Goodman Mfg IO-431 User Manual
ASPF
AIR HANDLERS
INSTALLATION & OPERATING INSTRUCTIONS
© 2007 - 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-431 Date: May 2012
CONTENTS
Important Safety Instructions............................................. 2
Shipping Inspection........................................................... 3
Codes & Regulations ........................................................ 3
Replacement Parts............................................................ 3
Pre-Installation Instructions ............................................... 3
Location............................................................................. 3
Ductwork ........................................................................... 3
Return Ductwork.............................................................. 4
Return Air Filters.............................................................. 4
Electric Heat...................................................................... 4
HKR Installation................................................................. 4
Electrical Supply Wire and MOP ....................................... 4
Building Electrical Service Inspection.............................. 5
Wire Sizing ...................................................................... 5
Maximum Overcurrent Protection (MOP) ........................ 5
Electrical Connections – Supply Voltage......................... 5
Air Handler Only (Non-Heat Kit Models) ..................... 5
Air Handler With Non-Circuit Breaker Heat Kits.......... 5
Air Handler With Heat Kits
Containing a Circuit Breaker ................................... 5
Low Voltage Connections ........................................... 6
Refrigerant Lines............................................................... 6
Tubing Preparation .......................................................... 6
Post Brazing .................................................................... 6
Piping Size ...................................................................... 6
Special Instructions ......................................................... 6
Downflow Conversion ....................................................... 7
Horizontal Conversion....................................................... 7
Condensate Removal........................................................ 8
Achieve 2% Low Leakage Rate ........................................ 9
ASPF Motor....................................................................... 9
CFM Delivery................................................................... 9
Start-Up Procedure ........................................................... 9
Regular Maintenance ........................................................ 9
ASPF Thermostat Connections ....................................... 10
Cooling Unit w/Optional Heat Kits
of 10kW and Below................................................... 10
Cooling Unit w/Optional Heat Kits
of 15kW and Above
and Room Thermostat w/Two Stages of Heat........... 11
Heat Pump Unit/Optional Heat Kits
of 10kW and Below................................................... 11
Heat Pump Unit w/Optional Heat Kits
of 15kW and Above................................................... 12
ASPF Wiring Diagram ..................................................... 13
RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.
ATTENTION INSTALLING PERSONNEL
Prior to installation, thoroughly familiarize yourself with this Installation Manual.
Observe all safety warnings. During installation or repair, caution is to be observed.
It is your responsibility to install the product safely and to educate the customer on its safe use.
Important Safety Instructions
The following symbols and labels are used throughout this
manual to indicate immediate or potential safety hazards. It
is the owner’s and installer’s responsibility to read and comply with all safety information and instructions accompanying
these symbols. Failure to heed safety information increases
the risk of personal injury, property damage, and/or product
damage.
HIGH VOLTAGE!
Disconnect ALL power before servicing.
Multiple power sources may be present.
Failure to do so may cause property damage,
personal injury or death .
Install ati on an d re pair of t his u ni t sho uld b e p erf orm ed
by indiv id uals me et ing t he requi re men ts of an
ONLY
“entry level technician” as specified by
the Ai r-Co ndi ti on in g, H eati ng a nd Re fri g erati on I nst i tu te
(AHRI). Attempting to install or repair this unit without
such ba ck grou nd may re sul t i n p r od uct damag e,
personal inju ry or death.
, at a minimum,
Do not connect to or use any device that is not designcertified by Goodman for use with this unit. Serious
property damage, personal injury, reduced unit
performance and/or hazardous conditions may result
from the use of such non-approved devices.
To prevent the risk of property damage, personal
injury , or dea th, do not store comb ustible m aterials or
use gasoline or other flammable liquids or vapors in
the vicin ity of this unit.
CARBON MONOX IDE POISON ING HAZ ARD
Special Warning for Installation of Furnace or Air Handling Units in
Enclosed Areas such as Garages, Utility Rooms or Parking Areas
This product is factory-shipped for use with
208/240/1/60 electrical power supply.
DO NOT
reconfigure this air handler to operate with any other
power supply.
To avoid property damage, personal injury or death
due to electrical shock, this unit MUST have an
uninterrupted, unbroken
electrical ground. The
electrical ground circuit may consist of an
appropriately sized electrical wire con necting the
ground lug in the unit control box to the building
electrical service panel.
Other meth ods of gro unding ar e p ermit te d i f pe rfo rmed
in accordance with the National Electric Code
(NEC) /Amer ican National Stan dards I nsti tute
(ANSI)/ Nati onal Fire P rotec tion A ssocia tion (NFP A) 70
and local /s ta te c ode s. I n Canada, e le ctr ica l gro undi ng
is to be in accordance wit h t he Cana di an El ec tri c Code
(CSA) C22.1.
When installing or servicing this equipment, safety
clothing, including hand and eye protection, is
strongly recommended. If installing in an area that has
special safety requirements (hard hats, etc.), observe
these requirements.
Carbon monoxide producing devices (such as an automobile, space
heater, gas water heater, etc.) should not be operated in enclosed areas
such as unventilated garages, utility rooms or parking areas because of
the danger of carbon monoxide (CO) poisoning resulting from the exhaust
emissions. If a furnace or air handler is installed in an enclosed area such
as a garage, utility room or parking area and a carbon monoxid e producing
device is operated therein, there must be adequate, direct outside
ventilation.
This ventilation is necessary to avoid the danger of CO poisoning which
can occur if a carbon monoxide producing device continues to operate in
the enclosed area. Carbon monoxide emissions can be (re)circulated
throughout the structure if the furnace or air handler is operating in any
mode.
CO can cause serious illness including permanent brain damage or death.
B10259-216
-
Important Note to the Owner regarding Product
Warranty
Your warranty certificate is supplied as a separate document
with the unit installed by your contractor. Read the limited
warranty certificate carefully to determine what is and is not
covered and keep the warranty certificate in a safe place. If
you are unable to locate the warranty certificate please contact your installing contractor or contact customer service (877254-4729) to obtain a copy.
To receive the 10 Year Parts Limited Warranty, online registration must be completed within 60 days of installation. Online
registration is not required in California or Quebec. Complete
warranty details are available from your local dealer or, for
Goodman® brand products, visit www.goodmanmfg.com and
for Amana® brand products, visit www.amana-hac.com.
is a registered trademark of Maytag Corporation or its related companies and is used under
license to Goodman Company, L.P., Houston, TX. All rights reserved.
2
®
IMPORTANT: To register your Goodman
www.goodmanmfg.com and click on “Warranty Registration”.
Complete registration as prompted.
To register your Amana
hac.com and click “Warranty Registraion”. Complete registration as prompted.
Product limited warranty certificates for models currently in
production can be viewed at
www.amana-hac.com. If your model is not currently in production or does not appear on the website, please contact
your installing contractor or contact customer service (877254-4729) to obtain a copy of your warranty certificate.
Each product overview page contains a Product Warranty
link; by clicking on it you will be able to view the limited warranty coverage for that specific product. To view warranty registration information, click on the Product Warranty text on
the left navigation panel on the home page of each website.
The Online Product Registration pages are located in this
same section.
Keep this literature in a safe place for future reference.
®
brand unit, go to www.amana-
www.goodmanmfg.com or
brand unit, go to
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.
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.
Replacement Parts
When reporting shortages or damages, or ordering repair
parts, give the complete product model and serial numbers
as stamped on the product. Replacement parts for this product are available through your contractor or local distributor.
For the location of your nearest distributor consult the white
business pages, the yellow page section of the local telephone
book or contact:
CONSUMER AFFAIRS
GOODMAN MANUFACTURING COMPANY, L.P.
7401 SECURITY WAY
HOUSTON, TEXAS 77040
(877) 254-4729
If replacing an 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.
Pre-Installation Instructions
Carefully read all instructions for the installation prior to installing product. Make sure each step or procedure is understood and any special considerations are taken into account
before starting installation. Assemble all tools, hardware
and supplies needed to complete the installation. Some items
may need to be purchased locally. Make sure everything
needed to install the product is on hand before starting.
Location
NOTE: Air handlers are designed for indoor installation
only.
Give special consideration to minimizing the length of refrig-
erant tubing when installing air handlers. Refer to Remote
Cooling/Heat Pump Service Manual, TP-107 Long Line Set
Application R-410A for guidelines. The unit clearance from a
combustible surface may be 0". However, service clearance
is to take precedence. In addition allow a minimum of 24" in
front of the unit for service clearance.
Do not install the air handler in a location that violates the
instructions provided with the condenser.
If the unit is located in an area with high ambient temperature and/or high humidity the air handler maybe subject to
nuisance sweating of the casing. On these installations a
wrap of 2” fiberglass insulation with a vapor barrier is recommended.
Consult all appropriate regulatory codes prior to determining
final clearances. When installing this unit in an area that may
become wet, elevate the unit with a sturdy, non-porous material. In installations that may lead to physical damage (i.e.
a garage) it is advised to install a protective barrier to prevent such damage.
Ductwork
This air handler is designed for a complete supply and return ductwork system.
Do not operate this product without all the ductwork
attached.
To ensure correct system performance, the ductwork is to
be sized to accommodate 375-425 CFM per ton of cooling
with the static pressure not to exceed .5" WC. Inadequate
duct work that restricts airflow can result in improper perfor-
mance and compressor or heater failure. Ductwork is to be
constructed in a manner that limits restrictions and maintains suitable air velocity. Ductwork is to be sealed to the
unit in a manner that will prevent leakage.
3
Return Ductwork
DO NOT TERMINATE THE RETURN DUCTWORK IN AN
AREA THAT CAN INTRODUCE TOXIC, OR OBJECTIONABLE FUMES/ODORS INTO THE DUCTWORK. The return
ductwork is to be introduced into the air handler bottom (upflow
configuration).
Return Air Filters
Each installation must include a return air filter. This filtering
may be performed at the air handler or externally such as a
return air filter grille. Air handlers mounted in the downflow
orientation, including “B” series, require external filtering. A
washable filter is available as an accessory. To ensure optimum performance frequent filter cleaning is advised. Refer
to Table 1 for the appropriate filter.
ASP F F ilter Number Qt y Req uir ed
1830 FIL 36-4 2 1
3137
FIL 48- 61 1
4260
Table 1
Electric Heat
Refer to this manual in combination with the instructions provided with the heat kit for the correct installation procedure.
The air handlers listed in this manual do not have factory
installed electric heat. Electric heat is available as an accessory. If installing this option, the ONLY heat kits that can be
used are the HKR series.
NOTE: The Amana® brand EHK, ECB, EDB, and EDK kits
are NOT approved for use with these air handlers.
The heating mode temperature rise is dependent upon the
system airflow, the supply voltage, and the heat kit size (kW)
selected. Use Tables 2, 3, and 4 to determine the temperature rise (ºF).
CFM
356810152021
600 18 28 35 41
800 13 21 26 31 42
1000 11 17 21 25 34 50
12009 14182128425662
14008 12151824364853
16007 10131521314246
1800 6 9 12 14 19 28 37 41
2000 5 8 11 12 17 25 34 37
230/1/60 Supply Voltage - Temperature Rise Table °F
HEAT KIT NOMINAL kW
Table 2
CFM
600 17 27 34 39
800 13 20 25 30 40
1000 10 16 20 24 32 48
12008 13172027405359
14007 11141723344651
16006 10131520304044
1800 6 9 11 13 18 27 36 39
2000 5 8 10 12 16 24 32 35
CFM
600 16 25 32 37
800 12 19 24 38 38
1000 10 15 19 22 30 46
12008 13161925385156
14007 11141622334348
1600 6 9 12 14 19 28 38 42
1800 5 8 11 12 17 25 34 37
2000 5 8 10 11 15 23 30 34
356810152021
220/1/60 Supply Voltage - Temperature Rise Table °F
356810152021
208/1/60 Supply Voltage - Temperature Rise Table °F
HEAT KIT NOMINAL kW
Table 3
HEAT KIT NOMINAL kW
Table 4
NOTE: For installations not indicated above the following
formula is to be used:
TR = (kW x 3412) x (Voltage Correction) x 1.08 / CFM
Where: TR = Temperature Rise
kW = Heater Kit Actual kW
3412 = Btu per kW
Voltage Correction =.96 (230 Supply Volts)
=.92 (220 Supply Volts)
=.87 (208 Supply Volts)
1.08 = Constant
CFM = Measured Airflow
NOTE: The Temperature Rise Tables can also be used to
determine the air handler airflow delivery. When using these
tables for this purpose set the room thermostat to maximum
heat and allow the system to reach steady state conditions.
Insert two thermometers, one in the return air and one in the
supply air. The temperature rise is the supply air temperature
minus the room air temperature.
Use HKR specification sheets to determine the HKR available for a given air handler.
HKR Installation
Follow instructions listed in Installation and Operating Instructions shipped with the heat kit.
Electrical Supply Wire and MOP
FIRE HAZARD!
To avoid the risk of property damage, personal injury
or fire, use only copper conductors.
4
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 .
HIGH VOLTAGE!
T o avoid prope rty dama ge , persona l injury or death
due to el ect rical shock, this uni t MUST have an
uninterrupted, unbroken
electrical ground circuit may consist of an
appro pri at ely sized electrical wi re connecting the
ground lug in the unit control box to the building
electrical service panel.
Other methods of grounding are permit ted if perform ed
in accordance with the National Electric Code
(NEC) /Americ an Nation al Standar ds Institut e
(ANSI)/National Fire Protection Association (NFP A) 70
and local/state codes. In Canada, electrical grounding
is to be in ac co rda nce w ith th e C ana dian Elec tric Cod e
(CSA) C22.1.
electrical ground. The
Building Electrical Service Inspection
This unit is designed for single-phase electrical supply. DO
NOT OPERATE ON A THREE-PHASE POWER SUPPLY.
Measure the power supply to the unit. The supply voltage
must be in agreement with the unit nameplate power requirements and within the range shown in Table 5.
Nominal Input Minimum Voltage Maximum Voltage
208/240 187 253
Table 5
Wire Sizing
Wire size is important to the operation of your equipment.
Use the following check list when selecting the appropriate
wire size for your unit.
• Wire size must carry the Minimum Circuit Ampac-
ity (MCA).
• Refer to the NEC (USA) or CSA (Canada) for wire sizing. The unit MCA for the air handler and the optional
electric heat kit can be found on the unit Series and
Rating Plate.
• Wire size allows for no more than a 2% voltage drop
from the building breaker/fuse panel to the unit.
Refer to the latest edition of the National Electric Code
or in Canada the Canadian Electric Code when determining the correct wire size. The following table shows
the current carrying capabilities for copper conductors
rated at 75oC with a 2% voltage drop. Use Table 6 to
determine the voltage drop per foot of various conductors.
Maximum Allowable Length in Feet
to Limit Voltage Drop to 2%*
Wire Size
(AWG)
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
Minimum Circuit Ampacity (MCA)
10 15 20 25 30 35 40 45
Table 6
Maximum Overcurrent Protection (MOP)
Every installation must include an NEC (USA) or CEC
(Canada) approved overcurrent protection device. Also,
check with local or state codes for any special regional requirements.
Protection can be in the form of fusing or HACR style circuit
breakers. The Series and Rating Plate can be used as a
guide for selecting the MAXIMUM overcurrent device.
NOTE: Fuses or circuit breakers are to be sized larger
than the equipment MCA but not to exceed the MOP.
Electrical Connections – Supply Voltage
USE COPPER CONDUCTORS ONLY.
A knockout is provided on the air handler top panel or side to
allow for the entry of the supply voltage conductors. If the
knockouts on the cabinet sides are used for electrical conduit, an adapter ring must be used in order to meet UL1995
safety requirements. An NEC or CEC approved strain relief
is to be used at this entry point. The wire is to be sized in
accordance with the “Electrical Wire and MOP” section of
this manual. Some areas require the supply wire to be enclosed in conduit. Consult your local codes.
Air Handler Only (Non-Heat Kit Models)
The building supply connects to the stripped black and red
wires contained in the air handler electrical compartment cavity. A ground screw is also contained in this area. Attach the
supply wires to the air handler conductors as shown in the
unit wiring diagram using appropriately sized solderless connectors or other NEC or CEC approved means.
Air Handler With Non-Circuit Breaker Heat Kits
A terminal block is provided with the HKR kit to attach the
power supply and air handler connections. Follow the HKR
Installation Manual and wiring diagram for complete wiring
details.
Air Handler With Heat Kits Containing a Circuit Breaker
HKR models with a “C” suffix contain a circuit breaker(s).
The air handler has a plastic cover on the access panel that
will require either one or both sections to be removed to allow the heat kit circuit breaker(s) to be installed. See the
HKR Installation Instructions for further details. The air handler wires and supply wires are installed directly onto the HKR
circuit breaker(s) as shown in the HKR Installation Manual
and wiring diagram.
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