ICP PHM324K00A1 User manual

Installation Instructions
PHM3 SERIES
PACKAGE HEAT PUMPS
TABLEOFCONTENTS
SAFETYLABELINGANDSIGNALWORDS ....................... 2
UNITDIMENSIONS ......................................... 3
SAFEINSTALLATIONREQUIREMENTS ......................... 3
LOCATINGTHE UNIT ....................................... 3
CLEARANCES ............................................ 4
INSTALLATION............................................ 4
INSTALLINGDUCTCOLLARS................................. 4
CONDENSATEDRAIN....................................... 5
UNITELECTRICALWIRING .................................. 5
LINEVOLTAGE............................................ 5
CONVERTING230VTO208V ................................. 6
LOWVOLTAGEWIRING ..................................... 6
THERMOSTATCONNECTIONS................................ 6
FINALELECTRICALCHECK.................................. 6
CONTROLBOXCONFIGURATIONANDWIRING ................... 7
WIRINGDIAGRAMS ........................................ 8
RAINSHIELDINSTALLATION................................ 10
AIR DISTRIBUTIONSYSTEM................................. 10
DUCTWORK............................................. 10
FILTERS................................................ 10
UNITELECTRICALWIRING ................................. 10
START-UPPROCEDURES.................................. 1!
SPEEDTAPS ............................................ 1!
CHECKBEFORESTARTING................................. 1!
DEFROSTINTERVAL ...................................... 12
SEQUENCEOFOPERATION................................. 13
OPERATION............................................. 14
LISTED
Printed in U.S.A. 11/8/05 427 O1 1101 OO

1. Safety Labelinq and Siqnal Words
Danger, Warning and Caution
The signal words DANGER, WARNING and CAUTION are
used to identify levels of hazard seriousness. The signal
word DANGER is only used on product labels to signify an
immediate hazard. The signal words WARNING and
CAUTION will be used on product labels and throughout
this manual and other manuals that may apply to the
product.
Danger Label
White lettering on a black background except the word
DANGER which is white with a red background.
Signal Words
DANGER - Immediate hazards which WILL result in
severe personal injury or death.
WARNING - Hazards or unsafe practices which COULD
result in severe personal injury or death.
CAUTION - Hazards or unsafe practices which MAY result
in minor personal injury or product or property damage,
Warning Label
White lettering on a black background except the word
WARNING which is black with an orange background,
Signal Words in Manuals
The signal word WARNING is used throughout this manual
in the following manner:
The signal word CAUTION is used throughout this manual
in the following manner:
Product Labeling
Signal words are used in combination with colors and/or
pictures on product labels. Following are examples of
product labels with explanations of the colors used,
Caution Label
White lettering on a black background except the word
CAUTION which is black with a yellow background,
2 427 01 1101 00

2. Dimensions
DIMENSIONS Unit
PHM324 /30
PHM336 to 54
ADim.
32-3/8 (821)
40-3/8 (1025)
IIIIII I Iil I I
RlllllllilII
RIIIIIIIilII
BIIIIIIIilII
_IIIIIII'III
RIIIIIIIIII
RIIIIIII,III
_lllllllilII
_lllllllilII
lllllllllilII
,.,,,,,,.,, _.
PRESSURE!
PORTS L_
COIL
ACCESS
PANEL
CONNECTION
3O"
(763)
51"
(1295)
7/8"LowVoltageWiring
/(22)
Alldimensionsin inches(mm)
ROUNDFLANGEWILL
ACCOMMODATE14"DIA.
RETURNDUCT
(301) (232)
41-1/8"
(lO45)
1-3/8"
(36)
36-1/3" 1-1/4"
(923)
1-1/4"
(33)*
(35)*
*ELECTRICALACCESSFORUNEVOLTAGEPOWERSUPPLY-ONEFORUNIT,ONEFORHEATER
3. Safe Installation Requirements
FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD
Installation or repairs made by unqualified persons can
result in hazards to you and others. Installation MUST
conform with local building codes or, in the absence of
local codes, with the ANSI Z223.1 and the National Elec-
trical Code NFPA70-current edition or in Canada the
National Standard CAN/CGA B149-1 and CSA C.22.1 -
Canadian Electrical Code Part 1.
Failure to carefully read and follow all instructions in
this manual could result in furnace malfunction, prop-
erty damage, personal injury and/or death.
The information contained in this manual is intended
for use by a qualified service technician familiar with
safety procedures and equipped with the proper tools
and test instruments.
• Seal supply and return air ducts.
42701 1101 oo
• Check to see that filters are installed correctly and are the
proper type and size.
NOTE: It is the personal responsibility and obligation of the
customer to contact a qualified installer to ensure that the
installation is adequate and conforms to governing codes and
REDUCED UNIT LIFE HAZARD
Failure to follow this caution may result in
property damage
Do NOT operate unit in a corrosive atmosphere con-
taining chlorine, fluorine, or any other corrosive
chemicals.
4. Locating The Unit
The unit is designed for outdoor installation only. Place the unit on
a platform at ground level. The unit may be installed on a concrete
slab of 48" (1219mm) x 48" (1219mm) dimensions. Concrete
blocks on a 3" sand footing will also work. The slab or blocks
3
ordinances.

SHOULD NOT be in contact with any part of the structure. Check Installation
local codes covering zoning, noise, platforms, etc..
Avoid locating next to fresh air intakes, vent or bedroom windows.
Noise may carry into the openings and disturb people inside.
Avoid installations under roof overhangs without guttering. Water
draining from the roof onto the unit could produce excessive
noise, and may cause ice to build up on coil or fan.
Placement of the unit should be in a well drained area or the unit
MUST be supported high enough so runoff will not enter the unit.
Do not locate unit where heat, lint or exhaust fumes wil! be
discharged on unit (as from dryer vents.)
Clearances
Minimum clearances, as specified in FIGURE 1, MUST be
maintained from adjacent structures to provide adequate air
circulation and room for service personnel.
While minimum clearances are acceptable for safety reasons,
they may not allow adequate air circulation around the unit for
proper operation. Whenever possible, it is desirable to allow
additional clearance, especially around the condenser inlet and
discharge openings.
Do NOT install the unit in a recessed or confined area that will
permit discharged air from the condenser to recirculate to the
condenser inlet.
Minimum Clearances to Combustible Construction
SERVICE ACCESS CLEARANCES
Blower Access Panel Side .................... 30" (762mm)
Evaporator/Electrical Access Panel Side ....... 30" (762mm)
OPERATIONAL CLEARANCES
Combustible Base
(Wood or Class A, B or C
roof covering material) ..................... 0"
Supply and Return Air Ducts ............................ 0"
Duct Connection Side
........................................ 0 sl
Clearance between Overhang
and Top of Unit ................ 48" (1219mm)
Clearance around Condenser Coil area to wall or shrubs . 10"
FIGURE i Minimum Clearances and Access Panels
Overhang
Evaporator 48" MinimumOverhangClearance
AccessPanel
10" around
fcondenser
coilarea
BlowedElectrical
AccessPanel
CoverPlate
NOTE:
The unit must be installed with a slope no greater than 1/8"
per foot (10mm per meter). For side to side leveling, the
condensate drain side side MUST always be lower.
The unit MUST be situated in such a way as to provide safe
access for servicing.
The platform may be made of either concrete or pressure
treated wood and MUST be level and strong enough to
support the unit's weight.
Position platform separate from the building's foundation.
install in a well-drained area, with the top surface of the
platform above grade level and above the average winter
snow levels to prevent coil blockage.
Platform MUST be high enough to allow for proper
condensate drainage.
Installing Duct Collars
Duct collars are supplied with the unit but are not factory installed.
The collars are shipped under the blower motor. See Figure 2.
1.Remove the collars from under the blower motor.
2.Position flange holes with existing screw holes on side
wrapper.
3.Install screw in each collar so it goes through both of the
holes in the collar and wrapper.
FIGURE2I Duct Collar Installation
Control Box
Collars
Installed Indoor Fan Assy.
Collars Shipped with Unit
4 427 01 1101 00

Condensate Drain
The condensate drain outlet is a 3/4" (19.1 mm) threaded female
PVC connection located at the bottom of the unit to the left of the
evaporator access panel.
The circulating blower and the condenser fan create a negative
pressure on the condensate drain line that wil! prevent the
condensate from draining properly without a trap. To combat this
negative pressure, a field supplied condensate trap that will allow
a standing column of water of at least 2" (50.Smm) MUST be
installed. The outlet of the trap must be at least 1" below the unit
drain connection. Install the trap as near to the unit as possible
for proper drainage.
A 3/4" (19.1 mm) drain line MUST be installed if required by local
codes or if location of unit requires it. Run the drain line to an open
drain or other suitable disposal point as designated by local code.
FIGURE 3 Condensate Drain Information *
3/4" (19,1mm)
Threaded Female
PVC Fitting
_4.Smm) mm>I
3/4" (19,1mm)
Drain Line
*Condensate trap MUST be installed.
Electric Heat
A variety of accessory electric heaters ranging from 5.0 to 20.0
KW provide heat in the unit when required. Each package has a
heater module that mounts on the blower inlet; mounting this
module requires removal of the blower assembly and attachment
of the module to the blower standoffs provided. Each package
also includes an associated remote mounted heater control
package. Integral harnesses provided with both the heater
module and control package allow connection of the two
components via in-line plugs. Heaters are available both with and
without circuit breakers.
See installation instructions provided with the electric heater for
specific installation and application details.
5. Unit Electrical Wiring
ELECTRICAL SHOCK HAZARD.
Failure to follow this warning could result in personal
injury, and/or death.
Turn off electric power supply at disconnect switch or
service panel before removing any access or service
panel from unit.
Unit MUST be ,grounded to electrical service panel.
NOTE: All electrical work MUST conform with the requirements of
local codes and ordinances and in the United States with National
Electrical Code ANSI/NFPA 70-1990 (orcurrent edition). Provide
line voltage power supply from a separate fused circuit with a
disconnect switch (when required) located within sight of the unit.
Supply voltage, amperage, fuse and disconnect switch sizes
MUST conform with local codes and ordinances.
Wiring MUST be protected from possible mechanical damage
and MUST NOT interfere with removal of access panels, filters,
etc.
All exposed line voltage connections MUST be made through
liquid tight conduit to prevent water from entering the unit through
the electrical access..
Ground Connections
A ground lug is installed on the control plate (or electric heat
mounting plate) for the ground connection. Use a copper
conductor of the appropriate size (as designated by local code)
from the unit to a grounded connection in the electrical service
panel or to a properly driven and electrically grounded ground rod.
See warning on this page.
Line Voltage Wiring
Do NOT complete line voltage connections until unit is
permanently grounded. All line voltage connections and the
ground connection MUST be made with copper wire.
Connections for line voltage are made on the unit electrical
control plate. For access, remove the Blower/Electrical access
panel.
Refer to applicable wiring diagram in this Manual. Complete the
line service connections to the contactor 'L' terminals on the
electrical control plate. Check all screw terminals to ensure they
are tight.
NOTE: All openings must be sealed to prevent moisture from
entering the control box.
427 01 1101 00 5

Converting 230V Units to 208V
To convert 230V units to 208V:
1.Turn electric power OFE
2.Remove the blower/electrical access panel.
3.Locate the 24V control transformer.
4.Remove wire from the terminal labeled "240V" on the 24V
control transformer and reconnect it to the 208V terminal of
the 24V control transformer.
5.Replace the electrical/compressor access panel.
Low Voltage Wiring
For access, remove the electrical control/blower access panel.
Refer to the connection wiring diagram for the applicable model
and to the instructions included with the thermostat.
Route low voltage wires through the port located on the rear panel
and up to the control box.
NOTE; If an Electric Heat Accessory is installed, see the Electric
Heat Accessory Installation manual for low voltage connections.
Thermostat Connections
The location of the thermostat has an important effect on the
operation of the unit. See the thermostat instructions for proper
connection. See FIGURE 4 for Low Voltage Wire Harness
Connections
Field Installed Equipment
Wiring to be done in the field between the unit and other devices,
or between separate devices which are field installed and located,
MUST NOT exceed the temperature limitations for type T wire
and MUST be installed in accordance with manufacturer's
instruction and applicable local codes.
Final Electrical Check
Make a final wiring check to be sure system is correctly wired.
Inspect field installed wiring and the routing to ensure that rubbing
or chafing due to vibration will not occur.
NOTE: Wiring MUST be installed so it is protected from possible
mechanical damage.
GuRE4 I Electr°nic Therm°stat L°w V°ltage wiring
Harness Connection Diagram
PHM324-42 Units
©
@
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C>-
Thermostat and subbase
Unit Control Power
PHM348-54 Units
@
@-
@-
Thermostat and subbase
Unit Control Power
6427 01 1101 O0

FIGURE 5 I Control Box Configuration Defrost Board
Indoor
Motor
Board
Capacitor
Strap
/
Transformer Condenser Fan/
Compressor
Capacitor
/
Control Box
\Contactor
POWER
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WT)_LK_
Low Voltage Shield
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Control Box Wiring for PHM024-42
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CT4_i
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_ROST TIWER_O B_ SE__r _o WIWUT_S
SINGLECAPACITYCONTROLBOX - 208/230/1
POWZR
PIGIAILS
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PIGIAILS
II .......
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Control Box Wiring for PHM048-54
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DUAL CAPACITY CONTROL BOX 208123D/1
427 01 1101 O0 7

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6. Rain Shield Installation
FIGURE 6 [Installing The Rain Shield
RAIN SHIELD
requirements. If the unit is connected to an existing system, the
ductwork MUST be checked to make sure it is adequate. Extra
runs or larger duct sizes may have to be installed.
Maximum recommended velocity in trunk ducts is 1000 feet per
minute (5.08m/s). Velocity in branches should not exceed 800
feet per minute (4.06m/s). Refer to the Technical Data Label on
the unit for unit air volume requirements and system sizing
recommendations.
NOTE: Ductwork sizing affects temperature rise and cooling
temperature differential. Be sure to properly size ductwork to the
capacity and airflow characteristics of your unit. Failure to do so
can affect limit controls, compressors, motors, and other
components and will lead to premature failure of components.
This will also adversely affect day to day unit performance.
Flexible Duct Kits are available from your supplier to effect proper
sizing and installation to Mobile Homes and other standard
construction,.
Refer to unit rating plate for proper Electric Heat Accessory sizing
and see the Temperature Rise Check section in the Electric Heat
Accessory Installation manual.
1.Remove all screws from the cover plate on Blower/Electrical Access
Panel.
2.Install adhesive backed gasket on Blower/Electrical Access
Panel.
3.Install lower frame of rain shield with 4 screws.
4.Install rain shield hinged cover with 4 screws.
5.Install circuit breaker filler plates (2 each per unused breaker
slot.)
&Re-install Blower/Electrical Access Panel.
NOTE: VERIFY ALL APPROPRIATE SEALS ARE IN PLACE.
SEE FIGURE 6.
7. Air Distribution System
For airflow data (blower performance data, blower speed tap
settings, etc.) see the Technical Data Sheet attached to the unit.
Duetwork
NOTE: The total heat gain of the structure to be conditioned as
expressed in total Btu/hr should be calculated by manufacturer's
method or in accordance with "A.S.H.R.A.E. Guide" or "Manual J
Load Calculations" published by the Air Conditioning
Contractors of America. The total heat gain calculated should be
equal to or less than the cooling capacity output based on D.O.E.
test procedures, steady state efficiency times input.
Ductwork, supply registers, and return air grilles MUST be
designed and sized to handle the unit's cooling air volume
Ductwork Insulation
It is recommended that ductwork installed outdoors have a
minimum of 2" (51mm) of fiberglass insulation and be covered by
a weatherproof vapor barrier that is protected against damage.
Caulking and flashings, or other means adequate to provide a
permanent weather seal, must be used.
It is recommended that ductwork installed in attics or other areas
exposed to outdoor temperatures have a minimum of 2" (51mm)
fiberglass insulation and have an indoor type vapor barrier.
Ductwork Connections
The use offlexible, non-combustible connectors between main
trunk ducts and supply and return air plenums is recommended to
minimize vibration transmission.
NOTE: Connect supply and return air plenums to unit in a manner
that will allow the top of the unit to be removed without removing
plenums. Plenums MUST be individually sealed to unit casing.
Ducts MUST be terminated inside structure.
Filters
All return air MUST pass through a field supplied filter before
entering the unit. if used, an electronic air cleaner MUST be
installed in the return air ductwork. Minimum recommended filter
areas are listed in FIGURE 7 and are based on a velocity of 300
ff./min. (1.2m/s) for disposable filters and 500 ft./min. (2.54m/s)
for washable high velocity filters.
NOTE:
Do NOT operate the unit without all filters in place.
FIGURE 7 Recommended Filter Sizes
NOTE: Some filters are marked with an arrow to indicate the proper direction of air flow through the filter. The air flow direction wilI be towards
the blower motor. Make sure filter is installed correctly.
Nominal Tons
Air Conditioning
2
2 1/2
3
3 1/2
4
5
Nominal Air Flow
Cubic Feet
per Minute
700 - 900
875 - 1125
1050 -1350
1225 -1575
1400-1800
1750 - 2000
10
Recommended Filter Sizes
Sq. In. Surface Area/Nominal Size
Disposable Filters
400 or 20 x 25
487 or 20 x 30
576 or 14 x 25 (2Req.)
865 or 16 x 25 (2Req.)
753 or 20 x 25 (2 Req.)
960 or 20 x 30 (2 Req.)
Gleanable Filters
246 or 15 x 20
301 or 14x25
356 or 16x25
411 or 20 x25
486 or 20 x 25
575 or 24 x 25
427 01 1101 00