© 2010-2012 Goodman Manufacturing Company, L.P.
5151 San Felipe, Suite 500, Houston, TX 77056
P/N: IO-402G Date: May 2012
CONDENSING AC UNIT
SINGLE / THREE PHASE AIR CONDITIONERS
INSTALLATION & SERVICE REFERENCE
NOTICE
CAUTION
THIS UNIT IS SHIPPED WITH A NITROGEN/HELIUM
HOLDING CHARGE ONLY. UNIT MUST BE EVACUATED
AND CHARGED PER INSTALLATION INSTRUCTIONS
WITH REFRIGERANT LISTED ON SERIAL RATING PLATE.
Scroll equipped units should never be used to evacuate
the air conditioning system. Vacuums this low can cause
internal electrical arcing resulting in a damaged or failed
compressor.
Important Note to the Owner Regarding
Product Warranty
Your warranty certificate is supplied as a separate document
with the unit installed by your contractor. Read the limited war-
ranty certificate carefully to determine what is and is not cov-
ered and keep the warranty certificate in a safe place. If you are
unable to locate the warranty certificate please contact your
installing contractor or contact customer service (877-254-4729)
to obtain a copy.
NOTICE
UNITS SHIPPED WITH A HOLDING CHARGE ARE
INTENDED FOR COMPONENT REPLACEMENT ONLY ON
EXISTING SYSTEMS, AND NOT INTENDED FOR USE IN
NEW SYSTEMS OR NEWLY CONSTRUCTED HOMES.
EPA REGULATIONS PROHIBIT THE SALE OR
DISTRIBUTION OF APPLIANCES PRE-CHARGED WITH
THE REFRIGERANT R-22 IF THOSE APPLIANCES ARE
MANUFACTURED AFTER JANUARY 1, 2010.
COMPONENTS OF EXISTING R-22 SYSTEMS MAY BE
REPAIRED AND/OR REPLACED.
Shipping Inspection
Always keep the unit upright; laying the unit on its side or top
may cause equipment damage. Shipping damage, and subse-
quent 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 transpor-
tation damage or installation of incorrectly shipped units.
NOTICE
UNITS MUST ONLY BE USED AS REPLACEMENT
COMPONENTS FOR PRE-2010 INSTALLED SYSTEMS.
See unit rating plate for initial charge.
Important Safety Instructions
Codes & Regulations
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 com-
ply 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.
This product is designed and manufactured to comply with na-
tional 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 equip-
ment installed in violation of any codes or regulations. Rated
performance is achieved after 72 hours of operation.
The United States Environmental Protection Agency (EPA)
has issued various regulations regarding the introduction
and disposal of refrigerants. Failure to follow these regu-
lations may harm the environment and can lead to the
imposition of substantial fines. Should you have any ques-
tions please contact the local office of the EPA.
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.
If replacing a condensing unit or air handler, the system must
be manufacturer approved and Air Conditioning, Heating and
Refrigeration Institute (AHRI) matched. NOTE: Installation of
unmatched systems is strongly discouraged.
ONLY individuals meeting (at a minimum) the
requirements of an “Entry Level Technician” as
specified by the Air-Conditioning, Heating and
Refrigeration Institute (AHRI) may use this
information. Attempting to install or repair this unit
without such background may result in product
damage, personal injury, or death.
Operating the unit in a structure that is not complete (either as
part of new construction or renovation) will void the warranty.
Use only refrigerant grade (dehydrated and sealed) copper tub-
ing to connect the condensing unit with the indoor evaporator.
After cutting the tubing, install plugs to keep refrigerant tubing
clean and dry prior to and during installation. Tubing should
always be cut square keeping ends round and free from burrs.
Clean the tubing to prevent contamination.
Do NOT let refrigerant lines come in direct contact with plumb-
ing, ductwork, floor joists, wall studs, floors, and walls. When
running refrigerant lines through a foundation or wall, openings
should allow for sound and vibration absorbing material to be
placed or installed between tubing and foundation. Any gap
between foundation or wall and refrigerant lines should be filled
with a pliable silicon-based caulk, RTV or a vibration damping
material. Avoid suspending refrigerant tubing from joists and
studs with rigid wire or straps that would come in contact with
the tubing. Use an insulated or suspension type hanger. Keep
both lines separate and always insulate the suction line.
These sizes are recommended for line lengths of 79 feet or
less. For other line sizing option or runs of more than fifty feet,
refer to Remote Cooling Service Manual, or TP-106 Long Line
Set Application R-22, or contact your distributor for assistance.
RECOMMENDED INTERCONNECTING TUBING (Ft)
Insulation is necessary to prevent condensation from forming
and dropping from the suction line. Armflex (or satisfactory
equivalent) with 3/8” min. wall thickness is recommended. In
severe conditions (hot, high humidity areas) 1/2” insulation may
be required. Insulation must be installed in a manner which
protects tubing from damage and contamination.
Cond
Unit
Tons
1 1/2
2
2 1/2
3
3 1/2
4
0-24
25-49
50-79*
Line Diameter (In. OD)
Suct
Liq
1/4
1/4
1/4
3/8
3/8
3/8
3/8
Suct
3/4
3/4
3/4
7/8
1 1/8
1 1/8
1 1/8
Liq
3/8
3/8
3/8
3/8
3/8
3/8
3/8
Suct
Liq
3/8
3/8
3/8
3/8
3/8
3/8
3/8
5/8
5/8
5/8
3/4
7/8
7/8
7/8
3/4
3/4
7/8
Where possible, drain as much residual compressor oil from
existing systems, lines, and traps; pay close attention to low
areas where oil may collect.
1 1/8
1 1/8
1 1/8
1 1/8
NOTE: If changing refrigerant types, ensure the indoor coil and
metering device is compatible with the type of refrigerant being
used; otherwise, the indoor coil must be replaced.
5
* Lines greater than 79 feet in length or vertical elevation
changes more than 50 feet
refer to the Remote Cooling
Service Manual or contact your distributor for assistance.
Burying Refrigerant Lines
If burying refrigerant lines can not be avoided, use the following
checklist.
1. Insulate liquid and suction lines separately.
2. Enclose all underground portions of the refrigerant lines
in waterproof material (conduit or pipe) sealing the ends
where tubing enters/exits the enclosure.
3. If the lines must pass under or through a concrete slab,
ensure lines are adequately protected and sealed.
3
3. After brazing, quench the joints with water or a wet cloth
to prevent overheating of the service valve.
Refrigerant Line Connections
NOTICE
4. Ensure the filter drier paint finish is intact after brazing. If
the paint of the steel filter drier has been burned or chipped,
repaint or treat with a rust preventative. This is especially
important on suction line filter driers which are continu-
ally wet when the unit is operating.
THIS UNIT IS SHIPPED WITH A NITROGEN/HELIUM
HOLDING CHARGE ONLY. UNIT MUST BE EVACUATED
AND CHARGED PER INSTALLATION INSTRUCTIONS
WITH REFRIGERANT LISTED ON SERIAL RATING PLATE.
NOTE: Be careful not to kink or dent refrigerant lines. Kinked
or dented lines will cause poor performance or compressor
damage.
NOTICE
UNITS SHIPPED WITH A HOLDING CHARGE ARE
INTENDED FOR COMPONENT REPLACEMENT ONLY ON
EXISTING SYSTEMS, AND NOT INTENDED FOR USE IN
NEW SYSTEMS OR NEWLY CONSTRUCTED HOMES.
EPA REGULATIONS PROHIBIT THE SALE OR
Do NOT make final refrigerant line connection until plugs are
removed from refrigerant tubing.
NOTE: Before brazing, verify indoor piston size by checking
DISTRIBUTION OF APPLIANCES PRE-CHARGED WITH
THE REFRIGERANT R-22 IF THOSE APPLIANCES ARE
MANUFACTURED AFTER JANUARY 1, 2010.
COMPONENTS OF EXISTING R-22 SYSTEMS MAY BE
REPAIRED AND/OR REPLACED.
the piston kit chart packaged with indoor unit.
Leak Testing (Nitrogen or Nitrogen-Traced)
WARNING
NOTICE
To avoid the risk of fire or explosion, never use
oxygen, high pressure air or flammable gases for leak
testing of a refrigeration system.
UNITS MUST ONLY BE USED AS REPLACEMENT
COMPONENTS FOR PRE-2010 INSTALLED SYSTEMS.
WARNING
NOTE: Holding charge must be removed before brazing. Open
service valves slowly to remove holding charge. Close valves
before brazing to prevent contaminants from entering system.
To avoid possible explosion, the line from the
nitrogen cylinder must include a pressure regulator
and a pressure relief valve. The pressure relief valve
must be set to open at no more than 150 psig.
IMPORTANT
To avoid overheating the service valve, TXV valve, or filter
drier while brazing, wrap the component with a wet rag, or
use a thermal heat trap compound. Be sure to follow the
manufacturer’s instruction when using the heat trap
compound. Note: Remove Schrader valves from service
valves before brazing tubes to the valves. Use a brazing
alloy of 2% minimum silver content. Do not use flux.
Pressure test the system using dry nitrogen and soapy water
to locate leaks. If you wish to use a leak detector, charge the
system to 10 psi using the appropriate refrigerant then use
nitrogen to finish charging the system to working pressure then
apply the detector to suspect areas. If leaks are found, repair
them. After repair, repeat the pressure test. If no leaks exist,
proceed to system evacuation.
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.
System Evacuation
Condensing unit liquid and suction valves are closed. The unit
is shipped with the valve stems closed and caps installed.
WARNING
REFRIGERANT UNDER PRESSURE!
Failure to follow proper procedures may cause
property damage, personal injury or death.
1. The ends of the refrigerant lines must be cut square, de-
burred, cleaned, and be round and free from nicks or dents.
Any other condition increases the chance of a refrigerant
leak.
NOTE: Scroll compressors should never be used to evacuate
or pump down a heat pump or air conditioning system.
2. “Sweep” the refrigerant line with nitrogen or inert gas dur-
ing brazing to prevent the formation of copper-oxide in-
side the refrigerant lines. This may cause a blockage or
failure of the metering device.
4
NOTICE
5000
4500
4000
3500
3000
2500
2000
1500
1000
500
THIS UNIT IS SHIPPED WITH A NITROGEN/HELIUM
HOLDING CHARGE ONLY. UNIT MUST BE EVACUATED
AND CHARGED PER INSTALLATION INSTRUCTIONS
WITH REFRIGERANT LISTED ON SERIAL RATING PLATE.
LEAK(S)
PRESENT
NOTICE
UNITS SHIPPED WITH A HOLDING CHARGE ARE
INTENDED FOR COMPONENT REPLACEMENT ONLY ON
EXISTING SYSTEMS, AND NOT INTENDED FOR USE IN
NEW SYSTEMS OR NEWLY CONSTRUCTED HOMES.
EPA REGULATIONS PROHIBIT THE SALE OR
CONDENSIBLES OR SMALL
LEAK PRESENT
NO LEAKS
NO CONDENSIBLES
DISTRIBUTION OF APPLIANCES PRE-CHARGED WITH
THE REFRIGERANT R-22 IF THOSE APPLIANCES ARE
MANUFACTURED AFTER JANUARY 1, 2010.
0
1
2
3
4
5
6
7
8
9
10
MINUTES
COMPONENTS OF EXISTING R-22 SYSTEMS MAY BE
REPAIRED AND/OR REPLACED.
•
If pressure rises above 1000 microns but holds steady
below 2000 microns, moisture and/or noncondensibles
may be present or the system may have a small leak.
Return to step 2: If the same result is encountered check
for leaks as previously indicated and repair as necessary
then repeat evacuation.
NOTICE
UNITS MUST ONLY BE USED AS REPLACEMENT
COMPONENTS FOR PRE-2010 INSTALLED SYSTEMS.
• If pressure rises above 2000 microns, a leak is present.
Check for leaks as previously indicated and repair as nec-
essary then repeat evacuation.
NOTE: Holding charge must be removed before brazing.
CAUTION
Prolonged operation at suction pressures less than 20
psig for more than 5 seconds will result in overheating of
the scrolls and permanent damage to the scroll tips, drive
bearings and internal seal.
Electrical Connections
WARNING
HIGH VOLTAGE!
1. Open service valves before attaching vacuum pump.
Disconnect ALL power before servicing.
Multiple power sources may be present.
Failure to do so may cause property damage,
personal injury or death due to electric shock.
Wiring must conform with NEC or CEC and all
local codes. Undersized wires could cause
poor equipment performance, equipment damage
or fire.
2. Connect the vacuum pump with 250 micron capability to
the service valves.
3. Evacuate the system to 250 microns or less using suc-
tion and liquid service valves. Using both valves is nec-
essary as some compressors create a mechanical seal
separating the sides of the system.
4. Close pump valve and hold vacuum for 10 minutes. Typi-
cally pressure will rise during this period.
WARNING
To avoid the risk of fire or equipment damage, use
copper conductors.
• If the pressure rises to 1000 microns or less and remains
steady the system is considered leak-free; proceed to
startup.
NOTICE
UNITS WITH RECIPROCATING COMPRESSORS AND
NON-BLEED TXV’S REQUIRE A HARD START KIT.
The condensing unit rating plate lists pertinent electrical data
necessary for proper electrical service and overcurrent protec-
tion. Wires should be sized to limit voltage drop to 2% (max.)
from the main breaker or fuse panel to the condensing unit.
Consult the NEC, CEC, and all local codes to determine the
correct wire gauge and length.
5
Local codes often require a disconnect switch located near the
unit; do not install the switch on the unit. Refer to the installa-
tion instructions supplied with the indoor furnace/air handler for
specific wiring connections and indoor unit configuration. Like-
wise, consult the instructions packaged with the thermostat
for mounting and location information.
System Start Up
CAUTION
POSSIBLE REFRIGERANT LEAK
To avoid a possible refrigerant leak, open the service
valves until the top of the stem is 1/8” from the retainer.
Overcurrent Protection
When opening valves with retainers, open each valve only until
the top of the stem is 1/8” from the retainer. To avoid loss of
refrigerant, DO NOT apply pressure to the retainer. When open-
ing valves without a retainer remove service valve cap and in-
sert a hex wrench into the valve stem and back out the stem
by turning the hex wrench counterclockwise. Open the valve
until it contacts the rolled lip of the valve body.
The following overcurrent protection devices are approved for
use.
•
•
Time delay fuses
HACR type circuit breakers
These devices have sufficient time delay to permit the motor-
compressor to start and accelerate its load.
NOTE: These are not back-seating valves. It is not necessary
Three Phase Compressor Rotation
to force the stem tightly against the rolled lip.
The service valve cap is the secondary seal for the valves and
must be properly tightened to prevent leaks. Make sure cap is
clean and apply refrigerant oil to threads and sealing surface
on inside of cap. Tighten cap finger-tight and then tighten addi-
tional 1/6 of a turn (1 wrench flat), or to the following specifica-
tion, to properly seat the sealing surfaces.
CAUTION
Use care when handling scroll compressors. Dome temp-
eratures could be hot.
Three phase compressors are power phase dependent and can
rotate in either direction.
1. 3/8” valve to 5 - 10 in-lbs
2. 5/8” valve to 5 - 20 in-lbs
3. 3/4” valve to 5 - 20 in-lbs
4. 7/8” valve to 5 - 20 in-lbs
Verify proper rotation for three phase compressors by ensuring
the suction pressure drops and discharge pressure rises when
the compressor is energized. NOTE: When operated in re-
verse, a three phase scroll compressors is noisier and its cur-
rent draw substantially reduced compared to marked values.
Do not introduce liquid refrigerant from the cylinder into the
crankcase of the compressor as this may damage the
compressor.
To correct, disconnect power and switch any two leads at the
unit contactor and re-observe.
High Voltage Connections
CAUTION
POSSIBLE REFRIGERANT LEAK
To avoid a possible refrigerant leak, open the service
valves until the top of the stem is 1/8” from the retainer.
Route power supply and ground wires through the high voltage
port and terminate in accordance with the wiring diagram pro-
vided inside the control panel cover.
Low Voltage Connections
Condensing unit control wiring requires 24 Volt minimum, 25VA
service from the indoor transformer. Route control wires through
the low voltage port and terminate in accordance with the wir-
ing diagram provided inside the control panel cover.
NOTICE
REFRIGERANT MUST BE ADDED TO THE SYSTEM AFTER
EVACUATION IS COMPLETE.
WARNING
REFRIGERANT UNDER PRESSURE!
• Do not overcharge system with refrigerant.
• Do not operate unit in a vacuum or at negative pres-
sure.
Failure to follow proper procedures may cause
property damage, personal injury or death.
1. Add refrigerant amount for the unit being installed. See
unit rating plate for initial charge.
Single-Stage Thermostat
with Two Low Voltage Wires to Remote
2. Set thermostat to call for cooling. Check indoor and out-
door fan operation and allow system to stabilize for 10
minutes for fixed orifices and 20 minutes for expansion
valves.
6
Charge Verification
CAUTION
Operating the compressor with the suction valve closed
may cause serious compressor damage.
WARNING
REFRIGERANT UNDER PRESSURE!
• Do not overcharge system with refrigerant.
• Do not operate unit in a vacuum or at negative pres-
sure.
Failure to follow proper procedures may cause
property damage, personal injury or death.
Final Charge Adjustment
The outdoor temperature must be 60°F or higher. Set the room
thermostat to COOL, fan switch to AUTO, and set the tem-
perature control well below room temperature.
After system has stabilized per startup instructions, check
subcooling and superheat as detailed in the following section.
CAUTION
Use refrigerant certified to AHRI standards. Use of used
refrigerant may cause compressor damage that is not
covered under warranty. Most portable machines cannot
clean used refrigerant to meet AHRI standards.
NOTICE
VIOLATION OF EPA REGULATIONS MAY RESULT IN
FINES OR OTHER PENALTIES
SYSTEM SUPERHEAT
Indoor Wet Bulb Temperature, °F
Outdoor
Dry Bulb
55
57
59
61
63
65
67
69
71
Temperature, °F
60
65
10
8
13
11
17
14
20
16
23
19
26
22
19
15
12
8
29
26
23
20
17
13
10
5
30
27
24
21
18
15
11
8
31
29
25
23
20
16
13
10
8
70
5
8
10
13
15
75
----
----
----
----
----
----
----
----
----
----
----
----
----
----
----
----
----
----
6
9
11
80
----
----
----
----
----
----
----
----
----
----
----
----
----
----
----
----
7
85
----
----
----
----
----
----
----
90
5
95
----
----
----
----
----
100
105
110
115
----
----
----
----
5
----
----
----
5
----
----
7
SATURATED SUCTION PRESSURE
TEMPERATURE CHART
SATURATED LIQUID PRESSURE
TEMPERATURE CHART
SATURATED SUCTION
TEMPERATURE ºF
SATURATED LIQUID
TEMPERATURE ºF
R-22
SUCTION PRESSURE
LIQUID PRESSURE
PSIG
PSIG
R-22
200
210
220
225
235
245
255
265
275
285
295
305
325
355
375
405
415
425
435
445
475
500
525
550
575
600
625
101
105
108
110
113
116
119
121
124
127
130
133
137
144
148
155
157
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
50
52
26
28
29
31
32
34
35
37
38
40
41
42
44
45
46
48
50
53
56
59
64
69
73
78
83
86
90
54
56
58
60
62
64
66
68
70
72
74
76
78
80
85
90
95
100
110
120
130
140
150
160
170
8
3. Check subcooling and superheat. Systems with TXV ap-
plication should have a subcooling of 7 ± 2 ºF and super-
heat of 8 ± 1 ºF.
Fixed Orifice
CAUTION
a. If subcooling and superheat are low, adjust TXV to
To prevent personal injury, carefully connect and disconnect
manifold gauge hoses. Escaping liquid refrigerant can cause
burns. Do not vent refrigerant into the atmosphere. Recover all
refrigerant during system repair and before final unit disposal.
8 ± 1 ºF superheat, then check subcooling.
NOTE: To adjust superheat, turn the valve stem clock-
wise to increase and counter clockwise to decrease.
b. If subcooling is low and superheat is high, add charge
to raise subcooling to 7 ± 2ºF then check super-
heat.
1. Purge gauge lines. Connect service gauge manifold to
base-valve service ports. Run system at least 10 minutes
to allow pressure to stabilize.
c. If subcooling and superheat are high, adjust TXV
2. Temporarily install thermometer on suction (large) line
near suction line service valve with adequate contact and
insulate for best possible reading.
valve to 8 ± 1 ºF superheat, then check subcooling.
d. If subcooling is high and superheat is low, adjust
TXV valve to 8 ± 1 ºF superheat and remove charge
to lower the subcooling to 7 ± 2ºF.
3. Refer to the superheat table provided for proper system
superheat. Add charge to lower superheat or recover
charge to raise superheat.
NOTE: Do NOT adjust the charge based on suction pres-
sure unless there is a gross undercharge.
4. Disconnect manifold set, installation is complete.
Superheat Formula = Suct. Line Temp. - Sat. Suct. Temp.
4. Disconnect manifold set, installation is complete.
Subcooling Formula = Sat. Liquid Temp. - Liquid Line Temp.
Expansion Valve System
NOTE: Check the Schrader ports for leaks and tighten valve
cores if necessary. Install caps finger-tight.
1. Purge gauge lines. Connect service gauge manifold
tobase-valve service ports. Run system at least 10 min-
utes to allow pressure to stabilize.
2. Temporarily install thermometer on liquid (small) line near
liquid line service valve with adequate contact and insu-
late for best possible reading.
9
Troubleshooting Information
System
Operating
Pressures
Unsatisfactory
Cooling
No Cooling
Complaint
POSSIBLE CAUSE
Test Method
Remedy
DOTS IN ANALYSIS
GUIDE INDICATE
"POSSIBLE CAUSE"
Power Failure
Blown Fuse
Loose Connection
Shorted or Broken Wires
Open Overload
Test Voltage
•
•
•
•
Impact Fuse Size & Type
Inspect Connection - Tighten
Test Circuits with Ohmmeter
Test Continuity of Overloads
Test Continuity of Thermostat and Wiring
Check Control Circuit with Voltmeter
Test Capacitor
Test Continuity of Overload
Test Motor Windings
Use Test Cord
•
•
•
•
•
•
•
•
•
•
•
•
•
Faulty Thermostat
Faulty Transformer
•
•
•
•
•
Shorted or Open Capacitor
Internal Compressor Overload Open
Shorted or Grounded Compressor
Compressor Stuck
Faulty Compressor Contactor
Faulty Fan Relay
•
•
•
•
•
•
•
•
•
•
•
Test Continuity of Coil and Contacts
Test Continuity of Coil and Contacts
Test Control Circuit with Voltmeter
Test Voltage
•
•
•
•
Open Control Circuit
Low Voltage
•
•
Faulty Evaporator Fan Motor
Shorted or Grounded Fan Motor
Improper Cooling Anticipator
Shortage or Refrigerant
Restricted Liquid Line
Undersized Liquid Line
Undersized Suction Line
Not Enough Air across Indoor Coil
Too Much Air across Indoor Coil
Overcharge of Refrigerant
Noncondensibles
Recirculation of Condensing Air
Infiltration of Outdoor Air
Improperly Located Thermostat
Air Flow Unbalanced
System Undersized
Broken Internal Parts
Repair or Replace
Test Motor Windings
Check Resistance of Anticipator
Test For Leaks, Add Refrigerant
Replace Restricted Part
Replace Line
Replace Line
Speed Blower, Check Duct Static Pressure
Reduce Blower Speed
Recover Part of Charge
Recover Charge, Evacuate, Recharge
Remove Obstruction to Air Flow
Check Windows, Doors, Vent Fans, Etc.
Relocate Thermostat
Readjust Air Volume Dampers
Refigure Cooling Load
Replace Compressor
Test Compressor Efficiency
Test Compressor Efficiency
Reset and Test Control
Test Voltage
Replace Valve
Replace Valve
Replace Valve
Replace Valve
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Broken Valves
Inefficient Compressor
High Pressure Control Open
Unbalanced Power, 3PH
Wrong Type Expansion Valve
Expansion Valve Restricted
Oversized Expansion Valve
Undersized Expansion Valve
Expansion Valve Bulb Loose
Inoperative Expansion Valve
Loose Hold-down Bolts
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Tighten Bulb Bracket
Check Valve Operation
Tighten Bolts
For detailed service information refer to the Remote Condensing Unit Service manual.
NOTICE
UNITS WITH ROTARY OR RECIPROCATING COMPRESSORS AND NON-BLEED
TXV’S REQUIRE A HARD START KIT.
10
THIS PAGE INTENTIONALLY LEFT BLANK
11
SPLIT SYSTEMS
AIR CONDITIONINGAND 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
CLEAN OUTSIDE COIL (QUALIFIED SERVICER ONLY)
IMPORTANT NOTE: Never operate unit without a filter installed
as dust and lint will build up on internal parts resulting in loss
of efficiency, equipment damage and possible fire.
An indoor air filter must be used with your comfort system. A
properly maintained filter will keep the indoor coil of your com-
fort 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.
Air must be able to flow through the outdoor unit of your com-
fort 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.
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.
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.
You may want to ask your dealer about high efficiency filters.
High efficiency filters are available in both electronic and non-
electronic types. These filters can do a better job of catching
small airborne particles.
COMPRESSOR
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.
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.
BEFORE CALLING YOUR SERVICER
•
Check the electrical panel for tripped circuit breakers or
failed fuses. Reset the circuit breakers or replace fuses
as necessary.
•
•
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 op-
eration 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.
•
•
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.
TO AVOID THE RISK OF EQUIPMENT DAMAGE OR FIRE, INSTALL
THE SAME AMPERAGE BREAKER OR FUSE AS YOU ARE
REPLACING. IF THE CIRCUIT BREAKER OR FUSE SHOULD OPEN
AGAIN WITHIN THIRTY DAYS, CONTACT A QUALIFIED SERVICER
TO CORRECT THE PROBLEM.
IF YOU REPEATEDLY RESET THE BREAKER OR REPLACE
THE FUSE WITHOUT HAVING THE PROBLEM CORRECTED,
YOU RUN THE RISK OF SEVERE EQUIPMENT DAMAGE.
•
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 oper-
ating noise, that might be coming from the outdoor unit.
If you hear unusual noise(s) coming from the unit, call a
qualified servicer.
12
© 2010 Goodman Manufacturing Company, L.P.
5151 San Felipe, Suite 500, Houston, TX 77056
P/N: IO-404A Date: May 2012
CONDENSINGAC UNIT
3-PHASE 7.5 & 10 TON AIR CONDITIONER
INSTALLATION & SERVICE REFERENCE
NOTICE
THIS UNIT IS SHIPPED WITH A NITROGEN/HELIUM HOLDING CHARGE ONLY. UNIT
MUST BE EVACUATED AND CHARGED PER INSTALLATION INSTRUCTIONS WITH
REFRIGERANT LISTED ON SERIAL RATING PLATE.
NOTICE
UNITS SHIPPED WITH A HOLDING CHARGE ARE INTENDED FOR COMPONENT
REPLACEMENT ONLY ON EXISTING SYSTEMS, AND NOT INTENDED FOR USE IN
NEW SYSTEMS OR NEWLY CONSTRUCTED HOMES.
NOTICE
UNITS MUST ONLY BE USED AS REPLACEMENT COMPONENTS FOR PRE-2010
INSTALLED SYSTEMS.
Codes & Regulations
Important Safety Instructions
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 equip-
ment installed in violation of any codes or regulations. Rated
performance is achieved after 72 hours of operation.
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.
The United States Environmental Protection Agency (EPA)
has issued various regulations regarding the introduc-
tion 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.
WARNING
HIGH VOLTAGE!
Disconnect ALL power before servicing.
Multiple power sources may be present.
Failure to do so may cause property damage,
personal injury or death.
If replacing a condensing unit or air handler, the system must
be manufacturer approved and Air Conditioning, Heating and
Refrigeration Institute (AHRI) matched.
ONLY individuals meeting the requirements of an
“Entry Level Technician”, at a minimum, as specified
by the Air Conditioning, Heating and Refrigeration
Institute (AHRI) may use this information. Attempting
to install or repair this unit without such background
may result in product damage, personal injury,
or death.
Refer to the unit Specification Sheet for the recommended in-
door model selection. NOTE: This unit must be used with a
purchased single stage room thermostat with 24 VAC control
circuitry.
Do not operate the unit in a structure that is not complete
(either as part of new construction or renovation). Such opera-
tion will void the warranty.
Shipping Inspection
Always keep the unit upright; laying the unit on its side or top
may cause equipment damage. Shipping damage, and subse-
quent investigation is the responsibility of the carrier. Verify
the model number, specifications, electrical characteristics,
and accessories are correct prior to installation. The distribu-
tor or manufacturer will not accept claims from dealers for trans-
portation damage or installation of incorrectly shipped units.
Installation Clearances
This unit is designed for outdoor installations only. Special
consideration must be given to location of the condensing unit(s)
in regard to structures, obstructions, other units, and any/all
other factors that may interfere with air circulation. Where
possible, the top of the unit should be completely unobstructed;
however, if vertical conditions require placement beneath an
obstruction there should be a minimum of 60 inches be-
tween the top of the unit and the obstruction(s). The speci-
fied dimensions meet requirements for air circulation only.
Consult all appropriate regulatory codes prior to determining
final clearances.
Another important consideration in selecting a location for the
unit(s) is the angle to obstructions. Either side adjacent the
valves can be placed toward the structure provided the side
away from the structure maintains minimum service clearance.
Corner installations are strongly discouraged.
12"
60"
12"
Use field-supplied spreader bars when lifting the unit to mini-
mize the possibility of lifting cable/straps damage. To protect
the cabinet louvers, use protective material such as plywood
behind the cable/straps. Arrange the straps to form a central
suspension point. NOTE: When raising and setting the unit,
observe all safety rules. Remove shipping skid and all protec-
tion and lifting material after the unit is in place.
24"
This unit can be located at ground floor level or on flat roofs. At
ground floor level, the unit must be on a solid, level foundation
that will not shift or settle. To reduce the possibility of sound
transmission, the foundation slab should not be in contact with
or be an integral part of the building foundation. The foundation
slab should be a minimum of 6” wider than the unit in all direc-
tions. Ensure the foundation is sufficient to support the unit. A
concrete slab raised above ground level provides a suitable
base.
Safe Refrigerant Handling
While these items will not cover every conceivable situation,
they should serve as a useful guide.
WARNING
Refrigerants are heavier than air. They can "push out"
the oxygen in your lungs or in any enclosed space.To
The selected site should be no greater than 50’ below or 70’
above the evaporator section. For optimum performance, the
minimum length interconnecting tubing is preferred. When pos-
sible minimize the amount of bends and turns.
avoid possible difficulty in breathing or death:
•
Never purge refrigerant into an enclosed room or
space. By law, all refrigerants must be reclaimed.
•
If an indoor leak is suspected, throughly ventilate the
area before beginning work.
Rooftop Installations
If it is necessary to install this unit on a roof structure, ensure
the roof structure can support the weight and that proper con-
sideration is given to the weather-tight integrity of the roof. Since
the unit can vibrate during operation, sound vibration transmis-
sion should be considered when installing the unit. Vibration
absorbing pads or springs can be installed between the con-
densing unit legs or frame and the roof mounting assembly to
reduce noise vibration.
• Liquid refrigerant can be very cold. To avoid possible
frostbite or blindness, avoid contact and wear gloves
and goggles. If liquid refrigerant does contact your
skin or eyes, seek medical help immediately.
• Always follow EPA regulations. Never burn refrig-
erant, as poisonous gas will be produced.
To avoid possible explosion:
Rigging
•
Never apply flame or steam to a refrigerant cylinder.
If you must heat a cylinder for faster charging,
partially immerse it in warm water.
•
Never fill a cylinder more than 80% full of liquid re-
frigerant.
To avoid possible injury or death, all panels must be
in position and secured before lifting this equipment
• Never add anything other than R-22 to an R-22 cy-
linder. The service
equipment used must be listed or certified for the
type of refrigerant used.
• Store cylinders in a cool, dry place. Never use a cy-
linder as a platform or a roller.
2
WARNING
To avoid possible explosion, use only returnable (not
disposable) service cylinders when removing refrig-
erant from a system.
• Ensure the cylinder is free of damage which could
lead to a leak or explosion.
• Ensure the hydrostatic test date does not exceed
5 years.
• Ensure the pressure rating meets or exceeds 400
lbs.
When in doubt, do not use cylinder.
Refrigerant Lines
NOTE: For improved refrigerant management, equip the
evaporator coil with a field-supplied thermal expansion valve
(TXV) and the liquid line with a field-supplied liquid line solenoid.
Ensure the solenoid is installed as close as possible to the
evaporator coil to prevent refrigeration migration in the
compressor “OFF” cycle.
Use only refrigerant grade (dehydrated and sealed) copper tub-
ing to connect the condensing unit with the indoor evaporator.
After cutting the tubing, install plugs to keep refrigerant tubing
clean and dry prior to and during installation. Tubing should
always be cut square keeping ends round and free from burrs.
Clean the tubing to prevent contamination.
Insulation is necessary to prevent condensation from forming
and dropping from the suction line. Armflex (or satisfactory
equivalent) with 3/8” min. wall thickness is recommended. In
severe conditions (hot, high humidity areas) 1/2” insulation may
be required. Insulation must be installed in a manner which
protects tubing from damage and contamination.
Do NOT let refrigerant lines come in direct contact with plumb-
ing, ductwork, floor joists, wall studs, floors, and walls. When
running refrigerant lines through a foundation or wall, openings
should allow for sound and vibration absorbing material to be
placed or installed between tubing and foundation. Any gap
between foundation or wall and refrigerant lines should be filled
with a pliable silicon-based caulk, RTV or a vibration damping
material. Avoid suspending refrigerant tubing from joists and
studs with rigid wire or straps that would come in contact with
the tubing. Use an insulated or suspension type hanger. Keep
both lines separate and always insulate the suction line.
Where possible, drain as much residual compressor oil from
existing systems, lines, and traps; pay close attention to low
areas where oil may collect. NOTE: If changing refrigerant
types, ensure the indoor coil and metering device is compat-
ible with the type of refrigerant being used; otherwise, the in-
door coil must be replaced. To facilitate oil return to the com-
pressor, a horizontal suction line should be pitched (1/2” per
10’ toward the condensing unit.
Filter Drier and Sight Glass
REFRIGERANT LINE LENGTH (ft)
A liquid line filter drier is factory installed. Field-install the sup-
plied sight glass/moisture indicator on the liquid line as close
as practical to the service valve.
Cond Unit
(Tons)
0-24
25-49*
50-74**
Line Diameter (In. OD)
Suct Liq Suct Liq Suct Liq
1 1/8 5/8 1 3/8 5/8 1 3/8 5/8
1 3/8 5/8 1 5/8 5/8 1 5/8 5/8
Burying Refrigerant Lines
If burying refrigerant lines can not be avoided, use the following
checklist.
7 1/2
10
* Full rating line size
1. Insulate liquid and suction lines separately.
** Lines greater than 74 feet in length or vertical elevation
2. Enclose all underground portions of the refrigerant lines
in waterproof material (conduit or pipe) sealing the ends
where tubing enters/exits the enclosure.
changes more than 50 feet
refer to the Remote Cooling
Service Manual or contact your distributor for assistance.
3. If the lines must pass under or through a concrete slab,
ensure lines are adequately protected and sealed.
3
Pressure test the system using dry nitrogen and soapy water
to locate leaks. If you wish to use a leak detector, charge the
system to 10 psi using the appropriate refrigerant then use
nitrogen to finish charging the system to working pressure then
apply the detector to suspect areas. If leaks are found, repair
them. After repair, repeat the pressure test. If no leaks exist,
proceed to system evacuation.
Refrigerant Line Connections
NOTICE
THIS UNIT IS SHIPPED WITH A NITROGEN/HELIUM
HOLDING CHARGE ONLY. UNIT MUST BE
EVACUATED AND CHARGED PER INSTALLATION
INSTRUCTIONS WITH REFRIGERANT LISTED ON
SERIAL RATING PLATE.
System Evacuation
Condensing unit liquid and suction valves are closed to contain
the charge within the unit. The unit is shipped with the valve
stems closed and caps installed.
NOTE: Holding charge must be removed before brazing. Open
service valves slowly to remove holding charge. Close valves
before brazing to prevent contaminants from entering system.
WARNING
REFRIGERANT UNDER PRESSURE!
Failure to follow proper procedures may cause
property damage, personal injury or death.
IMPORTANT: To avoid overheating the service valve, TXV
valve, or filter drier while brazing, wrap the component
with a wet rag, or use a thermal heat trap compound as
recommended by the compound manufacturer. Use a
brazing alloy of 2% minimum silver content. Do not use
flux.
NOTICE
THIS UNIT IS SHIPPED WITH A NITROGEN/HELIUM
1. The ends of the refrigerant lines must be cut square, de-
burred, cleaned, and be round and free from nicks or dents.
Any other condition increases the chance of a refrigerant
leak.
HOLDING CHARGE ONLY. UNIT MUST BE
EVACUATED AND CHARGED PER INSTALLATION
INSTRUCTIONS WITH REFRIGERANT LISTED ON
SERIAL RATING PLATE.
2. “Sweep” the refrigerant line with nitrogen or inert gas dur-
ing brazing to prevent the formation of copper-oxide in-
side the refrigerant lines.
NOTICE
UNITS SHIPPED WITH A HOLDING CHARGE ARE
3. After brazing, quench the joints with water or a wet cloth
to prevent overheating of the service valve.
INTENDED FOR COMPONENT REPLACEMENT
ONLY ON EXISTING SYSTEMS, AND NOT
INTENDED FOR USE IN NEW SYSTEMS OR NEWLY
CONSTRUCTED HOMES.
4. Ensure the filter drier paint finish is intact after brazing. If
the paint of the steel filter drier has been burned or chipped,
repaint or treat with a rust preventative. This is especially
important on suction line filter driers which are continu-
ally wet when the unit is operating.
NOTICE
UNITS MUST ONLY BE USED AS REPLACEMENT
NOTE: Be careful not to kink or dent refrigerant lines. Kinked
or dented lines will cause poor performance or compressor
damage.
COMPONENTS FOR PRE-2010 INSTALLED
SYSTEMS.
NOTE: Holding charge must be removed before brazing.
Do NOT make final refrigerant line connection until plugs are
removed from refrigerant tubing.
1. Openservice valves before attaching vacuum pump.
NOTE: Before brazing, verify indoor piston size by checking
the piston kit chart packaged with indoor unit.
2. Connect the vacuum pump with 250 micron capability to
the service valves.
Leak Testing (Nitrogen or Nitrogen-Traced)
3. Evacuate the system to 250 microns or less using suc-
tion and liquid service valves. Using both valves is nec-
essary as some compressors create a mechanical seal
separating the sides of the system.
WARNING
To avoid the risk of fire or explosion, never use
oxygen, high pressure air or flammable gases for leak
testing of a refrigeration system.
4. Close pump valve and hold vacuum for 10 minutes. Typi-
cally pressure will rise during this period.
WARNING
To avoid possible explosion, the line from the
nitrogen cylinder must include a pressure regulator
and a pressure relief valve. The pressure relief valve
must be set to open at no more than 150 psig.
4
RATED
VOLTAGE
MINIMUM SUPPLY MAXIMUM SUPPLY
5000
4500
4000
3500
3000
2500
2000
1500
1000
500
VOLTAGE
VOLTAGE
208/230V
460V
197
414
253
506
LEAK(S)
PRESENT
The condensing unit rating plate lists pertinent electrical data
necessary for proper electrical service and overcurrent protec-
tion. Wires should be sized to limit voltage drop to 2% (max.)
from the main breaker or fuse panel to the condensing unit.
Consult the NEC, CEC, and all local codes to determine the
correct wire gauge and length. The wire size must be sufficient
to carry the Minimum Circuit Ampacity (MCA) listed on the
serial plate.
CONDENSIBLES OR SMALL
LEAK PRESENT
NO LEAKS
NO CONDENSIBLES
0
1
2
3
4
5
6
7
8
9
10
The supply voltage can be unbalanced (phase to phase) within
2%. The following formula can be used to determine the per-
centage of voltage unbalance for your unit.
MINUTES
• If the pressure rises to 1000 microns or less and remains
steady the system is considered leak-free; proceed to
startup.
Percentage
Voltage
Max. Voltage Deviation Form
Average Voltage
=
Unbalance
Average Voltage
•
If pressure rises above 1000 microns but holds steady
below 2000 microns, moisture and/or noncondensibles
may be present or the system may have a small leak.
Return to step 2: If the same result is encountered check
for leaks as previously indicated and repair as necessary
then repeat evacuation.
Example:
L1-L2 = 220V
L2-L3 = 216V
Average Voltage = (220 + 216 + 213)/3
= 649/3
• If pressure rises above 2000 microns, a leak is present.
Check for leaks as previously indicated and repair as nec-
essary then repeat evacuation.
Maximum Deviation from Average = 220 - 216 = 4
Refer to the Remote Condensing Unit Service Manual for more
detailed instructions on system evacuation, preliminary charge
adjustment, and final charge adjustment.
% Voltage Unbalance = 100 x (4/216)
= 400/216
Electrical Connections
MAXIMUM ALLOWABLE LENGTH IN FEET
TO LIMIT VOLTAGE DROP TO 2%
WARNING
HIGH VOLTAGE!
Wire
Size
(AWG)
14
12
10
8
Minimum Circuit Ampacity (MCA)
Disconnect ALL power before servicing.
Multiple power sources may be present.
Failure to do so may cause property damage,
personal injury or death due to electric shock.
Wiring must conform with NEC or CEC and all
local codes. Undersized wires could cause
poor equipment performance, equipment damage
or fire.
10 15 20 25 30 35 40 45
75 50 37 NR NR NR NR NR
118 79 59 47 NR NR NR NR
188 125 95 75 63 54 NR NR
301 201 150 120 100 86 75 68
471 314 235 188 157 134 118 110
6
*Based on NEC 1996
WARNING
To avoid the risk of fire or equipment damage, use
copper conductors.
NOTICE
Units with reciprocating compressors and non-bleed TXV’s
require a Hard Start Kit.
This unit is designed for three phase operation. DO NOT OP-
ERATE ON A SINGLE PHASE POWER SUPPLY. Measure
the power supply to the unit. The supply voltage must be in
agreement with the unit rating plate power requirements.
5
To correct, disconnect power and switch any two leads at the
unit contactor and re-observe.
Example:
A 7 ½ Ton unit is to be installed. The distance from the
building to the unit is 75’. Calculate the minimum wire size
assuming no more than 2% voltage drop.
High Voltage Connections
Route power supply and ground wires through the high voltage
port and terminate in accordance with the wiring diagram pro-
vided inside the control panel cover.
MCA for 7 ½ Ton 230V unit = 43.3 (from S&R plate).
Applying previous table wire sizes less than #8 AWG
cannot be used for circuits which have a rating of 45A.
The #8 wire is not suitable since the maximum length for
a 45A circuit is 68’.
Low Voltage Connections
Condensing unit control wiring requires a two-conductor low
voltage circuit from the room thermostat. The wiring should be
no smaller than 18 AWG and the field connection for this cir-
cuit must be made in the unit control box using solderless
connectors (i.e. wire nuts). See the following diagram for a
typical low voltage hook-up.
Solution: Use a #6 AWG wire suitable up to 110’.
NOTE: It is the contractors’s responsibility to follow the
NEC (USA) or CEC (Canada) when sizing the service
wire for this unit.
SINGLE STATE LOW VOLTAGE HOOK-UP
THERMOSTAT CHT18-60
Local codes often require a disconnect switch located near the
unit; do not install the switch on the unit. Refer to the installa-
tion instructions supplied with the indoor furnace/air handler for
specific wiring connections and indoor unit configuration. Like-
wise, consult the instructions packaged with the thermostat
for mounting and location information.
Y1
R
G
W1
AIR
HANDLER
AH090/120
GREEN
RED
CONDENSING
UNIT
CKL090/120
Overcurrent Protection
The following overcurrent protection devices are approved for
use.
YELLOW
BLACK
WHITE
BLUE
BLUE
•
•
Time delay fuses
NOTES:
1). THERMOSTAT TO AIR HANDLER CABLE
MUST HAVE A MINIMUM OF (4) CONDUCTORS
HACR type circuit breakers
WIRE NUT
2). AIR HANDLER TO CONDENSING UNIT CABLE
MUST HAVE A MINIMUM OF (2) CONDUCTORS
These devices have sufficient time delay to permit the motor-
compressor to start and accelerate its load.
Refer to the unit serial plate and this table for the maximum
overcurrent protection permitted.
System Start Up
Never operate the compressor with the suction valve closed to
test the compressor’s pumping efficiency. In some cases, this
can result in serious compressor damage and loss of warranty
coverage.
Run all line voltage wiring a conduit from the service discon-
nect box to the unit. Refer to the NEC (USA) or CEC (Canada)
codes for the correct size conduit based on the wire size. The
conduit enters the control box through the hole provided in the
bottom. NOTE: The control box hole is sized for 3/4” conduit. If
permitted by code, a flexible conduit is preferred to minimize
vibration transmission from the unit to the building.
NOTICE
THIS UNIT IS SHIPPED WITH A NITROGEN/HELIUM
HOLDING CHARGE ONLY. UNIT MUST BE
EVACUATED AND CHARGED PER INSTALLATION
INSTRUCTIONS WITH REFRIGERANT LISTED ON
SERIAL RATING PLATE.
Connect the line voltage wires to the L1, L2, and L3 terminals
of the definite purpose contactor (located in the unit control
box). Refer to the wiring diagram attached to the unit when
making these connections.
Three Phase Compressor Rotation
NOTICE
UNITS SHIPPED WITH A HOLDING CHARGE ARE
CAUTION
Use care when handling scroll compressors. Dome temp-
eratures could be hot.
INTENDED FOR COMPONENT REPLACEMENT
ONLY ON EXISTING SYSTEMS, AND NOT
INTENDED FOR USE IN NEW SYSTEMS OR NEWLY
CONSTRUCTED HOMES.
Three phase scrolls are power phase dependent and can com-
press in more than one direction.
Verify proper rotation for three phase compressors by ensuring
the suction pressure drops and discharge pressure rises when
the compressor is energized. NOTE: When operated in re-
verse, a three phase scroll compressors is noisier and its cur-
rent draw substantially reduced compared to marked values.
NOTICE
UNITS MUST ONLY BE USED AS REPLACEMENT
COMPONENTS FOR PRE-2010 INSTALLED
SYSTEMS.
6
For the 7-1/2 ton unit starting charge should be 15 lb of R-22
and 18 lbs for the 10 ton unit. The length of line set, indoor unit
airflow, condensing unit location and number of tubing fittings
will have an impact on final unit charge amount. Turn the elec-
trical power on, and let the system run. Wait for the refrigerant
pressures to stabilize.
c. If subcooling and superheat are high, adjust TXV
valve to 9 ± 1 ºF superheat, then check subcooling.
d. If subcooling is high and superheat is low, adjust
TXV valve to 9 ± 1 ºF superheat and remove charge
to lower the subcooling to 11 ± 2ºF.
NOTE: Do NOT adjust the charge based on suction pres-
sure unless there is a gross undercharge.
Charge Verification
4. Disconnect manifold set, installation is complete.
WARNING
REFRIGERANT UNDER PRESSURE!
• Do not overcharge system with refrigerant.
• Do not operate unit in a vacuum or at negative pres-
sure.
Subcooling Formula = Sat. Liquid Temp. - Liquid Line Temp.
NOTE: Check the Schrader ports for leaks and tighten valve
cores if necessary. Install caps finger-tight.
Failure to follow proper procedures may cause
NOTE: Subsequent opening and replace of the cap will require
only 1/2 to 1 hex flat. See the table below for the torque required
for an effective seal on the valve bonnet (1/6 turn past finger
tight.
property damage, personal injury or death.
CAUTION
Use refrigerant certified to AHRI standards. Use of used
refrigerant may cause compressor damage that is not
covered under warranty. Most portable machines cannot
clean used refrigerant to meet AHRI standards.
TORQUE
TUBING SIZE
(ft-lbs)
5/8
14
16
1 3/8
NOTICE
After closing the valve bonnet, perform a final refrigerant leak
test on the valves and sweat connections. Return the room
thermostat to the desired settings.
Violation of EPA regulations may result in fines or other
penalties.
Troubleshooting
Qualified Installer/Servicer Only
CAUTION
Operating the compressor with the suction valve closed
may cause serious compressor damage.
When troubleshooting, the first step should always be to check
for clean coils, clean filter(s), and proper airflow. Indoor airflow
should be 375 to 425 CFM per ton of cooling based on the size
of the outdoor unit. The most common way of establishing
indoor airflow is heating temperature rise. Indoor airflow will
then be (Heating output of equipment) / (1.1 x temp. rise). In
other cases, measurement of external static pressure is help-
ful. For details, see the Installation Instructions for your indoor
unit.
Final Charge Adjustment
The outdoor temperature must be 60°F or higher. Set the room
thermostat to COOL, fan switch to AUTO, and set the tem-
perature control well below room temperature.
After system has stabilized per startup instructions, check
subcooling and superheat as detailed in the following section.
Expansion Valve System
1. Purge gauge lines. Connect service gauge manifold
tobase-valve service ports. Run system at least 10 min-
utes to allow pressure to stabilize.
2. Temporarily install thermometer on liquid (small) line near
liquid line service valve with adequate contact and insu-
late for best possible reading.
3. Check subcooling and superheat. Systems with TXV ap-
plication should have a subcooling of 11 ± 2 ºF and su-
perheat of 9 ± 1 ºF.
a. If subcooling and superheat are low, adjust TXV
to 9 ± 1 ºF superheat, then check subcooling.
NOTE: To adjust superheat, turn the valve stem clock-
wise to increase and counter clockwise to decrease.
b. If subcooling is low and superheat is high, add
charge to raise subcooling to 11 ± 2ºF then check
superheat.
7
TROUBLESHOOTING ANALYSIS TABLE
COMPLAINT
PROBABLE CAUSE
REMEDY
1. Excessive charge of refrigerant in system.
2. Inadequate supply of air across the
condenser coil.
1. Purge or pump-down excessive charge.
2. Make certain that coil is not fouled in any
1. High Head Pressure
way, or that air is not re-circulating.
3. Purge these gases from the system.
Recharge system, if necessary.
3. Non-condensate gases in the system.
1. System low on refrigerant.
2. Compressor valves broken.
1. Charge system until sight glass is clear of bubbles.
2. Replace compressor.
2. Low Head Pressure
1. Liquid line valve closed.
2. Restricted liquid line.
1. Open the liquid line valve.
2. Replace filter-dryer.
3. The bulb of the thermal expansion valve
has lost its charge.
3. Detach the bulb from the suction line and hold
in one hand. If no liquid refrigerant goes through
the valve, replace the valve.
3. Low Suction Pressure
4. System low on refrigerant.
4. Test the unit for leaks. Add refrigerant until sight
glass is free from bubbles, after repairing leak.
5. Clean or replace filter.
5. Dirty filters.
6. Coil frosted up.
6. Defrost and clean coil. Clean or replace filters.
7. Flash gas in the liquid line.
8. Quantity of air through evaporator not adequate.
7. Excessive liquid line drop. Check liquid line size.
8. Increase the blower speed.
1. Expansion valve stuck open.
2. Expansion valve bulb not in contact with
1. Correct valve action or replace the valve.
2. Fasten bulb securely to suction line.
4. High Suction Pressure
suction line.
3. Suction and/or discharge valve leaking or broken.
3. Replace compressor.
1. Disconnect switch open.
1. Close the disconnect switch.
2. Blow fuse or fuse at disconnect switch.
3. Thermostat set too high.
2. Check the cause of failure and replace the fuse.
3. Adjust to lower temperature.
5. Compressor will not start. 4. Selector switch in "Off" position.
5. Contactor and/or relay coils burned out.
6. Loose or open electrical connection in either
the control or power circuit.
4. Turn selector switch knob to "Cool" position.
5. Replace contactor and/or relay.
6. Inspect and secure all electrical connections.
Wiring Diagram
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.
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