Goodman Mfg IO-431 User Manual

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ASPF

AIR HANDLERS INSTALLATION & OPERATING INSTRUCTIONS

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

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.

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.

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.

Low Voltage Connections

Several combinations of low voltage schemes are available, depending on the presence of a heat kit and whether the heat kit is single-stage or multi-staging. The low voltage connections are determined by whether the outdoor unit is a condenser or heat pump. The 24V-control voltage connects the air handler to the room thermostat and condenser. Low voltage wiring is to be copper conductors. A minimum of 18AWG must be used for installations up to 50’ and 16AWG for installations over 50’. Low voltage wiring can be connected through the top of the cabinet or either side. See the “Thermostat Wiring” section of this manual for typical low voltage wiring connections.

Refrigerant Lines

This product is factory-shipped under pressure. Follow these instructions to prevent injury.

A quenc hing c loth is strongly recomme nde d to preven t scorching or marring of the equipmen t finish when welding cl o s e t o th e p ain t ed surfaces. Use bra z in g alloy of 5% minimum silver content.

Tubing Preparation

All cut ends are to be round, burr free, and clean. Failure to follow this practice increases the chances for refrigerant leaks. The suction line is spun closed and requires pipe cutters to remove the closed end.

IMPORTANT NOTE: 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. Heat trap or wet rags should be used to protect heat sensitive components such as service valves and TXV valves.

1. Loosen the 13/16 nut 1 TURN ONLY to allow high pressure tracer gas to escape. No gas indicates a possible leak.

2. After the gas has escaped, remove the nut and discard the black or brass cap.

3. Remove the check piston to verify it is correct and then replace the piston. See piston kit chart in instructions.

4. Use a tube cutter to remove the spin closure on the suction line.

5. Remove the tailpiece clamped to the exterior and slide

the 13/16 nut into place.

6. Braze tailpiece to the line set liquid tube.

PLASTIC or BRASS CAP

13/16” NUT

TAILPIECE

Post Brazing

Quench all welded joints with water or a wet rag.

Piping Size

For the correct tubing size, follow the specification for the condenser/heat pump.

CAUTION

Applying too much heat to any tube can melt the tube. Torch heat required to braze tubes of various sizes must be proportiona l to the s ize of th e tub e. S erv ice p ersonn el m u st use the appropriate heat level for the size of the tube being brazed.

Special Instructions

This coil comes equipped with a check style flowrator for refrigerant management. For most installations with matching applications, no change to the flowrator piston is required. However, in mix-matched applications, a flowrator piston change may be required. See the Goodman® piston kit chart or consult your local distributor for details regarding mixmatched piston sizing. If the mix-match application requires a different piston size, change the piston in the flowrator on the indoor coil before installing the coil and follow the procedure shown below.

WHITE TEFLON SEA L

Figure 1

PISTON

7. Insert the suction line into the connection, slide the insulation and the rubber grommet at least 18" away from the braze joint. Braze suction line.

8. AFTER THE TAILPIECE HAS COOLED, confirm position of the white Teflon® seal and hand tighten the 13/16 nut.

9. Torque the 13/16 nut to 7-25 ft-lbs. or tighten 1/6 turn.

Excessive torque can cause orifices to stick. Use the proper torque settings when tightening orifices.

10.Replace suction line grommet and insulation.

SUCTION LINE WITH SPIN CLOSURE

RUBBER GROMMET

Figure 2

Downflow Conversion

Conversion to downflow MUST be performed in an area that allows access to all sides prior to placing the air handler in its final location. To prevent the evaporator coil pan from “sweating” the DPI accessory insulation kit is to be used when performing this conversion. NOTE: The DPI kit is not supplied with this product and is to be purchased separately. See

Table 7 for the correct DPI kit.

ASPF Insulation Kit

1830 DPI36-42/20

313 7 / 4260 DPI48- 61/20

Table 7

Refer to Figures 3 through 5 for the location of the compo- nents referenced in the following steps. Figure 3 illustrates the new installation location for the removed components.

1. Before inverting the air handler, remove all access panels, the coil rear channel bracket, and the filter close-off panel.

2. Remove the evaporator coil and the horizontal drain pan. Discard horizontal drain pan.

3. Install the provided plastic plug into the vacated access panel.

4. Remove the two (2) zee coil support brackets and insulation retaining brackets.

5. Remove the tie bracket.

6. Install the DPI Insulation Kit onto the bottom of the drain pan.

RETURN AIR SIDE OF UNIT

ACCESS PANEL

REAR CHANNEL BRACKET

7. Install the zee coil supports and the wrapper stiffeners.

8. Install the tie bracket.

9. Install the rear channel bracket.

10.To prevent possible condensate “blow off” the insulation retainers are to be laid into the evaporator coil pan as shown in Figure 4.

3” FLAT INSULATION RETAINER (BOTH SIDES)

Figure 4

To complete the conversion, slide the evaporator coil into the chassis and attach the three (3) access panels. (Figure

5).

WRAPPER

INSULATION JACKET

ZEE COI L SUPPORT

WRAPPER STIFFENER

DRAIN PAN INSULATION KIT

BLOWER

SSEMBLY

ZEE COIL SUPPORT BRACKET

COIL RETAINING BRACKET

TIE BRACKET

NOTE: The filter provision is not applicable

in THIS down flo w application.

Figure 3

NOTE: When converted to downflow position, the coil may

protrude above the cabinet on some models.

Horizontal Conversion

The only field modification required for conversion to “Horizontal Right-Hand” is the removal of the plastic knockouts in the horizontal panel drain connections. To prevent the hori-

Figure 5

zontal drain pan from sweating in high humidity applications, it is recommended that a DPIH insulation accessory kit be used. NOTE: The DPIH insulation kit is not supplied with this product and should be purchased separately. See Table 8 for the correct DPIH kit.

ASPF Model Insulation Kit

1830 DPIH36-42

3137 / 4260 DPIH48-61

Table 8

The following describes converting to “Horizontal Left-Hand”. Conversion MUST be performed in an area that allows ac-

cess to all sides prior to placing the air handler in its final location (See Figure 6).

DPIH KIT

SECONDARY DRAIN

Figure 6

1. Remove the (3) air handler access panels.

2. Remove the “J” shaped bracket that retains the evaporator coil.

3. Remove the flowrator from the lower left side access panel and slide out the evaporator coil and horizontal drain pan.

4. Remove the gasket from the horizontal pan drain connections.

5. Remove the oval shaped plastic plug from the left side access panel. Remove the oval shaped rubber gasket seal from the lower right side access panel.

6. The drain connections for the horizontal pan are sealed with a thin coating of plastic. Carefully knock out this plastic seal with a screwdriver and hammer. Note: The

upper drain will become the secondary drain which is mandatory in many municipalities .

7. Install the plastic plug removed in step 5 to the right side lower access panel and the oval shaped rubber gasket to the lower left access panel.

8. Reinstall the evaporator coil with the horizontal panel on the left side. Note: Push the assembly completely to the rear to ensure the engagement of the upflow pan with the rear channel bracket.

PRIMARY DRAIN

tightened to a torque of approximately 37 in-lbs. to prevent damage to the drain pan connection. An insertion depth between .355 to .485 inches (3-5 turns) should be expected at this torque. Use the female (3/4 NPT) threaded fitting that protrudes outside of the enclosure for external connections.

1. Ensure drain pan hole is NOT obstructed.

2. To prevent potential sweating and dripping on to finished space, it may be necessary to insulate the condensate drain line located inside the building. Use Armaflex® or similar material.

A Secondary Condensate Drain Connection has been provided for areas where the building codes require it. Pitch the drain line 1/4" per foot to provide free drainage. Insulate drain lines located inside the building to prevent sweating. Install a condensate trap to ensure proper drainage. If the secondary drain line is required, run the line separately from the primary drain and end it where it can be easily seen.

NOTE: Water coming from this line means the coil primary drain is plugged and needs clearing.

CAUTION

If secondary drain is not installed, the secondary access must be plugged.

The installation must include a “P” style trap that is located as close as is practical to the evaporator coil. See Figure 7 for details of a typical condensate line “P” trap.

NOTE: Trapped lines are required by many local codes. In the absence of any prevailing local codes, please refer to the requirements listed in the Uniform Mechanical Building Code.

A drain trap in a draw-through application prevents air from being drawn back through the drain line during fan operation thus preventing condensate from draining, and if connected to a sewer line to prevent sewer gases from being drawn into the airstream during blower operation.

Field experience has shown condensate drain traps with an open vertical Tee between the air handler and the condensate drain trap can improve condensate drainage in some applications, but may cause excessive air discharge out of the open Tee. Goodman® does not prohibit this type of drain but we also do not recommend it due to the resulting air leakage. Regardless of the condensate drain design used, it is the installer’s responsibility to ensure the condensate drain system is of sufficient design to ensure proper condensate removal from the coil drain pan.

Drain

Connection

9. Install the “J” bracket (removed in step 2) to support the upflow pan to the tie channel.

10.Attach all panels and the metering device.

Condensate Removal

The coil drain pan has a primary and a secondary drain with 3/4" NPT female connections. The connectors required are 3/4" NPT male, either PVC or metal pipe, and should be hand

Air Handler

POSITIVE LIQUID SEAL REQUIRED

AT TR AP

2" MIN.

3" MIN.

Figure 7

Use of a condensate removal pump is permitted when necessary. This condensate pump should have provisions for shutting off the control voltage should a blocked drain occur. A trap must be installed between the unit and the condensate pump.

IMPORTANT NOTE: The evaporator coil is coated with oils that may dissolve styrofoam and certain types of plastics. Therefore, a removal pump or float switch must not contain any of these materials. Tip: Priming the “P” trap may avoid improper draining at the initial installation and at the beginning of the cooling season.

When coils are installed above ceilings, or in other locations where damage from condensate overflow may occur, it is MANDATORY to install a field fabricated auxiliary drain pan under the coil cabinet enclosure. Drain lines from the auxiliary pan must be installed and terminated so that the homeowner can see water discharges.

Achieve 2% Low Leakage Rate

Ensure that the Neoprene gasket with PSA remains intact on all surfaces that the access panels are secured to. These surfaces are the entire length of the wrapper and areas between the upper tie plate, upper and lower access panels. Be sure that upper access panel breaker insert gasket is intact and also flowrator gasket is installed on the lower access panel. An additional drain hole cover is required.

• Return and supply ducts are sealed.

• Unit is elevated when installed in a garage or where flammable vapors may be present.

• Unit is protected from vehicular or other physical damage.

• Return air is not obtained from any areas where there may be objectionable odors, flammable vapors or products of combustion such as carbon monoxide (CO), which may cause serious personal injury or death.

Regular Maintenance

HIGH VOLTAGE! Disconnect ALL power before servicing or installing this unit. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

The only item to be maintained on a regular basis by the user is the circulating air filter(s). Filter should be cleaned or replaced regularly. A certified service technician must perform all other services.

NOTE: DO NOT USE THESE DIAGRAMS FOR MODELS OTHER THAN ASPF. SEE INSTALLATION AND OPERATING INSTRUCTIONS SPECIFICALLY FOR EACH MODEL.

ASPF Motor

The ASPF air handler features an energy efficient blower motor. The motor is a constant torque motor with very low power consumption. The motor is energized by 24 VAC. Adjust the CFM by changing the 24 VAC leads to the desired speed on the terminal block.

The ASPF motor blower speed is programmed to deliver adequate airflow at rated external static pressure and with 60 second off time delay. For details, refer to the specification sheet applicable to your model.

CFM Delivery

Table 9 shows the CFM speed tap settings for the ASPF.

Start-Up Procedure

• Prior to start-up, ensure that all electrical connections are properly sized and tightened.

• All panels must be in place and secured. For Air Tight application, neoprene gasket must be positioned at prescribed locations to achieve 2% leakage.

• Tubing must be leak free.

• Unit should be elevated, trapped and pitched to allow for drainage.

Motor

Model

ASPF183016 3 920 900 850 840 815

ASPF313716 3 1165 1070 1020 960 915

ASPF426016 3

Speed

Tap 0.1" 0.2" 0.3" 0.4" 0.5"

1 700 670 650 595 510 2 820 785 765 745 705

4 1075 1055 1015 975 960 5 1130 1115 1085 1040 1000 1 1060 865 600 515 420 2 1105 910 795 745 690

4 1285 1240 1195 1140 1100 5 1435 1395 1350 1315 1265 1 1445 1275 1175 940 855 2 1545 1405 1325 1260 1145

4 5

against External Static Pressure

1660 1610 1555 1490 1415 1905 1870 1810 1750 1695 2115 2070 2000 1965 1915

Table 9

CFM deliverd

• Low voltage wiring is connected.

• Auxiliary drain is installed when necessary and pitched to allow for drainage.

• Drain pan and drain tubing has been leak checked.

ASPF Thermostat Connections

The following composite wiring diagrams detail various configurations in which the ASPF air handlers can be used. Examples include single-stage cooling and heat pump with single or two-stage electric heating. All these configurations can be applied with convenient connections to outdoor thermostat applications.

The following sections will be detailed:

• Single-Stage Cooling

• Heat Pump

Each diagram details the connections between room thermostat and ASPF air handlers, and the connections between the ASPF air handlers and the Condensing Unit (or Heat Pump) with optional connections to Outdoor Thermostats. For each configuration, refer to the explanation of the proper jumper(s) to remove for the corresponding blower speed that will result in the programmed EEM™ motor.

IMPORTANT: WHEN MATCHING THE ASPF AIR HANDLERS TO A SINGLE SPEED COOLING OR HEAT PUMP UNIT, REMEMBER TO CONNECT “Y” FROM THE THERMOSTAT TO THE “Y2” ON THE LOW VOLTAGE TERMINAL BOARD.

An equivalent thermostat can be used in place of the Goodman thermostat part number.

WARNING

HIGH VOLTAGE!

MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

YL BL

DISCONNECT ALL POWER BEFORE SERVICING.

#18 GA. 4 WIRES WITH COOLING 3 WIRES WITHOUT

RD GR WH

TO CONDENSING UNIT 24V CONNECTION

C R G

W1 W2

Y1 Y2

COOLING UNIT WITH OPTIONAL HEAT KITS OF 10 kW AND BELOW

NOTES:

1) OUTDOOR THERMOSTAT (OT-1) SHOULD BE THE FIRST TO CLOSE AND THE LAST TO OPEN.

2) JUMPER W1 AND W2 TOGETHER IF OT-2 IS NOT USED.

3) REMOVE WIRE WHEN USING OUTDOOR THERMOSTAT.

NOMENCLATURE: OT - OUTDOOR THERMOSTAT (OPTIONAL) EHR - EMERGENCY HEAT RELAY (OPTIONAL)

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

COLOR CODES RD - RED YL - YELLOW BL - BLUE BR - BROWN OR - ORANGE WH - WHITE

WARNING

HIGH VOLTAGE!

MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO

DISCO NNECT ALL POWER BEFORE SERVICING.

MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

#18 GA. 5 WIRES WITH COOLING 4 WIRES WITHOUT

YL BL

YGW

CONDENSING UNIT 24V CONNECTION

RD GR WH

YL YL

C R G

W1 W2

Y1 Y2

COOLING UNIT WITH OPTIONAL HEAT KITS OF 15 kW AND ABOVE

AND ROOM THERMOSTAT WITH TWO STAGES OF HEAT

R Y O

HEAT PU MP UNIT WITH OPTIONAL HEAT KITS OF 10 kW AN D BELOW

NOTES:

1) OUTDOOR THERMOSTAT (OT-1) SHOULD BE THE FIRST TO CLOSE AND THE LAST TO OPEN.

2) JUMPER W1 AND W2 TOGETHER IF OT-2 IS NOT USED.

3) REMOVE WIRE WHEN USING OUTDOOR THERMOSTAT.

#18 GA. 7 WIRE

GC R

NOMENCLATURE: OT - OUTDOOR THERMOSTAT (OPTIONAL) EHR - EMERGENCY HEAT RELAY (OPTIONAL)

C R G

W1 W2

Y1 Y2

COLOR CODES RD - RED YL - YELLOW BL - BLUE BR - BROWN OR - ORANGE WH - WHITE

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

WARNING

HIGH VOLTAGE!

DISCO NNECT ALL POWER BEFORE SERVICING. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

#18 GA. 7 WIRE

R Y O

GC R

R G

W1 W2

Y1 Y2

HEAT PUMP UNIT WITH OPTIONAL HEAT KITS OF 15 kW AND ABO VE

NOTES:

1) OUTDOOR THERMOSTAT (OT-1) SHOULD BE THE FIRST TO CLOSE AND THE LAST TO OPEN.

2) JUMPER W1 AND W2 TOGETHER IF OT-2 IS NOT USED.

3) REMOVE WIRE WHEN USING OUTDOOR THERMOSTAT.

NOMENCLATURE: OT - OUTDOOR THERMOSTAT (OPTIONAL) EHR - EMERGENCY HEAT RELAY (OPTIONAL)

COLOR CODES RD - RED YL - YELLOW BL - BLUE BR - BROWN OR - ORANGE WH - WHITE

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

WARNING

ASPF Wiring Diagram

HIGH VOLTAGE!

DISCO NNECT ALL POWER BEFORE SERVICING. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

L2L1 L1 L2

M1 M2

L1 L2

HTR1

HTR2

L2L1

M1M2M3

L2 L1 L2

HTR1

HTR2

HTR3

M1 M2

ONE (1) ELEMENT ROWS TWO (2) ELEMENT ROWS THREE (3) ELEMENT ROWS

NOTE: WHEN INSTALLING HEATER KIT, ENSURE SPEED TAP DOES NOT EXCEED MINIMUM BLOWER SPEED (MBS) SPECIFIED FOR THE AIRHANDLER/HEATER

KIT COMBINATION ON THIS UNIT'S S&R PLATE. AFTER INSTALLING OPTION

MARK ACCORDING TO NUMBER OF HEATER ELEMENT ROWS INSTALLED. NO MARK INDICATES NO HEAT KIT INSTALLED.

SEE NOTE 2

W2R W1CG 4Y1 OY2 1DH 32 5

BR WH

COPPER POWER SUPPLY

(USE RATING PLATE)

USE MIN. 75° C FIELD WIRE

IF REPLACEMENT OF THE ORIGINAL WIRES SUPPLIED WITH THIS ASSEMBLY IS NECESSAR Y, USE WIRE THAT CONFORMS TO THE NATIONAL ELECTRIC C OD E.

1 3

GRD

L2L1

PLM

PLF

SEE NOTE 3

EQUIPMENT GROUND

USE COPPER WIRE

4 5 678 9

4 5WH6789

1 2 3

24V

SEE NOTE 1

240

FUSE HOLDER

SEE NOTE 4

AL HEAT KIT, MARK A "X" IN THE PROVIDED ABOVE.

208/240 VOLTS

BRWHOR

21 43 5

PLM

PLF

FUSE

HOLDER

LGN

24V

SEE NOTE 1

PLF

W2R W1C G 4Y1 OY2 1DH 32 5

COLOR CODE

NC GL

BLYLBLUE

COMPONENT CODE EM

CR CONTRO L RELAY

EBTDR

NOTES:

1) RED WIRES TO BE ON TRANSFORMER TERMINAL "3" FOR 240 VOLTS AND ON TERMINAL "2" F OR 280 VOLTS.

2) SE E COMPLETE WIRING DIAGRAMS IN INSTALLATION IN STRUCT IONS FOR PROPER LOW VOLTAGE WIRING CONNECT IONS.

3) CONFIRM SPEED TAP SELECTION IS APPROPRIATE FOR APPLICATION. IF SPEED TAP NEEDS TO BE CHANGE D, CONNECT PURPLE WIRE FROM T ERMINAL 4 OF CR RELAY TO APPROPRIATE TAP A T TB

4) BROWN AND WHITE WIRES ARE USED FOR HEAT KITS ONLY.

GREEN

BLACK RED

PURPLE

YELLOW

BROWN WHITEWH

EVAPORA TOR M OTOR TERMINAL BOARD RELAY

ELECTRONIC BLOWER TIME DELAY RELAY

PLM

PLF

3 1

WIRING CODE

FACTORY WIRING HI GH VOLTAG E LOW VOLT AGE

FIELD WIRING HI GH VOLTAG E LOW VOLT AGE

PLF

PLM

FL FUSE LINK TL

HTR HEAT ELEMENTS

2 4

TRANSFORMER FEMALE PLUG CONNECTOR MALE PLUG CONNECTOR

THER MAL LIMI T

HTR1

HTR2

HTR3

HTR4

FOUR (4) ELEMENT ROWS

1 2

3 4

0140A00040-D

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

THIS PAGE LEFT INTENTIONALLY BLANK

SPLIT SYSTEMS

AIR CONDITIONING AND HEAT PUMP HOMEOWNER’S ROUTINE MAINTENANCE RECOMMENDATIONS

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 in-

stalled 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.

AVOID THE RISK OF EQUIPMENT DAMAGE OR FIRE, INSTALL

THE

SAME AMPERAGE BREAKER OR FUSE AS YOU ARE REPLACING AGAIN TO

CORRECT THE PROBLEM

F YOU REPEATEDLY RESET THE BREAKER OR REPLACE

THE YOU RUN THE RISK OF SEVERE EQUIPMENT DAMAGE

. IF

WITHIN THIRTY DAYS, CONTACT A QUALIFIED SERVICER

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.

NOTE: SPECIFICATIONS AND PERFORMANCE DATA LISTED HEREIN ARE SUBJECT TO CHANGE WITHOUT NOTICE.

5151 San Felipe, Suite 500, Houston, TX 77056

www.goodmanmfg.com - or - www.amana-hac.com

Goodman Mfg IO-431 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual