens 60 F 5 F 4 If not as above replace...

Page 50: ...installed between the partition panel and the expansion device Heat pump models will require a bi flow dryer BRAZING MATERIALS Copper to Copper Joints Sil Fos used without flux alloy of 15 silver 80...

Page 51: ...s to the high vacuum manifold set With the valve on the charging cylinder closed open the mani fold valve to the cylinder 5 Evacuate the system to at least 29 inches gauge before opening valve to ther...

Page 52: ...s regulation of the flow prevents the return of liquid refriger ant to the compressor The three forces which govern the operation of the valve are 1 the pressure created in the power assembly by the f...

Page 53: ...suction line ser vice valve at the outdoor unit 3 Record the gauge pressure and the temperature of the line 4 Convert the suction pressure gauge reading to tempera ture by finding the gauge reading in...

Page 54: ...thermometer or preferably a thermo couple type temperature tester to the liquid line as it leaves the condensing unit 2 Install a high side pressure gauge on the high side ser vice valve at the front...

Page 55: ...ave normal to high subcooling If a restriction is located replace the restricted part replace drier evacuate and recharge S 113 OVERCHARGE OF REFRIGERANT An overcharge of refrigerant is normally indic...

Page 56: ...ressure drop never exceeds the 6 8 PSIG the drier must be adequate and is trapping the contaminants and it is permissible to leave it in the system 10 If the pressure drop becomes greater then it must...

Page 57: ...pen allow unit to cool and retest 5 If still open replace the control S 301 TESTING AUXILIARY LIMIT CONTROL This control is preset nonadjustable control mounted in the blower compartment area It is co...

Page 58: ...ted by feeling for discharge air from the flue hood when the combustion blower is running but the unit is not firing If the above steps do not suggest the reason the control has tripped the furnace sh...

Page 59: ...f the furnace frequently has to be reset it means that a problem exists that should be corrected WARNING HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT MULTIPLE POWER SOURC...

Page 60: ...event distortion In no instance should an orifice be peened over and redrilled This will change the angle or deflection of the vacuum effect or entraining of pri mary air which will make it difficult...

Page 61: ...alignment to burner replace S 309 CHECKING FOR FLASHBACK Flashback will also cause burning in the burner venturi but is caused by the burning speed being greater than the gas air flow velocity coming...

Page 62: ...4V to control board Thermostat Ends Call for Heat Main and Pilot Valves Close Control board times out De energizes power to blower ACB Igniter stays on Pilot valve remains open Main valve closes Pilot...

Page 63: ...rt Self Check Trial For Ignition Main Burner Operation End Limit s open Limits closed No Igniter opens Board checks limit circuit Yes Control board times out applies power to blower ACB heating speed...

Page 64: ...PROCEDURE ACTION Measure voltage L1 L2 GR Measure voltage Control board GY 25 R 1 Measure voltage Control board molex plug OR 49 to BR 21 Must read 0 volts Check Voltage Red Violet Wires to ID blower...

Page 65: ...e Igniter flame sensor assembly and restart trouble shooting sequence Does main burner light correct unit grounding NO Verify unit is properly grounded Verify flames sense circuit Remove power to unit...

Page 66: ...As the unit fires the inclined manometer negative pres sure will drop to 90 W C for the small cabinets and 1 90 W C for the large cabinets 8 Begin to restrict the flue outlet until the pressure contr...

Page 67: ...ntrol flashes code 2 and waits for the pressure switch to close Once the pressure switch is closed the LED stops flash ing and the control begins timing the 15 second pre purge 3 2 1 6 5 4 9 8 7 12 11...

Page 68: ...rent Control will flash 7 times while continuing normal operation 8 Flashes Lock out due to five consecutive limit trips within a single call for heat Resets in 1 2 hour NOTE The flash rate is 0 25 se...

Page 69: ...sand paper the silicone in sand paper will further contaminate the sensor DSIDirectSparkIgnitionSystems WARNING DISCONNECT ELECTRICAL POWER SUPPLY 1 Disconnect the flame sensor wire from terminal FS o...

Page 70: ...NIT MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH 1 Ignitor cool approximately 70 75 F 2 Disconnect the ignitor from the Ignition Control Mo...

Page 71: ...L WIRE IS REPLACED 105 C WIRE MUST BE USED USE COPPER CONDUCTORS ONLY 3 EQUIPPED FOR 230 VOLT OR 208 VOLT 4 HEAT ON OFF FAN DELAY FACTORY SETTINGS 30 SECONDS ON AND 120 SECONDS OFF 5 UNUSED BLOWER MOT...

Page 72: ...WIRE IS REPLACED 105 C WIRE MUST BE USED USE COPPER CONDUCTORS ONLY 3 EQUIPPED FOR 230 VOLT OR 208 VOLT 4 HEAT ON OFF FAN DELAY FACTORY SETTINGS 30 SECONDS ON AND 120 SECONDS OFF 5 UNUSED BLOWER MOTO...

Page 73: ...EMENT PARTS MUST BE USED WHEN SERVICING 2 IF ANY ORIGINAL WIRE IS REPLACED 105 C WIRE MUST BE USED USE COPPER CONDUCTORS ONLY 3 EQUIPPED FOR 230 VOLT OR 208 VOLT 4 HEAT ON OFF FAN DELAY FACTORY SETTIN...

Page 74: ...1 HEATCRAFT ADJUSTABLE DEFROST INTERVAL FACTORY SETTING AS SHOWN 30 90 BU 34 GY 70 RD 13 BR 21 OR 49 YL 27 BU 34 RD 13 BR 21 OR 49 YL 27 VT 18 BK 26 CC DT RS DEFROST CONTROL A B B A TEST 60 90 30 Y O...

Page 75: ...90 BU 34 GY 70 RD 13 BR 21 OR 49 YL 27 BU 34 RD 13 BR 21 OR 49 YL 27 VT 18 BK 26 CC DT RS DEFROST CONTROL A B B A TEST 60 90 30 Y COM PS2 PS1 DF OUT O FAN Y O W R C G COM FAN HERM CAPACITOR YL 12 VT...

Page 76: ...K 26 CC DT RS DEFROST CONTROL A B B A TEST 60 90 30 Y COM PS2 PS1 DF OUT O FAN Y O W R C G COM FAN HERM CAPACITOR YL 12 VT 16 BK 27 BR 11 GND L2 T2 L1 T1 DEFROST CONTROL ELECTRIC HEAT RELAY COOLING SW...

Page 77: ...TORY SETTING AS SHOWN 30 90 BU 34 GY 70 RD 13 BR 21 OR 49 YL 27 BU 34 RD 13 BR 21 OR 49 YL 27 CC DT RS DEFROST CONTROL A B B A TEST 60 90 30 Y COM PS2 PS1 DF OUT O FAN Y O W R C G COM FAN HERM CAPACIT...

Page 78: ...LTAGE HI VOLTAGE FIELD FAN COMP OD FAN FAN MOTOR CIRCULATION ACB FOR PROPER OPERATION ON 208 VOLT THE FOLLOWING CHANGE MUST BE MADE MOVE RD6 WIRE FROM TRANSFORMER VT COMMON FAN SOLENOID PIN 1 PIN 2 PI...

Page 79: ...1 230 VOLT 4 FUSE 208 VOLT INSTALLATION LEADS MAY BE USED WITH ELECTRIC HEAT L O CA P STAR T DOWN PHCB10C1 5 COOLING COMMON PHCB15C1 COOLIN G S C AP BU BLUE 24V SP EED TAP FAN BR BRO WN MED H I MOVE R...

Page 80: ...LLATION INSTRUCTIONS OR ORANGE TAP HEAT 1 LOW 22303201 REV 1 230 VOLT 4 FUSE 208 VOLT INSTALLATION LEADS MAY BE USED WITH ELECTRIC HEAT LO CAP START DOWN PHCB10C1 5 C OOL ING CO MMO N PHCB15C1 COOLING...

Page 81: ...CT OR CC PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 GY 70 TO HEATER KIT BU 34 RD 13 BR 21 YL 27 COM FAN HERM CAPACITOR YL 12 BK 27 BR 11 GND L2 T2 L1 T1 W1 G E C R W O Y 24V COMMON CAP L2 S...

Page 82: ...ING RELAY ELECTRIC HEAT RELAY OL CB CB CB CB 208 230 60 1 CC DT RS DEFROST CONTROL A B B A TEST 60 90 30 Y COM PS2 PS1 DF OUT O FAN C G Y R W O G R FUSE COOLING RELAY 208 230 60 1 PS HEATER SEQ 1 W2 W...

Page 83: ...B M LO CB CB O COOLING RELAY ELECTRIC HEAT RELAY OL CB CB CB CB 208 230 60 1 CC DT RS DEFROST CONTROL A B B A TEST 60 90 30 Y COM PS2 PS1 DF OUT O FAN C G Y R W O G R FUSE COOLING RELAY 208 230 60 1 P...

Page 84: ...CAP ACB M LO CB CB O COOLING RELAY ELECTRIC HEAT RELAY OL CB CB CB CB 208 230 60 1 CC DT RS DEFROST CONTROL A B B A TEST 60 90 30 Y COM PS2 PS1 DF OUT O FAN C G Y R W O G R FUSE COOLING RELAY 208 230...

Page 85: ...20152301 10KW FIELD CONNECTION 208 240 VAC 1 USE COPPERCD B CONDUCTORSCD B ONLY 75 C MIN C G Y R W W1 W2 O 1 2 3 4 5 6 7 8 9 1 3 L4 L3 L2 L1 4 5 1 2 THERMOSTAT CB2 CB1 GY BU RD 0R GY BU RD BR BR BR BR...

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