PAYNE Package Units(both Units Combined) Manual L0610782
User Manual: PAYNE PAYNE Package Units(both units combined) Manual PAYNE Package Units(both units combined) Owner's Manual, PAYNE Package Units(both units combined) installation guides
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Installation Instructions NOTE: Read installation. the entire instruction TABLE manual before starting the OF CONTENTS Page SAFETY CONSIDERATIONS INTRODUCTION RECEIVING Unit Inspect Shipment Slab Mount 2 2 ................................ 2 .............................. 2 .................................... Mount 2 ................................. Clearances 2 ................................ 2 ....................................... Select and Install Ductwork Configuring Connect 2-10 ................................... Unit Support Place Unit ................ ................................. Identify Provide 2 AND INSTALLATION Ground 2 .................................. Check Equipment Provide ........................ Units for Downflow Condensate Install Electrical High-Voltage Routing Connecting Drain START-UP .......................... Connections ........................ 5 Leads Into Unit ..................... Lead to Unit Ground Power Electric Wires Heat Wiring A05194 3 5 Control PRE-START-UP . . . 3 ........................ Ground Accessory 2 (Vertical) Discharge Connections Power Routing 2 .......................... 6 ............. 6 ..................... 6 ..................... 6 ................................... 7 ..................................... 7-17 Fig. 1 - Unit PH3Z Cooling Operation ............................ Heating Operation .............................. Continuous Defrost Electric Start-Up Cooling Checking Charge No Charge and Heating Control 7 ............... Operation ................................ Cooling Indoor Airflow Unit Controls Adjustments 7 8 ............................ and Airflow ...... 8 ............................. Mode Charge 7 8 ..................................... Low Charge Heating ......................... and Make Adjustments Cooling Refrigerant Leaks 8 ............... .................................... Loss-of- Relief Valve Charge Switch Compressor Overload Compressor Rotation Sequence of Operation Fan Operation ........................ .......................... ............................ 18 ................................ and Motor Outdoor Fan Indoor 17 17-20 ....................................... (;oil, Indoor Coil. and Condensate and Wiring Circuit Airflow 18 .......................... .................................... Controls Refrigerant ....................... 18 Drain Pan .... 19 19 ...................... ................................ .................................. 19 20 20 8 9 9 9 9 ............................. 9 ............................. 9 .................................. Heating 17 ............................... Outdoor Metering Liquid High-Pressure Resistance Blower Electrical 17 ...................................... Unit Top Removal Indoor 17 Fan ................................ MAINTENANCE Air Filter Check for Refrigerant 9, 17 9 High Devices ................................ Line Strainers Flow Valves .............................. ................................ TROUBLESHOOTING START-UP CHECKLIST ............................. ........................... 20 20 20 20 24 SAFETY CONSIDERATIONS Installation and servicing ofthisequipment canbehazardous dueto mechanical andelectrical components. Onlytrained andqualified personnel should install, repair, orservice thisequipment. Untrained personnel canperform basic maintenance functions such ascleaning andreplacing airfilters. All other operations must be performed bytrained service personnel. When working onthis equipment, observe precautions intheliterature, ontags, andon labels attached to or shipped withtheunitandothersafety precautions thatmayapply. Follow allsafety codes. Installation mustbeincompliance with localandnational building codes. Wear safety glasses, protective clothing, andworkgloves. Have fireextinguisher available. Read these instructions thoroughly andfollowallwarnings orcautions included inliterature andattached totheunit. Recognize safety information. Thisisthesafety-alert symbol '_. When yousee thissymbol ontheunitandininstructions ormanuals, bealert tothepotential forpersonal injury. Understand these signal words: DANGER. WARNING, andCAUTION. These words are used withthesafety-alert symbol. DANGER identifies themost serious hazards whichwillresult insevere personal injuryordeath. WARNING signifies hazards which couldresult inpersonal injury ordeath. CAUTION isused toidentify unsafe practices which may result inminorpersonal injuryorproduct andproperty damage. NOTE isused tohighlight suggestions whichwillresult in enhanced installation, reliability, oroperation. Step 2--Provide For hurricane (Professional SLAB IDENTIFY UNIT The unit model informative INSPECT number and serial number plate. Check this information are printed against on the unit shipping papers. damage while unit is still on shipping pallet. If unit appears to be damaged or is torn loose from its anchorage, have it examined by transportation inspectors before removal. Forward claim papers directly to transportation company. Manufacturer is not responsible for details and PE if required. Place the unit on a solid, level concrete in. thick with 2 in. above grade. pad that is a minimum of 4 The slab should extend approximately 2 in. beyond the casing on all 4 sides of the unit. Do not secure the unit to the slab except when required by local codes. A 6-in. wide gravel apron should be used around the flat surface to prevent airflow blockage by grass or shrubs. The unit should be level To within properly. GROUND 1/4 in. This is necessary for the unit drain to function MOUNT The unit may be installed either on a slab or placed directly ground if local codes permit. Place the unit on level ground with gravel for condensate discharge. Step 3--Provide The required Adequate on the prepared Clearances minimum ventilation service clearances and outdoor are shown in Fig. 5. air must be provided. The outdoor fan draws air through the outdoor coil and discharges it through the top fan grille. Be sure that the fan discharge does not recirculate to the outdoor coil. Do not locate the unit in either a corner or under an overhead obstruction. The minimum clearance under a partial overhang (such as a normal house overhang) is 48 in. above the unit top. The maximum horizontal extension of a partial overhang must not exceed 48 in. Do not restrict outdoor either the outdoor-air to compressor airflow. An air restriction inlet or the fan discharge at may be detrimental life. Do not place the unit where water, ice. or snow from an overhang or roof will damage or flood the unit. Do not install the unit on carpeting or other combustible materials. Slab-mounted units should be at least 4 in. above the highest expected water and runoff levels. Do not use unit if it has been under water. Unit Unit can be moved with the rigging holds provided in the unit base. Refer to Table 1 for operating weights. Use extreme caution to prevent damage when moving the unit. Unit must remain in an upright position during all moving operations. The unit nmst be level within 1/4 in. for proper condensate drainage; the ground-level pad must be level before setting the unit in place. When a field-fabricated support is used. be sure that the support is level and that it properly Step 5--Select supports and Install the unit. Ductwork The design and installation of the duct system must be in accordance with the standards of the NFPA for installation of non-residence type air conditioning and ventilating systems. NFPA 90A residence type, NFPA 90B and/or local codes and ordinances. Select and size ductwork, supply- air registers, or and return air grilles according to ASHRAE (American Society of Heating, Refrigeration, and Air Conditioning Engineers) recommendations. SHIPMENT Inspect for shipping distributor Certificate, MOUNT Step 4--Place INTRODUCTION ThePH3Zpackaged heatpumpis fullyself-contained and designed foroutdoor installation (See Fig.1).Standard unitsare shipped inahorizontal-discharge configuration forinstallation on aground-level slab ordirectly ontheground iflocalcodes permit. Standard unitscanbeconverted todownflow (vertical) discharge configurations for rooftopapplications witha fieldsupplied plenum. RECEIVING ANDINSTALLATION Stepl--Check Equipment contact Engineering) IMPORTANT: ELECTRICAL SHOCK HAZARD Failure tofollowthiswarning could result inpersonal injury ordeath. Before installing orservicing system, always turnoffmain power tosystem. There maybemore thanonedisconnect switch. Turnoffaccessory heater power switch ifapplicable. Unit Support tie downs, for any damage incurred in transit. Check all items against shipping list. Immediately notify the nearest Payne office if any item is missing. To prevent loss or damage, leave all parts in original packages until installation. Use the duct flanges provided on the supplyand return-air openings on the side of the unit. See Fig. 5 for connection sizes and locations. The 14-in. round duct collars are shipped inside the unit attached to the base pan in the indoor blower compartment. They are field-installed and must be removed from the indoor blower compartment installation. prior to start-up, even if they are not used for When designing andinstalling ductwork, consider tirefollowing: UNITDAMAGE HAZARD Failure tofollowthiscaution mayresult indamage tounit components. When connecting ductwork tounits, donotdrilldeeper than 3/4inchin shaded area shown in Fig.2 or coilmaybe damaged. 1.Allunits should have field-supplied filters oraccessory filter rackinstalled in the return-airsideof the unit. Reconmmnded sizes forfilters areshown inTable 1. 2.Avoidabrupt ductsizeincreases andreductions. Abrupt change inductsizeadversely affects airperformance. IMPORTANT: Useflexible connectors between ductwork and unittoprevent transmission ofvibration. Usesuitable gaskets to ensure weather-tight andair-tightseal.Whenelectric heatis installed, usefireproof canvas (orsimilar heatresistant material) connector between ductwork andunitdischarge connection. If flexible ductisused, insert asheet metal sleeve inside duct. Heat resistant ductconnector (orsheet metal sleeve) must extend 24-in. fromelectric heater element. 3.Size ductwork forcooling airquantity (cfm). Theminimum airquantity forproper electric heater operation islisted in Table 2.Heater limitswitches maytripatairquantities below those recommended. 4.Seal, insulate, and weatherproof allexternal ductwork. Seal, insulate andcover withavapor barrier allductwork passing through conditioned spaces. Follow latest Sheet Metal and Air Conditioning Contractors NationalAssociation (SMACNA) andAirConditioning Contractors Association (ACCA) minimum installation standards forresidential heating andairconditioning systems. 5.Secure allducts tobuilding structure. Flash, weatherproof, andvibration-isolate ductopenings in wall or roof according togoodconstruction practices. Figure 4shows atypical ductsystem withPH3Z unitinstalled. CONFIGURING UNITSFORDOWNFLOW (VERTICAL) DISCHARGE ELECTRICAL 19.17 -----------_ _--- HAZARD Failure to follow this warning or death. could result in personal injury Before performing service or maintenance operations on the system, turn off main power to unit and install lockout tag. Units are dedicated side supply products. to vertical air supply. A field-supplied convert to vertical air discharge. Step 6--Connect Condensate installing They are not convertible plenum must be used to Drain NOTE: When comply with local codes and restrictions. condensate drain connection be sure to Unit removes condensate through a 1-3/64 in. ID hole (using 3/4-in. OD piping or tubing) which is located at the end of the unit. See Fig. 5 for location of condensate connection. Condensate water can be drained directly onto tire roof in rooftop installations (where permitted) or onto a gravel apron in ground level installations. Install a field-supplied condensate trap at end of condensate connection to ensure proper drainage. Make sure that the outlet of the trap is at least 1 in. lower than the drain pan condensate connection to prevent the pan from overflowing (See Fig. 3 and 4). When using a gravel apron, make sure it slopes away from the unit. If the installation requires draining the condensate water away from the unit, install a 2-in. trap using a 3/4-in. OD tubing or pipe. (See Fig. 3 and 4.) Make sure that the outlet of the trap is at least 1 in. lower than the unit drain-pan condensate connection to prevent the pan from overflowing. tube using a minimum Prime the trap with water. Connect a drain of 3/4-in. PVC, 3/4-in. CPVC, or 3/4-in. copper pipe (all field supplied). Do not undersize the tube. Pitch the drain tube downward at a slope of at least 1 in. for every 10 ft of horizontal run. Be sure to check the drain tube for leaks. Prinm trap at the beginning of the cooling season start-up. Allowable glues for condensate trap connection are: Standard ABS, CPVC, or PVC cenmnt.. 1" (25mm) •,_-._ SHOCK MIN. r'_,. TRAP ET ___ o X_ 2"(50mm)MIN. 099013 Fig. 3 - Condensate o o o Trap TRAP OUTLET o o o o 0 O O 2" min. A05195 Fig. 2 - Area Not to be Drined More Than 3/4-in. C00009 Fig. 4 - PVC Condensate Trap _GU_ BOITO_ OF U_IT I_DO0_ CLEARANCES TO CO_5T_LE MATL lop o} _ SIDE 6_ _[_ o OPPOSHED_C_ OPENINGS 0 NEC._E_ED_L_3R_. OUIDOOR COIL 6ROU_£_ S_RFAC_S PO_ER t_ SIDEO_ _T g12fl [3199_ _0110_ 0F SI_E OPPOS]_[ DUCTOP[NI_GS _OG68 [42 00_ ........ _2 0 [_000) UNII t LEFT SIDE VIEW A05201 UNIT PH3Z024 UNIT HEIGHT IN. [MM] UNIT WEIGHT ELECTRICAL CHARACTERISTICS 208/230-1-60 Ib 283 kg 133 CENTER OF GRAVITY IN. [MM] A X Y z 30.13 [765] 14.0 [356] 19.0 [483] 15.0 [381] 16.0 [4061 PH3Z030 208/230-1-60, 208/230-3-60 324 147 34.13 [867] 14.0 [356] 19.0 [483] PH3Z036 208/230-1-60, 208/230-3-60 377 171 42.13 [10701 14.0 [356] 19.0 [483] 19.8[503] PH3Z042 208/230-1-60, 208/230-3-60 389 177 42.13 [1070] 14.0 [356] 19.0 [483] 21.9 [556] PH3Z048 208/230-1-60, 208/230-3-60 384 175 42.13 [1070] 14.0 [356] 19.0 [483] 19.8[503] PH3Z060 208/230-1-60, 208/230-3-60 433 197 42.13 [1070] 14.0 [356] 19.0 [483] 21.9 [556] Fig. 5 - Unit Base Dimensions, PH3Z024-060 (UNIT AND -- Power WMng -- Control _ DRAIN CONNECTION Widng ondenser Evaporator Airflow Airflow "Separate disconnect per NEC National Electrical Code required i_r e ectr c heater when s ng epoint connection is not used C00008 Fig. 6 - Typical Installation Table UNIT SIZE NOMINAL CAPACITY OPERATING l--Physical Data 024 030 036 042 048 (ton) 2 2 - 1/2 3 3 - 1/2 4 5 (lb.) 293 324 377 389 384 433 WEIGHT COMPRESSOR Scroll REFRIGERANT Quantity (lb.) (R-22) REFRIGERANT METERING 7.5 Ultra Tech Scroll 10.3 10.3 DEVICE AccuRater 0.067 0.067 0.082 0.049 0.057 0.059 Copper Face Area (sq. ft.) 11.4 13.3 TXV Orifice OD (in.) Rows... Fins/in. 11.9 ® Orifice ID (in.) CONDENSER COIL 060 0.086 0.063 Tubes, Aluminum 0.070 0.073 Plate Fins 2...21 2...21 2...21 2...21 2...21 2...21 11.1 12.7 15.8 15.8 13.3 15.8 33OO CONDENSER FAN Propeller Nominal Cfm 2600 2600 3200 3200 32OO 20 20 20 20 2O 1/8 (825) 1/8 (825) 1/4 (1100) 1/4 (t100) 3...17 3...17 4...17 4.3 4.9 4.9 Diameter Motor HP (RPM) EVAPORATOR COIL Copper Rows... Fins/in. Face Area (sq. ft.) Tubes, Aluminum 2O 1/4 (t100) 1/2 (t100) 4...17 4...17 4...17 6.1 4.9 6.1 Plate Fins Direct Drive Evaporator blower Nominal Airflow (Cfm) 8OO 1000 1200 1400 16OO Size (in.) 10x8 10x8 11x9 11x9 11x10 1/2 (t050) 1/2 (t050) 3/4 (1050) 3/4 (1050) 1 (1050) 1(1050) 24 x 30 30 x 30 30 x 30 Motor HP (RPM) CONNECTING DUCT SIZES Round 14 Supply Air (in.) 14 Return Air (in.) Return-Air *Required 1875 11x10 24 x 24 Filters (in.)* Throwaway 24 x 24 filter sizes shown are based on the ARI (Air Conditioning & Refrigeration 24 x 24 Institute) rated airflow at a velocity of 300 ft/min for throwaway type or 450 ff/min for high capacity type. Recommended filters are I -in. thick. Table Unit Size 2--Minimum Airflow for Safe Electric Heater Operation 5kW Minimum Airflow (CFM) 7.5kW 10kW 15kW 20kW 024 500 650 750 030 600 800 1050 036 600 800 1050 1150 1200 042 600 800 1050 1150 1200 048 600 800 1050 1150 1200 060 600 800 1050 1150 1200 UNIT COMPONENT Electrical Connections HAZARD Failure to follow this caution may result in damage being installed. to the unit 1. Make with NEC all electrical ANSI/NFPA governing connections connections in accordance (latest edition) and local electrical codes such wiring. In Canada, all electrical must be in accordance with CSA standard (;22. i Canadian Step 7--Install DAMAGE Electrical ('ode Part i and applicable codes. Refer to unit wiring local diagram. 2. Use only copper conductor for connections between field-supplied electrical disconnect switch and unit. DO NOT USE ALUMINUM WIRE. ELECTRICAL SHOCK HAZARD Failure to follow this warning or death. could result in personal injury The unit cabinet must have an uninterrupted, unbroken electrical ground to minimize the possibility of personal injury if an electrical fault should occur. This ground may consist of an electrical wire connected to the unit ground screw in the control compartment, or conduit approved for electrical ground when installed in accordance with NEC, ANSI/NFPA American National Standards Institute/National Fire Protection Association (latest edition) (in Canada. Canadian Electrical Code CSA (;22.1) and local electrical codes. 3. Be sure that high-voltage voltage range indicated power to unit is within operating on unit rating plate. On 3-phase units, ensure phases are balanced within 2 percent. local power company for correction of improper and/or phase imbalance. Consult voltage 4. Do not damage internal components when drilling through any panel to mount electrical hardware, conduit, etc. HIGH-VOLTAGE CONNECTIONS The unit must have a separate field-supplied, waterproof disconnect electrical service with a switch mounted at, or within sight from the unit. Refer to the unit rating plate. NEC and local codes for maxinmm fuse/circuit breaker size and minimum circuit amps (ampacity) for wire sizing (See Table 5 for electrical data). The field-supplied disconnect may be mounted on the unit over the high-voltage inlet hole when the standard power and low-voltage entry points are used. See Fig. 6 and 7 for acceptable location. Operation ofunitonimproper linevoltage constitutes abuse and maycause unitdamage thatcould affect warranty. ROUTING POWER LEADS INTOUNIT Useonlycopperwirebetween disconnect andunit.The high-voltage leads should beinaconduit untiltheyenter theunit; conduit termination attheunitmustbewatertight. Runthe high-voltage leads through theholeonthecontrol boxside ofthe unit(See Fig.7).When theleads areinside theunit,runleads tothe control box(See Fig.8).Forsingle-phase units, connect leads tothe black andyellow wires(See Fig.9). CONNECTING GROUND LEADTOUNITGROUND Connect theground lead tothechassis using theunitground inthe control box(See Fig.8and9). ROUTING CONTROL POWER WIRES (24-V) Form adrip-loop withthethermostat leads before routing them into theunit.Route thethermostat leads through grommeted hole provided in unitintounitcontrol box(SeeFig.7).Connect thermostat leads and unitpower leads asshown inFig.9,10and11. Route thermostat wires through grommet providing adrip-loop at thepanel. Connect low-voltage leads tothethermostat asshown in Fig.10&11. Theunittransformer supplies 24-vpower forcomplete system including accessory electrical heater. Transformer isfactory wired for230-voperation. ACCESSORY ELECTRIC HEAT WIRING Referto accessory electric heatinstallation instructions for information oninstalling accessory electric heat. Accessory electric heat wiringisshown inFig.12,13,14and15. HIGH-VOLTAGE WIRING ENTRY POWER LOW-VOLTAGE HOLE ENTRY HEATER LOW •VOLTAGE PLUG A05388 Fig. 8 - Control Box Widng UNIT GROUND GROUND LEAD SINGLE-PHASE Z_ BLK- w CONNECTIONS 3-PHASE CONNECTIONS TO DISCONNEC_ L_ ...... _YELTO DISCONNECT PERNEC PER NEC L ................................ _:Z_BLU- CO00i2 Fig. 9 - Line Power WIRING Connections HOLE o; o// L °o/ ._ BRN RED GRN Thermostat and subbase Unit Control Power A05198 Fig. 7 - Unit Electrical Connection A05207 Fig. 10 I Control Connections (Sizes 024-042) d. Ensure wires do not touch refrigerant tubing or sharp sheet metal edges. e. Inspect coil handling, @- fins. If carefully 4. Verify the following damaged straighten during shipping and fins with a fin comb. conditions: a. Make sure that outdoor-fan blade is correctly positioned in fan orifice. Top edge of blade should be 3.125 in. down from outdoor __ coil outlet grille or hub should be 0.708-in. away from motor end bell (See Fig. 19). See Outdoor Adjustment section. Fan b. Make sure that air filter is in place. c. Make sure that condensate drain pan and trap are filled with water to ensure proper drainage. d. Make sure that all tools have been removed. Thermostat and subbase and miscellaneous loose parts START-UP Unit Control Power Step 1--Check for Refrigerant Leaks A05208 Fig. 11 - Control Connections PRE- Proceed as follows charge the unit: (Sizes 048-060) START- to locate 1. Locate leak and make sure that refrigerant has been relieved and reclaimed from UP low-pressure EXPLOSION, ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal or death and/or property damage. 1. Follow goggles recognized safety practices when checking or servicing and wear refrigerant NOTE: attempt to repair soldered connection 5. To remove a component, proceed as follows: a. Shut off electrical tag. wear power protective when as follows 1. Remove System and from unit. tubing stubs Oil can ignite when exposed when broken to inspect and prepare the unit for initial start- up: inspections: for shipping and handling damages, lines, loose parts, disconnected such as ,,vires, etc. b. Inspect for oil at all refrigerant tubing connections and on unit base. Detecting oil generally indicates a refrigerant leak. Leak test all refrigerant tubing connections using electronic leak detector, or liquid-soap refrigerant leak is detected, see Check Leaks section. c. Inspect all field- sure that connections operating Adjustments the unit. Do not operate CHECKING OPERATION COOLING Start and check follows: the unit for proper 2. Place SYSTEM to flame. with unit. a. Inspect and Make the unit in cooling mode AND HEATING cooling CONTROL control operation as in ON position and shuts down within 60 sec. (for 024-042) or 90 seconds (for 048 and 060) when FAN switch is placed in AUTO position. all access panels. 3. Make the following Cooling 1. Place room thermostat SYSTEM switch in OFF position. Observe that blower motor starts when FAN switch is placed 2. Read and follow instructions on all DANGER, WARNING. CAUTION. and INFORMATION labels attached to or shipped has been opened to unit and install lockout cutter and remove component d. Carefully unsweat remaining Proceed the system when the outdoor temperature is below 40°F (unless accesso_ low-ambient kit is installed). Do not rapid cycle the compressor. Allow 5 min. between "on" cycles to prevent compressor damage. b. Relieve and reclaim all refrigerant from system using both high- and low-pressure ports. c. Cut component connecting tubing with tubing necessary. practices. Complete the required procedures given in the Pre-Start-Up section before starting the unit. Do not jumper any safety devices while goggles accepted Install a filter drier whenever Step 2--Start-Up protective system. refrigerant system is under pressure. 4. Do not use torch to remove any component. contains oil and refrigerant under pressure. system pressure both high- and for repair. injury 2. Relieve and recover all refrigerant from system before touching or disturbing anything inside tenninal box if refrigerant leak is suspected around compressor terminals. 3. Never leak and to ports. 2. Repair leak following FIRE, and repair a refrigerant and factory-wiring are completed solution. If a for Refrigerant and tight. Be position and FAN switch motors start and that reversing valve shifts. Observe that cooling cycle shuts down when control setting is satisfied. Reversing 3. Place valve (RV) remains system switch energized. in HEAT position. Observe that compressor, indoor fan and outdoor fan energize (Reversing Valve is deenergized in heat pump heating mode). Set control above room temperature. Observe that heating cycle shuts down when control setting is satisfied. 4. When using an automatic changeover room thermostat, place both SYSTEM and FAN switches in AUTO positions. Observe that unit operates in Cooling temperature control is set to call for Cooling temperature), and unit operates in Heating temperature control is set to call for Heating temperature). connections. switch in COOL in AUTO position. Set control below room temperature. Observe that compressor, outdoor fan, and indoor blower mode when (below room mode when (above room Table 3--Required REQUIRED Mode[ Size 048 O6O 75 (24) 17.5 (9.7) 82 (28) 17 (9.4) 85 (29) 16.5 (9.2) 95 (35) 16 (8.9) 105 (41) 14 (7.8) 21 (11.7) 20.5 (11.4) 20 (11.1) 19 (10.6) 16 (8.9) Table 4--Required Liquid REQUIRED LIQUID LINE TEMPERATURE Required Subcooling (°F) 10 15 20 Pressure (kPa) 5 134 71 66 61 56 141 74 69 64 156 8O 75 70 163 83 78 17O 177 86 89 184 191 Line Temperature FOR A SPECIFIC SUBCOOLING (R-22) Required Subcooling (°F) 6 8 Pressure (kPa) 3 924 24 22 19 16 59 972 26 23 21 18 65 1075 3O 27 24 21 73 68 1124 31 28 26 23 81 84 76 79 71 74 1172 1220 33 34 30 31 27 29 24 26 91 86 81 76 1268 36 33 30 27 94 89 84 79 1317 37 34 31 29 198 2O5 96 98 91 93 86 88 81 83 1365 1413 38 4O 36 37 33 34 3O 31 213 101 96 91 86 1468 41 38 36 33 221 104 99 94 89 1524 43 40 37 34 229 106 101 96 91 1579 44 41 38 36 237 108 103 98 93 1634 45 42 40 37 245 253 111 113 106 108 101 103 96 98 1689 1744 47 48 44 45 41 42 38 4O 262 116 111 106 101 1806 49 46 44 41 271 118 113 108 103 1868 51 48 45 42 28O 121 116 111 106 1930 52 49 46 44 289 298 123 125 118 120 113 115 108 110 1992 2054 53 55 51 52 48 49 45 46 3O7 128 123 118 113 2116 56 53 50 48 317 130 125 120 115 2185 57 54 52 49 327 132 127 122 117 2254 59 56 53 5O 337 135 130 125 120 2323 6O 57 54 52 347 357 137 139 132 134 127 129 122 124 2392 2461 61 62 58 60 56 57 53 54 367 142 137 132 127 2530 64 61 58 55 28O 121 116 111 106 1930 52 49 46 44 289 298 123 125 118 120 113 115 108 110 1992 2054 53 55 51 52 48 49 45 46 3O7 128 123 118 113 2116 56 53 50 48 317 130 125 120 115 2185 57 54 52 49 327 132 127 122 117 2254 59 56 53 5O 337 135 130 125 120 2323 6O 57 54 52 347 357 137 139 132 134 127 129 122 124 2392 2461 61 62 58 60 56 57 53 54 367 142 137 132 127 2530 64 61 58 55 Step 3--Refrigerant Refrigerant nameplate Charge 2. Measure Charge --Amount of refrigerant charge is listed on unit and in Table 1. Refer to Payne Refrigerant Service Techniques Manual, Refrigerants section. Unit panels must be in place when unit is operating during charging procedure. Unit must operate a minimum of 15 minutes before checking charge. NO CHARGE Refer to Payne evacuating specified LOW Subcooling SUBCOOLING °F (°C) Outdoor Ambient Temperature techniques. amount CHARGE 024-042 Refrigerant After of refrigerant Service Techniques. evacuating system, Use standard weigh in the (refer to Table 1). units: line pressure 3. Insulate ambient suction sensing line temperature by attaching a device to it. the temperature sensing device so that the outdoor doesn't affect the reading. 4. Locate the measured suction line pressure in the top row of Table 7 and the measured outdoor ambient temperature in the left colunm of the table. Based on the two values, determine the required suction line temperature. 5. If the measured suction line temperature is greater than the tabulated temperature, add charge in the system. 048 and 060 units: COOLING 1. Measure suction service port. the temperature 11 by attaching a gauge to the 1. Measure discharge service port. 2. Measure temperature the line pressure liquid sensing line by attaching temperature device to it. by a gauge to the attaching a 3.Insulate thetemperature sensing device sothattheoutdoor ambient doesn't affect thereading. 4.Refer totherequired subcooling inTables 3and 4tofindthe required subcooling based onthenrodel size andtheoutdoor ambient temperature. 5.Interpolate if theoutdoor temperature liesinbetween the table values. Extrapolate ifthetemperature liesbeyond the table range. 6.Findthepressure valuecorresponding tothemeasured pressure onthecompressor discharge line. 7.Read across fromthepressure reading toobtain theliquid linetemperature forarequired subcooling. 8.Addcharge if themeasured temperature ishigher thanthe liquidlinetemperature value inthetable. 9.Addcharge using theservice connection onthesuction line ofthecompressor. HEATING MODE CHARGE Donotattempt toadjust charge bycooling methods whileinheat pump heating mode. Recover refrigerant and weigh inaccording to unitdata plate refrigerant data. Step4--Indoor Airflowand Airflow Adjustments NOTE: For cooling operation, the recommended 450 cfm for each 12,000 Btuh of rated cooling Table 6 shows dry coil air delivery Tables 8-10 show pressure airflow is 350 to for horizontal discharge units. SWITCH Located on the outdoor liquid line is a low-pressure switch which functions as a loss-of-charge switch. This switch contains a Schrader core depressor. This switch opens at 7 psig and closes at 22 psig. No adjustment is necessary. COMPRESSOR OVERLOAD This overload interrupts power to the compressor when current internal temperature excessive, or automatically level. become resets when the internal temperature either the and drops to a safe This overload may require up to 60 minutes (or longer) to reset: therefore, if the internal overload is suspected of being open, disconnect the electrical power to the unit and check the circuit through the overload with an ohmmeter or continuity tester. COMPRESSOR ROTATION On 3-Phase units it is important to be certain compressor is rotating in the proper direction. To determine whether or not compressor is rotating in the proper direction: 1. Connect fittings. service 2. Energize gauges the compressor. 3. The suction pressure should capacity. drops. NOTE: Be sure that all supplyfrom obstructions, and adjusted LOSS OF CHARGE to suction and discharge pressure should drop and the discharge pressure rise, as is normal on any start-up. If the suction pressure does not drop and the discharge not rise to normal levels: pressure does 1. Turn off power to the unit and tag disconnect. and return-air properly. grilles are open. free 2. Reverse any two of the unit power leads. 3. Turn on power to the unit. The suction and discharge ELECTRICAL SHOCK HAZARD Failure to follow this warning or death. Disconnect before electrical changing blower blower FOR 208/230V injury start-up NOTE: When the compressor unit makes levels should an elevated is rotating by changing are BLOWER the lead connections factory wired for rated of the airflow are as follows: RATED AIRFLOW HIGH AIRFLOW Tap 1 Tap 3 030 Tap 2 Tap 4 036 Tap 1 Tap 3 042 Tap 2 Tap 4 RATED AIRFLOW FAN OPERATION The FAN switch on the thermostat controls When switch in the the (indoor-fan thermostat. FAN is placed fan operation. the IFR relay) is energized through the G terminal on the The normally-open contacts close, which then provide power to the indoor (evaporator) fan motor (IFM). The IFM will run continuously when the FAN switch is set to ON. HIGH AIRFLOW High Stage Low Stage High Stage 048 060 Tap 1 Tap 1 Tap 3 Tap 3 Tap 2 Tap 2 Tap 4 Tap 4 Controls have the following RELIEF internal-protection controls. VALVE This valve opens when the pressure differential high side becomes excessive. between the thermostat the low and deenergizes the IFR (provided there is not a call for cooling). The contacts open and the IFM is deenergized. The IFM will be energized only when there is a call for cooling, in heat pump heating mode or if the unit NOTE: Some units are equipped with a time-delay units, the indoor fan remains on for 30 seconds Low Stage HIGH-PRESSURE indoor ON position, is equipped with accessory electric heat, the indoor-fan also run while the accessory electric heat is energized. SIZE All compressors the cooling. MOTORS connections 024 Step 5--Unit direction, of Operation When the FAN switch is set to AUTO, SIZE in the wrong level of noise and does not provide speed. motors The motor lead speed now move to their levels. Step 6--Sequence power to the unit and install lockout tag Airflow can be changed blower motor. All PH3Z operation. could result in personal pressure normal motor will relay. On these after G or Y is deenergized. COOLING OPERATION (SIZES 024-042) With a call for cooling (Y/Y2), the indoor fan energizes immediately whereas the contactor energizes after a 5 minute time delay (in case of initial start-up) starting the compressor and the outdoor fan motor. When the cooling demand is met. Y/Y2 de-energizes, shutting the compressor, indoor fan and the outdoor fan. F E_D SUPPLY DNII ONIY MAXIMUM WIRE SIZE 2 A_G SCHEMATIC ..... po_,_ '_'_ ......................... ] D{ 2081230-3-60 @ D_ ............ <3_>'<_"1-_ / _:_>_<:_:_ ................................................ "'_J-_ oM ....................................... _'.......................... _'_ i _EL H \_'"_1 _ RED DEEROST BOARD {DB) R R Y 0 D P SWI1CH SE:1[(NGS c I EGEND I I M \ F3Et_SPNCZ UN]T COMPONENT OUTDOOR _AN o T_R_]_ ARRANGEMENT _Ut_ARKE_} P o SPLICE O SPLICE _R_E_ ....... _AcroRYWIR}NG ...... FIZLD CONTROL_]RING F]F:LDPO_F:R_IR_NG ACC}:SSORY OR OPT}ONAL _]RjRG CONTROLBOX AR_ CC_ CO_ ClO @_ I)FT DR FC_ G_D _R TO I_DICAI_ CO_ON POI[_IAL O_#Ly NOT _0 REPR[S(NIW!R[_G Z_ NPS O_M RVS IRAN F_:.......... CAPACITOR CR_ C_SE _AT_ COmPReSSOR_010_ CO_PR£SSORTIM[ DELAY DZ}BOS_BOAR_ O_}ROS__HERMOSTAT D_FROST_ELAT FAN CO_RO_ 50AR_ GROURD _[AHR RE[A? {NDOORFAN _OTOR LO_ FBZSS_RES_]TCF_ >HGN PRESSURES_ITCH OUTDOORFAN _010R REVERSINGVALVESOLENO]_ iRANS_OR_ER IfA_Y OF TREORIGINA__RZS FUBO_EDARE RZ_AC[_ _ _us_ _E REPLACZ__i_ _ypZ 90 DEGREEC _IRE OR /[OUlP A_ QV C CTD (TtT2] COMPRESSOR DELAY ............. CLOSES TSA_ I S S_PPLIED _ 24V SPLICE OP_S _36=1 5 _[iOCATTO_IOF SP[[_ 7_PS MAY a[ REaU[R_9 $ _F_R_IS_ CORRECtsp_EpTAP S_INS _Do NOT_[SCONNECTP_UGUN_[RLOaD- A06404 Fig. 12 - Typical Single-Phase Unit Electrical i0 Diagram (Sizes 024-042) L_/ SCHEMATIC 208/230+60 SUPP Y POW R UNIT ONLY MAN MUM W[R SIZE 2 AWG OM Y_L COMP SOLENOID BL /77 SEF NOTE #6 BUN TRAN! D I I)£FROST BOARD (DB) BIK BtK L_f][_D UNIT ¢OMPONEN} SFL]CE ARRANGEM[NI ¢I_CUI_ _EA_[R COt_ROL BOX AREA s_cr;o_ O_TDOORFA# [i!i!:!! ........ [_'<_"l-_ / _:_>_<°':_ ................................................ "_J-_ 2081230-3-60 oM ...................................... _'.......................... _'_ i _EL .................... _P_Y_ N EODIP BU ] ,_ I GND H \_'"_1 ) OT I ) ............... _RN ......... i_R _ilu_ I.................................................................................... RED DEPROST BOARD {DB) R R Y O D P SWIICH I EGEND UNIT COMPONENT / k F_EL_sPrEE C_ _[R_NAL _R_ED} o T_R_]_ _Ut_RKE_} ARRANGEF4ENT o SPLICE OUTDOOR _A_ I C C_P CONT_CTOR C_P_CIrO_ CC_ CR_ ClO @_ I)FT DR CO_PR£SSORT[_[ DELAY DZ}BOS_BOAR_ O_}ROS__HERMOSTAT D_ROST RELAY SE f(NGS I # C_SE _T_ CONTROLBOX _,R_ ....... _AcroRYWIR}NG ...... FIELD CONTROL_]RING FH:LD PO_F:RWIRING ACC}_SSORY OR OPT!ONAL G_D TO I_DICAI_ CO_ON _R POI[_IAL O_#Ly NOT _0 REPR_S_NIW!R[_G _ NPS O_ RVS ]RAN F_:.......... I I _[QUIP [] ..... ............................ l_"i"s_-o_cf"_ S S_PPLIED GROUND _[MER _[[A? {NDOOR _OTOR LO_ FBESSgRESW]TCF_ }_iO_PRESSURES_ITCH OUTDOORFA_ _010R REVERSINGVALVESOLENOI_ IRANS_OR_ER IfA_ OF THEORIGINA__RZS FUB_ED AR_ R[_AC[_ AR O_ ........... 3 USE 75_[GRKI COPPER COndUCTORSFORf[[l_ ;NSTAIIAT]ON G 6 C CTD (TtT2] COMPRESSOR DELAY L _SEc_, ,....... CLOSES TSA_ OP_S _36=1 _4V SPIICF _F_IS_ CORRECtSP_EPTAP S_IN_ A06325 Fig. 14 - Typical Three-Phase []nit Electrical 12 Diagram (Sizes 030-042) I)) SCHEMATIC 208/230-3-60 UN!T ONLY MAN]MUM WIRE S[Z[ 2 AW6 YEL EONIPGND FOR WIRING WITH ELECTRIC HEAT['3RG J _'==_ GE SCHEMATIC _T ON IIEATE_( ACCESSORy. J _ J J _ C I L'-'.mS[ J J i _ I I I j ) I _/i 1< I r-_ = =-T->F7i i D i • imJ ................... i i i (lJ............ _>J (..... i) ( ' ' ......... C>) _ ( [](m_ ( i) i) (ii............. C_ r - I L 1 6 ........... GRN............... R ........................ RED Y! ....................... TEL .................... 0 ORN W2 ....................... WNT .......... Y2 ................. PNN ........... ws C UNIT COMPONENT V]O ....... BR ARRANGEMENT p': C_ EE:::} (]_]2} COmpRESSOR D{LAY _+_E_ _SI_G rlELD I_S_LLED [L_C;R_C _[AT_S CONSGLr _S%ALLAIIO_ ]_STRSCT]ONS TO 2_v POW{R ENIRy 5 _E%ERM[N{ CORRECT SPIED TAP $_:I11NG "DO _OT a)SCON_ECT ?t_G U_gER _O_D " A06326 Fig. 15 - Typical Three-Phase Unit Electrical 13 Diagram (Sizes 048-060) CONTROL P I JC BOARD __ STEP 1 W_T v;o ............... TO ill i I_ RELAY1 I ii • _ BRN • 2 RELAY 1 1 _41 8RN AUTO LIMIT AUTO LINIT I | EL2 _J BLN_YEL • _ _ I i , _L ,O,OLt_IT 3 _BLK I I YEL-_ RELAY 4 -- BRN_] EL4 BLK AUTO LIMIT "_ YEL ! A05209 Fig. 16 - Single-Phase Accessory Electric TO Heater Wiring UNIT POWER WIRING PINK ? W3 VIOLET CB_ TO #N f CO_fROL WI_XNG I / 24VAC '1 _ I MR3 ] ] L1 L2 BLACK BLAC]_ L3 _It YELLOW Jt Et_ _,vvvvvv'_ EL3 AUTO-LINIT AUTO.LINIT BLUE BLAC N A06327 Fig. 17 - Three-Phase Accessory Electric 14 Heater Wiring Table NOMINAL VOLTAGE (V-Ph-Hz) UNIT SIZE VOLTAGE RANGE Min Max 5--Electrical COMPRESSOR RLA LRA Data-PH3Z OFM FLA IFM ELECTRIC FLA 4.1 3.6/5 7.5/lO 18.1/20.8 36.1/41.7 5.4/7.2 26/30 --/-- 208/230-1 - 60 024 187 253 lO.9 54.0 0.9 - 60 030 187 253 13.5 72.5 0.9 4.1 3- 60 030 187 253 9.0 63.0 0.9 4.1 - 60 036 187 253 17.5 88.0 1.5 6.0 3- 60 036 187 253 11.7 77.0 1.5 6.0 - 60 042 187 253 19.4 lO4.O 1.5 6.0 208/230- 3- 60 042 187 253 88.0 1.5 6.0 - 60 048 187 253 24.7 116.o 1.5 7.7 3- 60 048 187 253 14.7 91.o 1.5 7.7 - 60 060 187 253 28.0 118.o 3.0 7.7 54.3/59.3 16.3/16.3 60/60 20/20 See Legend 3- 60 on following 060 187 253 21.5 123.o 3.0 page. 15 7.7 --/-- --/-- 3.6/5 10.4/12 29.3/31.3 35/35 7.5/1o 7.5/lO 20.8/24.1 20.8/24.1 42.3/46.3 42.3/46.3 45/45 45/45 29.4/29.4 52.0/55.4 35/35 60/60 --/-- 3.6/5 18.1/20.8 7.5/1o 36.1/41.7 74.5/61.5 80/60 11.3/15 5.4/7.2 54.2/62.5 26/30 97.1/107.5 61.9/66.9 100/100 70/70 3.6/5 10.4/12 22.1/22.1 35.1/37.1 30/30 40/45 7.5/lO 7.5/1o 20.8/24.1 20.8/24.1 48.2/52.2 48.2/52.2 50/50 50/50 11.3/15 15/2o 31.3/36.1 41.7/48.1 61.2/67.2 74.2/82.2 60/60 70/90 --/-- 31.7/31.7 40/40 3.6/5 7.5/lO 18.1/20.8 36.1/41.7 54.3/57.8 76.9/83.8 60/70 80/90 11.3/15 15/2o 54.2/62.5 72.2/83.3 99.4/109.9 122.0/135.9 100/110 110/150 5.4/7.2 26/30 64.2/69.2 22.9/22.9 70/80 30/30 --/-- --/-- 3.6/5 7.5/1o 10.4/12 20.8/24.1 35.9/37.9 48.9/53.0 45/45 50/50 7.5/1o 20.8/24.1 48.9/53.0 50/50 11.3/15 15/2o 31.3/36.1 41.7/48.1 62.0/68.0 75.0/83.0 60/70 70/80 3.6/5 18.1/20.8 40.0/40.0 62.6/66.1 50/50 80/80 7.5/1o 11.3/15 36.1/41.7 54.2/62.5 85.1/92.1 107.7/118.1 100/100 110/125 15/2o 5.4/7.2 72.2/83.3 26/30 130.3/144.2 72.5/77.5 125/125 90/90 --/-- 27.6/27.6 35/35 3.6/5 7.5/1o 10.4/12 20.8/24.1 40.6/42.6 53.7/57.7 50/50 60/60 7.5/1o 11.3/15 20.8/24.1 31.3/36.1 53.7/57.7 66.7/72.7 60/60 70/70 15/2o 41.7/48.1 79.7/87.7 45.7/45.7 80/90 60/60 --/-- --/-- 3.6/5 7.5/1o 18.1/20.8 36.1/41.7 68.2/71.7 90.8/97.8 90/90 100/110 11.3/15 54.2/62.5 113.4/123.8 125/125 45/45 60/70 3.6/5 10.4/12 37.6/37.6 50.6/52.6 11.3/15 11.3/15 31.3/36.1 31.3/36.1 76.7/82.7 76.7/82.7 90/90 90/90 15/2o 41.7/48.1 89.7/97.7 100/100 --/-- 208/230- 30/30 50/50 26/30 --/-- 208/230-1 50/50 5.4/7.2 --/-- 208/230- 51.1/56.1 70/70 90/100 --/-- 208/230-1 45/50 60/70 67.0/73.9 69.5/100.0 --/-- 12.3 25/25 41.2/44.7 63.8/70.7 36.1/41.7 54.2/62.5 --/-- 208/230-1 18.6/16.6 7.5/lO 11.3/15 --/-- 208/230- MOCP 18.1/20.8 --/-- 208/230-1 -/- MCA 3.6/5 --/-- 208/230- FLA POWER SUPPLY 21.6/21.8 44.4/47.9 --/-- 208/230-1 HEAT Nominal kW --/-- EXAMPLE: FLA LRA MOA MOCP RLA Full Load Amps Locked LEGEND Rotor An/ps Minimum Circuit An/ps Maxin/un/ Overcurrent Rated Load An/ps -- Supply voltage is 230-3-60. AB = 228 v AO = 227 v C US @ Average Voltage = 228 + 231 + 227 3 BG = 231 v = 68___£6 3 229 Protection NOTES: Determine n/aximun/ (AB) 229 - 228 (BO) 231 - 229 (AO) 229 - 227 Maxin/un/ deviation 1. In compliance with NEO (National Electrical Code) requirements for multht/otor and combination load equipment (refer to NEC Articles 430 and 440), the overcurrent protective device for the unit shall be Power Supply fuse. The CGA (Canadian Gas Association) units may be fuse or circuit breakel: 2. Minimum wire size is based on 60°0 copper wire. If other than 60°0 wire is used, or if length exceeds wire length in table, determine size from NEC. 3. Unbalanced 3-Phase Supply Voltage Never oper>_te a motor wher_ a phase irnbaF_nce in supply voltage is greater than 2%. Use the following formula to determine the percentage of voltage imbalance. % Voltage 100 Determine max voltage deviation average from average voltage percent of voltage imbalance. 2 100 x -229 0.6% This amount of phase imbalance maxin/un/ allowable 2%. Heater capacity (kW) based If power distribution voltage voltage, heater kW will vary on heater voltage to unit varies from accordingly. is satisfactory as it is below the voltage voltage more than IMPORTANT: in/mediately. . voltage. % Voltage Imbalance imbalance x deviation from average 1v 2 v 2 v is 2 v. 2%, If contact your the supply local phase electdo imbalance utility is company of 208v & 240v. rated heater 008014 Fig. 18 - Electrical Table 230 VOLT UNIT SIZE HORIZONTAL SPEED TAP 1 024 2 2 030 3 1 036 2 3 042 4 1 2 048 3 4 1 2 060 3 4 6--Dlw Coil (Deduct 10 percent Air Data Table Delivery" for Legend Horizontal 208 Volt Discharge Operation) DISCHARGE AIR DELIVERY 0,1 0.2 0.3 Watts 99 1O0 CFM 848 793 EXTERNAL 0,4 STATIC 0,5 PRESSURE 0.6 118 130 142 757 698 632 (IN.WG) 0,7 0,8 0.9 1,0 Watts 222 233 244 257 260 CFM 970 918 861 795 729 Watts 155 146 157 170 CFM 1108 995 951 884 Watts 261 275 286 291 315 CFM 1117 1053 1014 980 877 Watts 180 166 179 191 204 216 CFM 1344 1215 1172 1051 1136 1095 Watts 261 276 290 301 316 329 342 CFM 1343 1304 1272 1234 1190 1148 1100 Watts 269 283 305 321 336 349 360 CFM 1440 1404 1369 1333 1301 1273 1239 Watts 418 432 450 465 480 490 503 518 CFM 1572 1543 1504 1475 1441 1418 1380 1332 Watts 204 209 216 229 236 249 CFM 1129 1087 1027 994 932 881 Watts 233 245 254 266 276 289 CFM 1164 1122 1066 1025 954 906 Watts 386 398 409 418 425 435 438 441 451 CFM 1680 1652 1625 1583 1555 1515 1477 1444 1403 Watts 440 448 457 462 469 477 480 485 486 CFM 1745 1717 1684 1651 1612 1573 1537 1508 1470 Watts 224 235 251 266 277 291 298 CFM 1334 1288 1259 1224 1181 1157 1117 Watts 286 301 311 325 333 344 370 CFM 1333 1296 1261 1232 1199 1170 1062 Watts 608 626 643 660 668 685 697 CFM 1931 1900 1878 1844 1817 1789 1755 Watts 737 755 770 787 799 817 826 812 782 CFM 2093 2061 2028 2001 1971 1934 1899 1850 1757 *Air delivery values are based on operating voltage of 230v, wet coit, without filter or electric heater. Deduct filter and electric heater pressure drops to obtain static pressure available for ducting. NOTES: 1. Do not operate the unit at a cooling airflow that is less than 350 cfm for each 12,000 Btuh of rated cooling capacity. Evaporator flows below this point. 2. Dashes indicate portions of table that are beyond the blower motor capacity or are not recommended. ld coil frosting may occur at air- Table 7--Cooling Charging Chart SUCTION LINE TEMPERATURE (°F) Suction Line Pressure (PSIG) ODTemp. 52 54 56 59 61 64 67 55 60 64 69 53 57 62 66 70 53 57 62 70 73 76 66 71 75 56 61 53 79 82 66 71 76 58 63 67 72 50 54 58 62 66 105 50 53 57 60 64 115 49 52 55 58 61 50 53 56 59 544 566 589 612 636 (°F) 45 55 51 65 75 85 95 125 SUCTION LINE TEMPERATURE Suction OD Temp. (°C) 361 370 7 11 13 13 18 387 405 423 15 18 21 12 14 16 12 442 462 482 502 523 19 14 21 17 19 21 24 13 16 19 22 24 12 14 17 20 22 10 12 10 14 12 17 14 19 16 18 9 11 13 14 16 10 11 13 15 35 41 46 52 (SIZES 048 AND 060) These units utilize a 2 stage indoor thermostat. switching the compressor and the indoor fan into low stage heating. When the low stage heating demand is met, Y1 de-energizes shutting down the compressor, indoor fan and the outdoor fan. With a first stage call for cooling (Y1), the indoor fan (low stage) energizes immediately whereas the contactor energizes after a 5 minute time delay (in case CONTINUOUS FAN of an initial start-up) starting the compressor (low stage) and the outdoor fan motor. If the low stage operation cannot satisfy the With the continuous Indoor G is continuously energized. cooling demand, the compressor airflow setting is provided. the second stage cooling (Y2) energizes switching into high stage cooling through energizing an OPERATION (SIZES on the thermostat. units, the selected In case of 048 and 060 units, the system fan operation. DEFROST Y2 de-energizes switching the compressor and the indoor low stage cooling. When the low stage cooling demand is de-energizes shutting the compressor, indoor fan and the fan. HEATING fan option selected In case of 024-042 runs low stage (Y1) airflow for continuous internal solenoid valve inside the scroll compressor and switching the indoor fan into high stage. When second stage cooling is satisfied, fan into met, Y1 outdoor 92 (°C) 29 OPERATION 89 Line Pressure (kPa) 24 COOLING 85 Defrost board (DB) is a time and temperature control, which includes a field-selectable time period between checks for defrost (30, 60, 90 and 120 minutes). The time period is factory-set at 60 minutes and should only be adjusted by a trained service person. Electronic 024-042) energized With a call for heating (Y1), the indoor fan (low stage) energizes immediately whereas the contactor energizes after a 5 minute time Defrost timer and defrost and defrost cycle thermostat mode is identical start only (DFT) to Cooling when contactor is is closed. mode. The outdoor fan motor delay (in case of initial start-up) starting the compressor and the outdoor fan motor. If Y/Y2 cannot satisfy the heating demand, the stops because of "OF1" and "OF2" contacts opening on the defrost board, a bank of optional electric heat turns on to warm air supplying auxiliary or backup heat (W2) energizes. In case of staged heating, W3 is energized if the demand is not met. The highest airflow selected is run while the electric heat is in operation. When heating the conditioned demand shutting is met. W3. W2 and Y/Y2 sequentially the compressor, indoor fan and the outdoor HEATING OPERATION (SIZES ELECTRIC and in turn energizes the electric heaters. The IFR is energized which starts the indoor-fan motor. If the heaters are staged, W2 is energized when the second stage of heating is required. When the 048 AND 060) need for heating minute time delay (in case of initial start-up) starting the compressor (low stage) and the outdoor fan motor. If the low stage operation W2 and Y2 sequentially the heater and IFM are de-energized. To ensure continuing high performance, and to minimize the possibility of premature equipment failure, periodic maintenance must be performed on this equipment. This cooling unit should be inspected at least once each year by a qualified service person. To troubleshoot unit, refer to Troubleshooting Chart in back of book. backup heat is controlled by a third stage (W2). If the demand is not met, W3 is energized in case of staged heating. When heating W3, is satisfied, MAINTENANCE cannot satisfy the heating demand, the second stage heating (Y2) energizes switching the compressor into high stage heating through energizing an internal solenoid valve inside the scroll compressor and switching the indoor fan into high stage. The auxiliary or is satisfied, HEATING If accessory electric heaters are installed, on a call for "Emergency Heat" the thermostat energizes W which energizes the heater relay de-energize fan. With a first stage call for heating (Y1), the indoor fan (low stage) energizes immediately whereas the contactor energizes after a 5 demand space. RESISTANCE NOTE TO EQUIPMENT OWNER: about the availability of a maintenance de-energize 17 Consult contract. your local dealer PERSONAL INJURY ANDUNITDAMAGE The minimum follows: maintenance 1. Inspect air filter(s) necessary. 2. Remove screws on unit top cover flange. (Save all screws.) plenum) requirements for this equipment are as accumulated annually. each Clean when or replace indoor coil, drain pan, and condensate cooling season for cleanliness. are completed. Blower electrical proper drain each dirt and grease ELECTRICAL connections operation each for tightness cooling SHOCK and controls ELECTRICAL SHOCK Failure to follow injury or death: season. Service when in contact with 1. Remove refrigerant 2. Use extreme these HAZARD the blower could result in personal HAZARD warnings could result in personal caution when removing combustible Never operate panels any and parts. 2. Remove the filter becomes the unit without removing When performing a suitable installed. air filter See Table the blower wheel from the housing: d. Remove the filler panel at the discharge end of the blower housing by removing the two screws that fasten it to the housing. e. Remove (Outdoor-Coil maintenance that require 3. Remove Side) or service procedures top removal, and condensate the wheel the caked form the housing. on dirt from the wheel 4. Remove that including coil drain pan inspection and lint and dirt accumulations housing with attachment. all of the routine 5. Remove grease 6. Reassemble a vacuunr cleaner, c. Reinsert tag power personnel that require Refer to the fnllowing should to the unit injury the motor the mounting locations. before d. Tighten perform maintenance and unit top removal. top removal and brush and oil with a mild solvent. procedures: 18 assembly legs the mounting with the housing. service procedures could result in personal electrical a soft with the hub set screw b. Install the filler panel. HAZARD Failure to fnllow this warning or death. from the wheel using as follows: a. Slip the wheel back in the housing parented in the correct direction. SHOCK and the motor using a brush. cleaning. Disconnect and removing top. by hand bracket. c. Slide out the motor assembly (motor. belly band and the 3 mounting legs) from the hub of the wheel. 1 for with dust and lint. of the unit top, be sure to perform ELECTRICAL is supported the mounting b. Loosen the three mounting legs of the motor by removing the bolts that fasten themounting legs to the housing. replace the filter with the same clogged Top Removal procedures completely a. Loosen the set screw which secures the wheel to the motor Inspect air filter(s) at least once each month and replace (throwaway-type) or clean (cleanable-type) at least twice during each cooling season and twice during the heating season, or and cleaning, the mounting d. Slide the blower housing from the rails of the duct panel and place it outside the unit. either on or in contact dimensional size and type as originally recommended filter sizes. removal the side access panel and unscrew shaft. in the return- air duct system. Always Step 2--Unit housing: c. Make sure that the blower housing Filter IMPORTANT: service injury bracket that fastens the blower housing to the internal partition panel fo the control box assembly. before 3. Never place anything with the unit. Only qualified clean and motor a. Remove the screws on the external side of the duct panel that fasten the housing to the duct panel assembly. 1. Turn off electrical power to the unit before performing maintenance or service on this unit. inspection efficiency, wheel Disconnect and tag electrical power to the unit before cleaning and lubricating the blower motor and wheel. for b. Remove maintenance the blower To clean the blower wheel: 5. Ensure electric wires are not tubing or sharp metal edges. require and continuing from Failure to follow this warning or death. each cooling necessary. NOTE: and Motor For longer life, operating economy, (;lean when necessary. 4. Check whenever duct (or (;lean when necessary. 3. Inspect blower motor and wheel for cleanliness Step 1--Air by unit side that is opposite side. procedures Step 3--Indoor month. Set top on edge and make sure 4. Carefully replace and secure unit top to unit, using screws removed in 1 and 2 above, when maintenance and/or service on this equipment, other than those in the Owner's Manual. 2. Inspect season. (Save all screws.) that top is supported injury The ability to properly perform maintenance on this equipment requires certain expertise, mechanical skills, tools and equipment. If you do not possess these, do not attempt to perform any maintenance procedures recommended screws on unit top cover surface. 3. Lift top from unit carefully. HAZARD Failure to follow this warning could result in personal or death and possible unit component damage. i. Remove with in the wheel the housing hub and align mounting hold bolts to fasten the motor assembly Table UNIT SIZE 6O0 700 800 900 1000 024 .027 .034 040 .047 .053 .036 8--Wet Coil Pressure Drop STANDARD CFM (S.C.F.M.) 030 1100 1200 1300 1400 1500 1600 1700 1800 1900 .042 .050 .055 .063 .072 .081 036 - .050 .055 .063 .072 .081 .090 .097 042 - .042 .049 .052 .059 .065 .071 .078 .085 .091 048 - .072 .081 .090 .097 .108 .120 .129 .139 060 - .071 .078 .085 .091 .098 Table UNIT SIZE 9--Filter Pressure Drop FILTER SIZE 024-036 (in.) 24x24 042-060 30x30 2000 .114 (in. wg) CFM 500 0.06 600 0.07 700 0.08 800 0.08 900 0.09 1000 1100 1200 1300 1400 0.09 0.09 0.10 0.11 0.12 0.08 Table 10---Accessory Electric Heat 1500 1600 1700 1800 1900 2000 2100 2200 2300 0.14 0.15 0.09 0.10 0.11 Pressure Drop (in. 0.12 0.13 0.14 0.15 0.16 0.17 0.18 wg) CFM HEATER kW 5-20 600 800 1000 1200 1400 1600 1800 2000 2200 0.06 0.08 0.10 0.13 0.15 0.18 0.20 0.23 0.25 e. (;enter the wheel in the housing by sliding it, align the flat end of the shaft with the set screw and tighten the set screw. i. Shut off unit power 2. Remove supply outdoor-fan and fan) by removing unit top cover. f. Slide back the blower housing into the mounting rails in the duct panel and install the mounting bracket back in its and install lockout assembly screws 3. Loosen fan hub setscrews. 4. Adjust fan height (grille, motor, and flipping tag. motor cover, assembly onto position. as shown g. Install the screws on the external side of the duct panel to fasten duct panel with the housing. 5. Tighten setscrews. h. Replace 6. Replace outdoor-fan Step 4--Outdoor Pan Inspect the side access panel. Coil, Indoor the condenser Coil, and Condensate coil. evaporator coil in Fig. 19. assembly. Drain and condensate drain pan at least once each year. The coils are easily cleaned when dry; therefore, inspect and clean 12mm the coils either before or after each cooling season. Remove all obstructions, including weeds and shrubs, that interfere with the airflow through the condenser Straighten A06411 coil. Fig. 19 - Outdoor Fan Adjustment bent fins with a fin comb. If coated with dirt or lint, clean Step 6--Electrical the coils with a vacuum cleaner, using the soft brush attachment. Be careful not to bend the fins. If coated with oil or grease, clean the coils with a mild detergent and water solution. Rinse coils with clear Inspect Remove insulation, wiring, or air filter(s). For best results, spray condenser coil fins from inside to outside the unit. On units with an outer and controls power and wiring annually. Be to the unit. access panel to locate all the electrical controls and wiring. Check all electrical connections for tightness. Tighten all screw connections. If any smoky or burned connections are noticed, disassemble the connection, clean all the parts, re-strip the wire end the coils. Be sure to and reassemble Inspect the drain pan and condensate drain line when inspecting coils. Clean the drain pan and condensate drain by removing and Wiring and check the electrical sure to turn off the electrical water, using a garden hose. Be careful not to splash water on motors, inner condenser coil, be sure to clean between flush all dirt and debris from the unit base. Controls the all the connection properly and securely. Check to ensure no wires are touching refrigerant tubing or sharp sheet metal edges. Move and secure wires to isolate from tubing and foreign matter from the pan. Flush the pan and drain trough with clear water. Do not splash water on the insulation, motor, wiring, or sheet metal edges. air filter(s). If the drain trough is restricted, snake" or similar probe device. After inspecting the electrical controls and wiring, replace all the panels. Start the unit, and observe at least one complete cooling Step 5--Outdoor clear it with a "plumbers cycle to ensure proper operation. operating cycle, or if a suspected Fan each electrical instrumentation. checks. UNIT OPERATION Failure to follow components. HAZARD this caution may result in damage to unit component with Refer to the unit wiring Step 7--Refrigerant Circuit Inspect tubing all refrigerant accumulation annually. refrigerant leak. Keep the condenser fan free from all obstructions to ensure proper cooling operation. Never place articles on top of unit. If discrepancies are observed in malfunction has occurred, check connections Detecting oil the proper electrical label when making these and the unit base for oil generally indicates a If oil is detected or if low performance is suspected, leak test all refrigerant tubing using an electronic leak detector, or liquid-soap 19 solution. If a refrigerant leakis detected, referto Check for Refrigerant Leaks section. Ifnorefrigerant leaks arefound andlowperformance issuspected, refer toChecking andAdjusting Refrigerant Charge section. Step8--Indoor Airflow Theheating and/or cooling airflow does notrequire checking unless improper performance issuspected. If aproblem exists, besure that all supply-andreturn-air grillesareopenandfreefrom obstructions, andthattheairfilterisclean. Step 9--Metering Devices Refrigerant cooling metering device is an AccuRater (024-042) or TXV (048 and 060) located upstream of the indoor coil distributor assembly. Refrigerant heating mode metering device is an AccuRater located upstrem of the outdoor coil distributor Step lO--Liquid Line Strainers The liquid line strainers (to protect metering devices) are made of wire mesh and are located in the liquid lines on the inlet side of the metering devices. Step ll--High Flow Valves High flow valves are located on the compressor tubes. Large black plastic caps distinguish hot gas and suction these valves with O - rings located inside the caps. These valves can not be accessed for service in the field. Ensure the plastic caps are in place and tight or the possibility of refrigerant leakage could occur. TROUBLESHOOTING Refer to the Troubleshooting information. (;hart (Table 11) for troubleshooting assembly. START-UP Use the Start-Up 2O Checklist CHECKLIST at the back of this manual. OUTDOOR COIL A Check Valves Open B Ck)sed C Open D Ck)sed _ -- INDOOR COIL _ h LEGEND LCS Loss of Charge Switch ] Acutrol r_ Check Valve (Arrow Metering Device indicates direction of fk)w) HEATING 1. Hot gas from compressor flows through the 4-way valve and is directed to the cooling liquid line check valve. It is then condensed and directed through subcooling circuits and out to the strainer and the check valve in the heating liquid line. 2. The refrigerant then feeds the outdoor coil through the Acutrol metering device on each circuit. CYCLE 3. Each circuit evaporates the refrigerant and the circuits are combined in the outdoor header with some of the circuits flowing through the check valve. 4. The refrigerant then flows through the 4-way valve, accumulator, and back to the compressor. C95045 Fig. 20 - Typical Heat Pump Operation, Heating Mode OUTDOOR COIL Check Valves A Closed B Open C Ck)sed D Open LEGEND LCS Loss of Charge ] Acutrol Switch ] Check Valve (Arrow Metering Device indicates direction of flow) COOLING 1. Hot gas from compressor flows through the 4-way valve and is directed to the heating liquid line check valve. It is then condensed and subcooled th rough converging circuits. Refrigerant leaves the outdoor coil by way of the strainer and the check valve in the cooling liquid line. 2. The refrigerant then feeds the indoor coil through the Acutrol metering device on each circuit. CYCLE 3. Each circuit evaporates the refrigerant and the circuits are combined in the indoor coil header with some of the circuits flowing through the check valve. 4. The refrigerant then flows through the 4-way valve, accumulator, and back to the compressor. C95044 Fig. 21 - Typical Heat Pump Operation, 21 Cooling Mode Table ll--Troubleshooting SYMPTOM Compressor and outdoor will not start Compressor will not start fan but Chart CAUSE condenser fan runs REMEDY Power failure Call power company Fuse blown or circuit breaker tripped Replace fuse or reset circuit breaker Defective contactor, transformer, control relay, or high-pressure, lossof-charge or low-pressure switch Replace component Insufficient line voltage Determine Incorrect or faulty wiring Check wiring diagram and rewire correctly User Interface setting too low/too high Reset UI setting Faulty wiring or circuit Loose connections in compressor Check wiring end repair or replace Compressor Determine motor burned out, seized, or scroll compressor 060 unit) has a low pressure Replace compressor Defective run capacitor, overload, or PTC (positive temperature coefficient) thermistor Determine One leg of 3-phase Replace fuse or reset circuit breaker Determine cause power dead is rotating in the wrong direction or undercharge head Determine cause end correct Blocked outdoor coil Determine cause end correct Defective run/start capacitor, overload or start relay Determine cause end replace Faulty outdoor fan motor or capacitor Replace Restriction in refrigerant Locate restriction and remove system Replace filter for load Decrease set too low Locate leak, repair, end recharge Air in system Recover refrigerant, charge Outdoor coil dirty or restricted Clean coil or remove restriction Dirty air filter Replace filter Dirty indoor or outdoor coil Clean coil Refrigerant overcharged Recover excess refrigerant Air in system Recover refrigerant, charge Excessive Suction tOO low suction pressure evacuate system, and re- pressure or air short-cycling Low refrigerant charge pressure load or increase unit size Reset UI setting Low refrigerant charge Indoor or outdoor air restricted Head evacuate system, and reshown on rating plate Replace and determine cause UI temperature Excessive power leads to the unit Recover refrigerant, charge to capacities Insufficient line voltage Unit undersized operates continuously 3-phase Defective compressor Dirty air filter Compressor cause end correct Correct the direction of rotation by reversing the Scroll compressor Refrigerant overcharge Compressor cycles (other than normally satisfying) cooling/heating calls cause end replace Determine (size 030- differential cause internal overload open Low input voltage (20 percent low) Three=phase cause end correct pressure too low Determine evacuate system, and re- cause end correct Restriction in liquid tube High Heat load Check for leaks, repair and recharge Remove restriction Check for source end eliminate Reversing valve hung up or leaking internally Replace valve Refrigerant overcharged Dirty air filter Recover excess refrigerant Replace filter Low refrigerant charge Metering device or low side restricted Insufficient coil airflow Check for leaks, repair and recharge Remove source of restriction Temperature too low in conditioned Outdoor ambient below 55°F Reset UI setting Install low-ambient Filter drier restricted area Check filtemreplace Replace 22 if necessary kit START-UP (REMOVE CHECKLIST AND STORE IN JOB FILE) I. PRELIMINARY INFORMATION Model No ............................................................................................................................................................ Serial No ............................................................................................................................................................. Date ..................................................................................................................................................................... Technician .......................................................................................................................................................... Customer Information(Name/Address) ..................................................................................................................... II. PRE-START-UP __ Verify that all packing __ __ __ Verify that condensate connection is installed per installation instructions. Check all electrical connections and terminals for tightness. Check wire proximity to refrigerant tubes and sheet metal edges. __ __ Check that indoor (indoor) Verify that unit installation air filter is clean and in place. is level. __ Check for location fan wheel materials propeller have been removed in housing from unit. and setscrew tightness. III. START-UP Supply Voltage: L1-L2 Compressor Amps: LI(C) Indoor Fan Amps: L2-L3 L2(S) Outdoor Fan Amps: TEMPERATURE-Cooling Outdoor Air Temperature: Return-Air Temperature: Cooling Supply Mode DB DB Air: Mode psig Suction Line Temp* Refrigerant Discharge Discharge psig Tempt TEMPERATURE-Heating Mode DB Outdoor Air Temperature: Return-Air Temperature: Cooling Supply WB WB DB Mode Refrigerant Suction Suction Line Temp* psig Refrigerant Discharge Discharge Tempt Verify Refrigerant WB DB Air: PRESSURES-Heating __ WB WB WB DB PRESSURES - Cooling Refrigerant Suction L3-L1 L3(R) psig charge using charging *Measured at suction tMeasured at liquid line leaving tables inlet to compressor outdoor coil 23 g !_ 2006 Payne Heating & Cooling Manufacturer reserves Systems • 7310 W. Morris St. * Indianapolis, the right to change_ at any time_ specifications IN 46231 and design without Printed in the U.S.A. notice and without 24 Edition obligation. Date: 08/06 Catalo_l No: IM-PH3Z-02 Replaces: IM- PH3Z-0t
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