Goodman Mfg IO-402G User Manual

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