Goodman Mfg Air Conditioner CONDENSING AC UNIT SINGLE THREE PHASE AIR CONDITIONERS User Manual

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