Goodman Mfg IO-101G User's Manual
Contents
1. TABLE 3 Expansion Valve System 1 Fully open both base valves 2 Connect service gauge manifold to base valve service parts making sure lines are purged Run system at least 10 minutes to allow pressure to stabalize 3 Temporarily install the thermometer to liquid small line near condensing unit Be sure that the contact between thermometer and line is good Wrap thermometer with insulating material to ensure accurate reading 4 Referring to Table 4 adjust charge to obtain a temperature 12 15 F below the saturated liquid temperature Example If the Liquid Pressure is 260 PSIG then the Saturated Temperature will be 120 F Adjust the Saturated Temperature by subtracting 12 15 F This will give youa Liquid Line Temperature of 105 108 F SATURATED LIQUID TEMPERATURE LIQUID PRESSURE SATURATED TEMPERATURE RER CIE 102 TABLE 4 06 04 SPECIAL NOTE Systems with MORE than 15 of interconnecting tubing please refer to Table 5 for line charge allowance per foot of tubing LINE LIQUID SUCTION ee ee ee o ags 058 IL t fo tis DEE C E DEE EE De r ll E E EE TABLE 5 10 101G NOTE System with over 50 separation between condensing unit and evaporator may require oil charge adjustment OIL CHARGE ADJUSTMENT UNIT MODEL ADDITIONAL OIL CHARGE PER EACH TONS ADDITIONAL 10 OF LINE OZ 1 11 2 Use either Texaco WF 32 formerly cappella B or Suniso 3G S oil TABLE 6 062. 04 10 101G OUTDOOR CONTROL BOX COMPRESSORIFAN CAPACITOR FAN MOTOR Tinay START ASSIST FUSED x L CRANKCASE HEATER IF USED FACTORY WIRING CODE WIRING NOTES REPLACEMENT WIRE MUST BE SAME GAGE AND INSULATION THICKNESS 105 C APPLIANCE WIRING MATERIAL POWER SUPPLY SEE RATING PLATE USE COPPER CONDUCTORS ONLY WIRING CODE ronyons LI ow vourace Less E oP EC une seues LGS LI WIRING DIAGRAMS ALT DOUBLE POLE CONTACTOR OUTDOOR POWER SUPPLY bo crn yy F USED COMPRESSOR DO AOS AZOO OUTDOOR POWER COMPRESSOR SUPPLY SEE INTERNAL UNIT RATING OVERLOAD PLATE USE COPPER CONDUCTORS ONLY USE L1 FOR NEUTRAL OR GROUNDED SUPPLY IF USED EQUIPMENT GROUND SA CAPACITOR nl ta CONNECT TO APPROP CONTROL CIRCUIT HAVING MIN 40 VA 24 VOLT N E C CLASS 2 TRANSFORMER OR FOR CERTIFIED CSA CONTACTOR INSTALLATION USE CSA col CERTIFIED ENERGY LIMITED dee CLASS 2 TRANSFORMER SS FAN MOTOR THERMOSTAT COOL ANTICIPATOR ee eech FAN RELAY Co COLOR CODE WIRING FOR THERMOSTAT E S BE THERMOSTAT SYSTEM OPTIONS R RED BULB swiTcH y uow ba BE THERMOSTAT PU PURPLE ADL HEAT um LIGHT BLUE ANTICIPATOR BR BROWN D GREEN LOW VOLTAGE TRANSFORMER INDOOR POWER SUPPLY 3 98 REV A B17784 01 SINGLE PHASE OUTDOOR POWER SUPPLY Ge SE CONNECT To APPROP CONTROL CIRCUIT HAVING MIN 40 VA 24 VOLT N E C CALSS 2 TR
3. AMSFORMER OR FOR CERTIFIED C S A INSTALLATION USE C S A CERTIFIED ENERGY LIMITED CLASS 2 TRANSFORMER EQUIPMENT GROUND USE COPPER CONDUCTORS ONLY D COMPONENT CODE TRANSFORMER CM OUTDOOR FAN MOTOR COMP COMPRESSOR E vn contactor pe DEFROST CONTROL BK BLACK LDVR LOW VOLTAGE DEFROST RELAY R vn RED cH CRANKCASE HEATER D INTERNAL OVERLOAD LP LOW PRESSURE CONTROL BL BLUE COLOR CODE y uow HP HIGH PRESSURE CONTROL v voe NOTES oT OUTDOOR THERMOSTAT OPTIONAL iiras 1 TO INDOOR UNIT LOW FC m FAN CAPACITOR VOLTAGE TERMINAL BLOCK amp DFT DEFROST THERMOSTAT Pier BROWN INDOOR THERMOSTAT RVC REVERSING VALVE COIL D GREEN HVOR vn HIGH VOLTAGE DEFROST RELAY 2 SEE INDOOR UNIT amp OUTDOOR UNIT INSTALLATION w WHITE INSTRUCTIONS FOR CONNECTION CONTROLS SHOWN WITH UTILITIES IN ON POSITION OF OPTIONAL OUTDOOR THERMOSTAT AND THERMOSTAT IN OFF POSITION t t BENE Gags WEE THREE PHASE o orane 0797 REV D B17783 00 20 0 Ee 06 04 NOTE SPECIFICATIONS AND PERFORMANCE DATA LISTED HEREIN ARE SUBJECT TO CHANGE WITHOUT NOTICE Quality Makes the Difference All of our systems are designed and manufactured with the same high quality standards regardless of size or efficiency We have designed these units to significantly reduce the most frequent causes of product failure They are simple to service and forgiving to operate We use quality materials and components Finall
4. INSTALLATION amp OPERATING INSTRUCTIONS for SPLIT SYSTEM CONDENSING UNITS All information contained herein is subject to change without notice Goodman Manufacturing Company L P 10 101G 2550 North Loop West Suite 400 Houston TX 77092 06 04 www goodmanmfg com 2003 2004 Goodman Manufacturing Company L P INDEX Important Message to Homeowner ssssssseeeeeesss 2 Codes and Regulations cccceeceeeesneeeeeeeees 2 INSPOCHON 2325 t3n8 orient e a ante reeaate 2 Replacement Parts AAA 2 Important Safety Instructions 1 0 0 eee 2 Clearances and Accessibility cceeeeeees 2 LOGAN ON ies sists Qectceceives a a a 3 Electricals Sienen a aee aa o ae ai 3 Refrigerant Tubing ss sssssseesssseeseerrnressserrrerrnenessee 4 Evaporator Cols xicsascediccs lege enact 4 Quick Connect Coils e ci cats rete va teadereredteiectantey 4 System Start Up cet egebriegetEe rd eer 4 Processing Checks E 4 Charge Checks unn 5 Superheat Determination eeeeeeeeeeee teen 5 Expansion Valve System cecceeeeeeeeeeeeeeees 5 Wiring Diagrams e eNENNgee ee deg 6 IMPORTANT MESSAGE TO OWNER These instructions should be carefully read and kept near product for future reference While these instructions are addressed primarily to the installer useful maintenance information is included Have your installing dealer acquaint you with the operating characteristics of the product and periodic maintenance re
5. emove plugs and caps from connections c Check to be sure mating surfaces are clean d Lubricate rubber seal with clean refrigerant oil and thread couplings together by hand to be sure they are not cross threaded e Tighten connections using backup wrench on stationary fitting until coupling bottoms then tighten 1 6 turn to complete knife edge seal 2 Connect lines to condensing unit in the same manner as to evaporator coil Observe same precautions 3 After making all connections and opening valves check all piping for leaks SYSTEM START UP Processing Checks Condensing units are supplied R 22 charge sufficient for typical matching evaporator and approximately 15 of interconnecting tubing Condensing unit liquid and suction valves are closed to contain the charge within the unit 06 04 The recommended procedure for processing and charge adjustment is as follows 1 Connect vacuum pump to both base valve service ports 2 Evacuate tubing and evaporator through liquid and suction base valve ports to 500 microns or less for a minimum of 30 minutes Close valve to pump and wait 15 minutes Vacuum should not rise above 800 microns H unable to obtain 500 micorns or vacuum rises above 800 microns over a 15 minute period discontinue evacuation pressurize and check for leaks Repair any leaks found and repeat step 2 3 Close valve to vacuum pump and stop pump Break vacuum by opening liquid and suction base valves Fully op
6. en base valves and remove pump lines Connect service gauges making sure lines are purged 4 Set thermostat system switch to COOL and temperature to highest setting Close all disconnects 5 Setthermostat to call for cooling Check for operation of indoor and outdoor fans Allow for at least 10 minutes 6 Check charge and adjust if necessary Refer to appropriate Check Charge section Charge Checks gaits Tube Fixed Orifice System Fully open both base valves S Connect service gauge manifold to base valve service ports being sure to purge lines Run system at least 10 minutes to allow pressure to stabilize 3 Temporarily install thermometer on suction large line near condensing unit Be sure of good contact between the thermometer and line Wrap thermometer with insulating material to assure accurate reading 4 Refer to Table 2 for proper system superheat Add charge to lower superheat Remove charge to raise superheat 5 Remove gauge lines carefully A WARNING ESCAPING LIQUID REFRIGERANT CAN CAUSE BURNS AMBIENT CONDENSER RETURN AIR TEMPERATURE INLET TEMPERATURE FDRYBULB 75 80 5 5 10 17 25 29 TABLE 2 10 101G Superheat Determination 1 Read suction pressure Using Table 3 determine saturated suction temperature 2 Read suction line temperature 3 Use the following formula to determine superheat Superheat Suction Line Temp Saturated Suction Temp
7. en ordering parts give complete model and serial number as shown on the unit s rating plate Replacement parts for this appliance 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 SERVICE PARTS DEPARTMENT GOODMAN MANUFACTURING COMPANY L P 2550 NORTH LOOP WEST SUITE 400 HOUSTON TEXAS 77092 713 861 2500 IMPORTANT SAFETY INSTRUCTIONS Recognize Safety Symbols Words and Labels The following symbols and labels are used throughout this manual to indicate immediate or potential 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 property damage and or product damage serious personal injury or death DANGER IMMEDIATE HAZARDS WHICH WILL RESULT IN PROPERTY DAMAGE PRODUCT DAMAGE SEVERE PERSONAL INJURY AND OR DEATH A WARNING HAZARDS OR UNSAFE PRACTICES COULD RESULT IN PROPERTY DAMAGE PRODUCT DAMAGE SEVERE PERSONAL INJURY AND OR DEATH AXCAUTION HAZARDS OR UNSAFE PRACTICES WHICH_MAY RESULT IN PROPERTY DAMAGE PRODUCT DAMAGE AND OR PERSONAL INJURY CLEARANCES AND ACCESSIBILITY The condensing unit is designed to be located outside the building with unobstructed condenser air inlet and discharge Additio
8. ion i e pre formed concrete slab or other suitable base For rooftop application make sure the building construction can support the weight and that proper 06 04 consideration is given the weather tight integrity of the roof The condensing unit contains moving components and can vibrate therefore sound is also a consideration in rooftop application Since this unit discharges warm condenser air from the top with cooler air being drawn in three sides plantings can be made in relatively close proximity to the unit Owners should be advised to avoid lawn mower discharge toward the unit depositing debris on the fan coil surface reducing product efficiency ELECTRICAL Electrical installation will consist of power supply wiring to the condensing unit as well as control wiring between thermostat indoor unit and the condensing unit as shown on wiring diagram All wiring must be in accordance with National Electrical Code and or local codes that may apply The condensing unit rating plate and the table inside the front cover of this instruction lists pertinent electrical data necessary for the selection of proper size electrical service and over current protection The owner should be made familiar with the location of the over current protection the proper size for this application and the proper procedure for disconnecting power service to the unit The condensing unit control wiring requires a 24 Volt minimum 25 VA service from the i
9. ischarge air out from the overhang LOCATION If unit is to be located under an overhang there should be a minimum of 36 clearance and provisions made to deflect the water discharge air out from the overhang If the outdoor unit is mounted above the air handler the maximum lift should not exceed 70 suction line If air handler is mounted above condensing unit the lift should not exceed 50 liquid line Refer to Figure 3 and Table 1 for maximum refrigerant line lenghts OUTDOOR UNIT PITCH SUCTION LINE TOWARD OUTDOOR K UNIT 1 2 FOR EVERY 10 OF LINE INDOOR UNIT ABOVE OR LEVEL TO OUTDOOR UNIT INDOOR UNIT LIQUID LINE ADDITIONAL SUCTION LINE OIL TRAP ZOMAX FOR EACH 20 RISE OF PIPE e SEELEN J Si LIQDID CINE L SUCTION LINE OIL TRAPS WHEN INDOOR UNIT IS 4 ELOW FEET OR MORE DEL OUTDOOR UNIT INDOOR UNIT INDOOR UNIT BELOW OUTDOOR UNIT OUTDOOR UNIT INVERTED Ed l INDOOR UNIT 7 L LIQUID LINE a SUCTION LINE FIGURE 3 REFRIGERANT LINE LENGTH Ft Line Diameter In OD 50 74 3 1 2 i 7 8 required for full ratings 1 1 8 required for full ratings TABLE 1 The condensing unit must be mounted on a solid level foundat
10. ith a wet rag to cool the joint Evacuate and charge the connecting lines as outlined in these instructions 5 Remove valve top cap It is important to keep the cap in a clean area to assure proper sealing once replaced 6 Using a standard L shaped Allen wrench break open the valve body To expedite opening the valve body after it is broken use a ratchet wrench with a short Allen stub Please note that it is normal to see oil on the valve stem body once the cap is removed 7 Replace the valve cap and tighten with a wrench making sure that the the cap is sealed QUICK CONNECT COILS Precharged System Installation Installation procedure will differ when condensing units are provided for use with precharged refrigerant coils and lines Condensing units are provided with 6 and 11 male quick connects instead of liquid and suction valves attached to cabinet to contain the R 22 charge that is sufficient for matching evaporator coils and 15 of interconnecting lines Coils are provided with 6 and 11 male quick connects Line sets are required with 6 and 11 female quick connects on both ends Access ports are required in the fittings of both liquid and suction lines at condenser end Both coil and line sets include R 22 holding charge only 1 Connect lines to evaporator coil before connecting to the condensing unit locating access ports adjacent to condensing unit a Form tubing so it properly aligns with the coil connections b R
11. nally the unit must be situated to permit access for service and installation Condenser air enters from three sides Air discharges upward from the top of the unit Refrigerant tube electrical connections are made on the right side of the unit as you face the compressor compartment The best and most common application is for the unit to be located 10 from the back wall with the connection side facing the wall Refer to Figures 1 and 2 06 04 This close to the wall application minimizes exposed tubing and wiring and reduces the space for children to run around the unit This will help to avoid possible damage to the tubes or wiring and or personal injury 10 Min Service Access 18 Min 7 10 Min Service Access 18 Min FIGURE 1 10 Min Service Access 18 Min 10 Min ai Service Access 18 Min FIGURE 2 10 101G Close to the wall application assures free unobstructed air to the other two sides In more confined application spaces such as corners provide a minimum 10 clearance on all air inlet sides Allow 18 minimum for service access to the compressor compartment and controls The top of the unit should be completely unobstructed If units are to be located under an overhang there should be a minimum of 36 clearance and provisions made to deflect the warm d
12. ndoor transformer as shown on the wiring diagram REFRIGERANT TUBING Use only refrigerant grade dehydrated and sealed copper tubing of the size indicated in Table 1 to interconnect the condensing unit with the indoor evaporator Take extreme care to keep the refrigerant tubing clean and dry prior to and during installation Do not remove plugs from ends of tubing until connection is ready to be made Suction line insulation is necessary to prevent condensation from forming on and dropping from suction line Generally 3 8 wall thickness of Armflex or equivalent is satisfactory In severe application hot high humidity areas greater thickness may be required Apply suction line insulation by sliding it on the sealed tubing before cutting and making connections EVAPORATOR COILS A WARNING USE EXTREME CARE IN REMOVING THE CAPS FROM THE SUCTION AND LIQUID LINE FITTINGS AS THERE IS PRESSURE PRESENT A FITTING IS ON THE LIQUID LINE TO REMOVE PRESSURE A WARNING DO NOT REMOVE PROTECTIVE CAPS UNTIL INSTALLATION HAS BEEN COMPLETED AND FINAL CONNECTIONS ARE TO BE MADE 10 101G Field Connection to the Valve and Valve Opening 1 Tubing should be cut square Make sure it is round and free of burrs at the connecting ends Clean the tubing to prevent contaminants from entering the system 2 Wrap a wet rag around the copper valve stub before brazing 3 Braze or silver solder the joint 4 After brazing quench w
13. quirements CODES AND REGULATIONS This product is designed and manufactured to permit installation in accordance with National Codes It is the installers responsibility to install the product in accordance with National Codes and or prevailing local codes and regulations The manufacturer assumes no responsibility for equipment installed in violation of any code or regulations Important The United States Environmental Protection Agency EPA has issued various regulations regarding the introduction and disposal of refrigerants in this unit Failure to follow these regulations may harm the environment and can lead to the imposition of substantial fines Because regulations may vary due to passage of new laws we suggest a certified technician perform any work done on this unit Should you have any questions please contact the local office of the EPA INSPECTION Upon receiving the unit inspect it for damage from shipment Claims for damage either shipping or concealed should be filed immediately with the shipping 10 101G company Check the unit model number specifications electrical characteristics and accessories to determine if they are correct In the event an incorrect unit is shipped it must be returned to the supplier and must NOT be installed The manufacturer assumes no responsibility for installation of incorrectly shipped units REPLACEMENT PARTS Order all replacement parts through your local distributor Wh
14. y every unit is run tested before it leaves the factory That s why we know There s No Better Quality Visit our website at www goodmanmfg com for information on Goodman products e Warranties Customer Services e Parts Contractor Programs and Training e Financing Options 2003 2004 Goodman Manufacturing Company L P 10 101G 8 06 04
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