CONDENSING AC UNIT
SINGLE / THREE PHASE AIR CONDITIONERS
INSTALLATION & SERVICE REFERENCE
© 2010-2012 Goodman Manufacturing Company, L.P.
5151 San Felipe, Suite 500, Houston, TX 77056
www.goodmanmfg.com -or- www.amana-hac.com
P/N: IO-402G Date: May 2012
NOTICE
THIS UNIT IS SHIPPED WITH A NITROGEN/HELIUM
HOLDING CHARGE ONLY. UNIT MUST BE EVACUA TED
AND CHARGED PER INSTALLATION INSTRUCTIONS
WITH REFRIGERANT LISTED ON SERIAL RATING PLATE.
NOTICE
UNITS SHIPPED WITH A HOLDING CHARGE ARE
INTENDED FOR COMPONENT REPLACEMENT ONLY ON
EXISTING SYSTEMS, AND NOT INTENDED FOR USE IN
NEW SYSTEMS OR NEWLY CONSTRUCTED HOMES.
EP A REGULATIONS PROHIBIT THE SALE OR
DISTRIBUTION OF APPLIANCES PRE-CHARGED WITH
THE REFRIGERANT R-22 IF THOSE APPLIANCES ARE
MANUFACTURED AFTER JANUARY 1, 2010.
COMPONENTS OF EXISTING R-22 SYSTEMS MAY BE
REP AIRED AND/OR REPLACED.
NOTICE
UNITS MUST ONLY BE USED A S REPLACEMENT
COMPONENTS FOR PRE-2010 INSTALLED SYSTEMS.
See unit rating plate for initial charge.
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,
perso n a l i njury or death.
ONL Y individuals meeting (at a minimum) the
requirements of an “Entry Level T echnician” as
specified by the
Refrigeration Institute (AHRI)
info rmat i on. Attempting to i ns tal l o r r epa ir th is u nit
withou t suc h ba ck gro und may res ul t in p rod uc t
damage, personal injury, or death.
Air-Conditioning, Heating and
may use this
CAUTION
Scroll equipped units should never be used to evacuate
the air conditioning system. Vacuums this low can cause
internal electrical arcing resulting in a damaged or failed
compressor.
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 (877-254-4729)
to obtain a copy.
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.
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 ques-
tions please contact the local office of the EPA.
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.
NOT
RECOMMENDED
OK!
B
OK!
Safe Refrigerant Handling
While these items will not cover every conceivable situation,
they should serve as a useful guide.
WARNING
To avoid possible injury, ex plosion or de ath, pra c t ic e
safe handling of refrigerants.
WARNING
Refrigerants are hea vier 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, throughly ventilate the
area b efor e begi nning 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 EPA regulations. Never burn refrig erant, as poisonous gas will be produced.
B B B
AA AAA
C
AA
A
Model Type A B C AA
Residential
Light Co m mer ci a l
AA
Minimum Airflow Clearance
10" 10" 18" 20"
12" 12" 18" 24"
AA
C
AA
CC
AA
OK!
OK!
OK!
OK!
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.
To avoid possible explosio n:
Never apply flame or steam to a refrigerant cylinder.
•
If you must heat a cylinder for faster charging,
partially imm erse it in war m w ater.
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 . 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 pl atform or a roll e r.
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 use cylinder.
Refrigerant Lines
CAUTION
The compressor mineral oil for R-22 units is susceptible to
moistu re a bs orpt i on and cou ld cause compressor failu re .
Do not leave sys tem ope n to atm o sp he re any longe r than
necess ar y for insta lla tion .
2
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. For other line sizing option or runs of more than fifty feet,
refer to Remote Cooling Service Manual, or TP-106 Long Line
Set Application R-22, or contact your distributor for assistance.
RECOMMENDED INTERCONNECTING TUBING (Ft)
Cond
Unit
Tons Suct Liq Suct Liq Suct Liq
0-24 25-49 50-79*
Line Diamet er ( In. OD)
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.
refer to the Remote Cooling
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.
3
Refrigerant Line Connections
NOTICE
THIS UNIT IS SHIPPED WITH A NITROGEN/HELIUM
HOLDING CHARGE ONLY. UNIT MUST BE EVACUATED
AND CHARGED PER INSTALLATION INSTRUCTIONS
WITH REFRIGERANT LISTED ON SERIAL RATING PLA TE.
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.
NOTICE
UNITS SHIPPED WITH A HOLDING CHARGE ARE
INTENDED FOR COMPONENT REPLACEMENT ONL Y ON
EXISTING SYSTEMS, AND NOT INTENDED FOR USE IN
NEW SYSTEMS OR NEWLY CONSTRUCTED HOMES.
EP A REGULATIONS PROHIBIT THE SALE OR
DISTRIBUTION OF APPLIANCES PRE-CHARGED WITH
THE REFRIGERANT R-22 IF THOSE APPLIANCES ARE
MANUFACTURED AFTER JANUARY 1, 2010.
COMPONENTS OF EXISTING R-22 SYSTEMS MAY BE
REP AIRED AND/OR REPLACED.
NOTICE
UNITS MUST ONLY BE USED AS REPLACEMENT
COMPONENTS FOR PRE-2010 INSTALLED SYSTEMS.
NOTE: Holding charge must be removed before brazing. Open
service valves slowly to remove holding charge. Close valves
before brazing to prevent contaminants from entering system.
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.
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.
Leak T esting (Nitrogen or Nitrogen-Traced)
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. The unit
is shipped with the valve stems closed and caps installed.
WARNING
REFRIGERANT UNDER PRESSURE!
Failure to follow proper procedures may cause
proper ty damage, pe rsonal i njury or death.
NOTE: Scroll compressors should never be used to evacuate
or pump down a heat pump or air conditioning system.
2. “Sweep” the refrigerant line with nitrogen or inert gas during brazing to prevent the formation of copper-oxide inside the refrigerant lines. This may cause a blockage or
failure of the metering device.
4
NOTICE
THIS UNIT IS SHIPPED WITH A NITROGEN/HELIUM
HOLDING CHARGE ONLY. UNIT MUST BE EVACUATED
AND CHARGED PER INSTALLATION INSTRUCTIONS
WITH REFRIGERANT LISTED ON SERIAL RATING PLA TE.
NOTICE
UNITS SHIPPED WITH A HOLDING CHARGE ARE
INTENDED FOR COMPONENT REPLACEMENT ONL Y ON
EXISTING SYSTEMS, AND NOT INTENDED FOR USE IN
NEW SYSTEMS OR NEWLY CONSTRUCTED HOMES.
EP A REGULATIONS PROHIBIT THE SALE OR
DISTRIBUTION OF APPLIANCES PRE-CHARGED WITH
THE REFRIGERANT R-22 IF THOSE APPLIANCES ARE
MANUFACTURED AFTER JANUARY 1, 2010.
COMPONENTS OF EXISTING R-22 SYSTEMS MAY BE
REP AIRED AND/OR REPLACED.
NOTICE
UNITS MUST ONLY BE USED AS REPLACEMENT
COMPONENTS FOR PRE-2010 INSTALLED SYSTEMS.
5000
4500
4000
3500
MICRONS
3000
IN
2500
ACUUM
2000
V
1500
1000
500
0 1 2 3 4 5 6 7 8 9
CONDENSIBLES OR SMALL
LEAK PRESENT
NO LEAKS
NO CONDENSIBLES
MINUTES
LEAK(S)
PRESENT
10
• If pressure rises above 1000 microns but holds steady
below 2000 microns, moisture and/or noncondensibles
may be present or the system may have a small leak.
Return to step 2: If the same result is encountered check
for leaks as previously indicated and repair as necessary
then repeat evacuation.
NOTE: Holding charge must be removed before brazing.
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 intern al seal.
1. Open service valves before attaching vacuum pump.
2. Connect the vacuum pump with 250 micron capability to
the service valves.
3. 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.
4. 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.
• If pressure rises above 2000 microns, a leak is present.
Check for leaks as previously indicated and repair as necessary then repeat evacuation.
Electrical Connections
WARNING
HIGH VOLTAGE!
Disconnect ALL power before servicing.
Multiple power sources may be presen t .
Failure to do so may cause property damage,
personal injury or death due to electric shock.
Wiring must conform with NEC or CEC and all
local codes. Undersized wires cou ld cause
poor equipment per formance, equipment da m a ge
or fire.
WARNING
To avoid the risk of fire or equipment damage, use
copper conductors.
NOTICE
UNITS WITH RECIPROCATING COMPRESSORS AND
NON-BLEED TXV’S REQUIRE A HARD START KIT.
The condensing unit rating plate lists pertinent electrical data
necessary for proper electrical service and overcurrent protection. Wires should be sized to limit voltage drop to 2% (max.)
from the main breaker or fuse panel to the condensing unit.
Consult the NEC, CEC, and all local codes to determine the
correct wire gauge and length.
5
Local codes often require a disconnect switch located near the
unit; do not install the switch on the unit. Refer to the installation instructions supplied with the indoor furnace/air handler for
specific wiring connections and indoor unit configuration. Likewise, consult the instructions packaged with the thermostat
for mounting and location information.
Overcurrent Protection
The following overcurrent protection devices are approved for
use.
• Time delay fuses
• HACR type circuit breakers
These devices have sufficient time delay to permit the motorcompressor to start and accelerate its load.
Three Phase Compressor Rotation
System Start Up
CAUTION
POSSIBLE REFRIGERANT LEAK
To avoid a possible refrigerant leak, open the service
valves until the top of the stem is 1/8” from the retainer.
When opening valves with retainers, open each valve only until
the top of the stem is 1/8” from the retainer. To avoid loss of
refrigerant, DO NOT apply pressure to the retainer. When opening valves without a retainer remove service valve cap and insert a hex wrench into the valve stem and back out the stem
by turning the hex wrench counterclockwise. Open the valve
until it contacts the rolled lip of the valve body.
NOTE: These are not back-seating valves. It is not necessary
to force the stem tightly against the rolled lip.
CAUTION
Use care when handling scroll c ompressors. Dome temperatures could be hot.
Three phase compressors are power phase dependent and can
rotate in either direction.
Verify proper rotation for three phase compressors by ensuring
the suction pressure drops and discharge pressure rises when
the compressor is energized. NOTE: When operated in reverse, a three phase scroll compressors is noisier and its current draw substantially reduced compared to marked values.
To correct, disconnect power and switch any two leads at the
unit contactor and re-observe.
High Voltage Connections
Route power supply and ground wires through the high voltage
port and terminate in accordance with the wiring diagram provided inside the control panel cover.
Low Voltage Connections
Condensing unit control wiring requires 24 Volt minimum, 25VA
service from the indoor transformer. Route control wires through
the low voltage port and terminate in accordance with the wiring diagram provided inside the control panel cover.
The service valve cap is the secondary seal for the valves and
must be properly tightened to prevent leaks. Make sure cap is
clean and apply refrigerant oil to threads and sealing surface
on inside of cap. Tighten cap finger-tight and then tighten additional 1/6 of a turn (1 wrench flat), or to the following specification, to properly seat the sealing surfaces.
1. 3/8” valve to 5 - 10 in-lbs
2. 5/8” valve to 5 - 20 in-lbs
3. 3/4” valve to 5 - 20 in-lbs
4. 7/8” valve to 5 - 20 in-lbs
Do not introduce liquid refrigerant from the cylinder into the
crankcase of the compressor as this may damage the
compressor.
CAUTION
POSSIBLE REFRIGERANT LEAK
To avoid a possible refrigerant leak, open the service
valves until the top of the stem is 1/8” from the retainer.
NOTICE
REFRIGERANT MUST BE ADDED TO THE SYSTEM AFTER
EVACUATION IS COMPLETE.
Single-Stage Thermostat
with Two Low Voltage Wires to Remote
WARNING
REFRIGERANT UNDER PRESSURE!
• Do not overcharge system with refrigerant.
• Do not operate unit in a vacuum or at negative pres sure.
Failure to follow proper procedures may cause
proper ty damage, pe rsonal i njury or death.
1. Add refrigerant amount for the unit being installed. See
unit rating plate for initial charge.
2. Set thermostat to call for cooling. Check indoor and outdoor fan operation and allow system to stabilize for 10
minutes for fixed orifices and 20 minutes for expansion
valves.
6
Charge V erification
V
WARNING
REFRIGERANT UNDER PRESSURE!
• Do not overcharge system with refrigerant.
• Do not operate unit in a vacuum or at negative pres sure.
Failure to follow proper procedures may cause
proper ty damage, pe rsonal i njury or death.
CAUTION
Use refrige ra nt cert i fied standards. Use of used
refriger ant ma y ca us e co m p res s or da ma g e tha t is not
covered under warranty. Most po rtab le m ach ine s ca nn o t
clean used re friger a nt to meet tandar ds .
to AHRI
AHRI s
NOTICE
IOLATI ON OF EPA REGULATIONS MAY RESULT IN
FINES OR OTHER PENALTIES
CAUTION
Operating the compressor with the suction valve cl osed
may cause serious compressor damage.
Final Charge Adjustment
The outdoor temperature must be 60°F or higher. Set the room
thermostat to COOL, fan switch to AUTO, and set the temperature control well below room temperature.
After system has stabilized per startup instructions, check
subcooling and superheat as detailed in the following section.
Outdoor
Dry Bulb
Temperatu r e, °F
60
65
70
75
80
85
90
95
100
105
110
115
SYSTEM SUPERHEAT
In do or Wet Bu lb Te mp e ra tur e , °F
55 57 59 61 63 65 67 69 71
10 13 17 20 23 26 29 30 31
8 1114161922262729
5 8 10 13 15 19 23 24 25
--------6 91115202123
---- ---- ---- ---- 7 12 17 18 20
---- ---- ---- ---- ---- 8 13 15 16
---- ---- ---- ---- ---- 5 10 11 13
---- ---- ---- ---- ---- ---- 5 8 10
---------------------------- 5 8
-------------------------------- 5
------------------------------------
------------------------------------
7
SATURATED SUCTION PRESSURE
TEM PERAT URE CH ART
SUCTION PRESSURE
PSIG R-22
50 26
52 28
54 29
56 31
58 32
60 34
62 35
64 37
66 38
68 40
70 41
72 42
74 44
76 45
78 46
80 48
85 50
90 53
95 56
100 59
110 64
120 69
130 73
140 78
150 83
160 86
170 90
SATURATED SUCTION
TEMP ERATURE ºF
SATURATED LIQUID PRESSURE
TEMPERATURE CHART
LIQUID PRESSURE
PSIG R-2 2
200 101
210 105
220 108
225 110
235 113
245 116
255 119
265 121
275 124
285 127
295 130
305 133
325 137
355 144
375 148
405 155
415 157
425 n/a
435 n/a
445 n/a
475 n/a
500 n/a
525 n/a
550 n/a
575 n/a
600 n/a
625 n/a
SATURATED LIQUID
TEMPERATUR E ºF
8
Fixed Orifice
CAUTION
To prevent personal injury, carefully connect and disconnect
manifold gauge hoses. Escaping liquid refrigerant can cause
burns. Do not vent refrigerant into the atmosphere. Recover all
refrigerant during system repair and before final unit disposal.
1. Purge gauge lines. Connect service gauge manifold to
base-valve service ports. Run system at least 10 minutes
to allow pressure to stabilize.
2. Temporarily install thermometer on suction (large) line
near suction line service valve with adequate contact and
insulate for best possible reading.
3. Refer to the superheat table provided for proper system
superheat. Add charge to lower superheat or recover
charge to raise superheat.
4. Disconnect manifold set, installation is complete.
Superheat Formula = Suct. Line Temp. - Sat. Suct. Temp.
Expansion Valve System
1. Purge gauge lines. Connect service gauge manifold
tobase-valve service ports. Run system at least 10 minutes to allow pressure to stabilize.
2. Temporarily install thermometer on liquid (small) line near
liquid line service valve with adequate contact and insulate for best possible reading.
3. Check subcooling and superheat. Systems with TXV application should have a subcooling of 7 ± 2 ºF and superheat of 8 ± 1 ºF.
a. If subcooling and superheat are low, adjust TXV to
8 ± 1 ºF superheat, then check subcooling.
NOTE: To adjust superheat, turn the valve stem clock-
wise to increase and counter clockwise to decrease.
b. If subcooling is low and superheat is high, add charge
to raise subcooling to 7 ± 2ºF then check superheat.
c. If subcooling and superheat are high, adjust TXV
valve to 8 ± 1 ºF superheat, then check subcooling.
d. If subcooling is high and superheat is low, adjust
TXV valve to 8 ± 1 ºF superheat and remove charge
to lower the subcooling to 7 ± 2ºF.
NOTE: Do NOT adjust the charge based on suction pressure unless there is a gross undercharge.
4. Disconnect manifold set, installation is complete.
Subcooling Formula = Sat. Liquid Temp. - Liquid Line Temp.
NOTE: Check the Schrader ports for leaks and tighten valve
cores if necessary. Install caps finger-tight.
9
Troubleshooting Information
g
p
y
y
g
p
p
g
y
y
g
p
g
p
p
p
p
g
j
p
p
y
g
p
p
g
p
Complaint
POSSIBLE CAUSE
DOTS IN ANALYSIS
GUIDE INDICATE
"POSSIBLE CAUSE"
Power Failure
Blown Fuse
Loose Connection
Shorted or Broken Wires
Open Overload
Faulty Thermostat
Faulty Transformer
Shorted or Open Capacitor
Internal Com
Shorted or Grounded Compressor
Compressor Stuck
Faulty Compressor Contactor
Faulty Fan Relay
Open Control Circuit Test Control Circuit with Voltmeter
Low Voltage
Faulty Evaporator Fan Motor
Shorted or Grounded Fan Motor
Improper Cooling Anticipator
Shortage or Refrigerant
Restricted Liquid Line
Undersized Liquid Line
Undersized Suction Line
Not Enough Air across Indoor Coil
Too Much Air across Indoor Coil
Overcharge of Refrigerant
Noncondensibles
Recirculation of Condensing Air
Infiltration of Outdoor Air
Improperly Located Thermostat
Air Flow Unbalanced
System Undersized
Broken Internal Parts
Broken Valves
Inefficient Compressor
High Pressure Control Open
Unbalanced Power, 3PH
Wrong Type Expansion Valve
Expansion Valve Restricted
Oversized Expansion Valve
Undersized Expansion Valve
Expansion Valve Bulb Loose
Inoperative Expansion Valve
Loose Hold-down Bolts
ressor Overload Open
SYMPTOM
No Cooling
System will not start
Compressor will not start - fan runs
Compressor and Condenser Fan will not start
Evaporator fan will not start
Condenser fan will not start
•
•••
• •••
••••••
••
••• •
••
• •••
•
••
••
••• •
•
•••
••
•• •
•
•••
Compressor runs - goes off on overload
•• • ••
•• •
••• • ••
••• • •
•• •
Unsatisfactory
Cooling
Compressor cycles on overload
System runs continuously - little cooling
Too cool and then too warm
Not cool enough on warm days
Certain areas to cool others to warm
•• ••
•• ••
•• •
•• •
•
•• •
••••
•••
•
••
••
•••
System
Operating
Pressures
Compresso r is no is y
Low suction pressure
Low head pressure
High suction pressure
High head pressure
Test Volta
Impact Fuse Size & Type
Ins
Test Circuits with Ohmmeter
Test Continuit
Test Continuit
Check Control Circuit with Voltmeter
Test Ca
Test Continuity of Overload
Test Motor Windin
Use Test Cord
Test Continuit
Test Continuit
Test Volta
Re
Test Motor Windin
Check Resistance of Antici
Test For Leaks, Add Refrigerant
Re
Replace Line
•
•
•
••
••
•
Re
Speed Blower, Check Duct Static Pressure
Reduce Blower S
•
Recover Part of Charge
Recover Char
Remove Obstruction to Air Flow
Check Windows, Doors, Vent Fans, Etc.
Relocate Thermostat
Read
Refigure Cooling Load
Re
Test Compressor Efficiency
Test Com
Reset and Test Control
Test Volta
Replace Valve
Re
Replace Valve
Re
hten Bulb Bracket
Ti
Check Valve O
Tighten Bolts
Test Method
Remedy
e
ect Connection - Tighten
of Overloads
of Thermostat and Wirin
acitor
s
of Coil and Contacts
of Coil and Contacts
e
air or Replace
s
ator
lace Restricted Part
lace Line
eed
e, Evacuate, Recharge
ust Air Volume Dampers
lace Compressor
ressor Efficienc
e
lace Valve
lace Valve
eration
For detailed service information refer to the Remote Condensing Unit Service manual.
NOTICE
UNITS WITH ROTARY OR RECIPROCATING COMPRESSORS AND NON-BLEED
TXV’S REQUIRE A HARD START KI T.
10
THIS PAGE INTENTIONALL Y LEFT BLANK
11
SPLIT SYSTEMS
AIR CONDITIONING AND HEA T PUMP HOMEOWNER’S ROUTINE MAINTENANCE RECOMMENDA TIONS
We strongly recommend a bi-annual maintenance checkup be performed
before the heating and cooling seasons begin by a qualified servicer.
REPLACE OR CLEAN FILTER
IMPORTANT NOTE: Never operate unit without a filter installed
as dust and lint will build up on internal parts resulting in loss
of efficiency, equipment damage and possible fire.
An indoor air filter must be used with your comfort system. A
properly maintained filter will keep the indoor coil of your comfort system clean. A dirty coil could cause poor operation and/
or severe equipment damage.
Your air filter or filters could be located in your furnace, in a
blower unit, or in “filter grilles” in your ceiling or walls. The
installer of your air conditioner or heat pump can tell you where
your filter(s) are, and how to clean or replace them.
Check your filter(s) at least once a month. When they are
dirty, replace or clean as required. Disposable type filters should
be replaced. Reusable type filters may be cleaned.
You may want to ask your dealer about high efficiency filters.
High efficiency filters are available in both electronic and nonelectronic types. These filters can do a better job of catching
small airborne particles.
COMPRESSOR
The compressor motor is hermetically sealed and does not
require additional oiling.
MOTORS
Indoor and outdoor fan motors are permanently lubricated and
do not require additional oiling.
CLEAN OUTSIDE COIL (QUALIFIED SERVICER ONLY)
Air must be able to flow through the outdoor unit of your comfort system. Do not construct a fence near the unit or build a
deck or patio over the unit without first discussing your plans
with your dealer or other qualified servicer. Restricted airflow
could lead to poor operation and/or severe equipment damage.
Likewise, it is important to keep the outdoor coil clean. Dirt,
leaves, or debris could also restrict the airflow. If cleaning of
the outdoor coil becomes necessary, hire a qualified servicer.
Inexperienced people could easily puncture the tubing in the
coil. Even a small hole in the tubing could eventually cause a
large loss of refrigerant. Loss of refrigerant can cause poor
operation and/or severe equipment damage.
Do not use a condensing unit cover to “protect” the outdoor
unit during the winter, unless you first discuss it with your
dealer. Any cover used must include “breathable” fabric to avoid
moisture buildup.
BEFORE CALLING YOUR SERVICER
• Check the thermostat to confirm that it is properly set.
• Wait 15 minutes. Some devices in the outdoor unit or in
programmable thermostats will prevent compressor operation for awhile, and then reset automatically. Also, some
power companies will install devices which shut off air
conditioners for several minutes on hot days. If you wait
several minutes, the unit may begin operation on its own.
TO
AVOID THE RISK OF EQUIPMENT DAMAGE OR FIRE, INSTALL
SAME AMPERAGE BREAKER OR FUSE AS YOU ARE
THE
REPLACING
AGAIN
TO
F YOU REPEATEDLY RESET THE BREAKER OR REPLACE
I
THE
YOU RUN THE RISK OF SEVERE EQUIPMENT DAMAGE
. IF
WITHIN THIRTY DAYS, CONTACT A QUALIFIED SERVICER
CORRECT THE PROBLEM
FUSE WITHOUT HAVING THE PROBLEM CORRECTED
THE CIRCUIT BREAKER OR FUSE SHOULD OPEN
.
.
,
• Check the electrical panel for tripped circuit breakers or
failed fuses. Reset the circuit breakers or replace fuses
as necessary.
• Check the disconnect switch near the indoor furnace or
blower to confirm that it is closed.
• Check for obstructions on the outdoor unit . Confirm that
it has not been covered on the sides or the top. Remove
any obstruction that can be safely removed. If the unit is
covered with dirt or debris, call a qualified servicer to clean
it.
• Check for blockage of the indoor air inlets and outlets.
Confirm that they are open and have not been blocked by
objects (rugs, curtains or furniture).
• Check the filter. If it is dirty, clean or replace it.
• Listen for any unusual noise(s), other than normal operating noise, that might be coming from the outdoor unit.
If you hear unusual noise(s) coming from the unit, call a
qualified servicer.
12
CONDENSING AC UNIT
3-PHASE 7.5 & 10 TON AIR CONDITIONER
INSTALLATION & SERVICE REFERENCE
NOTICE
THIS UNIT IS SHIPPED WITH A NITROGEN/HELIUM HOLD ING CHARGE ONLY. UNIT
MUST BE EVACUATED AND CHARGED PER INSTALLAT I ON INSTRUCTIONS WITH
REFRIGERANT LISTED ON SERIAL RATING PLATE.
NOTICE
UNITS SHIPPED WITH A HOLDING CHARGE ARE INTENDED FOR COMPONENT
REPLACEMENT ONLY ON EXISTING SYSTEMS, AND NOT INTENDED FOR USE IN
NEW SYSTEMS OR NEWLY CONSTRUCTED HOMES.
NOTICE
UNITS MUST ONLY BE USED AS REPLACEMENT COMPONENTS FOR PRE-2010
INSTALLED SYSTEMS.
© 2010 Goodman Manufacturing Company, L.P.
5151 San Felipe, Suite 500, Houston, TX 77056
www.goodmanmfg.com -or- www.amana-hac.com
P/N: IO-404A Date: May 2012
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.
WARNING
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.
ONL Y individuals meeting the requirements of an
“Entry Level T echnician”, at a minimum, as specified
by the Air Conditioning, Heating and Refrigeration
Institute (AHRI) may use this information. Attempting
to install or r epair this u nit with out such backg round
may r esu lt i n p rod u ct dam age , per son al inj ur y,
or death.
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.
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.
If replacing a condensing unit or air handler, the system must
be manufacturer approved and Air Conditioning, Heating and
Refrigeration Institute (AHRI) matched.
Refer to the unit Specification Sheet for the recommended indoor model selection. NOTE: This unit must be used with a
purchased single stage room thermostat with 24 VAC control
circuitry.
Do not operate the unit in a structure that is not complete
(either as part of new construction or renovation). Such operation will void the warranty.
Installation Clearances
This unit is designed for outdoor installations only. 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 be-
tween 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.
60"
12"
24"
12"
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. The foundation
slab should be a minimum of 6” wider than the unit in all directions. Ensure the foundation is sufficient to support the unit. A
concrete slab raised above ground level provides a suitable
base.
The selected site should be no greater than 50’ below or 70’
above the evaporator section. For optimum performance, the
minimum length interconnecting tubing is preferred. When possible minimize the amount of bends and turns.
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.
Rigging
To avoid possible injury or death, all panels must be
in position and secured before lifting this equipment
Use field-supplied spreader bars when lifting the unit to minimize the possibility of lifting cable/straps damage. To protect
the cabinet louvers, use protective material such as plywood
behind the cable/straps. Arrange the straps to form a central
suspension point. NOTE: When raising and setting the unit,
observe all safety rules. Remove shipping skid and all protection and lifting material after the unit is in place.
Safe Refrigerant Handling
While these items will not cover every conceivable situation,
they should serve as a useful guide.
WARNING
Refrigerants are hea vier 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, throughly ventilate the
area befor e begi nning 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 EPA regulations. Never burn refrig erant, as poisonous gas will be produced.
To avoid possible ex plosion:
Never apply flame or ste am t o a refrigerant cylinder.
•
If you must heat a cylinder for faster charging,
partially im merse it in warm wa ter.
Never fill a cylinder mor e than 80% ful l of liquid re-
•
frigerant.
• Never add anything other than R-22 to an R-22 cy linder. The se r v ic e
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 p latform or a roller.
2
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 use cylinder.
Refrigerant Lines
NOTE: For improved refrigerant management, equip the
evaporator coil with a field-supplied thermal expansion valve
(TXV) and the liquid line with a field-supplied liquid line solenoid.
Ensure the solenoid is installed as close as possible to the
evaporator coil to prevent refrigeration migration in the
compressor “OFF” cycle.
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.
REFRIGERANT L INE LENGTH (ft)
Cond Unit
(Tons)
7 1/2 1 1/ 8 5/ 8 1 3/8 5/ 8 1 3/8 5/ 8
10 1 3/8 5/ 8 1 5/8 5/ 8 1 5/8 5/ 8
* Full rating line size
** Lines greater than 74 feet in length or vertical elevation
changes more than 50 feet
Servic e Manua l or contact your distributor for assistance.
0-24 25-49* 50-74**
Line Diameter (In. OD)
Suct Liq Suct Liq Suct Liq
refer to the Remote Cooling
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. To facilitate oil return to the compressor, a horizontal suction line should be pitched (1/2” per
10’ toward the condensing unit.
Filter Drier and Sight Glass
A liquid line filter drier is factory installed. Field-install the supplied sight glass/moisture indicator on the liquid line as close
as practical to the service valve.
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.
3
Refrigerant Line Connections
NOTICE
THIS UNIT IS SHIPP ED WIT H A NITROGEN /H E LIU M
HOLDING CHAR GE ONLY. UNIT MUST BE
EVACUATED AN D CHA RGED PER INSTALLA TIO N
INSTRUCTIONS WITH REFRIGERANT LISTED ON
SERIAL RATING PLATE.
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
NOTE: Holding charge must be removed before brazing. Open
service valves slowly to remove holding charge. Close valves
before brazing to prevent contaminants from entering system.
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 as
recommended by the compound manufacturer. Use a
brazing alloy of 2% minimum silver content. Do not use
flux.
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.
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.
Leak Testing (Nitrogen or Nitrogen-Traced)
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.
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.
WARNING
REFRIGERANT UNDER PRESSURE!
Failure to follow proper procedures may cause
proper ty damage, pe rsonal i njury or death.
NOTICE
THIS UNIT IS SHIPP ED WIT H A NITROGEN /H E LIU M
HOLDING CHAR GE ONLY. UNIT MUST BE
EVACUATED AN D CHA RGED PER INSTALLA TIO N
INSTRUCTIONS WITH REFRIGERANT LISTED ON
SERIAL RATING PLATE.
NOTICE
UNITS SHIPPED WITH A HOLDING CHARGE ARE
INTENDED FOR COMPONENT REPL ACEM E NT
ONLY ON EXISTING SYSTEMS, AND NOT
INTENDED FOR USE IN NEW SYSTEMS OR NEWLY
CONSTRUCTED HOMES.
NOTICE
UNITS MUST ONLY BE USED AS REPLACEMENT
COMPONENTS FOR PRE-2010 INSTALLED
SYSTEMS.
NOTE: Holding charge must be removed before brazing.
1. Openservice valves before attaching vacuum pump.
2. Connect the vacuum pump with 250 micron capability to
the service valves.
3. 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.
4. Close pump valve and hold vacuum for 10 minutes. Typically pressure will rise during this period.
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.
4
5000
4500
4000
3500
MICRONS
3000
IN
2500
ACUUM
2000
V
1500
1000
500
0 1 2 3 4 5 6 7 8 9
CONDENSIBLES OR SMALL
LEAK PRESENT
NO LEAKS
NO CONDENSIBLES
MINUTES
LEAK(S)
PRESENT
10
• If the pressure rises to 1000 microns or less and remains
steady the system is considered leak-free; proceed to
startup.
• If pressure rises above 1000 microns but holds steady
below 2000 microns, moisture and/or noncondensibles
may be present or the system may have a small leak.
Return to step 2: If the same result is encountered check
for leaks as previously indicated and repair as necessary
then repeat evacuation.
• If pressure rises above 2000 microns, a leak is present.
Check for leaks as previously indicated and repair as necessary then repeat evacuation.
Refer to the Remote Condensing Unit Service Manual for more
detailed instructions on system evacuation, preliminary charge
adjustment, and final charge adjustment.
RATED
VOLTAGE
MINIMUM SUPPLY
VOLTAGE
MAXIMUM SUPPLY
VOLTAGE
208/230V 197 253
460V 414 506
The condensing unit rating plate lists pertinent electrical data
necessary for proper electrical service and overcurrent protection. Wires should be sized to limit voltage drop to 2% (max.)
from the main breaker or fuse panel to the condensing unit.
Consult the NEC, CEC, and all local codes to determine the
correct wire gauge and length. The wire size must be sufficient
to carry the Minimum Circuit Ampacity (MCA) listed on the
serial plate.
The supply voltage can be unbalanced (phase to phase) within
2%. The following formula can be used to determine the percentage of voltage unbalance for your unit.
Percentage
Voltage
Unbalance
Max. Voltage Deviation Form
=
Average Voltage
Average Voltage
Example:
L1-L2 = 220V
L2-L3 = 216V
Average Voltage = (220 + 216 + 213)/3
=649/3
Maximum Deviation from Average = 220 - 216 = 4
% Voltage Unbalance = 100 x (4/216)
= 400/216
Electrical Connections
WARNING
HIGH VOLTAGE!
Disconnect ALL power before servicing.
Multiple power sources may be presen t .
Failure to do so may caus e property da m a ge,
personal injury or death due to electric shock.
Wiring must conform with NEC or CEC and all
local codes. Undersized wires could cause
poor equipment per formance, equipment da m a ge
or fire.
WARNING
To avoid the risk of fire or equipment damage, use
copper conductors.
NOTICE
Units with reciprocating compressors and non-bleed TXV’s
require a Hard Start Kit.
This unit is designed for three phase operation. DO NOT OPERATE ON A SINGLE PHASE POWER SUPPLY. Measure
the power supply to the unit. The supply voltage must be in
agreement with the unit rating plate power requirements.
MAXIMUM ALLOWABLE LENGTH I N FEET
TO LIMIT VOLTAGE DROP TO 2%
Wire
Minim um Circuit Ampa city (MCA)
Size
(AWG)
10 15 20 25 30 35 40 45
14 75 50 37 NR NR NR NR NR
12 118 79 59 47 NR NR NR NR
10 188 125 95 75 63 54 NR NR
8 301 201 150 120 100 86 75 68
6 471 314 235 188 157 134 118 110
*Based on NEC 1996
5
Example:
A
7 ½ Ton unit is to be installed. The distance from the
building to the unit is 75’. Calculate the minimum wire size
assuming no more than 2% voltage drop.
MCA for 7 Ton 230V uni t = 43.3 (from S&R plate).
½
Applying previous table wire sizes less than #8 AWG
cannot be used for circuits which have a rating of 45A.
The #8 wire is not suitable since the maximum length for
a 45A circuit is 68’.
Solution: Use a #6 AWG wire suitable up to 110’.
NOTE: It is the contractors’s responsibility to follow the
NEC (USA) or CEC (Canada) when sizing the service
wire for this unit.
To correct, disconnect power and switch any two leads at the
unit contactor and re-observe.
High Voltage Connections
Route power supply and ground wires through the high voltage
port and terminate in accordance with the wiring diagram provided inside the control panel cover.
Low Voltage Connections
Condensing unit control wiring requires a two-conductor low
voltage circuit from the room thermostat. The wiring should be
no smaller than 18 AWG and the field connection for this circuit must be made in the unit control box using solderless
connectors (i.e. wire nuts). See the following diagram for a
typical low voltage hook-up.
SINGLE STATE LOW VOLTAGE HOOK-UP
Local codes often require a disconnect switch located near the
unit; do not install the switch on the unit. Refer to the installation instructions supplied with the indoor furnace/air handler for
specific wiring connections and indoor unit configuration. Likewise, consult the instructions packaged with the thermostat
for mounting and location information.
Overcurrent Protection
The following overcurrent protection devices are approved for
use.
• Time delay fuses
• HACR type circuit breakers
These devices have sufficient time delay to permit the motorcompressor to start and accelerate its load.
Refer to the unit serial plate and this table for the maximum
overcurrent protection permitted.
Run all line voltage wiring a conduit from the service disconnect box to the unit. Refer to the NEC (USA) or CEC (Canada)
codes for the correct size conduit based on the wire size. The
conduit enters the control box through the hole provided in the
bottom. NOTE: The control box hole is sized for 3/4” conduit. If
permitted by code, a flexible conduit is preferred to minimize
vibration transmission from the unit to the building.
Connect the line voltage wires to the L1, L2, and L3 terminals
of the definite purpose contactor (located in the unit control
box). Refer to the wiring diagram attached to the unit when
making these connections.
THERMOSTAT CH T18-60
Y1
RG
W1
AIR
HANDLER
AH090/120
CONDENSING
UNIT
CKL090/120
YELLOW
BLACK
BLUE BLUE
NOTES:
1). THERMOSTA T TO A IR HANDLE R CABLE
MUST HAVE A MINIMUM OF (4) CONDUCT ORS
2). AIR HANDLER TO CONDENSING UNI T CABLE
MUST HAVE A MINIMUM OF (2) CONDUCT ORS
GREEN
RED
WHITE
WIRE NUT
System Start Up
Never operate the compressor with the suction valve closed to
test the compressor’s pumping efficiency. In some cases, this
can result in serious compressor damage and loss of warranty
coverage.
NOTICE
THIS UNIT IS SHIPP ED WIT H A NITROGEN /H E LIU M
HOLDING CHAR GE ONLY. UNIT MUST BE
EVACUATED AN D CHA RGED PER INSTALLA TIO N
INSTRUCTIONS WITH REFRIGERANT LISTED ON
SERIAL RATING PLATE.
Three Phase Compressor Rotation
NOTICE
CAUTION
Use care when handling scroll c ompressors. Dome temperatures could be hot.
Three phase scrolls are power phase dependent and can compress in more than one direction.
Verify proper rotation for three phase compressors by ensuring
the suction pressure drops and discharge pressure rises when
the compressor is energized. NOTE: When operated in reverse, a three phase scroll compressors is noisier and its current draw substantially reduced compared to marked values.
UNITS SHIPPED WITH A HOLDING CHARGE ARE
INTENDED FOR COMPONENT REPL ACEM E NT
ONLY ON EXISTING SYSTEMS, AND NOT
INTENDED FOR USE IN NEW SYSTEMS OR NEWLY
CONSTRUCTED HOMES.
NOTICE
UNITS MUST ONLY BE USED AS REPLACEMENT
COMPONENTS FOR PRE-2010 INSTALLED
SYSTEMS.
6
For the 7-1/2 ton unit starting charge should be 15 lb of R-22
and 18 lbs for the 10 ton unit. The length of line set, indoor unit
airflow, condensing unit location and number of tubing fittings
will have an impact on final unit charge amount. Turn the electrical power on, and let the system run. Wait for the refrigerant
pressures to stabilize.
Charge V erification
WARNING
REFRIGERANT UNDER PRESSURE!
• Do not overcharge system with refrigerant.
• Do not operate unit in a vacuum or at negative pres sure.
Failure to follow proper procedures may cause
proper ty damage, pe rsonal i njury or death.
CAUTION
Use refrige ra nt cert if ied to AHRI standards . Use of used
refriger ant ma y ca us e co m p res s or da ma g e tha t is not
covered under warranty. Most po rtab le m ach ine s ca nn o t
clean used refri ger a nt to meet AHRI standa r ds .
c. If subcooling and superheat are high, adjust TXV
valve to 9 ± 1 ºF superheat, then check subcooling.
d. If subcooling is high and superheat is low, adjust
TXV valve to 9 ± 1 ºF superheat and remove charge
to lower the subcooling to 11 ± 2ºF.
NOTE: Do NOT adjust the charge based on suction pressure unless there is a gross undercharge.
4. Disconnect manifold set, installation is complete.
Subcooling Formula = Sat. Liquid Temp. - Liquid Line Temp.
NOTE: Check the Schrader ports for leaks and tighten valve
cores if necessary. Install caps finger-tight.
NOTE: Subsequent opening and replace of the cap will require
only 1/2 to 1 hex flat. See the table below for the torque required
for an effective seal on the valve bonnet (1/6 turn past finger
tight.
TUBING SIZE
5/8 14
1 3/ 8 16
TORQUE
(ft-lbs )
NOTICE
Violation of EPA regulations may result in fines or other
penalties.
CAUTION
Operating the compressor with the suction valve cl osed
may cause serious compressor damage.
Final Charge Adjustment
The outdoor temperature must be 60°F or higher. Set the room
thermostat to COOL, fan switch to AUTO, and set the temperature control well below room temperature.
After system has stabilized per startup instructions, check
subcooling and superheat as detailed in the following section.
Expansion Valve System
1. Purge gauge lines. Connect service gauge manifold
tobase-valve service ports. Run system at least 10 minutes to allow pressure to stabilize.
2. Temporarily install thermometer on liquid (small) line near
liquid line service valve with adequate contact and insulate for best possible reading.
3. Check subcooling and superheat. Systems with TXV application should have a subcooling of 11 ± 2 ºF and superheat of 9 ± 1 ºF.
a. If subcooling and superheat are low, adjust TXV
to 9 ± 1 ºF superheat, then check subcooling.
NOTE: To adjust superheat, turn the valve stem clock-
wise to increase and counter clockwise to decrease.
b. If subcooling is low and superheat is high, add
charge to raise subcooling to 11 ± 2ºF then check
superheat.
After closing the valve bonnet, perform a final refrigerant leak
test on the valves and sweat connections. Return the room
thermostat to the desired settings.
Troubleshooting
Qualified Installer/Servicer Only
When troubleshooting, the first step should always be to check
for clean coils, clean filter(s), and proper airflow. Indoor airflow
should be 375 to 425 CFM per ton of cooling based on the size
of the outdoor unit. The most common way of establishing
indoor airflow is heating temperature rise. Indoor airflow will
then be (Heating output of equipment) / (1.1 x temp. rise). In
other cases, measurement of external static pressure is helpful. For details, see the Installation Instructions for your indoor
unit.
7
TROUBLESHOOTING ANALYSIS T ABLE
COMPLAINT PROBABLE CAUSE REMEDY
1. Excessive charge of refrigerant in system. 1. Purge or pump-down excessive charge.
2. Inadequate supply of air across the 2. Make certai n that coil is not fouled in any
1. H igh Hea d Pressure
2. Low Head Pressure
3. Low Suction Pressure
4. High Suction Pressure
5. C omp res sor wi ll not s tart.
condenser coil. way, or that air is not re-circulating.
3. Non-condensate gases in the system. 3. Purge these gas es from the system.
Recharge system, if necessary.
1. System l o w o n refrigerant. 1. Charge system until sight glass is clear of bubbles.
2. Compressor v alves broken . 2. Replace compr essor.
1. Liquid line valve closed. 1. Open the liquid line valve.
2. Restricted liquid line. 2. Replace filter-dryer.
3. The bulb of the thermal expansion valve 3. Detach the bulb from the suction line and h old
has lost its charge. in one hand. If no liquid refrigerant goes through
the valve, repla ce the valve.
4. System low on refrig erant. 4. Test the unit for leaks. Add refrigerant until sight
glass is free from bubbles, after repairing l e ak.
5. Dirty filters. 5. Clean or replace filter.
6. Coil frosted up. 6. Defrost and clean coil. Clean or replace filters.
7. Flash gas in the liquid line. 7. Excessive liquid line drop. Check liquid line size.
8. Quantity of air through evaporator not adequate. 8. Increase the blo wer speed.
1. Expansion valve stuck open. 1. Correct valve action or replace the valv e.
2. Expansion valve bulb not in contact with 2. Fasten bulb securely to suction line.
suction line.
3. Suction and/or discharge valve leaking or broken. 3. Replace compressor.
1. Disconnect switch open. 1. Clos e the disconnect switch.
2. Blow fuse or fuse at disconnect switch. 2. Check the cause of failure and replace the fuse.
3. Thermostat set too high. 3. Adjust to lower temperature.
4. Selector switch in "Off" position. 4. Turn selector switch knob to "Cool" position.
5. Contactor and/or relay coils burned out. 5. Replace contactor and/or relay.
6. Loose or open electrical connection in ei ther 6. Inspect and secure all electrical connections.
the control or power circuit.
Wiring Diagram
HIGH VOLTAGE!
ISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT
D
ULTIPLE POWER SOURCES MAY BE PRESENT
M
CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH
. F
AILURE TO DO SO MAY
.
.
8
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