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
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.
5
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
6
Downflow Conversion
A
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.
7
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
8
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.
9
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
YW
GR
RD GR WH
YL
TO CONDENSING UNIT 24V CONNECTION
YL
BL
C R G
W1 W2
Y1 Y2
O
TB
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.
10
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
W2
BR
YL BL
YGW
YL
CONDENSING UNIT 24V CONNECTION
R
BR
RD GR WH
BR
YL YL
BL
C R G
W1 W2
Y1 Y2
O
TB
COOLING UNIT WITH OPTIONAL HEAT KITS OF 15 kW AND ABOVE
AND ROOM THERMOSTAT WITH TWO STAGES OF HEAT
W2
YC
O
R Y O
YL
RD
YL
OR
WH
BL
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
W2
GC R
WH
WH
BL
NOMENCLATURE: OT - OUTDOOR THERMOSTAT (OPTIONAL) EHR - EMERGENCY HEAT RELAY (OPTIONAL)
GR
E
BR
BR
RD
WH
YL
OR
BL
BL
YL
C R G
W1 W2
Y1 Y2
O
TB
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.
11
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
W2
YC
O
R Y O
YL
OR
RD
YL
OR
WH
BL
OR
BL
W2
WH
WH
OR
GC R
GR
BR
BR
E
C
RD
GR
YL
WH
OR
RD
WH
RD
BL
R G
W1 W2
Y1 Y2
O
TB
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.
12
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.
BK
RD
BL
YL
L2L1 L1 L2
FL
FL
FL
FL
M1 M2
BK
RD
BK
L1 L2
FL
FL
R
BK
HTR1
BK
TL
BK
BK
M1
M2
RD
BL
WH
1
2
RD
3
PU
4
5
6
7
8
9
HTR1
FL
HTR2
RD
BK
R
BK
RD
L2L1
M1M2M3
BK
RD
TL
TL
BK
BK
RD
PU
BL
M4
WH
1
2
RD
3
4
5
6
7
8
9
BK
L1
RD
FL
FL
FL
YL
L2 L1 L2
TL
HTR1
HTR2
HTR3
BK
M1 M2
BK
RD
BK
TL
RD
TL
BK
1
YL
RD
BL
M3
M1
M4
M2
R2
R1
YL
BK
RD
2
PU
3
RD
BL
4
5
BR
6
WH
7
8
9
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
RD
GR
BL
RD
WH
BR WH
CR
4
RD
GR
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.
52
1 3
BL
RD
GRD
L2L1
PLM
PLF
PU
WH
BL
SEE NOTE 3
1
1
BK
23
2
RD
BK
RD
3
BK
C
BL
RD
EQUIPMENT GROUND
USE COPPER WIRE
4 5 678 9
4 5WH6789
BR
BL
1 2 3
5
24V
BL
RD
4
SEE NOTE 1
240
TR
BL
FUSE HOLDER
RD
SEE NOTE 4
BL
BK
AL HEAT KIT, MARK A "X" IN THE PROVIDED ABOVE.
208/240 VOLTS
L1
1
BRWHOR
21 43 5
EM
PLM
1
PLF
FUSE
HOLDER
EM
LGN
23
24V
65
5
SEE NOTE 1
4
PLF
1
TR
4
W2R W1C G 4Y1 OY2 1DH 32 5
COLOR CODE
GR
BK
PU
YL
NC GL
RD
BLYLBLUE
COMPONENT CODE EM
TB
R
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
PU
PURPLE
YELLOW
BR
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
TR
PLF
PLM
FL FUSE LINK TL
HTR HEAT ELEMENTS
L2
2
2
2 4
TRANSFORMER FEMALE PLUG CONNECTOR MALE PLUG CONNECTOR
THER MAL LIMI T
TL
HTR1
HTR2
HTR3
HTR4
BK
BK
TL
RD
TL
YL
TL
BL
PU
RD
BL
M5
M3
M7
M6
M4
M8
R1
R2
WH
YL
BL
BK
RD
FOUR (4) ELEMENT ROWS
5
CR
1 2
EM
3 4
C
5
0140A00040-D
BK
1
2
3
RD
BL
4
5
BR
6
7
8
9
Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.
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14
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.
TO
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
I
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.
15
NOTE: SPECIFICATIONS AND PERFORMANCE DATA LISTED HEREIN ARE SUBJECT TO CHANGE WITHOUT NOTICE.
© 2007 - 2012 Goodman Manufacturing Company, L.P.
5151 San Felipe, Suite 500, Houston, TX 77056
www.goodmanmfg.com - or - www.amana-hac.com
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