Goodman MBE Series, MBE1200, MBE1600, MBE2000, MBR0800 Installation Instructions Manual

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MBE/MBR
BLOWER CABINET INSTALLATION INSTRUCTIONS
THIS PRODUCT CONTAINS ELECTRONIC COMPONENTS WHICH REQUIRE A DEFINITE GROUND. PROVISIONS ARE MADE FOR CONNECTION OF THE GROUND. A DEDICATED GROUND FROM THE MAIN POWER SUPPLY OR
AN EARTH GROUND MUST BE PROVIDED.
INTRODUCTION
This booklet contains the installation and operating instruc­tions for your modular blower cabinet. All warnings and pre­cautions within this booklet must be observed. Improper in­stallation can result in unsatisfactory operation or dangerous conditions and void the warranty. Read this booklet and any instructions packaged with accessories prior to installation. Give this booklet to the user and explain its provisions. The user should retain this booklet for future reference.
CHECKING PRODUCT RECEIVED
Upon receiving the unit, inspect it for damage from shipment. Claims for damage, either shipping or concealed, should be filed immediately with the shipping company. Check the unit model number, specifications, electrical characteristics and accessories to determine if they are correct. In the event an incorrect unit is shipped, it must be returned to the supplier and must NOT be installed. The manufacturer assumes no responsibility for installation of incorrectly shipped units.
REPLACEMENT PARTS
ORDERING P ARTS
When reporting shortages or damages, or ordering repair parts, give the complete unit model and serial numbers as stamped on the unit’s nameplate.
Replacement parts for this appliance are available through your contractor or local distributor. For the location of your nearest distributor, consult the white business pages, the yellow page section of the local telephone book or contact:
SERVICE PARTS DEPARTMENT
GOODMAN MANUFACTURING COMPANY, L.P.
5151 SAN FELIPE, SUITE 500
HOUSTON, TEXAS 77056
(713) 861 – 2500
IMPORTANT SAFETY INSTRUCTIONS
RECOGNIZE SAFETY SYMBOLS, WORDS, AND LABELS
The following symbols and labels are used throughout this manual to indicate immediate or potential hazards. It is the owner’s responsibility to read and comply with all safety infor­mation and instructions accompanying these symbols. Fail­ure to heed safety information increases the risk of property damage, product damage, personal injury or death.
Goodman Manufacturing Company, L.P. © 2004-2009 5151 San Felipe, Suite 500, Houston, TX 77056 www.goodmanmfg.com -or- www.amana-hac.com P/N: IO-239E Date: July 2009
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.
Inst a llation and r e pa i r o f th is u n it shoul d be performe d
by individuals meeting the requirements of an
ONLY “entry level technician” as specified by the Air Conditioning, Heating, and Refrigeration Institute (AHRI). Attempting to install or repair this unit without such ba ckground ma y r es u l t i n p r od uc t dama g e , personal injury or death.
CARBON M O NOXIDE POISONING HAZARD
Special Warning for Installation of Furnace or Air Handling Units in Enclosed Areas such as Garages, Utility Rooms or Parking Areas
Carbon monoxide producing devices (such as an automobile, space heater, gas water heater, etc.) should not be operated in enclosed areas such as unventilated garages, utility rooms or parking areas because of the danger of carbon monoxide (CO) poisoning resulting from the exhaust emissions. If a furnace or air handler is installed in an enclosed area such as a garage, utility room or parking area and a carbon monoxide producing device is operated therein, there must be adequate, direct outside ventilation.
This ventilation is necessary to avoid the danger of CO poisoning which can occur if a carbon monoxide producing device continues to operate in the enclosed area. Carbon monoxide emissions can be (re)circulated throughout the structure if the furnace or air handler is operating in any mode.
CO can cause serious illness including permanent brain damage or death.
B10259-216
-
GENERAL INFORMATION
The MBR/MBE Blower Cabinets are used in combination with a cased evaporator coil. This combination of blower and coil functions as the indoor part of a split air-conditioning system, and may be matched with a remote condensing or heat pump unit. The blower cabinet can also function as an electric fur­nace when used with an electric heater.
NOTE: The electric heating elements for electric furnace in­stallation are not shipped with the cabinet and are field-installed.
Contents
INTRODUCTION ............................................................................................................................................1
CHECKING PRODUCT RECEIVED ..............................................................................................................1
REPLACEMENT PARTS ................................................................................................................................1
ORDERING PARTS......................................................................................................................................................................... 1
IMPORTANT SAFETY INSTRUCTIONS.......................................................................................................1
RECOGNIZE SAFETY SYMBOLS, WORDS, AND LABELS............................................................................................................ 1
GENERAL INFORMATION ............................................................................................................................1
CLEARANCES AND ACCESSIBILITY ............................................................................................................................................ 3
INSULA TION .................................................................................................................................................................................. 3
INSTALLATION INSTRUCTIONS ..................................................................................................................3
BLOWER WITH CASED EVAPORA TOR COIL INSTALLA TION ..................................................................................................... 3
UPFLOW INSTALLA TION .............................................................................................................................................................. 3
COUNTERFLOW INST ALLATION .................................................................................................................................................. 3
HORIZONTAL INSTALLA TION ....................................................................................................................................................... 4
ELECTRICAL CONNECTIONS .....................................................................................................................4
HIGH VOLT AGE WIRING ................................................................................................................................................................ 4
LOW VOL TAGE WIRING................................................................................................................................................................ 5
MISCELLANEOUS ELECTRICAL ................................................................................................................................................... 5
THERMOST AT CONNECTIONS ..................................................................................................................................................... 5
MBE MOTOR ................................................................................................................................................................................. 5
MOTOR SPEED ADJUSTMENT ..................................................................................................................................................... 5
DIPSWITCH FUNCTIONS .............................................................................................................................................................. 5
CF M DE LI VER Y .............................................................................................................................................................................. 5
THERMOSTA T “FAN ONL Y” MODE ............................................................................................................................................... 6
CFM TRIM ADJUST ....................................................................................................................................................................... 6
HUMIDITY CONTROL ..................................................................................................................................................................... 6
TWO STAGE HEA TING................................................................................................................................................................... 6
THERMOSTA T WIRING.................................................................................................................................................................. 6
MBR MOTOR ................................................................................................................................................................................. 6
BLOWER PERFORMANCE DAT A .................................................................................................................................................. 6
SINGLE STAGE COOLING WITH SINGLE OR TWO STAGE HEATING ...................................................9
HEAT PUMP WITH SINGLE OR TWO-STAGE HEATING (OPTIONS FOR EMERGENCY HEAT) ........10
TWO-STAGE COOLING WITH CONVENTIONAL TWO-STAGE THERMOSTA T....................................13
HEAT PUMP WITH SINGLE OR TWO STAGE HEATING WITH CONVENTIONAL THERMOSTAT
(OPTIONS FOR EMERGENCY HEAT) .................................................................................................15
2 SPEED HEAT PUMP WITH SINGLE OR TWO-STAGE HEATING
(OPTIONS FOR EMERGENCY HEAT) WITH CONVENTIONAL TWO-STAGE THERMOSTAT.......17
TWO STAGE COOLING WITH CONVENTIONAL TWO STAGE THERMOSTAT
(ENCLOSED WITH ADD ON 1N006 DIODES) ......................................................................................20
TSTWK01 KIT REQUIRED ..........................................................................................................................20
ENCODED TWO STAGE COOLING WITH GMC THERMOSTAT PART #CHET18-60 TSTWKO1 KIT
REQUIRED..............................................................................................................................................21
TROUBLESHOOTING ENCODED TWO STAGE COOLING THERMOSTATS OPTIONS ....................22
2
Systems should be properly sized by heat gain and loss cal­culations made according to methods of the Air Conditioning Contractors Association (ACCA) or equivalent. It is the contractor’s responsibility to ensure the system has adequate capacity to heat or cool the conditioned space.
CLEARANCES AND ACCESSIBILITY
The unit can be positioned for upflow, counterflow, horizontal right or horizontal left operation. Zero clearance is allowed on all sides for combustible materials. Thirty-six inches should be allotted on the door side for maintenance and service.
To reduce risk of rusting, do not install the unit blower directly on the ground or on a floor that is likely to be wet. In such environments, the unit must be elevated by use of a sturdy, nonporous material.
INSULATION
To ensure efficient operation, review the following precautions.
If the unit is located in an area with high ambient tem­perature and/or high humidity, the air handler may be subject to nuisance sweating of the casing. On these installations, a wrap of 2” fiberglass insulation with a vapor barrier is recommended.
The factory recommends insulating the duct running through any unconditioned spaces.
To reduce operating sound and vibration transmission use flex­ible canvas duct connections at the cabinet.
INSTALLATION INSTRUCTIONS
3. Attach supply ductwork. Seal connections between unit and ductwork as required to reduce/eliminate air leak­age.
4. Make electrical connections as specified in “Electrical” section of this manual.
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Figure 2 - Upflow Application
COUNTERFLOW INST ALLATION
For counterflow installations, the evaporator coil cabinet must sit on top of the blower cabinet (Figure 3). NOTE: All panels should be in place when installing the unit.
BLOWER WITH CASED EVAPORATOR COIL INST ALLATION
TOP CABINET
BOTTOM CABINET
Figure 1
Secure the coil and blower together with the two connector plates and screws supplied in the blower bag assembly. Use one connector plate and six screws on each side of the unit.
If accessory electric heat is to be added, install now per the instructions shipped with the heater kit.
UPFLOW INST ALLA TION
For upflow installations, the blower cabinet must sit on top of the coil cabinet (Figure 2). NOTE: All panels should be in place before installing the cabinet.
1. Place the blower and coil cabinet assembly upright on the return duct or duct opening. Ensure that there is ample support for the cabinet assembly and all attached ductwork.
2. Connect refrigerant and condensate drain connections per the evaporator coil installation instructions. Ensure re­frigerant and drain lines do not interfere with service ac­cess to the unit.
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figure 3 - Counterflow Application
NOTE: Supply ductwork for counterflow applications, must be
Class I. However, if combustible ductwork is used, sheet metal protection is required.
1. Place the blower and coil cabinet assembly supply outlet on the supply duct or duct opening. Ensure there is ample support for the unit and all attached ductwork.
2. Connect refrigerant and condensate drain connections per the evaporator coil installation instructions. Ensure re­frigerant and drain lines do not interfere with service ac­cess to the unit.
3. Attach return ductwork. Seal connections between unit and ductwork as required to reduce/eliminate air leak­age.
4. Make electrical connections as specified in “Electrical” section of this manual.
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HORIZONT AL INST ALLATION
For horizontal installations, the coil cabinet must be upstream of the blower cabinet (Figures 5 and 6). NOTE: All panels should be in place when installing the unit.
1. Set the unit near its final installation place. The unit must be supported along the entire length of the unit. Rubber isolation pads may be used to reduce sound and vibration transmission. Ensure there is ample support for the unit and all attached ductwork.
Blower Cabinet
Air Flow
Support
FIGURE 5 - Attic Installation
Rods
Air Flow
Support
FRONT VIEW
FOR OPTIONAL SAFETY GND USE MOUNTING BOLTS
SIDE VIEW
FEMALE CONNECTION S
FIGURE 4 - MBE Motor Orientation
Electrical Connections
Consult the local power company and local codes before in­stalling this unit. All wiring must be in accordance with the National Electrical Code as well as all local codes. Knockouts have been provided on side and top of the cabinet for the instal­lation of the electrical conduit. If the knockouts on the cabinet sides are used for electrical conduit, an adapter ring must be used in order to meet UL1995 safety requirements. Use Mini­mum Circuit Ampacity and type of wire to determine proper wire size. The unit MUST be properly grounded. A ground lug is provided in the unit.
Check all factory connections before connecting electrical power to unit to ensure none were loosened or disconnected during shipping and handling.
FIGURE 6 - Hanging Installation
2. If installed above a finished ceiling or living space, be sure to put a secondary drain pan under the entire unit, and pipe the drain separately from the main condensate drain.
3. Connect refrigerant and condensate drain connections per the coil section installation instructions. Ensure refriger­ant and drain lines do not interfere with service access to the unit.
4. Attach return and supply ductwork. Seal connections.
5. Make electrical connections as specified in “Electrical” section of this manual.
MBE Only: Counterflow and Horizontal Applications
Loosen motor mount and rotate motor (See Figure 4). Be sure motor is oriented with the female connections on the casing pointing down. If the motor is not oriented with the connec­tions pointing down, water will collect in the motor and cause premature failure.
NOTE: After rotating motor, tighten motor mount to secure motor. Be sure that the gap between the motor and the insu­lation is the same as it was before loosening the motor mount. This will ensure that the blower wheel is properly spaced in­side the blower housing.
TO PREVENT PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK , DISCONNECT THE ELECTRICAL POWER BEFORE ELECTRICALLY CONNECTING THE UNIT.
TO AVOID THE RISK OF PROPERTY DAMA GE, PER SON AL INJURY OR FIRE USE ONLY COPPER CONDUCTORS.
CAUTION
TO AVOID THE RISK OF PERSONAL INJURY, WIRING TO THE UNIT MUST BE PROPERLY POLARIZED AND GROUNDED.
WARNING
ALL WI RING MU S T COMPLY WITH APPLI CABLE LOCAL AND NATIONAL C O DES. TYPE AND LOCATION OF FUSED DISCONNECT SWITCH(ES) MUST COMPLY WITH ALL APPLICABLE CODES AND PROVIDE OVERCURRENT PROTECTION AS SHOWN ON THE NAMEPLATE.
HIGH VOL T AGE WIRING
If heater kits will not be installed, remove the proper size knock­out for the electrical conduit connection. Connect electrical conduit to the unit using two washers to make an approved connection.
The power supply wires must be connected to the red and black power wiring. Two wire nuts are provided in the bag assembly for this connection. Wrap the wire nuts with electri-
4
cal tape. (Insulated crimp type connectors, field supplied, may be substituted for the wire nuts and electrical tape provided proper size connectors are used.) A ground wire MUST be connected to the ground lug inside the unit.
LOW VOL T AGE WIRING
Low voltage wiring connections are made at the top of the cabi­net. See the “Thermostat Wiring” section of this manual for typical low voltage wiring connections. A minimum 18 AWG wire must be used for installations up to 50 feet and 16 AWG wire for installations over 50 feet.
MISCELLANEOUS ELECTRICAL
The unit transformer is factory connected for 240 V operation. If unit is to operate on 208 V, disconnect the red wires from terminal 3 of the unit transformer and connect them to terminal 2 of the unit transformer.
INSTALLER: It is important to follow these instructions when installing the MB series of air handlers.
THERMOST AT CONNECTIONS
The following composite wiring diagrams detail various con­figurations in which your MB air handler can be used. Examples include single stage cooling, two stage cooling and heat pump with single or two stage electric heating. All these configura­tions can be applied with convenient connections to outdoor thermostat applications.
The following sections will be detailed:
Single Stage Cooling (GMC Thermostat part # CHT18­60 or equivalent)
Heat Pump (GMC Thermostat part #HPT18-60 or equiva­lent)
Two Stage Cooling with Conventional Two Stage Ther­mostat (GMC Thermostat part #CHT90-120 or equiva­lent)
Two Stage Cooling with Conventional Two Stage Ther­mostat (Encoded with Add-on Diodes)
Two Stage Encoded Thermostat from Goodman Manu­facturing Part #CHET18-60
Each diagram details the connections between room thermo­stat and MB air handlers, and the connections between the MB air handlers and the Condensing Unit (or Heat Pump) with optional connections to Outdoor Thermostats. For each con­figuration,
refer to the explanation of the proper jumper(s) to remove for the corresponding blower speed that will result in the pro­grammed ECM
TM
motor on MBE units.
Important: When matching the MBE air handlers to a single stage cooling unit or heat pump, remember to connect the “Y/ Y2” thermostat connection on the Variable speed board (VSTB) to the thermostat. Connecting “Y1” will result in first stage cooling blower speed.
Note: The two stage configurations are illustrated to detail con­nections to the two capacity condensing units and heat pumps.
An equivalent thermostat can be used in place of the Goodman thermostat part number. The GMC thermostats listed are mercury type.
When utilizing the encoded version of a conventional two stage cooling and heating electronic thermostat (add-on diodes), a hard wire “C” (common of 24V secondary voltage) must be used. This encoded version will not work with a “power robbing” thermostat (i.e. no common connection). One TSTWK01 kit is required for the encoded applications on MBE units.
NOTE: When using a conventional two stage thermostat for cooling or heat pump applications with a two stage compressor, dip switch #4 must be set to the “OFF” position on MBE units.
MBE MOTOR
This section references the operation characteristics of the MBE model motor only. The ECM control board is factory set with the dipswitch #4 in the “ON” position and all other dipswitches are factory set in the “OFF” position. For most
applications, the settings are to be changed according to the electric heat size and the outdoor unit selection.
The MBE product uses a General Electric ECM
TM
motor. This motor provides many features not available on the traditional PSC motor. These features include:
Improved Efficiency
Constant CFM
Soft Start and Stop
Improved Humidity Control
MOTOR SPEED ADJUSTMENT
Each ECM™ blower motor has been preprogrammed for op­eration at 4 distinct airflow levels when operating in Cooling/ Heat Pump mode or Electric Heat mode. These 4 distinct levels may also be adjusted slightly lower or higher if desired. The adjustment between levels and the trim adjustments are made by changing the dipswitch(s) either to an "OFF" or "ON" position.
DIPSWITCH FUNCTIONS
The MBE air handler motor has an electronic control that con­tains an eight (8) position dip switch. The function of these dipswitches are shown in Table 1.
Dipswitch Number Function
1 2 3 4 5 6 7 8
Table 1
Elec tric H e a t
N/A
Indoor Thermostat
Cooling & Heat Pump CFM
CFM Trim Adjust
CFM DELIVERY Tables 2 and 3 show the CFM output for dipswitch combina-
tions 1-2, and 5-6.
5
Model Switch 1 Switch 2 Electric Heat CFM
OFF OFF 1200
MBE1200
ON OFF 1000
OFF ON 800
ON ON 600
OFF OFF 1600
MBE1600
ON OFF 1400
OFF ON 1200
ON ON 1000
OFF OFF 1900
MBE2000
ON OFF 1600
OFF ON 1400
ON ON 1200
Table 2
Model Switch 5 Switch 6 Coo ling/HP CFM
OFF OFF 1200
MBE1200
ON OFF 1000
OFF ON 800
ON ON 600
OFF OFF 1600
MBE1600
ON OFF 1400
OFF ON 1200
ON ON 1000
OFF OFF 2000
MBE2000
ON OFF 1800
OFF ON 1600
ON ON 1200
Table 3
THERMOST A T “FAN ONL Y” MODE
During Fan Only Operations, the CFM output is 30% of the cooling setting.
CFM TRIM ADJUST
Minor adjustments can be made through the dip switch combi­nation of 7-8. Table 4 shows the switch position for this fea­ture.
NOTE: The airflow will not make the decreasing adjustment in Electric Heat mode.
CFM Switch 7 Switch 8
+10% ON OFF
-1 5 % O FF O N
TWO ST AGE HEA TING
When using staged electric heat, cut jumper PJ4 on the con­trol board.
THERMOST A T WIRING
Use thermostat wiring diagram Figures 7 through 37 and those provided with the thermostat when making these con­nections.
NOTE: If the MBE blower is used with heat pumps, remove the “Y1-O” production wire.
MBR MOTOR BLOWER PERFORMANCE DAT A
SPEED
HIGH
MEDIUM
LOW
Exter nal static is for b lower @ 230 vo lts. It doe s not includ e coi l, air filter or electric heaters .
STATIC
0.1 1240 1500 1800 2160
0.2 1170 1460 1740 2080
0.3 1120 1360 1680 1990
0.4 1060 1280 1610 1890
0.5 980 1200 1520 1790
0.6 900 1110 1430 1690
0.1 900 1380 1540 1730
0.2 850 1320 1490 1670
0.3 790 1270 1450 1590
0.4 740 1200 1400 1520
0.5 680 1140 1350 1420
0.6 605 1040 1280 1320
0.1 650 1170 1130 1520
0.2 590 1130 1100 1450
0.3 540 1080 1070 1360
0.4 500 1020 1030 1290
0.5 430 950 990 1200
0.6 330 830 930 1090
SCFM
MBR0800**-*
SCFM
MBR1200**-*
SCFM
MBR1600**-*
SCFM
MBR2000**-*
Table 4
NOTE: If no adjustment is required, dipswitches 7 & 8 should be left
in the OFF position.
HUMIDITY CONTROL
When using a Humidistat (normally closed), cut jumper PJ6 on the control board. The Humidistat will only affect cooling airflow by adjusting the Airflow to 85%.
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WARNING
HIGH VOLTAGE!
DISCO NNECT ALL POWER BEFORE SERV ICING. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
ROOM THER MO ST AT
R
WY
G
#18 GA. 4 WIRES W ITH COOLING 3 WIRES WITHOUT
MBR UNIT
CONTACT OR
COIL
R
G
W
Y
TO CONDENSING U NIT 24V. CONNE CTIO N S
#18 GA . 2 W IR ES
RED
GREEN
WHITE
BLUE
Figure 7- Low Voltage Wiring Diagram for Cooling Unit with optional heat kit 10KW and below
ROOM THERM OSTAT
W2
YGR
W
MBR UNIT
#18 G A. 4 WIRE WITH COOLING 3 WIRE WITHOUT
OUTDOOR THERMO STAT (OP T IO NA L )
#18 GA. 2 WIRES
CONTACTOR
COIL
COND EN S ING UNI T 2 4 V. CON N EC TIO NS
#18 GA. 2 W IRES
Y
W
R
G
RED
GREEN
WHITE
BROWN
BLUE
Figure 8 - Low Voltage Wiring Diagram for Cooling Unit with optional heat kit 15KW and above
Wiring is subject to change, always refer to the wiring diagram on the unit for the most up-to-date wiring.
7
WARNING
HIGH VOLTAGE!
DISCO NNECT ALL POWER BEFORE SERV ICING. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
MBR
SYSTEM COMPOSITE DIAGRAM
800-2000
10 KW & BELOW
HEAT PUMP
W2
O
C
YR
O
W
BL
#18 GA. 5 WIRE
OUTDOOR THERMOSTAT
(OPTIONAL) MAKE ON FALL
CONVENTIONAL
ROOM THERMOSTAT
Y
CW2GRE
O
R
Y
SEE NOTE
G
3
W
BL
#18 GA. 6 WIRE NEEDED WHEN O T IS USED
FIGURE 9
#18 GA. 7 WIRE
MBR UNIT
RED
R
BR
GREEN
WHITE
BLUE
SYSTEM COMPOSITE DIAGRAM
NOTES
1) OUTDOOR THERMOSTAT (OT-1) SHOULD BE THE FIRST TO CLOSE AND THE FIRST TO OPEN.
2) IF OUTDOOR THERMOSTAT IS NOT USED. TIE WHITE AND BROWN WIRES FROM AIR HANDLER TOGETHER.
3) REMOVE WIRE WHEN USING OUTDOOR T-STAT. #18 GA. 7 WIRE NEEDED WHEN (2) OTs ARE USED
1200-2000
ABOVE 10 KW
C
B L U E
SEE NOTE 1
HEAT PUMP
O
W
H T
E
W2
I
O R A N G E
YR
Y E L L O
W
BL
R E D
R
Y
O
W
OT-1 OT-2
#18 GA. 7 WIRE NEEDED WHEN (2) OTs ARE USED
MBR
CONVENTIONAL
ROOM THERMOSTAT
YOCW2GR
SEE NOTE
E
G
SEE
3
NOTE
W
1
EHR
3
BL
#18 GA. 5 WIRE
NOMENCLATURE OT - OUTDOOR THERMOSTAT (OPTIONAL) MOF - MAKE ON FALL EHR - EMERGENCY HEAT RELA Y (OP T IONAL)
FIGURE 10
#18 GA. 7 WIRE
MBR UNIT
RED
R
GREEN
2
2
4
WHITE
BROWN
BLUE
COLOR CODES R - RED O - ORANGE Y - YELLOW W - WHITE BL - BLUE PK - PINK V - VIOLET G - GREEN BR - BROWN
Wiring is subject to change, always refer to the wiring diagram on the unit for the most up-to-date wiring.
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