Install Instructions
Contents
1. ANALYSIS Remedy GUIDE INDICATE POSSIBLE CAUSE SYMPTOM System will not start Compressor will not start fan runs Compressor and Condenser Fan will not start Evaporator fan will not start Condenser fan will not start Compressor runs goes off on overload Compressor cycles on overload System runs continuously little cooling Too cool and then too warm Not cool enough on warm days Certain areas to cool others to warm Compressor is noisy Low suction pressure Low head pressure High suction pressure High head pressure Test Voltage Impact Fuse Size amp 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 Test Continuity of Coil and Contacts Test Control Circuit with Voltmeter Test Voltage 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 R2. a mechanical seal separating the sides of the system Close pump valve and hold vacuum for 10 minutes Typi cally pressure will rise during this period 5000 4500 4000 LEAK S PRESENT 3500 3000 2500 VACUUM IN MICRONS 2000 CONDENSIBLES OR SMALL LEAK PRESENT 1500 1000 NO LEAKS NO CONDENSIBLES 500 MINUTES If the pressure rises to 1000 microns or less and remains steady the system is considered leak free proceed to startup e f 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 If 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 compresso
3. 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 suitable for line lengths of 74 feet or less Ifa run of more than fifty feet is required refer to Remote Cooling Service Manual or TP 106 Long Line Set Application R 22 or TP 107 Long Line Set Application R 410A or contact your dis tributor for assistance REFRIGERANT LINE LENGTH Ft Line Diameter In OD Cond Unit Tons Liq __Suct_ __Suct_ Suct 3 8 3 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 Cooling Service Manual or contact your distributor for assistance Liquid Line Suction Line 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 top of the coil Mounting the condensing unit above the evaporator coil will require oil traps at equal in
4. CONDENSING UNIT AIR CONDITIONING 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 installers 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 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 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 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 Codes amp Regulation
5. ed 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 Safe Refrigerant Handling While these items will not cover every conceivable situation they should serve as a useful guide AA WARNING To avoid cere 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 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 lis
6. eplace Valve Replace Valve Replace Valve Replace Valve Loose Connection Shorted or Broken Wires Faulty Thermostat Faulty Transformer Shorted or Open Capacitor Internal Compressor Overload Open Shorted or Grounded Compressor Compressor Stuck Faulty Compressor Contactor Faulty Fan Relay 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 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 Tighten Bulb Bracket Inoperative Expansion Valve Check Valve Operation Loose Hold down Bolts Tighten Bolts For detailed service information refer to the Remote Condensing Unit Service manual
7. hart 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 are 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
8. ier 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 device 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 c
9. ow adjust TXV to 7 to 9 F superheat then check subcooling NOTE To adjust superheat turn the valve stem clock wise to increase and counter clockwise to decrease c If subcooling and superheat are high adjust TXV b If subcooling is low and superheat is high add charge valve to 7 to 9 F superheat then check subcooling to raise subcooling to 5 to 7 F then check super d If subcooling is high and superheat is low adjust heat TXV valve to 7 to 9 F superheat and remove charge c If subcooling and superheat are high adjust TXV to lower the subcooling to 7 2 F valve to 7 to 9 F superheat then check subcooling d If subcooling is high and superheat is low adjust NOTE Do NOT adjust the charge based on suction pres sure unless there is a gross undercharge TXV valve to 7 to 9 F superheat and remove charge to lower the subcooling to 5 to 7 F 4 Disconnect manifold set installation is complete Subcooling Formula Sat Liquid Temp Liquid Line Temp NOTE Do NOT adjust the charge based on suction pres sure unless there is a gross undercharge 4 Disconnect manifold set installation is complete Subcooling Formula Sat Liquid Temp Liquid Line Temp NOTICE Units with reciprocating compressors and non bleed TXV s require a Hard Start Kit Troubleshooting Information System Operating Pressures Unsatisfactory Cooling Complaint No Cooling POSSIBLE CAUSE Test Method DOTS IN
10. peed Application Two Speed Application Run the remote on low stage cooling for 10 minutes until refrig erant pressures stabilize Follow the guidelines and methods below to check unit operation and ensure that the refrigerant charge is within limits Charge the unit on low stage 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 Temporarily install thermometer on liquid small line near liquid line service valve with adequate contact and insu late for best possible reading 1 Purge gauge lines Connect service gauge manifold to base valve service ports 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 7 2 F and super heat of 7 to 9 F a If subcooling and superheat are low adjust TXV to 7 to 9 F superheat then check subcooling 3 Check subcooling and superheat Systems with TXV ap plication should have a subcooling of 5 to 7 F and super 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 2 F then check superheat heat of 7 to 9 F a If subcooling and superheat are l
11. r 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 Fixed Orifice AQ 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 Refer to the superheat table provided for proper system superheat Add charge to lower superheat or recover charge to raise superheat SYSTEM SUPERHEAT Return Air Temperature F Drybulb Ambient Condenser Inlet Temp F Drybulb 4 Disconnect manifold set installation is complete Superheat Formula Suct Line Temp Sat Suct Temp SATURATED SUCTION PRESSURE TEMPERATURE CHART SATURATED SUCTION SUCTION PRESSURE TEMPERATURE F R 410A SATURATED LIQUID PRESSURE TEMPERATURE CHART LIQUID PRESSURE SATURATED LIQUID TEMPERATURE F R 410A gt o e j a Expansion Valve System Single S
12. rs 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 4 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 location information Overcurrent Protection The following overcurrent protection devices are approved for use e Time delay fuses e HACR type circuit breakers These devices have sufficient time delay to permit the motor compressor to start and accelerate its load Three Phase Compressor Rotation AA 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 compre
13. s 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 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 systems is strongly discouraged Operating the unit in a structure that is not complete either as Bee Goodman Manufacturing Company L P 2005 2006 2550 North Loop West Suite 400 Houston TX 77092 www goodmanmfg com or www amana hac com P N 10 258D Date October 2006 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 str
14. ssors 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 Se Thermostat 74 Single Stage Heating I 5 yo with Single Stage Coolin w FURNACE OR AIR HANDLER KOR ANS f We Rob cae KF A ao REMOTE Single Stage Thermostat with Two Low Voltage Wires to Remote NOTE For two stage condensing units refer to the Installation Instructions supplied with the variable speed indoor units for field wiring connections Thermostat Two Stage Heating with Two Stage Cooling FURNACE OR AIR HANDLER oo NI ON N NM N Loa ay o j YLovyi v2 Be jf R wi j w2 PENN ae oS DP wf ea Se et SCA OD UNIT Two S
15. tage Thermostat with Three Low Voltage Wires to Remote 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 refrigerant 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 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 5 AQ 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 AQ 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 o
16. ted 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 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 AX 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 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
17. tervals 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 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 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 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 dr
18. ucted 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 Pp A B C AA to fo aor fo ae 10 10 18 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 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 consider
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