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.
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
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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