Goodman CONDENSING UNIT Installation Manual

CONDENSING UNIT

AIR CONDITIONING INSTALLATION & SERVICE REFERENCE

Important Safety Instructions

The following symbols and labels are used throughout this manual to indicate immediate or potential safety hazards. It is the owner’s and installer’s responsibility to read and comply with all safety information and instructions accompanying these symbols. Failure to heed safety information increases the risk of personal injury, property damage, and/or product damage.

HIGH VOLTAGE!

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

Important Note to the Owner regarding Product Warranty

Your warranty certificate is supplied as a separate document with the unit installed by your contractor. Read the limited warranty certificate carefully to determine what is and is not covered and keep the warranty certificate in a safe place. If you are unable to locate the warranty certificate please contact your installing contractor or contact customer service (877254-4729) to obtain a copy.

IMPORTANT: To receive the 10-Year Parts Limited Warranty, online registration must be completed within 60 days of installation. Online registration is not required in California or Quebec. Complete warranty details available from your local dealer or, for Goodman® brand products, visit www.goodmanmfg.com, and for Amana® brand products, visit www.amana-hac.com.

IMPORTANT: To register your Goodman® brand unit, go to www.goodmanmfg.com and click “Warranty Registration”. Complete registration as prompted.

To register your Amana® brand unit, go to www.amana-hac.com and click “Warranty Registration”. Complete registration as prompted.

Product limited warranty certificates for models currently in production can be viewed at www.goodmanmfg.com or www.amana-hac.com. If your model is not currently in production or does not appear on the website, please contact your installing contractor or contact customer service (877-254-4729) to obtain a copy of your warranty certificate.

Each product overview page contains a Product Warranty link; by clicking on it you will be able to view the limited warranty coverage for that specific product. To view warranty registration information, click on the Product Warranty text on the left navigation panel on the home page of each website. The Online Product Registration pages are located in this same section.

Shipping Inspection

Always keep the unit upright; laying the unit on its side or top may cause equipment damage. Shipping damage, and subsequent investigation is the responsibility of the carrier. Verify the model number, specifications, electrical characteristics, and accessories are correct prior to installation. The distributor or manufacturer will not accept claims from dealers for transportation damage or installation of incorrectly shipped units.

Codes & Regulations

This product is designed and manufactured to comply with national codes. Installation in accordance with such codes and/ or prevailing local codes/regulations is the responsibility of the installer. The manufacturer assumes no responsibility for equipment installed in violation of any codes or regulations. Rated performance is achieved after 72 hours of operation.Rated performance is delivered at the specified airflow. See outdoor unit specification sheet for split system models or product specification sheet for packaged and light commercial models. Specification sheets can be found at www.goodmanmfg.com for Goodman® brand products or www.amana-hac.com for Amana brand products. Within either website, please select the residential or commercial products menu and then select the submenu for the type of product to be installed, such as air conditioners or heat pumps, to access a list of product pages that each contain links to that model’s specification sheet.

The United States Environmental Protection Agency (EPA) has issued various regulations regarding the introduction and disposal of refrigerants. Failure to follow these regulations may harm the environment and can lead to the imposition of substantial fines. Should you have any

questions please contact the local office of the EPA.

is a registered trademark of Maytag Corporation or its related companies and is used under

If replacing a condensing unit or air handler, the system must be manufacturer approved and Air Conditioning, Heating and Refrigeration Institute (AHRI) matched. NOTE: Installation of unmatched systems is strongly discouraged.

Operating the unit in a structure that is not complete (either as part of new construction or renovation) will void the warranty.

Installation Clearances

Special consideration must be given to location of the condensing unit(s) in regard to structures, obstructions, other units, and any/all other factors that may interfere with air circulation. Where possible, the top of the unit should be completely unobstructed; however, if vertical conditions require placement beneath an obstruction there should be a minimum of 60

inches between the top of the unit and the obstruction(s).

The specified dimensions meet requirements for air circulation only. Consult all appropriate regulatory codes prior to determining final clearances.

Another important consideration in selecting a location for the unit(s) is the angle to obstructions. Either side adjacent the valves can be placed toward the structure provided the side away from the structure maintains minimum service clearance. Corner installations are strongly discouraged.

This unit can be located at ground floor level or on flat roofs. At ground floor level, the unit must be on a solid, level foundation that will not shift or settle. To reduce the possibility of sound transmission, the foundation slab should not be in contact with or be an integral part of the building foundation. Ensure the foundation is sufficient to support the unit. A concrete slab raised above ground level provides a suitable base.

Rooftop Installations

If it is necessary to install this unit on a roof structure, ensure the roof structure can support the weight and that proper consideration is given to the weather-tight integrity of the roof. Since the unit can vibrate during operation, sound vibration transmission should be considered when installing the unit. Vibration absorbing pads or springs can be installed between the condensing unit legs or frame and the roof mounting assembly to reduce noise vibration.

T o avoid possible injury, explosion or death, practice safe handling of refr ig erants.

Safe Refrigerant Handling

NOT

RECOMMENDED

B B B

AA AAA

Model Type A B C AA

Residential

Light Commercia l

Minim um Airf low Clearance

10" 10" 18" 20" 12" 12" 18" 24"

OK!

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

Refrigerants are heavier than air. They can "push out" the oxygen in your lungs or in any enclosed space. To avoid possible difficulty in breathing or death:

Never purge refrigerant into an enclosed room or

•

space. By law, all refrigerants must be reclaimed.

If an indoor leak is suspected, thoroughly ventilate the

•

area before beginning work.

• Liquid refrigerant can be very cold. To avoid possible frostbite or blindness, avoid contact and wear gloves and goggles. If liquid refrigerant does contact your skin or eyes, seek medical help immediately.

• Always follow EP A regulations. Never burn refrigerant, as poisonous gas will be produced.

To av oi d po s sible explosion: Never apply flame or steam to a refrigerant cylinder.

•

If you must heat a cylinder for faster charging, partially imm erse it in wa rm water.

Never fill a cylinder more than 80% full of liquid re-

•

frigerant.

• Never add anything other than R-22 to an R-22 cy linder or R-410A to an R-410A cylinder. The service equipment used must be listed or certified for the type of refrigerant used.

• Store cylinders in a cool, dry place. Never use a cy linder as a platform or a roller.

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 excee d 5 years.

• Ensure the pressure rating meets or exceeds 400 lbs.

When in doubt, do not us e cylinder.

Refrigerant Lines

CAUTION

The compressor POE oil for R-410A units is extremely susceptible to moisture absorption and c ould cause compressor failure. Do not leave system open to atmosphere any longer than necessary for installation.

Use only refrigerant grade (dehydrated and sealed) copper tubing to connect the condensing unit with the indoor evaporator. After cutting the tubing, install plugs to keep refrigerant tubing clean and dry prior to and during installation. Tubing should always be cut square keeping ends round and free from burrs. Clean the tubing to prevent contamination.

Do NOT let refrigerant lines come in direct contact with plumbing, ductwork, floor joists, wall studs, floors, and walls. When running refrigerant lines through a foundation or wall, openings should allow for sound and vibration absorbing material to be placed or installed between tubing and foundation. Any gap between foundation or wall and refrigerant lines should be filled with a pliable silicon-based caulk, RTV or a vibration damping material. Avoid suspending refrigerant tubing from joists and studs with rigid wire or straps that would come in contact with the tubing. Use an insulated or suspension type hanger. Keep both lines separate and always insulate the suction line.

These sizes are recommended for line lengths of 79 feet or less to obtain optimum performance. For alternate line sizing options or runs of more than 79 feet, refer to Remote Cooling Service Manual or TP-107 Long Line Set Application R-410A or contact your distributor for assistance.

RECOMMENDED INTERCONNECTING TUBING (Ft)

Cond

Unit

Tons Suct Liq Suct Liq Suct Liq

1 1/2 5/8 1/4 3/4 3/8 3/4 3/8

2 5/81/43/43/83/43/8

2 1/2 5/8 1/4 3/4 3/8 7/8 3/8

3 3/4 3/8 7/8 3/8 1 1/8 3/8

3 1/2 7/8 3/8 1 1/8 3/8 1 1/8 3/8

4 7/ 8 3/8 1 1/8 3/8 1 1/8 3/8 5 7/ 8 3/8 1 1/8 3/8 1 1/8 3/8

* Lines greater than 79 feet in length or vertical elevation changes more than 50 feet

Service Manual or contact your distributor for assistance.

0-24 25-49 50-79*

Line Di ameter (I n. OD )

refer to the Remote Cool ing

Insulation is necessary to prevent condensation from forming and dropping from the suction line. Armflex (or satisfactory equivalent) with 3/8” min. wall thickness is recommended. In severe conditions (hot, high humidity areas) 1/2” insulation may be required. Insulation must be installed in a manner which protects tubing from damage and contamination.

Where possible, drain as much residual compressor oil from existing systems, lines, and traps; pay close attention to low areas where oil may collect. NOTE: If changing refrigerant types, ensure the indoor coil and metering device is compatible with the type of refrigerant being used; otherwise, the indoor coil must be replaced.

Burying Refrigerant Lines

If burying refrigerant lines can not be avoided, use the following checklist.

1. Insulate liquid and suction lines separately.

2. Enclose all underground portions of the refrigerant lines in waterproof material (conduit or pipe) sealing the ends where tubing enters/exits the enclosure.

3. If the lines must pass under or through a concrete slab, ensure lines are adequately protected and sealed.

Refrigerant Line Connections

Leak T esting (Nitrogen or Nitrogen-Traced)

IMPORTANT

To avoid overheating the service valve, TXV valve, or filter drier while brazing, wrap the component with a wet rag, or use a thermal heat trap compound. Be sure to follow the manufacturer’s instruction when using the heat trap compound. Note: Remove Schrader valves from service valves before brazing tubes to the valves. Use a brazing alloy of 2% minimum silver content. Do not use flux.

Torch heat required to braze tubes of various sizes is proportional to the size of the tube. Tubes of smaller size require less heat to bring the tube to brazing temperature before adding brazing alloy. Applying too much heat to any tube can melt the tube. Service personnel must use the appropriate heat level for the size of the tube being brazed. Note: The use of a heat shield when brazing is recommended to avoid burning the serial plate or the finish on the unit.

1. The ends of the refrigerant lines must be cut square, deburred, cleaned, and be round and free from nicks or dents. Any other condition increases the chance of a refrigerant leak.

2. “Sweep” the refrigerant line with nitrogen or inert gas during brazing to prevent the formation of copper-oxide inside the refrigerant lines. The POE oils used in R-410A applications will clean any copper-oxide present from the inside of the refrigerant lines and spread it throughout the system. This may cause a blockage or failure of the metering device.

3. After brazing, quench the joints with water or a wet cloth to prevent overheating of the service valve.

4. Ensure the filter drier paint finish is intact after brazing. If the paint of the steel filter drier has been burned or chipped, repaint or treat with a rust preventative. This is especially important on suction line filter driers which are continually wet when the unit is operating.

NOTE: Be careful not to kink or dent refrigerant lines. Kinked or dented lines will cause poor performance or compressor damage.

Do NOT make final refrigerant line connection until plugs are removed from refrigerant tubing.

NOTE: Before brazing, verify indoor piston size by checking the piston kit chart packaged with indoor unit.

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.

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.

System Evacuation

Condensing unit liquid and suction valves are closed to contain the charge within the unit. The unit is shipped with the valve stems closed and caps installed. Do not open valves until

the system is evacuated.

WARNING

REFRIGERANT UNDER PRESSURE!

Failure to follow proper procedures may cause proper ty damag e , pe rsonal injury or death.

NOTE: Scroll compressors should never be used to evacuate

or pump down a heat pump or air conditioning system.

CAUTION

Prolonged operation at suction pressures less than 20 psig for more than 5 seconds will result in overheating of the scrolls and permanent damage to the scroll tips, drive bearings and internal seal.

1. Connect the vacuum pump with 250 micron capability to the service valves.

2. Evacuate the system to 250 microns or less using suction and liquid service valves. Using both valves is necessary as some compressors create a mechanical seal separating the sides of the system.

3. Close pump valve and hold vacuum for 10 minutes. Typically pressure will rise during this period.

• If the pressure rises to 1000 microns or less and remains

steady the system is considered leak-free; proceed to startup.

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