Amana IO-4003 Horizontal Two-Way Indoor Coil with Internal TXV Instruction Manual

HORIZONTAL TWO-WAY COIL
INSTALLATION INSTRUCTIONS

Important Safety Instructions

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.
WARNING
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.

WARNING
ONLY PERSONNEL THAT HAVE BEEN TRAINED TO INSTALL, ADJUST, SERVICE OR REPAIR(HEREINAFTER, “SERVICE”) THE EQUIPMENT SPECIFIED IN THIS MANUAL SHOULD SERVICE THE EQUIPMENT. THE MANUFACTURER WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES. IF YOU SERVICE THIS UNIT, YOU ASSUME RESPONSIBILITY FOR ANY INJURY OR PROPERTY DAMAGE THAT MAY RESULT. IN ADDITION, IN JURISDICTIONS THAT REQUIRE ONE OR MORE LICENSES TO SERVICE THE EQUIPMENT SPECIFIED IN THIS MANUAL, ONLY LICENSED PERSONNEL SHOULD SERVICE THE EQUIPMENT. IMPROPER INSTALLATION, ADJUSTMENT, SERVICING OR REPAIR OF THE EQUIPMENT SPECIFIED IN THIS MANUAL, OR ATTEMPTING TO INSTALL, ADJUST, SERVICE OR REPAIR THE EQUIPMENT SPECIFIED IN THIS MANUAL WITHOUT PROPER TRAINING MAY RESULT IN PRODUCT DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH.

Shipping Inspection
Upon receiving the product, inspect it for damage from shipment. Shipping damage and subsequent investigation is the responsibility of the carrier. Verify the model number, specifications, and accessories are correct prior to installation. The distributor or manufacturer will not accept claims from dealers for transportation damage or installation of incorrectly shipped units.

Handling
Use caution when transporting/carrying unit. Do not carry units with hooks or sharp objects. The preferred method of carrying the unit after arrival at the job site is to carry by two-wheel hand truck from the back or sides or by hand by carrying at the cabinet corners.
Codes & Regulations
This product is designed and manufactured to comply with national codes. Installation in accordance with such codes and/or prevailing local codes/regulations is the responsibility of the installer. The manufacturer assumes no responsibility for equipment installed in violation of any codes or regulations.
The United States Environmental Protection Agency (EPA) has issued various regulations regarding the introduction 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.

Replacement Parts

Inspect the unit to verify all required components are present and intact. Report any missing components immediately to the manufacturer or to the distributor. Make sure to include the full product model number and serial number when reporting and/or obtaining service parts. Replacement parts for this product are available through your contractor or local distributor. For the location of your nearest distributor consult the white business pages, the yellow page section of the local telephone book or contact:
HOMEOWNER SUPPORT GOODMAN MANUFACTURING COMPANY, L.P.
19001 KERMIER ROAD WALLER, TEXAS 77484
877­ 254 ­ 4729

Pre-Installation Instructions

Carefully read all instructions for the installation prior to installing the product. Make sure each step or procedure is understood and any special considerations are taken into account before starting installation. Assemble all tools, hardware, and supplies needed to complete the installation. Some items may need to be purchased locally. Make sure everything needed to install the product is on hand before starting.

IO-4003 6/2021
19001 Kermie Rd., Waller, TX 77484
© 2021 Goodman Manufacturing Company, L.P.
www.goodmanmfg.com

System Matches
The entire system (combination of indoor and outdoor sections) must be manufacturer-approved and Air Conditioning, Heating, and Refrigeration Institute (AHRI) listed. NOTE: Installation of unmatched systems is not permitted. Damage or repairs due to the installation of unmatched systems is not covered under the warranty.

Application Information

Install this coil upstream (discharge air) of the furnace and install downstream (return air) of the air handler. This coil is a bi-directional coil and can be installed in either the left or right direction. Determine the coil direction by the side that allows the best access.
Note: These Coils are designed for indoor installation only. If the unit is located in an unconditioned area with high ambient temperature and/or high humidity, the coil may be subject to nuisance sweating of the casing. On these installations, a wrap of 2″ fiberglass insulations with a vapor barrier is recommended
Clearances
Refrigerant lines must be routed depending on the configuration of unit to maintain the required 24″ minimum clearance for service. Consult all appropriate regulatory codes prior to determining final clearances. In installations that may lead to physical damage (i.e. a garage) it is advised to install a protective barrier to prevent such damage. Always install units such that a positive slope in condensate line (1/4″ per foot) is allowed.

Furnace to Coil Attachment
There is no conversion required to reverse from right to left application. Attach the duct flanges to the discharge side of the unit. If the coil and furnace combination are not similar in depth and width, use a field-supplied transition to center the furnace and coil openings (see figure 5).

1. Using the hardware and brackets provided, attach the coil to the furnace then attach the plenum to the coil (Figure 5). Use tape or mastic seal between the coil and furnace and the coil and plenum.
2. Please use Z-Bracket provided with units to fill the transition gap between furnace & coil when the coil is one size larger than a furnace. Additional gaps must be filled with insulated tape or putty to prevent air leakage. Figure 3 indicates the incorrect coil/furnace attachment method.
3. Optionally a transition duct can be used to attach the coil with the furnace if a z-bracket is not preferred to be used (see figure 5).

CAUTION

IF THE DRAIN PAN EXTENSION IS NOT LOCKED CORRECTLY, THE AIRFLOW PATH WILL BE BLOCKED AND FLOODING MAY OCCUR.

Drain Pan Extension

1.  A drain pan extension is shipped with coil in the accessory kit box. (Figure 4A). This extension is to be used only for horizontal left applications used only for higher than normal humid applications. During horizontal right application, this Drain Pan Extension is not required.. (There are accessories recommended for the horizontal right application, see page-4). This extension will have to be locked in position for proper application.

Note: To install drain pan extension, built-in duct flanges on the wrapper must be bent inward or outward as needed. Remove the drain pan extension from the accessory box and from a plastic bag. Follow Illustration #4B below to install drain pan extension.
To lock extension, rotate downward away from drain pan until snaps into position. It will act as an extension for the drain pan and must not be left loose or in the path of airflow.

Duct Attachment
This coil’s casing is perforated for duct attachment. However, Duct flanges (Qty: 2) are shipped in a box from the factory separately for the sides that have rails and perforation can not be used. These flanges are to be used over rails. Remove center rail screw and lay over the flange on top of rails, then attach the screw back on to secure the flange over rails. For horizontal left application, there is only one rail (bottom) hence only one duct flange is needed and other can be stored. For the horizontal right application, there are two rail (top & bottom) and both duct flanges should be used. Duct flanges can also be attached using all three screws for the rails if additional strength is needed.

Condensate Drain Piping

During cooling application, where damage from condensate overflow may occur, it is MANDATORY to install a Secondary drain pan under the entire coil cabinet with a separate drain line properly sloped and terminated in an area visible to the owner to be able to see water discharge. This secondary drain pan can provide extra protection to the area under the unit should the primary drain plug up and overflow. For coils with “A” Cabinets (14″ wide), use a float switch if a secondary drain line is not installed. Refer to product nomenclature from product specification literature to identify coil models with “A” cabinets. As expressed in our product warranty, we will not be liable for any damages, structural or otherwise due to the failure to follow this installation requirement.
The coil drain pan has a primary and an optional secondary drain with 3/4″ NPT female connections. The connectors required can be 3/4″ NPT male either PVC or metal pipe and should be hand tightened to a torque of no more than 37 in-lbs. to prevent damage to the drain pan connection. An insertion depth between .355 to .485 inches (3-5 turns) should be expected at this torque. If using a copper drain line, solder a short piece of pipe to the connector before installing a drain fitting. DO NOT over-torque the 3/4″ copper connector to the plastic drain connection. Insulate PVC drain lines/pipes with high heat resistive tape within 1″ furnace flue/vent pipe. Foil-Mastic Sealant tape is the preferred wrapping material.

1. Ensure drain pan hole is NOT obstructed.
2. To prevent potential sweating and dripping on finished

A Secondary Condensate Drain Connection has been provided for areas where the building codes require it. Pitch the drain line 1/4″ per foot to provide free drainage. Insulate drain lines (primary and secondary) located inside the building to prevent sweating. Install a condensate trap in the primary drain line to ensure proper drainage. If the second line is required, run the line separately from the primary drain and end it where it can be easily seen. NOTE: Water coming from this line means the coil primary drain is plugged and needs clearing.
CAUTION
IF THE SECONDARY DRAIN IS NOT INSTALLED, THE SECONDARY ACCESS MUST BE PLUGGED.

NOTE: Trapped lines are required by many local codes. In the absence of any prevailing local codes, please refer to the requirements listed in the Uniform Mechanical Building Code. A drain trap in a draw-through application prevents air from being drawn back through the drain line during fan operation thus preventing condensate from draining, and if connected to a sewer line to prevent sewer gases from being drawn into the airstream during blower operation. In a blow-through application, the drain trap prevents conditioned air from escaping.
The installation must include a “P” style trap that is located as close as is practical to the evaporator coil. See Figure 6 for details of a typical condensate line “P” trap. NOTE: Units operating in high static pressure applications may require a deeper field-constructed “P” style trap than is shown in Figure 6 to allow proper drainage and prevent condensate overflow. Use of a condensate removal pump is permitted when necessary. This condensate pump should have provisions for shutting off the control voltage should a blocked drain occur. A trap must be installed between the unit and the condensate pump.
IMPORTANT NOTE: The evaporator coil is fabricated with oils that may dissolve Styrofoam and certain types of plastics. Therefore, a removal pump or float switch must not contain any of these materials.
Tip: Priming the “P” trap may avoid improper draining at the initial installation and at the beginning of the cooling season.

Horizontal Right Coil Accessories

In an application where the Horizontal coil is installed in the right position, and the return air environment sees humidity level above 65% relative humidity coupled with total external static levels above 0.5″ e.s.p, a condensate management accessory kit is available for field application. Sold separately, please refer to kit installation instruction IOG-7008.

Refrigerant Lines
WARNING

A QUENCHING CLOTH IS STRONGLY RECOMMENDED TO PREVENT SCORCHING OR MARRING OF THE EQUIPMENT FINISH WHEN BRAZING CLOSE TO THE PAINTED SURFACES. USE BRAZING ALLOY OF 5% MINIMUM SILVER CONTENT.
All cut ends are to be round, burr-free, and cleaned. Any other condition increases the chance of a refrigerant leak. Use a pipe cutter to remove the closed end of the spun closed suction line. To avoid overheating after brazing, quench all welded joints with water or a wet rag. For the correct tubing size, follow the specification for the condenser/heat pump
CAUTION
THE COIL IS SHIPPED UNDER PRESSURE WITH A R-410A GAS MIXTURE. USE APPROPRIATE SERVICE TOOLS AND FOLLOW THESE INSTRUCTIONS TO PREVENT INJURY.

CAUTION
APPLYING TOO MUCH HEAT TO ANY TUBE CAN MELT THE TUBE. TORCH HEAT REQUIRED TO BRAZE TUBES OF VARIOUS SIZES MUST BE PROPORTIONAL TO THE SIZE OF THE TUBE. SERVICE PERSONNEL MUST USE THE APPROPRIATE HEAT LEVEL FOR THE SIZE OF THE TUBE BEING BRAZED.
NOTE: Tubes of smaller size require less heat to bring the tube to brazing temperature before adding brazing alloy. The use of a heat shield when brazing is recommended to avoid burning the serial plate or the finish on the unit. Refrigerant tubing must be routed to allow adequate access for servicing and maintenance of the unit. Do not handle coil assembly with manifold or flowrate tubes. Doing so may result in damage to the tubing joints. Always use clean gloves for handling coil assemblies.
Tubing Size/Length
For the correct tubing size, follow the specification for the condenser/heat pump. Give special consideration to minimizing the length of refrigerant tubing when installing coils. Refer to Remote Cooling/Heat Pump Technical Publication TP-107* Long Line Set Application R-410A for guidelines for line lengths over 80′. Leave a minimum 3″ straight inline set from braze joints before any bends.
Tubing Preparation
All cut ends are to be round, burr-free, and cleaned. Any other condition increases the chance of a refrigerant leak. Use a pipe cutter to remove the closed end of the spun closed suction line. Note: To prevent possible damage to the tubing joints, do not handle coil assembly with manifold or flowrate tubes. Always use clean gloves when handling coil assemblies.
Brazing
Braze joints should be made only with the connections provided external to the cabinet. Do not alter the cabinet nor braze inside the cabinet. To avoid overheating after brazing, quench all brazed joints with water or a wet rag.
Tubing Connections for TXV Version
TXV models come with factory-installed adjustable TXV with the bulb permanently located on the suction tube.

1. Remove the coil access panel and rubber grommets.
2. Remove access valve fitting cap and depress the valve stem in access fitting to release pressure. No pressure indicates a possible leak.
3. Reinstall the Coil Access Panel & rubber grommets.
4. Remove the spin closure on both the liquid and suction
   tubes using a tubing cutter. DO NOT USE A CUTTING METHOD THAT WOULD RESULT IN THE GENERATION OF COPPER SHAVINGS OR COPPER DUST.
   CAUTION
   EXCESSIVE TORQUE CAN CAUSE TXV RETAINING RING TO WEAKEN & CREATE A LEAK AND WILL BECOME DIFFICULT TO RE-INSTALL TXV. USE THE PROPER TORQUE (180-240 IN. LBS) SETTINGS WHEN TIGHTENING THE TXV OR HAND TIGHTEN PLUS 1/2 TURN.
5. Insert liquid line set into liquid tube expansion and slide grommet about 18″ away from brazing joint.
6.  Insert suction line set into suction tube expansion and slide insulation and grommet about 18″ away from brazing joint.
7. Braze suction and liquid line joints.

9.5 Thermal Expansion Valve System Adjustment
Run the system at Cooling for 10 minutes until refrigerant pressures stabilize. Use the following guidelines and methods to check unit operation and ensure that the refrigerant charge is within limits. Charge the unit on low stage.
Purge gauge lines. Connect service gauge manifold to base valve service ports.

Temporarily install a thermometer on the liquid line at the liquid line service valve and 4-6″ from the compressor on the suction line. Ensure the thermometer makes adequate contact and is insulated for best possible readings. Use liquid line temperature to determine subcooling and vapor temperature to determine to superheat.
Check to subcool and superheat. Systems with TXV application should have a subcooling of 7 to 9ºF and superheat of 7 to 9 ºF.
a. If subcooling and superheat are low, adjust TXV to 7 to 9 ºF superheat, then check to subcool. NOTE: To adjust superheat, turn the valve stem clockwise to increase and counterclockwise to decrease.
b. If subcooling is low and superheat is high, add a charge to raise subcooling to 7 to 9ºF then check to superheat.
c. If subcooling and superheat are high, adjust the TXV valve to 7 to 9 ºF superheat, then check to subcool.

d. If subcooling is high and superheat is low, adjust TXV valve to 7 to 9 ºF superheat and remove charge to lower the subcooling to 7 to 9ºF.
NOTE: Do NOT adjust the charge based on suction pressure unless there is a gross undercharge.
Disconnect manifold set, installation is complete.
NOTE: Check the Schrader ports for leaks and tighten valve cores if necessary. Install caps finger-tight.
SUBCOOL FORMULA = SAT. LIQUID LINE TEMP. – LIQUID LINE TEMP.
SUPERHEAT FORMULA = SUCT. LINE TEMP. – SAT. SUCT. TEMP.

Filler Plates

Filler plates are supplied on all 17.5, 21, & 24.5-inch chassis to be used for adapting the unit to a furnace one size smaller. If the plenum and furnace openings are the same size, the filler plates must be removed. See Figure 10.

Figure 10
Block-off Plates & Duct Flange Detail

Drain Line and Flue Vent Piping

A minimum of 2.0” distance from the top of the furnace and the bottom of the coil pan is required.
NOTE: The coil must be installed with the line set and drain openings to the front of the furnace.

Plastic Drain Pan Application

WARNING
DO NOT USE THE COIL PAN SHIPPED WITH THE UNIT ON OIL FURNACES OR ANY APPLICATION WHERE THE TEMPERATURE OF THE DRAIN PAN MAY EXCEED 300°F. A HIGH-TEMPERATURE DRAIN PAN SUCH AS KITS HTP-A, -B, -C, AND -D FOR NORMAL CABINET WIDTHS OF 14, 17.5, 21, AND 24.5 INCHES, RESPECTIVELY, SHOULD BE USED FOR APPLICATIONS WHERE THE TEMPERATURE EXCEEDS 300°F AND BELOW 450°F. A FIELD FABRICATED METAL DRAIN PAN CAN ALSO BE USED FOR APPLICATIONS WHERE TEMPERATURE EXCEEDS 300°F. FAILURE TO FOLLOW THIS WARNING MAY RESULT IN PROPERTY DAMAGE AND/OR PERSONAL INJURY.

NOTE: Water coming from the second line means the coil primary drain is plugged and needs immediate attention.
Install a trap in the drain line below the bottom of the drain pan. If using a copper drain line, solder a short piece of pipe, minimum 6″ length, to the connector before installing a drain fitting.
DO NOT over-torque the 3/4″ copper connector to the plastic drain connection. Using a wet rag or heatsink material on the short piece to protect the plastic drain pan, complete the drain line installation. Use Figure 6 as a template for typical drainpipe routing. This figure shows how to avoid interference with vent piping.

Return Ductwork
DO NOT TERMINATE THE RETURN DUCTWORK IN AN AREA THAT CAN INTRODUCE TOXIC OR OBJECTIONABLE FUMES/ODORS INTO THE DUCTWORK.
Sealing Along The Panel Gap
IMPORTANT NOTE: To prevent cabinet sweating and airflow leak, apply field-provided insulation tape along all joining surfaces between the coil, gas furnace, ductwork and panels. See Figure 13.

Aluminum Indoor Coil Cleaning

(Qualified Servicer Only)
This unit is equipped with an aluminum tube evaporator coil. The safest way to clean the evaporator coil is to simply flush the coil with water. This cleaning practice remains as the recommended cleaning method for both copper tube and aluminum tube residential cooling coils.
An alternate cleaning method is to use one of the products listed in the technical publication TP-109 (shipped in the literature bag with the unit) to clean the coils. The cleaners listed are the only agents deemed safe and approved for use to clean round tube aluminum coils. TP-109 is available on the website in Partner Link > Service Toolkit.
NOTE: Ensure coils are rinsed well after use of any chemical cleaners.
Top flanges can be bent for ease in installation to the duct flanges.

Removing Coil from Cabinet 

In an event of removing taller coils from the cabinet to service or replace; remove the access panel, remove top tie rail to allow the coils to slide out of the cabinet.
After service or replacement slide the coil back in the cabinet and secure the top tie rail and re-install the access panel.
See Figure 14.

Clean Comfort brand UV coil purifiers also can be purchased from distributors. The maximum UV lamp diameter to be used per
delta plate knockout design is 1.375” to reduce the possibility of air leak.
Refer to UV coil purifiers product specification and installation manual for additional details.

Start-Up Procedure

WARNING
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.

• Prior to start-up, ensure that all electrical wires are properly sized and all connections are properly tightened.
• All panels must be in place and secured. For Air Tight application, the gasket must be positioned at prescribed locations to achieve 1.4% leakage.
• Tubing must be leak-free.
• Condensate line must be trapped and pitched to allow for drainage.
• Low voltage wiring is properly connected.
• An auxiliary drain is installed when necessary and pitched to allow for drainage.
• Unit is protected from vehicular or other physical damage.
• Return air is not obtained from, nor are there any return air duct joints that are unsealed in, areas where there may be objectionable odors, flammable vapors or products of combustion such as carbon monoxide (CO), which may cause serious personal injury or death.

Air Handler / Coil
Model Number———-
Serial Number————-

ELECTRICAL
Line Voltage (Measure L1 and L2 Voltage)
L1 – L2
Secondary Voltage (Measure Transformer Output Voltage)
R – C
Blower Amps
Heat Strip 1 – Amps
Heat Strip 2 – Amps
BLOWER EXTERNAL STATIC PRESSURE
Return Air Static Pressure
IN. W.C.
Supply Air Static Pressure
IN. W.C.
Total External Static Pressure (Ignoring +/- from the reading above, add total here)
IN. W.C.
TEMPERATURES
Return Air Temperature (Dry bulb / Wet bulb)
DB °F
WB °F
Cooling Supply Air Temperature (Dry bulb / Wet bulb)
DB °F
WB °F
Heating Supply Air Temperature
DB °F
Temperature Rise
DB °F
Delta T (Difference between Supply and Return Temperatures)
DB °F
Air Handler / Coil – (Inverter Matched)
INVERTER AH / COIL ONLY
Check EEV and EEV wiring is secure (no adjustment required)
Additional Checks
Check wire routings for any rubbing
Check product for proper draining
Check screw tightness on the blower wheel
Check factory wiring and wire connections
Check product for proper clearances as noted by installation instructions
°F to °C formula: (°F – 32) divided by 1.8 = °C °C to °F formula: (°C multiplied by 1.8) + 32 = °F

CUSTOMER FEEDBACK
We are very interested in all product comments.
Please fill out the feedback form on one of the following links:

Daikin Products: (https://daikincomfort.com/contact-us)
Goodman®Brand Products: (http://www.goodmanmfg.com/about/contact-us).
Amana ®Brand Products: (http://www.amana-hac.com/about-us/contact-us).
You can also scan the QR code on the right for the product brand you purchased to be directed to the feedback page.

PRODUCT REGISTRATION
Thank you for your recent purchase. Though not required to get the protection of the standard warranty, registering your product is a relatively short process, and entitles you to additional warranty protection, except that failure by California and Quebec residents to register their product does not diminish their warranty rights.
For Product Registration, please register as follows:

Daikin Products: (https://daikincomfort.com/owner-support/product-registration).
Goodman® Brand products: (https://www.goodmanmfg.com/product-registration).
Amana® Brand products: (http://www.amana-hac.com/product-registration).
You can also scan the QR code on the right for the product brand you purchased
to be directed to the Product Registration page.

NOTE: SPECIFICATIONS AND PERFORMANCE DATA LISTED HEREIN ARE SUBJECT TO CHANGE WITHOUT NOTICE 
19001 Kermie Rd, Waller, TX 77484
© 2021 Goodman Manufacturing Company, L.P.
www.goodmanmfg.com
Amana is a registered trademark of Maytag Corporation or its related companies and is used under license. All rights reserved.