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REMOTE CONDENSING UNIT

1. Tubing Size Torque Foot Pounds 3 8 10 1 2 5 8 3 4 14 7 8 1 1 8 16 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 DESIRED SUPERHEAT vs OUTDOOR TEMPERATURE 36 34 l l l A e N 30 28 Q 2 m 24 p 2 el 18 L X 16 LLI A 4 m N 2 10 H 7 8 L 6 l 4 50 60 70 80 90 100 110 120 OUTDOOR TEMPERATURE Troubleshooting Qualified Servicer Only When troubleshooting the first step should always be to check for clean coils clean filter s and proper airflow Indoor airflow should be 350 to 450 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 helpful For details see the Installation Manual for your indoor equipment If further information is needed see the Remote Cooling Service Manual 13 System Checklist 1 Does the condenser fan blade rotate freely and is it tight on the shaft E Does the refrigerant tubing flex freely and not touch another tube to cause rub 3 Are both indoor and outdoor sections level 4 Are the units properly supported
2. Use a male hex head wrench 3 16 for liquid 5 16 for suction to carefully open the suction and liquid valve stem on the unit These valves do not back seat OPEN EACH VALVE ONLY UNTIL THE TOP OF THE STEM IS 1 8 FROM THE RETAINER TO AVOID LOSS OF REFRIG ERANT DO NOT APPLY PRESSURE TO THE RETAINER The outdoor unit is factory charged with enough R 22 for the matching indoor blower coil or matching A coil plus 15 feet of liquid line Check the Product Data Book applicable to your model for factory charge amount Adjust the charge for line lengths different from what is specified per the following 1 4 OD LIQUIDLINE 20 oz per foot 5 16 OD LIQUID LINE 40 oz per foot 3 8 OD LIQUIDLINE 60 oz per foot 1 2 OD LIQUIDLINE 1 30 oz per foot IMPORTANT e Use only refrigerant which is certified to meet ARI Standard 700 Used refrigerant may cause com pressor damage and will void the warranty Most portable machines cannot clean used refrigerant well enough to meet this ARI Standard e If adding additional refrigerant to a system add only refrigerant vapor not liquid through the suction valve low side on the outdoor unit Any other practice may cause compressor damage 11 Final Charge Adjustment Matching Systems Cooling Operation IMPORTANT Never operate the compressor with the suction valve closed to test the compressor s pumping efficiency In some cases this can result in serious
3. s outdoor section properly located on concrete base or equivalent Are the refrigerant lines correctly installed according to the relative position of the outdoor and indoor sections Is the refrigerant tubing properly supported by isolation hangers ES Is the system completely free of refrigerant leaks E Has the system been properly evacuated Does the system have the correct refrigerant charge 4 Is the outdoor unit protected by the correct size time delay type fuses or breakers in the indoor power box Are the power supply wires to units the correct size Are all electrical connections tight Check the amperage on the indoor blower motor Is it within the limits shown on the nameplate of the motor Are all access panels installed and secured Does the compressor sound normal 7 1 Do controls function properly Are manual reset switches in the reset position high pressure cutouts relays etc Check the voltage with unit running Does it check within the tolerance of 207 to 18 253V for 230V or 198 to 228V If using 208V power indoors have you modified the transformer wiring as necessary Has the air flow across the indoor coil been checked and adjusted Has the air distribution system been balanced Are all grilles diffusers and dampers properly adjusted and locked Has the system operated at least 30 minutes before leaving the job Does the owner know where the filters are located Does the owner know when
4. and how the filter s should be cleaned or changed Does the owner know whom to call for service Has the User s Guide been filled out and left with the owner Does the owner understand the operation of the unit and the thermostat 2003 2004 Goodman Company L P 14 March 2004
5. compressor damage and loss of warranty coverage If installing a non matching system the outdoor tempera ture must be 60 F or higher to perform the final charge adjustment If the outdoor temperature is 60 F or higher set the room thermostat to COOL fan switch to AUTO and set the temperature control well below room temperature Turn the electrical power on and let the system run for several minutes It will take some time for the refrigerant pressures to stabilize If you are using the Matched Combination see the Product Data Book applicable to your model Compare the operating pressures and outdoor unit amp draw to the numbers listed If pressures and amp draw are too low add charge If pressures and amp draw are too high remove charge If you are not using the Matched Combination which is listed in the Product Data Book check subcooling TEV coils or superheat cap tube or flowrator coils as detailed in the following section System Startup Final Charge Adjustment Non Matching Systems Cooling Operation INDOOR Co wm EXPANSION VALVE At stabilized cooling conditions and with an outdoor tem perature of 60 F or higher the system should have from 9 F to 15 F subcooling For a proper subcooling reading measure the refrigerant pressure and temperature at the outdoor unit s liquid line service valve If you have less than 9 F subcooling add charge If you have more than 15 F subcooling r
6. ACUUM HOSES LOW SIDE VALVE HIGH SIDE VALVE VACUUM PUMP THERMOCOUPLE GAUGE E MANIFOLD GAUGE CHARGING CYLINDER M OOWD HIGH VACUUM PUMP Figure 3 Electrical Connections A WARNING To avoid personal injury shock or death open the electrical disconnect switch before electrically connecting the unit Wiring must conform with NEC or CEC and all local codes To avoid the risk of fire or equipment damage use only copper conductors Consult the National Electrical Code or a qualified electrician for proper wire size Undersized wires could cause poor equipment performance equipment damage or fire A WARNING To avoid electrical shock injury or death wiring to the unit must be properly grounded The wiring diagram for this unit can be found on the control box door NOTE Local codes will usually require that a disconnect switch be located near the unit Do not locate the disconnect switch on the unit itself WIRING Wire size is important to ensure proper unit operation Wire size must be sufficient to carry the minimum circuit ampacity listed on the unit serial data plate We recom mend sizing the wires to limit the voltage drop to a maxi mum of 2 from the main breaker or fuse panel to the outdoor unit Use Table 1 as a guide for wire gauge and length of run 1 To connect the unit to the power supply route the power supply and ground wires through the high voltage entranc
7. ESEEEEEEEEEEEE ERC EE EEEEEEEEEEN 4 Applicati miN LKE 4 Refrigerant Piping BE 5 Retrigerant Vapor Line SIZING usteet 5 Refrigerant Vapor i ccicscccccccccccssccecesccvssceeecccetesccceecccceassuececeectssteeecceceasestceesceceasseueeseeeeesstecesecesesteeeceeceavsteneseeecssaneeecees 5 and LIQUIG Lines ROUTING sisson ege 5 Sweat Connections isis esccccsccsvesescecsssesseceeceteseaessccecessseseeeceeesssetececcetssevessccncesssaaecceeeeessesesceeeessesseceeeedeseanseeceetistenaecs 5 Safe Refrigerant Handling EE 6 Leak TeSting E E A E eceeneeeeeeece 7 System EVACUACION gees g ene a E ANTAA REO sas AEEA AAO e SCENE Ee 8 El ctrical Connections ec Se eee ede sass sees densa a a aa aaa arae Ee re aee E eea aee Ee E e er E AE EEEa Eaa Eea E EaR EErEE 9 System Startup ota eaten we cece aeaaea aE cece eee 11 Preliminary Charge AdjUStMeNt 55 iccccciccsccccecec sees cesccceeces ssceceeteceescossecee cess sosseeee cvascessuoueescesczsaneeecccasseeeesvescssancererss 11 alle e EU d EE 11 Matching Systems Cooling Operation cceeeccceceeeeeeeeeeeeeeeeneeeeeeeeeeeeseeeeeeneeeeseeeeeeseeeeseeeseeeeeaeseeeeseeeseeeeeeeenes 11 Final Charge AGjUStMOIM ciciccccccciccccccccccccesscscccececcaseseeececcessseueeccescassnceeccceeasseeceeceecedseeeeesceccssaneceacedsseeeesceccasaneeeees 12 Non Matching Systems Cooling Operation ccececcceeeeeneee eee eeeeeeeeeeeeeeeeeeeeseeeeeeneeeeseeeeeeseeaeseeeeesseeaeeeeeeseaes 12 Troubleshooting E 13 Copp S
8. Heating amp Air Conditioning REMOTE CONDENSING UNIT ana INSTALLATION INSTRUCTIONS LASTS AND LASTS AND LASTS These installation instructions cover the outdoor instal lation of remote condensing units See the Product Data Cc Book applicable to your model for information regarding accessories NOTE Please contact your distributor or our website for the applicable product data book referred to in this manual Amana is a trademark of Maytag Corporation and is used under license to Goodman Company L P All rights reserved Goodman Company L P Part No 10652423 Rev 1 2003 2004 Goodman Company L P Printed in U S A 1810 Wilson Parkway Fayetteville Tennessee 37334 Bee www amana hac com Table Of Contents Safety IDS ECON Seege eege A Recognize Safety Symbols Words and Labels 0 cccccceeeeeeeeeee eee eeeeeeeeeeeeeeeeeeeeeeeeeeesneeeeeeeeeneneeeeeeeeensseseeeeeenenes 3 General TL e ge Oe ee eo ee eee ene ener er 4 Shipping and Handling ei cvissciccccecsvcssscceccvsesssccseceveeesssecees cvedasscceecseeessscctes evevesssecees ceeessscaceceveesictenceveeasscttesevevssstaeecvs 4 Clearances and ACCeSSIDIN ity tic cc scccccpcicesececegti eegene ccueseecutneceesntecaqec cceneecapuekccegssnaanteecensesssiecennaaasntnecensnssengeienss 4 Rooftops Installations On esssseeeeeeEEEEEEEEESEEEEEEEEEEESEEEEEEEEEENEEEREEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEERE
9. LE 1 MAXIMUM ALLOWABLE WIRE LENGTH IN FEET TO LIMIT VOLTAGE DROP TO 2 MINIMUM CIRCUIT AMPACITY OF OUTDOOR UNIT MCA JL z s 43 37 NR NR NR NR NR NR NR NR pa ns 2 e 59 5 LC NR NR NR NR NR NR 10 18 150 1235 1097 95 La Le 6e Le 5s 54 NR NR 8 21 21 172 150 134 129 109 100 93 86 80 75 SC A ELE ERREECHEN EE 7 45 l 134 25 8 N R NOT RECOMMENDED Wire ampacity and voltage drop calculation based on copper conductors with 75 degree C insulation per 1996 National Electrical Code NEC Conductors in 86 degree F ambient See NEC for ampacity derating for higher ambients This table is provided as a guide only Wire sizing may be regulated by local codes Local inspection is the final authority on wire sizing ROOM THERMOSTAT L1 L2 10 System Startup IMPORTANT See the wiring diagram or Product Data Book applicable to your model to determine if this unit has a crankcase heater If it does you must connect electrical power to the unit for four 4 hours before operating the compressor Failure to do so could result in compressor damage During all installation and service work follow all regulations of the Environmental Protection Agency This system uses R 22 an HCFC Hydrogenated Chlorofluorocarbon Violation of EPA regulations may result in fines or other penalties Preliminary Charge Adjustment
10. d line must be outside the vapor line insulation If part of the liquid line must run through an area that will be hotter than 120 F then that portion of the liquid line must be insulated Avoid burying refrigerant lines If you must bury them first dig the trench so it gradually slopes toward the compressor at least 1 inch per 10 feet Then insulate the liquid and suction lines separately Enclose all underground portions of the refrigerant lines in waterproof material conduit or pipe If the lines must pass under or through a concrete slab be sure they are adequately protected e Seal the holes where the refrigerant piping enters the building e Be careful not to kink or dent the refrigerant lines Kinked or dented lines will cause poor performance or compressor damage NOTE The service valve connections are oriented ata 45 angle to the unit Either side of the unit adjacent to the valves can be conveniently located toward the house Sweat 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 manu facturer Use a brazing alloy of 2 minimum silver content Do not use flux The ends of the refrigerant lines must be cut square deburred cleaned and be round and free from nicks or dents Any other condition increases the chance of a refrigerant leak 2 After bra
11. e in the unit 2 Connect the power supply wires to the contactor Connect the ground wire to the ground lug 3 Route the low voltage wiring through the low voltage entrance in the unit Connect the low voltage wires to the terminal strip if present or to the wire leads Route the low voltage wire through the wire tie pro vided in the unit for restraint 4 Ifa proper room thermostat is not already present install one at a suitable indoor location Consult the instructions packaged with the thermostat for mounting and location instructions Typical wiring fora gas furnace is shown in Figure 5 The thermostat instructions may include typical wiring for other types of indoor equipment 6 Ensure all factory wiring connections are tight NOTE Some indoor furnaces for cooling operation will require that a fan relay and or a 40VA transformer be added For proper cooling performance the indoor equipment and ductwork must be adequate for moving about 400 CFM of indoor air for every ton of cooling capacity to be installed If it is not modify the ductwork or indoor equipment accordingly IMPORTANT Hard start components are required when single phase reciprocating compressors are used with indoor coils which have non bleed thermal expansion valves Some units have hard start components factory installed See the Product Data Book applicable to your model for hard start component requirements Electrical Connections TAB
12. ectit from the gauge manifold If you plan to use an electronic leak detector add a trace of R 22 to the 3 Open the hand valve a minimal amount on the line system if permitted by current EPA regulations coming on tie nigger cyllnder 5 Check for leaks using an approved chloride free soap 4 Open the high pressure valve on the gauge mani solution on all connections and joints If you see fold Pressurize the refrigerant lines and the indoor bubbles you have a leak Mark these locations coil to 150 psig 1034 kPA To reach 150 psig you 6 Use the gauge manifold to carefully release the nitro may need to further open the hand valve on the ni gen from the system If leaks were found repair them trogen cylinder After repair repeat the above pressure test If no leaks exist proceed to system evacuation VAPOR LINE SERVICE VALVE LIQUID LINE SERVICE VALVE Figure 2 Safe Refrigerant Handling System Evacuation Connect the vacuum pump high vacuum manifold 6 Evacuate the system to about 29 inches Hg as mea set with high vacuum hoses thermocouple vacuum sured by the compound low side gauge gauge and charging cylinder as shown Begin with 7 Open the valve to the thermocouple vacuum gauge all valves fully closed Evacuate until the gauge reads 250 microns or less If service dill valves are used for evacuation use a 8 Close the valve to the vacuum pump Wait f
13. emove charge INDOOR Co WITH ORIFICE OR Cap TUBE For a proper superheat reading measure the refrigerant pressure and temperature at the outdoor unit vapor line service valve The superheat should be within 3 F of that shown on the Desired Superheat vs Outdoor Temperature chart following page If the superheat is more than 3 F higher than shown on the chart add charge If the superheat is more than 3 F lower than shown on the chart remove charge EXAMPLE The low side pressure is 84 psi The low side temperature is 80 F The outdoor temperature is 95 F The indoor temperature is 85 F By referring to a pressure temperature chart you will see that 84 psi equals a satu rated temperature of 50 F The superheat is 80 50 30 F The chart shows a superheat of 20 F is ideal for these conditions Since our superheat is 30 20 10 F higher than ideal charge must be added If the system is performing properly reinstall the service port caps and the valve bonnets With the valve opened the valve bonnet is the primary seal against refrigerant leaks Apply two drops of clean oil to the cap threads allowing the oil to run down to the inner cap seal surface Close caps finger tight Then tighten cap an additional two to three hex flats 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
14. ervicer EAR 13 Safety Instructions Recognize Safety Symbols Words and Labels 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 A WARNING WARNING Hazards or unsafe practices which COULD result in severe personal injury or death AA CAUTION CAUTION Hazards or unsafe practices which COULD result in minor or moderate personal injury product damage property damage To avoid personal injury shock or death ensure the electrical disconnect switch es is are in the OFF position before installing modifying or servicing the unit Lock out and tag the switch with a suitable warning label Wiring must conform with NEC or CEC and all local codes A Safety Guidelines Allow only qualified experienced technicians to install or service this unit Install the system in accordance with all local codes If no local codes exist follow National Codes NEC in the U S CEC in Canada Open the electrical disconnect switch es before electrically connect ing the unit Before operating the unit be certain it is properly grounded The unit contains refrigerant gas under pressure Avoid puncturing or breaking a
15. ive min core remover to lift the valve core It provides utes then check the pressure on the thermocouple greater efficiency vacuum gauge Confirm proper pump and gauge operation Open a If the pressure is not more than 1500 microns the the shutoff valve which leads to the high vacuum system is leak free and properly evacuated Pro gauge manifold Start the pump When the com ceed to Step 9 pound gauge low side reading drops approximately b If the pressure rises but holds at about 5000 mi 29 inches of vacuum open the valve to the thermo crons moisture and noncondensibles are still couple vacuum gauge and evacuate until the gauge present Open the valve to the vacuum pump and go reads 250 microns or less back to Step 7 Close the valve to the thermocouple vacuum gauge c If the pressure rises above 5000 microns a leak is This avoids potential gauge damage from pegging il Refer to the previous section Leak Test the meter H Open the high and low side valves on the gauge 9 Close the valve to the thermocouple vacuum gauge l Close the valve to the vacuum pump Shut off the manifold Keeping the valve on the charging cylinder im closed open the valve on the gauge manifold that pump leads to the cylinder THERMOCOUPLE VACUUM GAUGE DIAL A CHARGE HARGING CYLINDER TO RELATED GAUGE LOW SIDE PORTS OF GAUGE COND UNIT RW HIGH vacuum Se MANIFOLD Le LARGE DIAMETER XS BRAIDED V
16. ny tubing Before operating the unit complete the refrigerant connections General Information Shipping and Handling Units are securely packed in shipping containers approved by the International Safe Transit Association Check the carton upon arrival for external damage If damage is found file a request in writing for inspection by the carrier agent immediately The carrier is responsible for making prompt inspection of damage and for a thorough investiga tion of each claim The distributor or manufacturer will not accept claims from dealers for transportation damage If no damage is found carefully remove all shipping material and properly dispose of it Keep the unit as upright as possible Laying the unit on its side or top could cause equipment damage Clearances and Accessibility DO NOT locate the unit Directly under a vent termination for a gas appliance Within three feet of a clothes drier vent Where water may rise into the unit Where the noise would prove to be a nuisance to the customer i e windows patios decks etc DO locate the unit In accordance with the minimum clearances described in Figure 1 To minimize the length of refrigerant piping required To provide adequate service clearances On a level concrete pad or other sturdy weather resistant platform Isolated from the building structure to avoid transmis sion of vibrations In general short runs
17. of refrigerant piping are better than long runs If practical locate the unit accordingly Locate the unit to provide safe access for future mainte nance and service If possible discuss unit location with the owner before proceeding This unit is for outdoor installation only It cannot be completely enclosed Refer to Figure 1 for clearances from the sides of the unit to full walls and other objects Minimum clearances are required to avoid air recircula tion and keep the unit operating at peak efficiency A minimum six inch clearance is required on one side of the unit and a minimum of twelve on two other sides The remaining side of the unit must be unrestricted Ensure that there is at least five feet clearance above the unit These minimum clearances do not guarantee adequate service access Sufficient clearances for servicing the unit s must be provided If installing two or more units at the same location allow at least 24 inches between the units when using the 6 12 12 guidelines in Figure 1 The space between two units may be reduced to 12 if the clearances in Figure 1 are increased to 12 24 24 MINIMUM CLEARANCES SIDE VIEW Figure 1 Rooftops Installations Only Place the unit on a level weather resistant platform Be sure the roof will support the weight of the unit and platform For approximate unit weight see the Product Data Book applicable to you
18. r R 22 Store cylinders in a cool dry place Never use a cylinder as a platform or a roller To avoid possible explosion use only returnable not disposable service cylinders when removing refrigerant from a system e Ensure the cylinder is free of damage which could lead to a leak or explosion e Ensure the hydrostatic test date does not exceed 5 years e Ensure the pressure rating meets or exceeds 400 Ibs When in doubt do not use cylinder Safe Refrigerant Handling A WARNING To avoid the risk of fire or explosion never use oxygen high pressure air or flammable gasses for leak testing of a refrigeration 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 1 Be sure both hand valves on the gauge manifold are closed relative to the center port e turned IN all A WARNING the way Attach this gauge manifold to the service valves on the unit see Figure 2 Do not open the unit service valves Do not use refrigerant from the To avoid possible explosion or equipment damage unit for leak testing it has been precisely measured do not exceed 150 psig when pressure testing at the factory for optimum performance 2 Connect a cylinder of dry nitrogen to the center port After you reach 150 psig close the valve on the nitrogen on the gauge manifold cylinder Disconn
19. r model If in doubt about the adequacy of the roof it is your responsibility to contact a qualified architect or structural engineer before installing the unit Application Note For proper performance the indoor equipment and duct work must be adequate for moving about 400 CFM of indoor air for every ton of cooling capacity to be installed If they are not modify the ductwork or indoor equipment accordingly Refrigerant Piping Refrigerant Vapor Line Sizing See the Product Data Book applicable to your model for required tubing sizes Using smaller vapor lines may decrease performance up to 10 These sizes are suit able for line lengths of fifty feet or less It also assumes that the indoor coil will not be more than forty feet above or below the outdoor unit Longer runs and greater lifts are not recommended If a run of more than fifty feet is required refer to the Remote Cooling Service Manual or contact your distributor for assistance Check the indoor coil liquid and vapor line diameter A bushing or coupling may be needed to match with the line sizes used If mix matching to a restrictor orifice indoor coil check the Product Data Book applicable to your model for the proper orifice size to be used with this outdoor unit Piston orifices are supplied with the outdoor unit Refrigerant Vapor and Liquid Lines Routing All of the vapor line must be insulated The insulation must include a vapor barrier The liqui
20. zing quench the joints with water or a wet cloth This will also help prevent overheating of the service valve NOTE Please contact your distributor for the applicable product data book referred to in this manual Safe Refrigerant Handling While these items will not cover every conceivable situation they should serve as a useful guide To avoid possible injury explosion or death practice safe handling of refrigerants Refrigerants are heavier than air They can push out the oxygen in your lungs or in any enclosed space To avoid possible death or difficulty in breathing Never sniff a refrigerant Never purge refrigerant into an enclosed room or space In fact all refrigerants must BY LAW be reclaimed If an indoor leak is suspected thoroughly 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 get medical help immediately Always follow EPA regulations Never burn refrigerant as poisonous gas will be produced 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 Never fill a cylinder more than 80 full of liquid refrigerant Never add anything other than R 22 to an R 22 cylinder Service equipment used must be listed or certified fo

REMOTE CONDENSING UNIT

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