Goodman Mfg Air Conditioner IO 101G User Manual

INSTALLATION & OPERATING  
INSTRUCTIONS for  
SPLIT SYSTEM  
CONDENSING UNITS  
All information contained herein is subject to change without notice.  
Goodman Manufacturing Company, L.P.  
2550 North Loop West, Suite 400, Houston, TX 77092  
I0-101G  
06/04  
© 2003-2004 Goodman Manufacturing Company, L.P.  
 
This “close to the wall” application minimizes exposed  
tubing and wiring and reduces the space for children to  
run around the unit. This will help to avoid possible  
damage to the tubes or wiring and/or personal injury.  
Close to the wall application assures free, unobstructed  
air to the other two sides. In more confined application  
spaces, such as corners, provide a minimum 10” clearance  
on all air inlet sides. Allow 18” minimum for service access  
to the compressor compartment and controls.  
The top of the unit should be completely unobstructed. If  
units are to be located under an overhang, there should  
be a minimum of 36” clearance and provisions made to  
deflect the warm discharge air out from the overhang.  
10" Min.  
Service Access  
18" Min.  
LOCATION  
If unit is to be located under an overhang, there should be  
a minimum of 36” clearance and provisions made to deflect  
the water discharge air out from the overhang. If the  
outdoor unit is mounted above the air handler, the  
maximum lift should not exceed 70’ (suction line). If air  
handler is mounted above condensing unit, the lift should  
not exceed 50’ (liquid line.). Refer to Figure 3 and Table 1  
for maximum refrigerant line lenghts.  
OUTDOOR UNIT  
10" Min.  
PITCH SUCTION LINE TOWARD OUTDOOR  
UNIT 1/2" FOR EVERY 10' OF LINE  
Service Access  
18" Min.  
INDOOR UNIT ABOVE OR  
LEVEL TO OUTDOOR UNIT  
INDOOR UNIT  
10"  
LIQUID LINE  
OUTDOOR UNIT  
10"  
ADDITIONAL SUCTION LINE OIL TRA P  
FOR EACH 20' RISE OF PIPE  
70' MAX.  
LIQUID LINE  
SUCTION LINE OIL TRA PS  
WHEN INDOOR UNIT IS  
FEET OR MORE BELOW  
OUTDOOR UNIT  
4
INDOOR UNIT  
INDOOR UNIT BELOW  
OUTDOOR UNIT  
FIGURE 1  
8'  
INVERTED LOOP  
OUTDOOR UNIT  
INDOOR UNIT  
LIQUID LINE  
SUCTION LINE  
50' MAX.  
10" Min.  
FIGURE 3  
Service Access  
18" Min.  
REFRIGERANT LINE LENGTH (Ft)  
0-24  
25-49  
50-74***  
Cond  
Unit  
Tons  
1 1/2  
2
2 1/2  
3
3 1/2  
4
Line Diameter (In. OD)  
Suct  
5/8  
3/4  
3/4  
3/4  
3/4  
7/8  
7/8  
Liq  
1/4  
3/8  
3/8  
3/8  
3/8  
3/8  
3/8  
Suct  
3/4  
3/4  
Liq  
3/8  
3/8  
3/8  
3/8  
3/8  
3/8  
3/8  
Suct  
Liq  
3/8  
3/8  
1/2  
1/2  
1/2  
1/2  
1/2  
3/4  
3/4  
7/8  
3/4*  
3/4**  
7/8***  
1 1/8  
1 1/8  
7/8  
10" Min.  
1 1/8  
1 1/8  
1 1/8  
5
10" .  
* 7/8" required for full ratings  
** 1 1/8" required for full ratings  
Service Access  
18" Min.  
TABLE 1  
10" .  
The condensing unit must be mounted on a solid, level  
foundation, i.e. pre-formed concrete slab or other suitable  
base. For rooftop application, make sure the building  
construction can support the weight and that proper  
FIGURE 2  
3
IO-101G  
06/04  
 
consideration is given the weather-tight integrity of the roof.  
The condensing unit contains moving components and can  
vibrate; therefore, sound is also a consideration in rooftop  
application. Since this unit discharges warm condenser  
air from the top with cooler air being drawn in three sides,  
plantings can be made in relatively close proximity to the  
unit. Owners should be advised to avoid lawn mower  
discharge toward the unit depositing debris on the fan coil  
surface reducing product efficiency.  
Field Connection to the Valve and Valve Opening  
1. Tubing should be cut square. Make sure it is round  
and free of burrs at the connecting ends. Clean the  
tubing to prevent contaminants from entering the  
system.  
2. Wrap a wet rag around the copper valve stub before  
brazing.  
3. Braze or silver solder the joint.  
4. After brazing, quench with a wet rag to cool the joint.  
Evacuate and charge the connecting lines as outlined  
in these instructions.  
5. Remove valve top cap. It is important to keep the cap  
in a clean area to assure proper sealing once replaced.  
6. Using a standard L shaped Allen wrench, break open  
the valve body. To expedite opening the valve body  
after it is broken, use a ratchet wrench with a short  
Allen stub. Please note that it is normal to see oil on  
the valve stem body once the cap is removed.  
7. Replace the valve cap and tighten with a wrench  
making sure that the the cap is sealed.  
ELECTRICAL  
Electrical installation will consist of power supply wiring to  
the condensing unit as well as control wiring between  
thermostat, indoor unit and the condensing unit as shown  
on wiring diagram. All wiring must be in accordance with  
National Electrical Code and/or local codes that may apply.  
The condensing unit rating plate and the table inside the  
front cover of this instruction lists pertinent electrical data  
necessary for the selection of proper size electrical service  
and over-current protection. The owner should be made  
familiar with the location of the over-current protection,  
the proper size for this application and the proper  
procedure for disconnecting power service to the unit.  
QUICK CONNECT COILS  
Precharged System Installation  
Installation procedure will differ when condensing units  
are provided for use with precharged refrigerant coils and  
lines. Condensing units are provided with #6 and #11  
male quick connects instead of liquid and suction valves  
attached to cabinet to contain the R-22 charge that is  
sufficient for matching evaporator coils and 15’ of  
interconnecting lines.  
The condensing unit control wiring requires a 24 Volt  
minimum 25 VA service from the indoor transformer as  
shown on the wiring diagram.  
REFRIGERANT TUBING  
Use only refrigerant grade (dehydrated and sealed) copper  
tubing of the size indicated in Table 1 to interconnect the  
condensing unit with the indoor evaporator. Take extreme  
care to keep the refrigerant tubing clean and dry prior to  
and during installation.  
Coils are provided with #6 and #11 male quick connects.  
Line sets are required with #6 and #11 female quick  
connects on both ends. Access ports are required in the  
fittings of both liquid and suction lines at condenser end.  
Both coil and line sets include R-22 holding charge only.  
1. Connect lines to evaporator coil before connecting to  
the condensing unit locating access ports adjacent to  
condensing unit.  
Do not remove plugs from ends of tubing until connection  
is ready to be made. Suction line insulation is necessary  
to prevent condensation from forming on and dropping  
from suction line. Generally 3/8" wall thickness of Armflex  
or equivalent is satisfactory. In severe application (hot, high  
humidity areas) greater thickness may be required. Apply  
suction line insulation by sliding it on the sealed tubing  
before cutting and making connections.  
a. Form tubing so it properly aligns with the coil  
connections.  
b. Remove plugs and caps from connections.  
c. Check to be sure mating surfaces are clean.  
d. Lubricate rubber seal with clean refrigerant oil and  
thread couplings together by hand to be sure they are  
not cross threaded.  
e. Tighten connections using backup wrench on  
stationary fitting until coupling bottoms; then tighten  
1/6 turn to complete knife edge seal.  
EVAPORATOR COILS  
WARNING  
USE EXTREME CARE IN REMOVING THE CAPS  
FROM THE SUCTION AND LIQUID LINE FITTINGS  
AS THERE IS PRESSURE PRESENT. A FITTING IS  
ON THE LIQUID LINE TO REMOVE PRESSURE.  
2. Connect lines to condensing unit in the same manner  
as to evaporator coil. Observe same precautions.  
3. After making all connections and opening valves,  
check all piping for leaks.  
WARNING  
DO NOT REMOVE PROTECTIVE CAPS UNTIL  
INSTALLATION HAS BEEN COMPLETED AND FINAL  
CONNECTIONS ARE TO BE MADE.  
SYSTEM START UP  
Processing Checks  
Condensing units are supplied R-22 charge sufficient for  
typical matching evaporator and approximately 15’ of  
interconnecting tubing. Condensing unit liquid and suction  
valves are closed to contain the charge within the unit.  
4
IO-101G  
06/04  
 
Superheat Determination  
1. Read suction pressure. Using Table 3, determine  
saturated suction temperature.  
The recommended procedure for processing and charge  
adjustment is as follows:  
1. Connect vacuum pump to both base valve service  
ports.  
2. Read suction line temperature.  
3. Use the following formula to determine superheat:  
2. Evacuate tubing and evaporator through liquid and  
suction base valve ports, to 500 microns or less for a  
minimum of 30 minutes. Close valve to pump and  
wait 15 minutes. Vacuum should not rise above 800  
microns. If unable to obtain 500 micorns, or vacuum  
rises above 800 microns over a 15 minute period,  
discontinue evacuation, pressurize and check for  
leaks. Repair any leaks found and repeat step 2.  
3. Close valve to vacuum pump and stop pump. Break  
vacuum by opening liquid and suction base valves.  
Fully open base valves and remove pump lines.  
Connect service gauges making sure lines are purged.  
4. Set thermostat system switch to “COOL” and  
temperature to highest setting. Close all disconnects.  
5. Set thermostat to call for cooling. Check for operation  
of indoor and outdoor fans. Allow for at least 10  
minutes.  
Superheat = Suction Line Temp. - Saturated Suction Temp.  
SATURATED SUCTION PRESSURE (R-22)  
SUCTION  
SATURATED SUCTION  
PRESSURE PSIG  
TEMPERATURE °F  
50  
53  
55  
58  
61  
63  
66  
69  
72  
75  
78  
81  
26  
28  
30  
32  
34  
36  
38  
40  
42  
44  
46  
48  
6. Check charge and adjust if necessary. Refer to  
appropriate “Check Charge” section.  
TABLE 3  
Expansion Valve System  
Charge Checks  
Capillary Tube/Fixed Orifice System  
1. Fully open both base valves.  
2. Connect service gauge manifold to base-valve service  
parts making sure lines are purged. Run system at  
least 10 minutes to allow pressure to stabalize.  
3. Temporarily install the thermometer to liquid (small)  
line near condensing unit. Be sure that the contact  
between thermometer and line is good. Wrap  
thermometer with insulating material to ensure  
accurate reading.  
1. Fully open both base valves.  
2. Connect service gauge manifold to base-valve service  
ports being sure to purge lines. Run system at least  
10 minutes to allow pressure to stabilize.  
3. Temporarily install thermometer on suction (large) line  
near condensing unit. Be sure of good contact  
between the thermometer and line. Wrap thermometer  
with insulating material to assure accurate reading.  
4. Refer to Table 2 for proper system superheat. Add  
charge to lower superheat. Remove charge to raise  
superheat.  
4. Referring to Table 4, adjust charge to obtain a  
temperature 12-15°F below the saturated liquid  
temperature.  
5. Remove gauge lines carefully.  
Example:  
If the Liquid Pressure is 260 PSIG then the Saturated  
Temperature will be 120°F. Adjust the Saturated  
Temperature by subtracting 12-15°F. This will give you a  
Liquid Line Temperature of 105° - 108°F.  
WARNING  
ESCAPING LIQUID REFRIGERANT CAN CAUSE  
BURNS.  
SATURATED LIQUID TEMPERATURE  
SYSTEM SUPERHEAT  
LIQUID PRESSURE  
SATURATED  
AMBIENT CONDENSER  
INLET TEMPERATURE  
°F DRYBULB  
RETURN AIR TEMPERATURE  
( °F DRYBULB)  
(PSIG)  
200  
210  
220  
230  
240  
250  
260  
270  
280  
290  
300  
TEMPERATURE °F  
102  
105  
108  
111  
114  
117  
120  
123  
126  
128  
131  
65  
70  
75  
80  
85  
100  
95  
90  
85  
80  
75  
70  
65  
60  
5
5
5
7
5
5
12  
17  
21  
25  
28  
32  
33  
18  
20  
26  
29  
32  
35  
37  
5
5
10  
12  
17  
20  
26  
30  
5
5
13  
17  
10  
14  
19  
25  
TABLE 4  
TABLE 2  
5
IO-101G  
06/04  
 
NOTE: System with over 50’ separation between  
condensing unit and evaporator may require oil charge  
adjustment.  
SPECIAL NOTE: Systems with MORE than 15’ of  
interconnecting tubing, please refer to Table 5 for line  
charge allowance per foot of tubing.  
LINE CHARGE ALLOWANCE (R-22) (oz./ft.)  
OIL CHARGE ADJUSTMENT  
LINE  
LIQUID  
LINE  
SUCTION  
LINE  
UNIT MODEL  
(TONS)  
ADDITIONAL OIL CHARGE PER EACH  
ADDITIONAL 10' OF LINE (OZ.)*  
O. D. (IN)  
1/4  
3/8  
1/2  
5/8  
3/4  
7/8  
1 1/8  
1 3/8  
0.22  
0.58  
1.14  
1.86  
1 - 1 1/2  
2 - 5  
0.25  
0.5  
*Use either Texaco WF-32 (formerly cappella B)  
or Suniso 3G-S oil  
0.04  
0.06  
0.08  
0.15  
0.22  
TABLE 6  
TABLE 5  
6
IO-101G  
06/04  
 
WIRING DIAGRAMS  
ALT. DOUBLE  
POLE CONTACTOR  
OUTDOOR CONTROL BOX  
OUTDOOR POWER SUPPLY  
CRANKCASE HEATER  
PU  
T1  
T2  
R
C
C
O
N
T
A
C
T
C
O
N
T
A
C
T
R
Y
L2  
T2  
L1  
T1  
(IF USED)  
F
R
L1  
L2  
HERM  
R
BK  
Y
BK  
R
BR  
O
R
COMPRESSOR  
MOTOR  
O
R
C
COMPRESSOR/FAN  
CAPACITOR  
R
T1  
L1  
T2  
OUTDOOR POWER  
SUPPLY - (SEE  
UNIT RATING  
COMPRESSOR  
INTERNAL  
OVERLOAD  
S
Y
PLATE)  
USE COPPER  
CONDUCTORS ONLY  
PU  
L2  
USE L1 FOR  
NEUTRAL OR  
GROUNDED SUPPLY  
IF USED  
START ASSIST  
FAN MOTOR  
START ASSIST  
Y
(IF USED)  
PU  
(START ASSIST  
IF USED)  
EQUIPMENT GROUND  
FAN MOTOR  
CAPACITOR  
PU  
COMPRESSOR  
C
BK  
BR  
CONNECT TO APPROP.  
CONTROL CIRCUIT HAVING  
MIN. 40 VA 24 VOLT  
BK  
S
BK  
N.E.C. CLASS 2  
Y
TRANSFORMER OR FOR  
CERTIFIED C.S.A.  
PU  
CONTACTOR  
COIL  
ON  
INSTALLATION. USE C.S.A.  
CERTIFIED ENERGY LIMITED  
CLASS 2 TRANSFORMER.  
R
THERMOSTAT  
FAN SWITCH  
G
R
AUTO  
BK  
BK  
THERMOSTAT  
BK  
CRANKCASE HEATER IF USED  
COOL  
FAN RELAY  
COIL  
ANTICIPATOR  
Y
COOL  
R
COLOR CODE  
THERMOSTAT  
SYSTEM  
WIRING FOR  
FACTORY  
OPTIONS  
FIELD  
WIRING  
FACTORY  
WIRING  
BLACK  
OFF  
HEAT  
24V  
BK  
R
WIRING CODE  
THERMOSTAT  
BULB  
RED  
SWITCH  
Y
YELLOW  
BLUE  
HIGH VOLTAGE  
LOW VOLTAGE  
BL  
PU  
LTBL  
BR  
G
COIL  
THERMOSTAT  
PURPLE  
ADJ. HEAT  
ANTICIPATOR  
W
WIRE NUT  
LIGHT BLUE  
C
R
OPTIONAL START ASSIST  
BROWN  
GREEN  
LOW VOLTAGE  
TRANSFORMER  
NOTES:  
REPLACEMENT WIRE MUST BE SAME  
GAGE AND INSULATION THICKNESS,  
105° C APPLIANCE WIRING MATERIAL.  
INDOOR POWER SUPPLY  
3/98 REV. A  
B17784-01  
SINGLE PHASE  
OUTDOOR POWER SUPPLY  
HP  
BL  
Y
V
Y
CH  
BR  
V
L3  
L2  
L1  
L1  
R
BK  
C
C
C
C
BK  
R
BR  
V
BL  
R
V
CONNECT TO APPROP. CONTROL CIRCUIT HAVING  
MIN. 40 VA. 24 VOLT N.E.C. CALSS 2  
T3  
T1  
T2  
2
T1  
Y
TRAMSFORMER OR FOR CERTIFIED C.S.A  
INSTALLATION. USE C.S.A. CERTIFIED ENERGY  
T1  
L1  
T2  
L2  
T3  
L3  
LIMITED CLASS  
2
TRANSFORMER.  
C
FC  
EQUIPMENT GROUND USE  
3
1
COMP  
CAP  
COPPER CONDUCTORS ONLY  
MOTOR  
BK  
POWER SUPPLY  
BK  
(SEE RATING PLATE)  
USE COPPER CONDUCTORS ONLY  
ON  
THERMOSTAT  
FAN SWITCH  
MAIN  
G
CONTACTOR  
COIL  
Y
S
AUTO  
V
AUX  
THERMOSTAT  
COOL  
BR  
BK  
CM  
ANTICIPATOR  
FAN RELAY  
COIL  
Y
IO  
COOL  
BK  
R
C
R
COMP  
R
THERMOSTAT  
SYSTEM  
THERMOSTAT  
BULB  
BK  
OFF  
SWITCH  
BK  
HEAT  
THERMOSTAT  
ADJ. HEAT  
ANTICIPATOR  
COIL  
CH  
W
24V  
R
C
LOW VOLTAGE  
TRANSFORMER  
COMPONENT CODE  
OUTDOOR FAN MOTOR  
COMPRESSOR  
CM  
COLOR CODE  
COMP  
INDOOR POWER SUPPLY  
C
CONTACTOR  
DEFROST CONTROL  
BK  
R
BLACK  
RED  
DC  
LOW VOLTAGE DEFROST RELAY  
CRANKCASE HEATER  
LDVR  
CH  
Y
YELLOW  
INTERNAL OVERLOAD  
IO  
BL  
V
BLUE  
LOW PRESSURE CONTROL  
HIGH PRESSURE CONTROL  
OUTDOOR THERMOSTAT (OPTIONAL)  
FAN CAPACITOR  
LP  
NOTES:  
1) TO INDOOR UNIT LOW  
HP  
VIOLET  
OT  
LIGHT BLUE  
LTBL  
BR  
G
WIRING CODE  
FC  
VOLTAGE TERMINAL BLOCK &  
INDOOR THERMOSTAT.  
BROWN  
GREEN  
ORANGE  
WHITE  
DEFROST THERMOSTAT  
REVERSING VALVE COIL  
HIGH VOLTAGE DEFROST RELAY  
DFT  
RVC  
HVDR  
FACTORY WIRING  
FIELD WIRING  
HIGH VOLTAGE  
LOW VOLTAGE  
WIRE NUT  
2) SEE INDOOR UNIT  
&
O
OUTDOOR UNIT INSTALLATION  
W
INSTRUCTIONS FOR CONNECTION  
OF OPTIONAL OUTDOOR THERMOSTAT.  
CONTROLS SHOWN WITH UTILITIES IN 'ON'POSITION  
AND THERMOSTAT IN 'OFF' POSITION.  
LINE SPLICE  
USE N.E.C. CLASS 2 WIRE  
07/97 REV.  
D
B17783-00  
THREE PHASE  
7
IO-101G  
06/04  
 
NOTE: SPECIFICATIONS AND PERFORMANCE DATA LISTED HEREIN  
ARE SUBJECT TO CHANGE WITHOUT NOTICE  
Quality Makes the Difference!  
All of our systems are designed and manufactured with the same high quality standards regardless of size or  
efficiency. We have designed these units to significantly reduce the most frequent causes of product failure.  
They are simple to service and forgiving to operate. We use quality materials and components. Finally, every  
unit is run tested before it leaves the factory. That’s why we know. . .There’s No Better Quality.  
• Goodman products  
• Warranties  
• Customer Services  
• Parts  
• Contractor Programs and Training  
• Financing Options  
© 2003-2004 Goodman Manufacturing Company, L.P.  
8
IO-101G  
06/04  
 

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