ASX16-18 IO MANUAL
Contents
1. 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 Ibs When in doubt do not use cylinder Refrigerant Lines AQ CAUTION The compressor POE oil for R 410A units is extremely susceptible to moisture absorption and could cause compressor failure Do not leave system open to atmos phere any longer than necessary for installation 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 These sizes are suitable for line lengths of 74 feet or less Ifa run of more than fifty feet is required refer to the Remote Cool ing Service Manual or contact your distributor for assistance REFRIGERANT LINE LENGTH Ft Cond 0 24 25 49 Unit Line Diameter In OD Tons Suct Liq 1 1 2 5 8 1 4 2 5 8 1 4 2 1 2 3 4 3 8 3 3 4 3 8 3 1 2 3 4 3 8 4 7 8 3 8 5 7 8 3 8 7 8 required for full ratings 1 1 8 required for full ratings Lines greater than 74 feet in length or vertical elevation changes more than 50 feet refer to the Remote Co2. 18GA 7 WIRE E INDOOR UNIT Dooce PECEEEQI B w O Y L H R E U IJ A L E T N L E G O E W pream o 4 pes W H H I N 77 r A i L O OPTIONAL OUTDOOR THERMOSTAT CLOSE ON TEMPERATURE FALL 18 GA 6 WIRE NEEDED WHEN OT IS USED SYSTEM COMPOSITE DIAGRAM HEAT PUMPS ABOVE 10 KW P TYPICAL H P HEAT PUMP ROOM THERMOSTAT 18 GA 7 WIRE OOOGO INDOOR UNIT L H R E E I i Hi gt Shs ar uU A L D Lott A ee E N L Bey J G Oo a PO A ri E w I ott ott y bs E 1 1 OPTIONAL OUTDOOR THERMOSTAT CLOSE ON TEMPERATURE FALL 18 GA 7 WIRE NEEDED WHEN TWO OT S ARE USED NOTES NOMENCLATURE 1 OUTDOOR THERMOSTAT OT 1 SHOULD BE THE OT OUTDOOR THERMOSTAT OPTIONAL FIRST TO CLOSE AND THE LAST TO OPEN EHR EMERGENCY HEAT RELAY OPTIONAL 2 CONNECT WHITE AND BROWN WIRES FROM AIR HANDLER TOGETHER IF OT 2 IS NOT USED 3 REMOVE WIRE WHEN USING OUTDOOR THERMOSTAT 4 TERMINAL BLOCK MARKINGS ARE FOR AMANA AIRHANDLERS COLOR CODES R RED Y YELLOW BLBLUE BR BROWN 0O ORANGE W WHITE G GREEN Thermostat with Low Voltage Wires to Heat Pump Unit NOTE For two stage units refer to the Installation Instructions supplied with the variable speed indoor units for field wiring connections System Start Up Adequate refrigerant charge for a matching evaporator and 15 feet lineset is supplied with the condensing unit NOTE If lineset exceeds 15 feet in length refriger
3. 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 Codes amp 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 equip ment installed in violation of any codes or regulations Goodman Manufacturing Company L P 2005 2550 North Loop West Suite 400 Houston TX 77092 www goodmanmfg com or www amana hac com P N 10 259 Date December 2005 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 If replacing a condensing unit or air handler the system must be manufacturer approved and Air Conditioning and Refrigera tion Institute ARI matched NOTE Installation of unmatched syst
4. previously indicated and repair as necessary then repeat evacuation e f pressure rises above 2000 microns a leak is present Check for leaks as previously indicated and repair as nec essary then repeat evacuation Electrical Connections AA 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 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 AA 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 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 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 loca
5. the base valve Operate the system for 10 minutes Using an accurate electronic thermometer measure the temperature of the discharge gas at the probe and the outdoor ambient temperature The temperature measured on the vapor service valve line should be equal to the outdoor ambient temperature plus 110 F 4 For example if the outdoor ambient tem perature is 45 F then the temperature measured by the thermometer probe at the vapor service valve line should be 155 F for a system that is properly charged If the temperature measured by the thermometer probe is higher than the outdoor ambient plus 110 F the system charge should be adjusted by adding refrigerant to lower the tem perature If the temperature measured is lower than the outdoor ambient plus 110 F the system charge should be adjusted by recovering charge to raise the tempera ture NOTE When adjusting the charge in this manner allow the system to operate for at least 10 minutes before tak ing the next temperature reading Troubleshooting Information Complaint POSSIBLE CAUSE DOTS IN ANALYSIS GUIDE INDICATE POSSIBLE CAUSE SYMPTOM System will not start Comp and Cond Fan will not start Compressor will not start fan runs Evaporator fan will not start No Cooling Condenser fan will not start Compressor runs goes off on overload Compressor cycles on overload System Operating Pressures Unsatisfactory Cooling Hea
6. CONDENSING UNIT HEAT PUMP INSTALLATION amp SERVICE REFERENCE Important Safety Instructions The following symbols and labels are used throughout this manual to indicate immediate or potential safety hazards Itis 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 AA WARNING Hazards or unsafe practices could result in property damage product damage severe personal injury or death AX CAUTION Hazards or unsafe practices which may result in property damage product damage personal injury or death AA WARNING HIGH VOLTAGE N Disconnect ALL power before servicing Multiple power sources may be present Failure to do so may cause property damage personal injury or death AA WARNING ONLY individuals meeting the requirements of an Entry Level Technician as specified by the Air Conditioning and Refrigeration Institute ARI may use this information Attempting to install or repair this unit without such background may result in product damage personal injury or death CAUTION 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 Shipping Inspection Always
7. amp Seat or Replace Flowrator Heating Cycle Only Heat Pump For detailed service information refer to the Remote Condensing Unit Service manual
8. ant should be added at 6 ounces per foot of liquid line 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 1 Break vacuum by fully opening liquid and suction base valves 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 Charge Verification AA 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 A CAUTION Use refrigerant certified to ARI standards Used refrigerant may cause compressor damage and will void the warranty Most portable machines cannot clean used refrigerant to meet ARI standards NOTICE Violation of EPA regulations may result in fines or other penalties AX CAUTION Operating the compressor with the suction valve closed will void the warranty and cause serious compressor damage 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 followin
9. ems is strongly discouraged Operating the unit in a structure that is not complete either as part of new construction or renovation will void the warranty Installation Clearances Special consideration must be given to location of the con densing 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 unob structed however if vertical conditions require placement be neath an obstruction there should be a minimum of 60 inches between the top of the unit and the obstruction s The specified dimensions meet requirements for air circulation only Consult all appropriate regulatory codes prior to deter mining 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 k NOT RECOMMENDED Minimum Airflow Clearance __ModelType a B C AA 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
10. g section Fixed Orifice AX CAUTION 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 1 Purge gauge lines Connect service gauge manifold to base valve service ports Run system at least 10 minutes to allow pressure to stabilize 2 Temporarily install thermometer on suction large line near suction line service valve with adequate contact and insulate for best possible reading 3 Refer to the superheat table provided for proper system superheat Add charge to lower superheat or recover charge to raise superheat SYSTEM SUPERHEAT 2 Temporarily install thermometer on liquid small line near liquid line service valve with adequate contact and insu Ambient Condenser Return Air Temperature late for best possible reading Inlet Temp F Drybulb F Drybulb 3 Check subcooling and superheat Systems with TXV ap 65 70 75 80 85 plication should have a subcooling and superheat of Oo ee S ee ee 9 3 F Po 00 f J 5 s5 a If subcooling and superheat are low adjust TXV to Sr aaa ae Ssss 9 3 F then check subcooling O o ee ee b If subcooling is low and superheat is high add charge O s to to raise subcooling to 9 3 F then check super o 5j ejajf l heat c If subcooling and superhea
11. hanging 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 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 Refrigerant Line Connections 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 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 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 The POE oils used in R 410A applications will clean any copper oxide present from the inside of the refrigerant lines and spread it throughout the system This may cause a blockage or failure of the me tering de
12. ide AA WARNING To avoid pone injury explosion or death practice safe handling of refrigerants AA WARNING Refrigerants are heavier than air They can push out the oxygen in your lungs or in any enclosed space To avoid possible difficulty in breathing or death e 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 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 AA WARNING To avoid possible explosion e Never apply flame or steam to a refrigerant cylinder If you must heat a cylinder for faster charging partially immerse it in warm water e Never fill a cylinder more than 80 full of liquid re frigerant Never add anything other than R 22 to an R 22 cy linder or R 410A to an R 410A cylinder 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 AA WARNING To avoid possible explosion use only returnable not disposable service cylinders when removing refrig erant from a system
13. integral part of the building foundation Ensure the foundation is sufficient to support the unit A concrete slab raised above ground level provides a suitable base 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 NOTE These units require special location consideration in areas of heavy snow accumulation and or areas with prolonged continuous subfreezing temperatures Heat pump unit bases have cutouts under the outdoor coil that permit drainage of frost accumulation Situate the unit to permit free unobstructed drainage of the defrost water and ice A minimum 3 clearance under the outdoor coil is required in the milder climates In more severe weather locations it is recommended that the unit be elevated to allow unobstructed drainage and air flow The following elevation minimums are recommended Design Temperature Suggested Minimum Elevation 15 and above 2 1 2 Po 5o A S Safe Refrigerant Handling While these items will not cover every conceivable situation they should serve as a useful gu
14. lement or Limit on Elec Heater Remove Restriction Replace Restricted Part Test Heater Element and Controls Dirty Air Filter nspect Filter Clean or Replace Dirty Indoor Coil Not enough air across Indoor Coil nspect Coil Clean Check Blower Speed Duct Static Press Filter Too much air across Indoor Coil Reduce Blower Speed Overcharge of Refrigerant Recover Part of Charge Dirty Outdoor Coil Noncondensibles pect Coil Clean Recover Charge Evacuate Recharge Recirculation of Condensing Air Remove Obstruction to Air Flow Infiltration of Outdoor Air Check Windows Doors Vent Fans Etc Improperly Located Thermostat Air Flow Unbalanced Relocate Thermostat Readjust Air Volume Dampers System Undersized Refigure Cooling Load Broken Internal Parts Replace Compressor Broken Valves Test Compressor Efficiency Inefficient Compressor Test Rep Oversized Expansion Valve Remove Re ace Va Undersized Expansion Valve Expansion Valve Bulb Loose lace Va Tighten Bulb Bracket Inoperative Expansion Valve Check Valve Operation Loose Hold down Bolts Tighten Bolts Faulty Reversing Valve Replace Valve or Solenoid Faulty Defrost Control Test Contro Faulty Defrost Thermostat Test Defrost Thermostat Cooling or Heating Cycle Heat Pump Check Flowrator
15. oling Service Manual or contact your distributor for assistance Liquid Line 0 Suction Line l Mounting the evaporator coil above the condensing unit will require an inverted loop in the suction line adjacent or near the connection to the evaporator The top of the loop must be slightly higher than the CECU NN Ea top of the coil Mounting the condensing unit above the evaporator coil will require oil traps at equal intervals along the suction line Install 1 oil trap for a height difference of 15 25 feet between indoor and outdoor units Install 2 oil traps for a difference of 26 50 feet 3 for 51 100 feet and 4 for 101 150 feet iil WII ODU WID DUUN u Ul INU UN I iJ Di IN IU Ca Of gt 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 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 c
16. re found repair them After repair repeat the pressure test If no leaks exist proceed to system evacuation 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 Do not open valves until the system is evacuated AA WARNING REFRIGERANT UNDER PRESSURE Failure to follow proper procedures may cause property damage personal injury or death 1 Connect the vacuum pump with 250 micron capability to the service valves 2 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 3 Close pump valve and hold vacuum for 10 minutes Typi cally pressure will rise during this period 5000 4500 4000 LEAK S 3900 PRESENT 3000 2500 VACUUM IN MICRONS 2000 CONDENSIBLES OR SMALL LEAK PRESENT 1500 1000 NO LEAKS 309 NO CONDENSIBLES MINUTES e Ifthe pressure rises to 1000 microns or less and remains steady the system is considered leak free proceed to startup 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
17. t are high adjust TXV valve to 9 3 F then check subcooling Pos Sf gf f a2 3 d If subcooling is high and superheat is low adjust D o eee TXV valve to 9 3 F superheat and remove charge 4 Disconnect manifold set installation is complete to lower the subcooling to 9 3 F Superheat Formula Suct Line Temp Sat Suct NOTE Do NOT adjust the charge based on suction pres Temp sure unless there is a gross undercharge SATURATED SUCTION PRESSURE 4 Pose laee manifold set idole is Complete l TEMPERATURE CHART Subcooling Formula Sat Liquid Temp Liquid Line SATURATED SUCTION Temp TEMPERATURE F SATURATED LIQUID PRESSURE TEMPERATURE CHART SATURATED LIQUID LIQUID PRESSURE TEMPERATURE F R22 Raoa 210 oon a 90 Ooo o B 4s f 3 Expansion Valve System 1 Purge gauge lines Connect service gauge manifold to base valve service ports Run system at least 10 min utes to allow pressure to stabilize 2 2 2 3 3 3 3 3 3 4 4 4 4 4 4 2 2 2 2 2 2 2 2 2 3 1 3 4 7 10 11 13 14 15 16 17 19 20 21 6 8 9 1 2 4 5 7 8 0 1 2 4 5 6 8 200 20 25 35 45 55 65 75 85 95 05 25 Hot Gas Method System charge can be checked in the heating mode by mea suring the hot discharge gas at the compressor 1 2 Allow the system to operate at least 20 minutes Attach and insulate an electronic thermometer probe to the vapor service valve large line at
18. ting System runs continuously little cooling htg Too cool and then too warm Not cool enough on warm days Certain areas too cool others too warm Compressor is noisy System runs blows cold air in heating Unit will not terminate defrost Unit will not defrost Low suction pressure Low head pressure High suction pressure High head pressure Test Method Remedy Test Voltage Inspect Fuse Size amp Type Unbalanced Power 3PH Test Voltage Loose Connection Inspect Connection Tighten Shorted or Broken Wires Open Fan Overload Test Circuits With Ohmmeter Test Continuity of Overload Faulty Thermostat Test Continuity of Thermostat amp Wiring Faulty Transformer Check Control Circuit with Voltmeter Shorted or Open Capacitor Internal Compressor Overload Open Test Capacitor Test Continuity of Overload Shorted or Grounded Compressor Test Motor Windings Compressor Stuck Use Test Cord Faulty Compressor Contactor Faulty Fan Relay Test Continuity of Coil amp Contacts Test Continuity of Coil And Contacts Open Control Circuit Test Control Circuit with Voltmeter Low Voltage Test Voltage Faulty Evap Fan Motor Shorted or Grounded Fan Motor Repair or Replace Test Motor Windings Improper Cooling Anticipator Check Resistance of Anticipator Shortage of Refrigerant Test For Leaks Add Refrigerant Restricted Liquid Line Open E
19. tion information Three Phase Compressor Rotation Ad CAUTION Use care when handling scroll compressors Dome temp eratures could be hot 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 To correct disconnect power and switch any two leads at the unit contactor and re observe 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 Low Voltage Connections Condensing unit control wiring requires 24 Volt minimum 25VA service from the indoor transformer Low voltage wiring for two stage units depends on the thermostat used and the number of control wires between the indoor unit and the condensing unit Route control wires through the low voltage port and ter minate in accordance with the wiring diagram provided inside the control panel cover SYSTEM COMPOSITE DIAGRAM HEAT PUMPS 10 KW amp BELOW TYPICAL H P HEAT PUMP ROOM THERMOSTAT
20. vice 3 After brazing quench the joints with water or a wet cloth to prevent overheating of the service valve 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 NOTE Be careful not to kink or dent refrigerant lines Kinked or dented lines will cause poor performance or compressor damage Do NOT make final refrigerant line connection until plugs are removed from refrigerant tubing NOTE Before brazing verify indoor piston size by checking the piston kit chart packaged with indoor unit Leak Testing Nitrogen or Nitrogen Traced AA 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 AA 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 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 a
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