Daikin A/GPDM3 Series, Service And Troubleshooting

Page 1: ...R WINDINGS PSC MOTORS 21 CHECKING EEM MOTORS 21 CHECKING COMPRESSOR 22 RESISTANCE TEST 22 GROUND TEST 23 OPERATION TEST 23 LOCKED ROTOR TEST 24 TESTING CRANKCASE HEATER OPTIONAL ITEM 24 CHECKING REVERSING VALVE AND SOLENOID 24 TESTING DEFROST CONTROL 25 TESTING DEFROST THERMOSTAT 25 REFRIGERATION REPAIR PRACTICE 25 STANDING PRESSURE TEST 26 LEAK TESTING NITROGEN OR NITROGEN TRACED 26 SYSTEM EVACUA...

Page 2: ...NAL INJURY OR DEATH 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 REFRIGERANT CHARGE CHECK 28 CHECKING SUPERHEAT 28 CHECKING SUBCOOLING 28 CHECKING COMPRESSOR EFFICIENCY 29 FIXED ORIFICE RESTRICTION DEVICES 32 CHECKING EQUALIZATION TIME 32 CHECKING RESTRICTED LIQUID LINE 32 REFRIGERANT OVERCHARGE 32 NON CONDENSABLE...

Page 3: ...of refrigerants WARNING The compressor POE oil for R 410A units is extremely susceptible to moisture absorption and could cause compressor failure Do not leave system open to atmosphere any longer than necessary for installation 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...

Page 4: ...être effectués par un installateur ou une entreprise d entretien qualifié ou le fournisseur de gaz WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow instructions could result in severe personal injury or death due to carbon monoxide poisoning if combustion products infiltrate into the building Check that all openings in the outside wall around the vent and air intake pipe s are sealed to ...

Page 5: ... single phase 60 Hz Unit Type Refrigerant D Dual Fuel 4 R 410A Heat Input Airflow 060 60 MBTU H 080 80 MBTU H 100 100 MBTU H M Multi position Efficiency Tonnage Nominal 3 13 4 SEER2 24 2 tons 42 3 tons 30 2 tons 48 4 tons 36 3 tons Nomenclature G P D M 3 36 080 4 1 A A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Brand Minor Revision G Goodman Brand A Major Revision A Product Category Electrical P Packaged Un...

Page 6: ...41AA Goodman Brand Package Dual Fuel Units 14SEER with R410A Initial release of 81 AFUE models A GPD1436080M41AB Amana Brand Goodman Brand Package Dual Fuel units 14 SEER with R410A Compressor Change Single Phase Package Gas Units Model Description A GPDM3 24 48 M41A Amana Brand Goodman Brand Package Dual Fuel Units 13 4 SEER 2 R410A Multi Position gas electric units Initial release of models meet...

Page 7: ... 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 Heat Pump Models 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 th...

Page 8: ...ves are energized along with the igniter for trial for ignition period Igniter is de energized when flame is detected 5 Flame is achieved and detected during trial for ignition period Flame stabilization period begins when flame is detected 6 Gas valve and induced draft blower remain at high stage and high speed 7 Air circulating blower is energized at high heat speed after heat ON delay time expi...

Page 9: ... blower on delay 4 The unit is now operating the heat pump in the heating mode 5 If the thermostat cannot be satisfied or the outdoor thermostat changes to gas heating operations W1 is energized and Y is de energized 6 The compressor and outdoor fan are turned off 7 Gas heating cycle begins Heating Cycle Natural Gas LP 1 The Dual Fuel unit will operate in gas heat mode when the thermostat calls fo...

Page 10: ...e selected by setting the circuit board jumper to 30 60 and 90 respectively Accumulation of time for the timing period selected starts when the sensor closes approximately 30 F and when the wall thermostat calls for heat At the end of the timing period the unit s defrost cycle will be initiated provided the sensor remains closed Upon a call for defrost the blower will continue to run and the defro...

Page 11: ...ERATION 11 Indoor Coil Accumulator Outdoor Coil Reversing Valve Energized Indoor Coil Accumulator Outdoor Coil Reversing Valve De Energized Typical Heat Pump System in Cooling Typical Heat Pump System in Heating ...

Page 12: ...is used to monitor the flame The board has the option of using a single or two stage thermostat The board also controls the indoor blower and has an adjustable heat fan off delay There is also a fault recall button for recalling the last 5 fault codes To recall the fault codes depress the fault recall button for at least 2 seconds but not more than 4 seconds To clear the fault code memory depress ...

Page 13: ...used 5 24VAC 24VAC Common 6 24VAC Pressure Switch Output 7 24VAC Main Valve High Output 8 24VAC Pressure Switch Input 9 Unused Main Valve Low Output Table 2 Circuit Definitions and Voltage Ratings for the 9 Circuit Connector Circuits Terminal Label Line Voltage L1 L1 Transformer Line L1 L1 Air Circulating Blower Line 1 L1 Induced Draft Blower Low Speed DI Low or Inducer Low Induced Draft Blower Hi...

Page 14: ... OFF Delay 0 Seconds Ignition Attempts 3 Recycles Infinite Automatic Restart 60 Minutes Pressure Switch Lockout Delay 5 Minutes Factory Test Mode Active Time 2 Minutes Maximum Flame Failure Response Time Table 4 Control Timings Color Function LED Flashes Status Normal On Intrnal Gas Valve Fault Off Lockout 1 Pressure Switch Stuck Open 2 Pressure Switch Stuck Closed 3 Open High Temperature Limit 4 ...

Page 15: ...rner flame and microamp signal Adjust if necessary 10 Start the system and run a Heating Performance Test If the results of the test are not satisfactory see the Service Problem Analysis Guide for the possible cause Test Equipment 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 t...

Page 16: ... your natural gas BTU HR input 8 Should the figure you calculated not fall within five 5 percent of the nameplate rating of the unit adjust the gas valve pressure regulator or resize orifices To adjust the pressure regulator on the gas valve turn downward clockwise to increase pressure and input and upward counterclockwise to decrease pressure and input A properly operating unit must have the BTU ...

Page 17: ... 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 Branch Circuit Am pacity 15 20 25 30 35 40 45 50 SUPPLY WIRE LENGTH FEET 200 6 4 4 4 3 3 2 2 150 8 6 6...

Page 18: ...r Relays 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 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 clos...

Page 19: ...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 Checking Low Pressure Control 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 l...

Page 20: ...nce of shock to the servicer See the Servicing Section for specific information concerning capacitors 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...

Page 21: ...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 Checking EEM Motors The EEM motor is a one piece fully encapsulated 3 phase brushless DC single phase AC input motor with ball bearing construction Th...

Page 22: ... 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 e...

Page 23: ...ately 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 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 C...

Page 24: ...mpound gages will give the same symptoms as bad compressor valves or broken scroll flanks The temperature between true suction and the suction line after the valve should not be greater than 4 degrees Note The center tube is always the suction line and should be cold Troubleshooting the Reversing Valve for Electri cal Failure 1 Place unit into the cooling mode Test for 24 volts at the solenoid If ...

Page 25: ... 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 ...

Page 26: ... and a pressure relief valve The pressure relief valve must be set to open at no more than 450 psig Leak test the system using dry nitrogen and soapy water to identify leaks If you prefer to use an electronic leak detector charge the system to 10 PSIG with the appropriate system refrigerant see Serial Data Plate for refrigerant identification Do not use an alternative refrigerant Using dry nitroge...

Page 27: ...inutes Break the vacuum with dry nitrogen again bring the system pressure back to 2 3 PSIG and hold for 20 minutes 3 Evacuate the system to 500 microns and hold for 60 minutes 4 If the pressure rises to 1000 microns or less and remains steady the system is considered leak free proceed to start up LOW SIDE GAUGE AND VALVE HIGH SIDE GAUGE AND VALVE Evacuation Charging WARNING REFRIGERANT UNDER PRESS...

Page 28: ...g 4 Record the gauge pressure corresponding temperature and the temperature of the suction line 5 Refer to the superheat table for proper system superheat Add charge to lower superheat recover charge to raise superheat 100 10 10 95 10 10 10 90 12 15 18 85 10 13 17 20 80 10 15 21 26 75 10 13 17 25 29 70 10 17 20 28 32 65 13 19 26 32 35 60 17 25 30 33 37 Ambient Condenser Inlet Temp F Drybulb 65 70 ...

Page 29: ...ot enter the compressor 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 Checking Compressor Efficiency The reason for compressor ineffi...

Page 30: ... 60 8 6 162 0 57 0 264 0 87 4 366 0 110 4 468 0 129 0 600 0 149 0 62 10 0 164 0 57 7 266 0 87 9 368 0 110 8 470 0 129 3 604 0 149 5 64 11 3 166 0 58 4 268 0 88 4 370 0 111 2 472 0 129 7 608 0 150 1 66 12 6 168 0 59 0 270 0 88 9 372 0 111 6 474 0 130 0 612 0 150 6 68 13 8 170 0 59 8 272 0 89 4 374 0 112 0 476 0 130 3 616 0 151 2 70 15 1 172 0 60 5 274 0 89 9 376 0 112 4 478 0 130 7 620 0 151 7 72 1...

Page 31: ...9 88 86 84 82 80 78 308 90 88 86 84 82 80 317 92 90 88 86 84 82 326 94 92 90 88 86 84 335 96 94 92 90 88 86 345 98 96 94 92 90 88 354 100 98 96 94 92 90 364 102 100 98 96 94 92 374 104 102 100 98 96 94 384 106 104 102 100 98 96 395 108 106 104 102 100 98 406 110 108 106 104 102 100 416 112 110 108 106 104 102 427 114 112 110 108 106 104 439 116 114 112 110 108 106 450 118 116 114 112 110 108 462 1...

Page 32: ... 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 If a restriction is located replace the restricted part replace drier evacuate and recharge Refrigerant Overchar...

Page 33: ...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 an...

Page 34: ... EEM motors EEM motors are constant torque motors with very low power consumption This motor is energized by 24VAC Adjust the CFM for the unit by changing the 24VAC leads to the speed terminal block on the motor NOTE Heating airflow must be adjusted to provide the temperature rise shown on rating plate A higher speed tap may not provide more airflow Blower speeds are programmed to deliver adequate...

Page 35: ...in the combustion chamber is sufficiently lowered 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 Remove electrical power to unit Some units may have more than one source of power 2 Remove the wires from the limit control terminals 3 Using an ohmmeter test for contin...

Page 36: ...ol is designed to open should a flame roll out occur An over firing condition or flame impingement on the heat shield can also cause the control to open If the rollout control has opened the circuit between the ignition control and gas valve will be interrupted and the ignition control module will go into lockout The servicer should reset the ignition control by opening and closing the thermostat ...

Page 37: ...n blower running all flames are not drawn into the tubes either the collector box combustion blower or flue outlet is obstructed If the combustion blower or flue outlet is obstructed the pressure switch should have opened preventing the unit from firing also inspect the unit pressure switch and wiring C If the burner flame is not drawn into the tube only when the air circulation blower is running ...

Page 38: ... into consideration such as inlet manifold gas pressure alignment and positioning specific gravity and BTU content of the gas being consumed The only time resizing is required is when a reduction in firing rate is required for an increase in altitude Orifices should be treated with care in order to prevent damage They should be removed and installed with a box end wrench in order to prevent distor...

Page 39: ...ves 2 Connect a water manometer or adequate gauge to the inlet pressure tap of the gas valve or hose barb fitting on predrilled cap With Power And Gas On 3 Put unit into heating cycle and turn on all other gas consuming appliances INLET GAS PRESSURE Natural Min 5 0 W C Max 10 0 W C Propane Min 11 0 W C Max 13 0 W C NOTE Inlet Gas Pressure Be Within the Minimum and Maximum Value Shown in the Inlet ...

Page 40: ...aused by the burning speed being greater than the gas air flow velocity coming from a burner port Flashback may occur at the moment of ignition after a burner heats up or when the burner turns off The latter is known as extinction pop Since the end results of flashback and delayed ignition can be the same burning in the burner venturi a definite attempt should be made to determine which has occurr...

Page 41: ... fuel the air temperature rise must be within the range listed on the unit nameplate Refer to the Installation Manual provided with the LP kit for conversion from natural gas to propane gas and for altitude adjustments When this package unit is installed at high altitude the appropriate High Altitude orifice kit must be installed As altitude increases there is a natural reduction in the density of...

Page 42: ...od replace ignition control E Voltage present at gas valve replace gas valve 2 Board set for 1 stage thermostat A Wait the selected delay time either 5 or 10 minutes depending on jumper setting B Check for 24 volts at gas valve terminals C and HI C No voltage present check 9 pin connector and wires from ignition control to gas valve If wires and connections at 9 pin connector check good replace ig...

Page 43: ...ontrol will de energize the gas valve and retry for ignition or lockout DSI Direct Spark Ignition Systems 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 Disconnect the flame sensor wire from terminal FS of the ignition control module Flame Sensor Flame Sensor 2 Conn...

Page 44: ...86 173 51 1164 302 52 908 158 1118 260 1249 333 0 5 835 182 54 1131 314 53 857 166 1071 268 1211 345 0 6 781 188 58 1086 319 55 784 175 1023 275 1168 348 0 7 731 200 62 1038 319 58 732 180 973 283 1126 360 0 8 677 202 X 984 322 61 673 188 923 290 1082 362 A GPDM33008041A Rise Range 35 65 E S P T1 1ST Stage Heating Speed T2 2nd Stage Heating Speed T3 Cooling Speed T4 Cooling Speed T5 Cooling Speed ...

Page 45: ...se Range 35 65 E S P T1 1ST Stage Heating Speed T2 2 nd Stage Heating Speed T3 Cooling Speed T4 Cooling Speed T5 Cooling Speed CFM WATTS RISE CFM WATTS RISE CFM WATTS CFM WATTS CFM WATTS 0 1 1098 167 51 1423 324 53 1164 180 1542 420 1677 540 0 2 1038 178 54 1375 335 55 1100 188 1491 429 1633 551 0 3 991 184 57 1322 347 57 1037 196 1440 435 1579 555 0 4 932 192 60 1275 347 59 974 204 1390 338 1537 ...

Page 46: ...SOR GAS VALVE CHECK PRESSURE SWITCH 3 FLASHES 2 FLASHES 4 FLASHES 5 FLASHES FALSE FLAME DETECTED OPEN LIMIT SWITCH WITHOUT INDUCER ON PRESSURE SWITCH OPEN CHECK FOR SHORTS IN FLAME SENSOR WIRING NORMAL FLAME PRESENT DIAGNOSTIC LED AMBER GAS PRESSURE FLAME SENSOR GAS VALVE GAS FLOW CHECK GAS VALVE ON OFF 1 FLASH 2 FLASHES FALSE FLAME DETECTED LOW FLAME SIGNAL NO FLAME PRESENT STATUS CHECK NOTE Faul...

Page 47: ...tuck Open 3 Flashes Pressure Switch Stuck Closed 4 Flashes Thermal Protection Device Open 5 Flashes Flame Detected with Gas Valve Closed 6 Flashes Short Cycle Compressor Delay Cooling Only 7 Flashes Limit Opened Five 5 Times Within The Same Call For Heat 8 Flashes Indoor Outdoor Thermostat Open Cooling Only Devices Not present On All Models 9 Flashes High Pressure Loss of Charge Switch Open Coolin...

Page 48: ... RS VM ALS PS GV IGN H C F LO HEAT 6 3 1 2 4 5 OR BL PU YL OR BR OR P1 PIN 3 P1 PIN 5 P1 PIN 9 P1 PIN 2 BR YL P1 PIN 6 P1 PIN 7 YL P1 PIN 8 RD P1 PIN 1 BL P1 PIN 5 BK BL PK BL OR OR OR OR RD RD RD BL BK BK RD RD PU PU RD BL BL BL BK BK BK PU BL YL WH BR YL OR OR RD RD RD PK RD PK PU PU PU PU YL PU YL RD BK BK BK BK PU PU PU RD BK RD RD BL BL BL BL BL BL BL BL BL BL BL BL YL OR PU PU OR OR WH WH WH...

Page 49: ...WIRING LOW VOLTAGE LOW VOLTAGE BK BLACK WIRE CODE PK PINK OR ORANGE GR GREEN BR BROWN BL BLUE RD RED WH WHITE YL YELLOW PU PURPLE COOL HI HEAT LO HEAT P2 2 6 3 1 2 8 6 3 1 2 L1 L1 HI LO HI DR C R W Y O C HI M RS PS LS ALS TR EM VM H F RCCF C L2 T2 208 230 1 60 CM L1 R T1 S COMP C SUPPLY VOLTAGE P1 REPLACE CONTROL CHECK CHECK FOR SHORTS IN FLAME SENSOR WIRING NORMAL FLAME PRESENT DIAGNOSTIC LED AMB...

Page 50: ...X 3597706 500 48926 002 ORANGE 1 X 78 GROUND 1 X 50 COLOR CODES FOR PLUG 1 8 O ORANGE GROUND G GREEN WIRE LENGTHS FOR PLUG 1 9 8 7 3 2 1 G Y2 TSTAT Y1 CONTACTOR COMMON Y1 TSTAT O 6 5 4 CC1 Y Y2 CONTACTOR CC2 1 P PURPLE Y YELLOW 4 1 2 6 5 4 1 2 6 5 Y1 Y2 W2 R G C Y1 Y2 W2 R G C COOL 1 HEAT FAN ECON PLUG PLUG ECON GMC TERMINAL BLOCK ROOM THERMOSTAT 8 8 O O RV RV REVERSING VALVE ENERGIZED IN COOLING ...

Page 51: ...t us Amana Brand Products http www amana hac com about us contact us You can also scan the QR code on the right for the product brand you purchased to be directed to the feedback page GOODMAN BRAND AMANA BRAND 2020 2022 Daikin Comfort Technologies Manufacturing L P Brand is a registered trademark of Maytag Corporation or its related companies and is used under license All rights reserved ...