Payne PA5GXXA series User manual

Installation Instructions
NOTE: Read the entire instruction manual before starting the
installation.
NOTE: Installer: Make sure the Owner's Manual and Service
Instructions are left with the unit after installation.
TABLE OF CONTENTS
PAGE
SAFETY CONSIDERATIONS ......................... 1
INTRODUCTION ................................... 2
RECEIVING AND INSTALLATION .................. 2-9
Check Equipment .................................. 2
Identify Unit .................................... 2
Inspect Shipment ................................. 2
Provide Unit Support ............................... 2
Roof Curb ...................................... 2
Slab Mount ..................................... 2
Provide Clearances ................................. 2
Field Fabricate Ductwork ............................ 2
Rig and Place Unit ................................. 6
Inspection ...................................... 6
Rigging/Lifting of Unit ............................ 7
Connect Condensate Drain ........................... 7
Install Duct Connections ............................. 7
Configuring Units for Downflow (Vertical) Discharge .... 7
Install Electrical Connections ......................... 8
High-Voltage Connections ......................... 9
Special Procedures for 208v Operation ................ 9
Control Voltage Connections ........................ 9
Standard Connection .............................. 9
Transformer Protection ............................ 9
PRE-START-UP ................................... 11
START-UP ..................................... 11-13
Check for Refrigerant Leaks ......................... 11
Start-Up Adjustments .............................. 11
Checking Cooling Control Operation ................ 11
Checking and Adjusting Refrigerant Charge ........... 11
Indoor Airflow and Airflow Adjustments ............. 12
Continuous Fan Operation ........................ 12
MAINTENANCE ................................ 18-21
Air Filter ...................................... 18
Indoor Blower and Motor ......................... 18
Outdoor Coil, Indoor Coil, and Condensate Drain Pan ... 19
Outdoor Fan ................................... 19
Electrical Controls and Wiring ..................... 19
Refrigerant Circuit ............................... 20
Evaporator Airflow .............................. 20
R-410A Items .................................. 20
TROUBLESHOOTING .............................. 23
START-UP CHECKLIST ............................ 24
SAFETY CONSIDERATIONS
Installation and servicing of this equipment can be hazardous due
to mechanical and electrical components. Only trained and
qualified personnel should install, repair, or service this equipment.
A11624
Fig. 1 - Unit PA5G--A
Untrained personnel can perform basic maintenance functions such
as cleaning and replacing air filters. All other operations must be
performed by trained service personnel. When working on this
equipment, observe precautions in the literature, on tags, and on
labels attached to or shipped with the unit and other safety
precautions that may apply.
Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Use quenching cloth for brazing operations.
Have fire extinguisher available. Read these instructions
thoroughly and follow all warnings or cautions included in
literature and attached to the unit. Consult local building codes, the
current editions of the National Electrical Code (NEC) NFPA 70.
In Canada refer to the current editions of the Canadian Electrical
Code CSA C22.1.
Recognize safety information. This is the safety-alert symbol Z_.
When you see this symbol on the unit and in instructions or manu-
als, be alert to the potential for personal injury. Understand these
signal words: DANGER, WARNING, and CAUTION. These
words are used with the safety-alert symbol. DANGER identifies
the most serious hazards which will result in severe personal injury
or death. WARNING signifies hazards which could result in per-
sonal injury or death. CAUTION is used to identify unsafe practic-
es which may result in minor personal injury or product and prop-
erty damage. NOTE is used to highlight suggestions which will
result in enhanced installation, reliability, or operation.
ELECTRICALSHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before installing or servicing system, always turn off main
power to system and install lockout tag. There may be
more than one disconnect switch. Turn off accessory heater
power switch if applicable.

H
PERSONAL INJURY AND ENVIRONMENTAL
HAZARD
Failure to relieve system pressure could result in personal
iniury and/or death.
1. Relieve pressure and recover all refrigerant before
servicing existing equipment, and before final unit disposal.
Use all service ports and open all flow-control devices,
including solenoid valves.
2. Federal regulations require that you do not vent
refrigerant into the atmosphere. Recover during system
repair or final unit disposal.
CUT HAZARD
Failure to follow this caution may result in personal injury.
When removing access panels (See Fig. 15) or performing
maintenance functions inside your unit, be aware of sharp
sheet metal parts and screws. Although special care is taken to
reduce sharp edges to a minimum, be extremely careful and
wear appropriate protective clothing, safety glasses and
gloves when handling parts or reaching into the unit.
INTRODUCTION
The PA5G--A packaged air conditioner is fully self-contained and
designed for outdoor installation (See Fig. 1). See Fig. 2 and 3 for
unit dimensions. All unit sizes have discharge openings for both
horizontal and downflow configurations, and are factory shipped
with all downflow duct openings covered. The unit may be
installed either on a rooftop or on a ground-level cement slab. (See
Fig. 4 for roof curb dimensions.)
RECEIVING AND INSTALLATION
Step 1 -- Check Equipment
IDENTIFY UNIT
The unit model number and serial number are printed on the unit
informative plate. Check this information against shipping papers.
INSPECT SHIPMENT
Inspect for shipping damage before removing packaging materials.
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 any damage incurred in transit.
Check all items against shipping list. Immediately notify the
nearest equipment distribution office if any item is missing. To
prevent loss or damage, leave all parts in original packages until
installation.
If the unit is to be mounted on a curb in a downflow application,
review Step 7 to determine which method is to be used to remove
the downflow panels before rigging and lifting into place. The
panel removal process may require the unit to be on the ground.
Step 2 -- Provide Unit Support
IMPORTANT: The unit must be secured to the curb by installing
screws through the bottom of the curb flange and into the unit base
rails. When installing large base units onto the common curb, the
screws must be installed before allowing the full weight of the unit
to rest on the curb. A minimum of six screws are required for large
base units. Failure to secure unit properly could result in an
unstable unit. See Warning near Rigging/Lifting information and
accessory curb instructions for more details.
For hurricane tie downs, contact distributor for details and PE
(Professional Engineering) Certificate if required.
ROOF CURB
Install accessory roof curb in accordance with instructions shipped
with curb (See Fig. 4). Install insulation, cant strips, roofing, and
flashing. Ductwork must be attached to curb.
IMPORTANT: The gasketing of the unit to the roof curb is
critical for a water tight seal. Install gasketing material supplied
with the roof curb. Improperly applied gasketing also can result in
air leaks and poor unit performance.
Curb should be level to within 1/4 in. (6.35 mm) (See Fig. 6). This
is necessary for unit drain to function properly. Refer to accessory
roof curb installation instructions for additional information as
required.
Installation on older "G" series roof curbs.
Two accessory kits are available to aid in installing a new "G"
series unit on an old "G" roof curb.
1. Accessory kit number CPADCURB001A00, (small chassis)
and accessory kit number CPADCURB002A00, (large
chassis) includes roof curb adapter and gaskets for the
perimeter seal and duct openings. No additional
modifications to the curb are required when using this kit.
2. An alternative to the adapter curb is to modify the existing
curb by removing the outer horizontal flange and use
accessory kit number CPGSKTKIT001A00 which includes
spacer blocks (for easy alignment to existing curb) and
gaskets for the perimeter seal and duct openings. This kit is
used when existing curb is modified by removing outer
horizontal flange.
UNIT/STRUCTURAL DAMAGE HAZARD
Failure to follow this caution may result in property damage.
Ensure there is sufficient clearance for saw blade when cutting
the outer horizontal flange of the roof curb so there is no
damage to the roof or flashing.
SLAB MOUNT
Place the unit on a solid, level pad that is at least 2 in. (51 mm)
above grade. The pad should extend approximately 2 in. (51 mm)
beyond the casing on all 4 sides of the unit (See Fig. 7). Do not
secure the unit to the pad except when required by local codes.
Step 3-- Provide Clearances
The required minimum service clearances are shown in Fig. 2 and
3. Adequate ventilation and outdoor 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. (1219 mm) above the unit top. The maximum horizontal
extension of a partial overhang must not exceed 48 in. (1219 mm)
IMPORTANT: Do not restrict outdoor airflow. An air restriction
at either the outdoor-air inlet or the fan discharge may be
detrimental to compressor 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 2 in. (51 mm) above the highest expected water
and runoff levels. Do not use unit if it has been under water.
Step 4 -- Field-Fabricate Ductwork
Secure all ducts to roof curb and building structure on vertical
discharge units. Do not connect ductwork to unit. For horizontal
applications, unit is provided with flanges on the horizontal
openings. All ductwork should be secured to the flanges. Insulate
and weatherproof all external ductwork, joints, and roof openings
with counter flashing and mastic in accordance with applicable
codes.

I
I
=
_°
32 5/8
[8287]
LEFT SIDEVIEW
15 15/!8 _.
[4048]
OUTDOOR
t
Y
INDOOR COIL_t' _OUTDOOR COIL
TOP VIEW
t
[1224 O]
FRONT VIEW
ELECTRICAL
CHARACTERISTICS
208/230 1 60
REQUIRED CLEARANCES TO COMBUSTIBLE MATL INCHES [MM]
TOP OF UNIT ............................................. 14 [3556]
DUCT SIDE OF UNIT .................... 2 [508]
SIDE OPPOSITE DUCTS..................................... 14 [355R]
BOTTOM OF UNIT ........................................... O [DO]
ELECTRICAL PANEL ............................. 36 [9144]
NED REQUIRED CLEARANCES INCHES [MM]
BETWEEN UNITS, POWER ENTRY SIDE ........................ 42 [10668]
UNIT AND UNGROUNDEDSURFACES, POWER ENTRY SIDE ....... B6 [914 O]
UNIT AND BLOCK OR CONCRETE WALLS AND OTHER
GROUNDEDSURFACES, POWER ENTRY SIDE .................... 42 [10668]
REQUIRED CLEARANCE FOR OPERATION AND SERVICING INCHES [MM]
EVAP COIL ACCESS SIDE .................................. 36 [9140]
POWERENTRY SIDE ........................................ _2 [10868]
(EXCEPT FOR NEC REQUIREMENTS}
UNIT TOP................................................ _8 [12192]
SIDE OPPOSITE DUCTS..................................... 36 [9140]
DUCT PANEL.............................. 12 [3048]_
_MINIMUM DISTANCES:IF UNIT IS PLACED LESS THAN i2 [304 8] FROM WALL
SYSTEM,THEN SYSTEM PERFORMANCEMAYBE COMPROMISED
DIMENSIONS IN [] ARE IN MILLIMETERS
[325 4] 7 1/4
B 1/16_
[87B]
4 ]3/16
[i222]
®
@
7/8 [222] DIA
HOLE CONTROL ENTRY
RIGHT SIDE VIEW
t
15 718
[403 2]
6 9/16 '_
[166 7]
6 t f
[48]
3 7116
[873]
SUPPLY
DUCT
_OPENING
jO •
i
Io ®
21 S/8
[S493]
RETURN
DUCT
OPENING
9 7/8
[250 8]
REAR VIEW
50ES500632

I
I
I
m-w
=
0
o)
_42-15/16--I
[10906]
DRAIN
5/4" 1i91] N PT
× 7/8" [2221 DEEP 1328 6]
[1122_]
LEFT SIDE VIEW
3-7/16
[875]
2-13/16--
171 4]
t l
5-15/16
1404 81
OUTDOOR
I
it
INDOOR COIL_
TOP VIEW
i
B-5/8
[937]
PANEL
48-5/16 --
[122551
FRONTViEW
PANEL
COIL
--ELECTRICAL
ACCESS
PANEL
UNIT
36
48
60
ELECTRICAL UNIT WT UNIT HEIGHT IN/MM
CHARACTERISTICS LB KG "A"
208/230-1-60 447 203.0 48-5/4 1238.3
208/230-1-60 4!5 215.0 50-3/4 1289 1
208/230-1-60 526 259.0 54-3/4 1390,7
CENTER OF GRAVITY IN/MM
XYZ
120-I/4 514,4 7-I/2 4445 16-5/8 422.3
120-1/4 514.4 1-1/2 444 5 17-5/8 447.7
20-1/4 514.4 7-1/2 444,5 18 457.2
UNIT VOLTAGE "i "
36 208/230 89.4 406
48 208/250 95.0 432
60 208/230 1052 478
CORNER WEIGHT LB/KG
"2 .... 3 .... 4"
71.5 52.5 107 4 48 8 178 9 81.5
76 0 54.6 114 1 51.9 190 i 86 4
84,2 38,8 126,5 57 4 210. 95 7
REQUIRED CLEARANCES TO COMBUSTIBLE WATL INCHES [MM]
TOP OF UNIT ............................................. 1_ [B556]
DUCT SIDE or UNIT ........................................ 2 [SO8]
SIDE OPPOSITE DUCTS..................................... 14 [3556]
BOTTOM OF UNIT .............................. 0 [O0]
ELECTRICAL PANEL ................................. 56 [9144]
NED REQUIRED CLEARANCES INCHES [MW]
BETWEEN UNITS, POWER ENTRY SIDE ........................ 42 [10568]
UNIT AND UNGROUNDED SURFACES, POWER ENTRY SIDE ......... 56 [Nl_O]
UNIT AND BLOCH OR CONCRETE WALLS AND OTHER
GROUNDED SURFACES, POWER ENTRY SIDE .................... 42 [I0668]
REQUIRED CLEARANCE FOR OPERATION AND SERVICING INCHES [MM]
EVAP COIL ACCESS SIDE ......................... 36 [9140]
POWER ENTRY SIDE .......................... 42 [I0668]
(EXCEPT FOR NEC REQUIREMENTS)
UNIT TOP ................................................ 48 [12192]
SIDE OPPOSITE DUCTS..................................... 36 [9140]
DUCT PANEL .............................................. 12 [3048]_
{MINIMUM DISTANCES:IF UNIT IS PLACED LESS THAN 12 [3048] FROM WALL
SYSTEM,THEN SYSTEM PERFORMANCE MAYBE COMPROMISED
DIMENSIONS IN [1 ARE IN MILLIMETERS
1-3/4" [4451 DIA
POWER ENTRY ®
14-13116
[3762] 9-i/4 @
[81 3]
[1222]
1222] DIA _3/i6
HOLE CONTROL ENTRY [48]
RIGHTSIDE VIEW
i5-7/8
[4032]
6-5/8 I
[16_
3-7/16_
[873] [346 i1
REAR VIEW
50E3500653 R[__

HVAC unit HVAC unit
base rNIs basepan
Anchor screw/"
Flashing field
supplied
Roofing material
field supplied --
Cant strip
field supplied
Gasket
Roof curb
Insulation
ROOF CURB DETAIL
A09090
SMALL/COMMON CURB
Dashed lines show cross support
location for large basepan unts
A09413 !1
¢
F A
¢
G
LARGE CURB l/ A09415
1
I
I
i_i!_i1_I_iii1i_iiiiii`_i11iiiiii!iHii11ii_iiiiiiiiiii1iM_;;ii1[iii_1iii_i!
iiiiiiiiiiii_i'_
SMALL
BASE
UNIT
Y
LARGE
BASE
UNIT
"-a
UNIT PLACEMENT ON
COMMON CURB
SMALL OR LARGE BASE UNIT
A09094
A09414
B
UNIT CATALOG A (small/common
SIZE NUMBER IN. base)
(mm) IN, (mm)*
11
Small CPRFCURB010A00 (279)
or 14 10 (254)
Large CPRFCURB011A00 (356)
11
CPRFCURB012A00 (279)
Large 14 (356)
14
CPRFCURB013A00 (356)
BCD E F
(large base) IN. IN. IN. IN.
IN. (mm)* (mm) (mm) (mm) (mm)
32.4
(822)
16 47.8
14 (356) (406) (1214) 2.7 (69)
43.9
(1116)
G H
IN. (mm) IN. (mm)
30.6 (778)
46.1 (1170)
42.2 (1072)
*Part Numbers CPRCURB010A00 and CPRCURB011A00 can be used on both small and large basepan units. The cross supports must be located based on
whether the unit is a small basepan or a large basepan.
NOTES:
1. Roof curb must be set up for unit being installed.
2. Seal strip must be applied, as required, to unit being installed.
3. Roof curb is made of 1d-gauge steel.
4. Attach ductwork to curb (flanges of duct rest on curb).
5. Insulated panels: 1-in. (25.4 mm) thick fiberglass 1 lb. density.
Fig. 4 - Roof Curb Dimensions

CAUTION - NOTICE TO RIGGERS
PRUDENCE - AVIS AUX NIANIPULATEUR
ACCESS PANELS MUST BE IN PLACE WHEN RIGGING.
PANNEAUX D'ACCES DOlT ETRE EN PLACE POUR MANIPULATION.
Use top skid as spreader bar, /Utiliser la palette du haut comme barre de r6partition
MINIMUM HEIGHT: 36" (914,4 ram)
HAUTEUR MINIMUM
V01R D£TAILA
SEAL STRIP MUST BE IN BANDE SCEL_NT DOIT ETRE
UNIT HEIGHT _ PLACE BEFORE pLACING EN P_CE AVANT DE P_CER
HAUTEUR D'UNIT£ _ UNITON ROOF CURB L UNITESUR LABASE DE TOIT
DETAIL A
VOIR DETAIL A
50CY502286 2.0
A09051
Unit*
Rigging
Weight
SMALL CABINET LARGE CABINET
24 48
Ib Ib
371
Unit*
kg
166 Rigging
Weight
36
Ib kg
458 208 486
kg
22O
6O
Ib kg
537 244
NOTE: See dimensional drawing for corner weights.
Fig. 5 -PASG--A Unit Suggested Rigging
Ducts passing through an unconditioned space must be insulated
and covered with a vapor barrier. If a plenum return is used on a
vertical unit, the return should be ducted through the roof deck to
comply with applicable fire codes. See unit rating plate for any
required clearances around ductwork. Cabinet return-air static
shall not exceed -.25 IN. W.C.
Step 5 -- Rig and Place Unit
Rigging and handling of this equipment can be hazardous for
many reasons due to the installation location (roofs, elevated
structures, etc.).
Only trained, qualified crane operators and ground support staff
should handle and install this equipment.
When working with this equipment, observe precautions in the
literature, on tags, stickers, and labels attached to the equipment,
and any other safety precautions that might apply.
Training for operators of the lifting equipment should include, but
not be limited to, the following:
1. Application of the lifter to the load, and adjustment of the
lifts to adapt to various sizes or kinds of loads.
2. Instruction in any special operation or precaution.
3. Condition of the load as it relates to operation of the lifting
kit, such as balance, temperature, etc.
Follow all applicable safety codes. Wear safety shoes and work
gloves.
INSPECTION
Prior to initial use, and at monthly intervals, all rigging shackles,
clevis pins, and straps should be visually inspected for any damage,
evidence of wear, structural deformation, or cracks. Particular
attention should be paid to excessive wear at hoist hooking points
and load support areas. Materials showing any kind of wear in
these areas must not be used and should be discarded.
A-B
1/4 (6.35)
MAXIMUM ALLOWABLE
DIFFERENCE in. (mm)
B-C A-C
1/4 (6.35) 1/4 (6.35)
Fig. 6 - Unit Leveling Tolerances
UNIT FALLING HAZARD
Failure to follow this warning could result in personal
iniury or death.
Never stand beneath rigged units or lift over people.
A07925
PROPERTY DAMAGE HAZARD
Failure to follow this warning could result in personal
When straps are taut, the clevis should be a minimum of 36
in. (914 mm) above the unit top cover.
1. Leave top shipping skid on the unit for use as a spreader bar
to prevent the rigging straps from damaging the unit. If the
skid is not available, use a spreader bar of sufficient length
to protect the unit from damage.

Riu_inu/Liftinu of Unit (See Fire 5)
[]NIT FALLING HAZARD
Failure to follow this warning could result in personal
iniury or death.
Large base units must be secured to common curb before
allowing full weight of unit to rest on curb. Install screws
through curb into unit base rails while rigging crane is still
supporting unit.
Lifting holes are provided in base rails as shown.
1. Attach shackles, clevis pins, and straps to the base rails of
the unit. Be sure materials are rated to hold the weight of the
unit (See Fig. 5).
2. Attach a clevis of sufficient strength in the middle of the
straps. Adjust the clevis location to ensure unit is lifted level
with the ground.
After the unit is placed on the roof curb or mounting pad, remove
the top skid.
2"
(50.8ram)
±
EVAR COIL COND, COIL
, I
I
1
I
I
1
I
I
II 1
I
I
1
I
A07926
Fig. 7 -Slab Mounting Detail
Step 6 -- Connect Condensate Drain
NOTE: When installing condensate drain connection be sure to
comply with local codes and restrictions.
Model PA5G--A disposes of condensate water through a 3/4 in.
NPT fitting which exits through the base on the evaporator coil
access side. See Fig. 2 & 3 for location.
Condensate water can be drained directly onto the roof in rooftop
installations (where permitted) or onto a gravel apron in ground
level installations. Install a field-supplied 2-in. (51 mm)
condensate trap at end of condensate connection to ensure proper
drainage. Make sure that the outlet of the trap is at least 1 in. (25
mm) lower than the drain pan condensate connection to prevent the
pan from overflowing (See Fig. 8). When using a gravel apron,
make sure it slopes away from the unit.
Connect a drain tube using a minimum of 3/4 -in. PVC or 3/4 -in.
copper pipe (all field-supplied) at the outlet end of the 2-in. (51
mm) trap. Do not undersize the tube. Pitch the drain tube
downward at a slope of at least l-in. (25 mm) for every 10 ft (3.1
m) of horizontal run. Be sure to check the drain tube for leaks.
Prime trap at the beginning of the cooling season start-up.
.......ml
{'2-in (51
A09052
Fig. 8 -Condensate Trap
Step 7 -- Install Duct Connections
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 or residence type, NFPA 90B and/or local codes and
ordinances.
Select and size ductwork, supply-air registers, and return air grilles
according to ASHRAE (American Society of Heating,
Refrigeration, and Air Conditioning Engineers) recommendations.
The unit has duct flanges on the supply- and return-air openings
on the side of the unit.
When designing and installing ductwork, consider the following:
1. All units should have field-supplied filters or accessory
filter rack installed in the return-air side of the unit.
Recommended sizes for filters are shown in Table 1.
2. Avoid abrupt duct size increases and reductions. Abrupt
change in duct size adversely affects air performance.
IMPORTANT: Use flexible connectors between ductwork and
unit to prevent transmission of vibration. Use suitable gaskets to
ensure weather-tight and airtight seal. When electric heat is
installed, use fireproof canvas (or similar heat resistant material)
connector between ductwork and unit discharge connection. If
flexible duct is used, insert a sheet metal sleeve inside duct. Heat
resistant duct connector (or sheet metal sleeve) must extend 24-in.
(610 mm) from electric heater element.
3. Size ductwork for cooling air quantity (cfm). The minimum
air quantity for proper electric heater operation is listed in
Table 2. Heater limit switches may trip at air quantities
below those recommended.
4. Seal, insulate, and weatherproof all external ductwork. Seal,
insulate and cover with a vapor barrier all ductwork passing
through conditioned spaces. Follow latest Sheet Metal and
Air Conditioning Contractors National Association
(SMACNA) and Air Conditioning Contractors Association
(ACCA) minimum installation standards for residential
heating and air conditioning systems.
5. Secure all ducts to building structure. Flash, weatherproof,
and vibration-isolate duct openings in wall or roof
according to good construction practices.
CONFIGURING UNITS FOR DOWNFLOW
_VERTICAL) DISCHARGE
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
iniury or death.
Before performing service or maintenance operations on the
system, turn off main power to unit and install lockout tag.
There may be more than one disconnect switch.
1. Open all electrical disconnects and install lockout tag before
starting any service work.
2. Remove horizontal (metal) ductcovers to access vertical
(downflow) discharge duct knockouts in unit basepan. (See
Fig. 9.)
3. To remove downflow return and supply knockout covers,
break front and right side connecting tabs with a
screwdriver and hammer. Push cover down to break rear
and left side tabs.
NOTE: These panels are held in place with tabs similar to an
electrical knockout. Reinstall horizontal duct covers (Fig. 9)
shipped on unit from factory. Insure openings are air and
watertight.
H

H
NOTE: The design and installation of the duct system must be in
accordance with the standards of the NFPA for installation of
nonresidence-type air conditioning and ventilating systems, NFPA
90A or residence-type, NFPA 90B; and/or local codes and
ordinances.
Adhere to the following criteria when selecting, sizing, and
installing the duct system:
1. Units are shipped for side shot installation.
2. Select and size ductwork, supply-air registers, and
return-air grilles according to American Society of Heating,
Refrigeration and Air Conditioning Engineers (ASHRAE)
recommendations.
3. Use flexible transition between rigid ductwork and unit to
prevent transmission of vibration. The transition may be
screwed or bolted to duct flanges. Use suitable gaskets to
ensure weather-tight and airtight seal.
4. All units must have field-supplied filters or accessory filter
rack installed in the return-air side of the unit.
Recommended sizes for filters are shown in Table 1.
5. Size all ductwork for maximum required airflow (either
heating or cooling) for unit being installed. Avoid abrupt
duct size increases or decreases or performance may be
affected.
6. Adequately insulate and weatherproof all ductwork located
outdoors. Insulate ducts passing through unconditioned
space, and use vapor barrier in accordance with latest issue
of Sheet Metal and Air Conditioning Contractors National
Association (SMACNA) and Air Conditioning Contractors
of America (ACCA) minimum installation standards for
heating and air conditioning systems. Secure all ducts to
building structure.
7. Flash, weatherproof, and vibration-isolate all openings in
building structure in accordance with local codes and good
building practices.
V
Horizontal Duct Covers
A09510
Basepan
Downflow
(Ve_ical)
Supply Basepan
Downflow
Return
Knockout
Fig. 9 - Supply and Return Duct Opening
A09511
Step 8-- Install Electrical Connections
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
iniury or death.
The unit cabinet must have an uninterrupted, unbroken
electrical ground to minimize the possibility of personal
iniury 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 NFPA
70 (NEC) (latest edition) (in Canada, Canadian Electrical
Code CSA C22.1) and local electrical codes.
HIGH VOLTAGE
(SEE UNIT WIRING
LABEL)
1-PHASE USES
TWO POWER
LEADS EQUIP GR
CONTROL BOX
LOW -VOLTAGE
POWER LEADS
(SEE UNIT
WIRING LABEL)
l
I_,=,
SPLICE BOX
JSUPPLY
FIELD -SUPPLIED
FUSED DISCONNECT
WHT (W2)
VlO (W3)
YEL (Y1)
PNK {::I-
GRN(G)b-
RED(R!b_
D-@
D-@
D-@
@
©
4-__)
BRN(C)b-@ .
Fig. 10 -High- and Control-Voltage Connections
O
E
€-
A12005
[]NIT COMPONENT DAMAGE HAZARD
Failure to follow this caution may result in damage to the
unit being installed.
1. Make all electrical connections in accordance with
NFPA 70 (NEC) (latest edition) and local electrical codes
governing such wiring. In Canada, all electrical
connections must be in accordance with CSA standard
C22.1 Canadian Electrical Code Part 1 and applicable
local codes. Refer to unit wiring diagram.
2. Use only copper conductor for connections between
field-supplied electrical disconnect switch and unit. DO
NOT USE ALUMINUM WIRE.
3. Be sure that high-voltage power to unit is within
operating voltage range indicated on unit rating plate. On
3-phase units, ensure phases are balanced within 2
percent. Consult local power company for correction of
improper voltage and/or phase imbalance.
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 electrical service with a
field-supplied, waterproof disconnect switch mounted at, or within
sight from the unit. Refer to the unit rating plate, NEC and local
codes for maximum fuse/circuit breaker size and minimum circuit
amps (ampacity) for wire sizing.
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. 2 and 3 for acceptable
location.
See unit wiring label (Fig. 12 and Fig. 10 for reference when
making high voltage connections. Proceed as follows to complete
the high-voltage connections to the unit.
Single phase units:
1. Run the high-voltage (L1, L2) and ground lead into the
control box.
2. Connect ground lead to chassis ground connection.
3. Locate the black and yellow wires connected to the line side
of the contactor.
4. Connect field LI to black wire on connection 11 of the
compressor contactor.
5. Connect field wire L2 to yellow wire on connection 23 of
the compressor contactor.
SPECIAL PROCEDURES FOR 208-V OPERATION
ELECTRICALSHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before installing or servicing system, always turn off main
power to system and install lockout tag. With disconnect
switch open, move black wire from transformer (3/16
in.)(4.8 mm) terminal marked 230 to terminal marked 208.
This retaps transformer to primary voltage of 208 vac.
CONTROL VOLTAGE CONNECTIONS
NOTE: Do not use any type of power-stealing thermostat. Unit
control problems may result.
Use no. 18 American Wire Gage (AWG) color-coded, insulated
(35°C minimum) wires to make the control voltage connections
between the thermostat and the unit. If the thermostat is located
more than 100 ft (30.5 m) from the unit (as measured along the
control voltage wires), use no. 16 AWG color-coded, insulated
(35 ° C minimum) wires.
STANDARD CONNECTION
Locate the seven low voltage thermostat leads in 24 volt splice
box. See Fig. 10 for connection diagram. Run the low-voltage
leads from the thermostat, through the control wiring inlet hole
grommet (Fig. 2 and 3), and into the low-voltage splice box.
Provide a drip loop before running wires through panel. Secure
and strain relief all wires so that they do not interfere with
operation of unit.
If an accessory electric heater is installed, low voltage leads from
heater must be connected to factory supplied control leads from
Indoor Fan Board P4 connector.
NOTE: If the unit 24V wires do not have a matching receptacle,
cut the 24V wires from the electric heater plug, strip the ends, and
wire nut together to match the schematic connections. If the electric
heater 24V wires do not have a matching plug, cut the 24V wires
from the unit receptacle, strip the ends, and wire nut together to
match the schematic connections.
Factory wires are provided for electric heat staging WI and W2
(W2 and W3 on IFB). If room thermostat has only one stage of
supplemental heat, connect white and violet wires shown in Fig. 10
to second stage heat field wire.
Some electric heaters have four control wires (plus common wire).
Consult unit wiring diagram and electric heater wiring diagram for
additional details.
TRANSFORMER PROTECTION
The transformer is of the energy-limiting type, however adirect
short will likely blow asecondary fuse. If an overload or short is
present, correct overload condition and check for blower fuse on
Indoor Fan Board. Replace fuse as required with correct size and
rating.
!1

Table 1 - Physical Data-Unit PA5G--A
UNIT SIZE 24 36 48 60
NOMINAL CAPACITY (ton) 2 3 4 5
SHIPPING WEIGHT lb. 371 458 486 537
SHIPPING WEIGHT (kg) 168 208 220 244
COMPRESSOR TYPE Two Stage Scroll Compressor
REFRIGERANT (R-410A)
Quantity Ib 10.1 9.5 15.3 15.8
Quantity (kg) 4.6 4.3 6.9 7.2
REFRIGERANT METERING DEVICE TXV
SIZE 2 TON 3 TON 4 TON 5 TON
PART NUMBER EA36YD129 EA36YD139 EA36YD149 EA36YD159
OUTDOOR COIL
Rows...Fins/in, 2...21 2...21 2...21 2...21
Face Area (sq ft) 13.6 17.5 19.4 23.3
OUTDOOR FAN
Nominal Airflow (CFM) 2700 2800 3300 3300
Fan Diameter (in.) 22 22 22 22
Diameter Motor HP (RPM) 1/8 (825) 1/8 (825) 1/4 (1100) 1/3 (1110)
INDOOR COIL
Rows...Fins/in, 3...17 3...17 3...17 4...17
Face Area (sq ft) 3.7 4.7 5.7 5.7
INDOOR BLOWER
Nominal Low Stage Cooling Airflow (CFM) 600 850 1100 1200
Nominal Low Stage Cooling Airflow (CFM) 800 1200 1600 1750
Blower Wheel Size in. x in. 10xl 0 11xl 0 11xl 0 11xl 0
mm x mm 254x254 279x254 279x254 279x254
Motor (HP) 1/2 3/4 1.0 1.0
HIGH-PRESSURE SWITCH (peig)
Cut-out 670 +/- 10
Reset (Auto) 470 +/- 25
HIGH-PRESSURE SWITCH 2 (peig)
Compressor Solenoid
Cutout 565 +/-15
Reset (Auto) 455 +/- 15
LOSS-OF-CHARGE/LOW-PRESSURE SWITCH
(Liquid Line) (peig)
Compressor Solenoid
Cutout 23 +/-5
Reset (Auto) 55 +/- 5
RETURN-AIR FILTERSt
Throwaway Size in. 20x24x1 20x30x1 24x36x1
Throwaway Size (mm) 508x508x25 508x610x25 610x914x25
1- Required filter sizes shown are based on the larger of the AHRI (Air Conditioning, Heating and Refrigeration Institute) rated cooling airflow or the heating
airflow velocity of 300 if/minute for throwaway type or 450 if/minute for high-capacity type. Air filter pressure drop for non-standard filters must not exceed 0.08
IN. W.C.
Table 2- Minimum Airflow for Safe Electric Heater Operation (CFM)
SIZE 24 36 48 60
AIRFLOW (CFM) 800 1200 1600 1750
10

PRE-START-UP
ENVIRONMENTAL, FIRE,
ELECTRICAL SHOCK HAZARD EXPLOSION,
Failure to follow this warning could result in personal
iniury or death and/or property damage.
1, Follow recognized safety practices and wear protective
goggles when checking or servicing refrigerant system.
2, Relieve and recover all refrigerant from system before
touching or disturbing compressor plug if refrigerant
leak is suspected around compressor terminals.
3, Never attempt to repair soldered connection while
refrigerant system is under pressure.
4. Do not use torch to remove any component. System
contains oil and refrigerant under pressure.
5. To remove a component, wear protective goggles and
proceed as follows:
a. Shut off electrical power to unit and install
lockout tag.
b. Relieve and reclaim all refrigerant from system
using both high- and low-pressure ports.
c. Cut component connecting tubing with tubing
cutter and remove component from unit.
d. Carefully unsweat remaining tubing stubs when
necessary. Oil can ignite when exposed to torch
flame.
Use the Start-Up Checklist supplied at the end of this book and
proceed as follows to inspect and prepare the unit for initial
start-up:
1. Remove all access panels (see Fig. 15).
2. Read and follow instructions on all DANGER, WARNING,
CAUTION, and INFORMATION labels attached to, or
shipped with unit.
3. Make the following inspections:
a. Inspect for shipping and handling damages, such as
broken lines, loose parts, disconnected wires, 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 solution. If a refrigerant leak is detected, see
following Check for Refrigerant Leaks section.
c, Inspect all field- and factory-wiring connections. Be
sure that connections are completed and tight, Ensure
wires do not touch refrigerant tubing or sharp sheet
metal edges.
d. Inspect coil fins. If damaged during shipping and
handling, carefully straighten fins with a fin comb.
4. Verify the following conditions:
a. Make sure that outdoor-fan blade is correctly positioned
in fan orifice.
b. Make sure that air filter(s) 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 and miscellaneous loose parts
have been removed
5. Each unit system has two (2) Schrader-type ports, one low-
side Schrader fitting located on the suction line, and one
high-side Schrader fitting located on the compressor
discharge line. Be sure that caps on the ports are tight.
START-UP
Step 1-- Check Cooling and Accessory Electric
Heat (if applicable) Operation
Start and check the unit for proper control operation as follows:
1. Place room thermostat SYSTEM switch or MODE control
in OFF position. Observe that blower motor starts when
FAN mode is placed in FAN ON position and shuts down
when FAN MODE switch is placed in AUTO position.
2. Thermostat:
On a typical two stage thermostat, when the room temper-
ature rises 1 or 2 degrees above the cooling control setting
of the thermostat, the thermostat completes the circuit
between thermostat terminal R and terminals YI,1 and G.
These completed circuits through the thermostat connect the
contactor coil (C) (through unit wire YI) and indoor fan
board (through unit wire G) across the 24-v. secondary of
transformer (TRAN).
3. If your unit contains accessory electric heat, place system
switch or MODE control in HEAT position. Set control
above room temperature. Observe that inte indoor blower is
operating and warm air is flower through the supply air
vents inside your home. Observe that the heating cycle
shuts down when the control setting is satisfied.
If your unit does not contain accessory electric heat and you
would like to obtain it, please contact your local dealer for
more information.
4. When using an automatic changeover room thermostat
place both SYSTEM or MODE control and FAN mode
stitches in AUTO positions. Observe that unit operates in
Cooling mode when temperature control is set to "call for
Cooling" (below room temperature).
NOTE: Once the compressor has started and then has stopped, it
should not be started again until 5 minutes have elapsed.
Step 2 -- Check for Refrigerant Leaks
Proceed as follows to locate and repair a refrigerant leak and to
charge the unit:
1. Locate leak and make sure that refrigerant system pressure
has been relieved and reclaimed from both high-and low-
pressure ports.
2. Repair leak following Refrigerant Service procedures.
NOTE: Install a filter drier whenever the system has been opened
for repair.
3. Add a small charge of R-410A refrigerant vapor to system
and leak-test unit.
4. Recover refrigerant from refrigerant system and evacuate to
500 microns if no additional leaks are found.
5. Charge unit with R-410A refrigerant, using an electronic
scale. Refer to unit rating plate for required charge.
Step 3-- Start-Up Adjustments
Complete the required procedures given in the Pre-Start-Up
section before starting the unit. Do not jumper any safety devices
when operating the unit. Do not operate the unit in cooling mode
when the outdoor temperature is below 40°F (4°C) (unless
accessory low-ambient kit is installed).
Checking and Adjusting Refrigerant Charge
The refrigerant system is fully charged with R-410A refrigerant
and is tested and factory sealed.
NOTE: Adjustment of the refrigerant charge is not required
unless the unit is suspected of not having the proper R-410A
charge.
A subcooling charging chart is attached to the inside of the
compressor access panel. The chart includes the required liquid line
temperature at given discharge line pressures and outdoor ambient
temperatures.
!1
11

#
An accurate thermocouple- or thermistor-type thermometer, and a
gauge manifold are required when using the subcooling charging
method for evaluating the unit charge. Do not use mercury or small
dial-type thermometers because they are not adequate for this type
of measurement.
NOTE: Allow system to operate on high stage cooling for a
minimum of 15 minutes before checking or adjusting refrigerant
charge.
IMPORTANT: When evaluating the refrigerant charge, an
indicated adjustment to the specified factory charge must always be
very minimal. If a substantial adjustment is indicated, an abnormal
condition exists somewhere in the cooling system, such as
insufficient airflow across either coil or both coils.
1. Remove caps from low- and high-pressure service fittings.
2. Using hoses with valve core depressors, attach low- and
high-pressure gauge hoses to low- and high-pressure
service fittings, respectively.
3. Start unit and let run until system pressures stabilize.
4. Measure and record the following:
a. Outdoor ambient-air temperature (°F [°C] db).
b. Liquid line temperature (°F [°C]) at TXV.
c. Discharge (high-side) pressure (psig).
d. Suction (low-side) pressure (psig) (for reference
only).
5. Using Cooling Charging Charts (See Fig. 13) compare
outdoor-air temperature (°F [°C] db) with the discharge line
pressure (psig) to determine desired system operating liquid
line temperature (See Fig. 13).
6. Compare actual liquid line temperature with desired liquid
line temperature. Using a tolerance of -2°F (-I.I°C), add
refrigerant if actual temperature is more than 2°F (I.I°C)
higher than proper liquid line temperature, or remove
refrigerant if actual temperature is more than 2°F (I.I°C)
lower than required liquid line temperature.
NOTE: If the problem causing the inaccurate readings is a
refrigerant leak, refer to Check for Refrigerant Leaks section.
Indoor Airflow and Airflow Adjustments
[:NIT OPERATION HAZARD
Failure to follow this caution may result in unit damage.
For cooling operation, the recommended airflow is 350 to
450 cfm for each 12,000 Btuh of rated cooling capacity. For
heating operation, the airflow must produce a temperature
rise that falls within the range stamped on the unit rating
plate.
All blower motors are factory wired for nominal high stage and
low stage cooling airflow operation at minimum external static
pressure. See Table 2.
NOTE: Be sure that all supply- and return-air grilles are open,
free from obstructions, and adjusted properly.
Table 3- Color Coding for Indoor Fan Motor Leads
Black = High Speed
Orange =Med-High Speed
Red = Med Speed
Pink = Med-Low Speed
Blue = Low Speed
ELECTRICALSHOCK HAZARD
Failure to follow this warning could result in personal
iniury or death.
Disconnect electrical power to the unit and install lockout
tag before changing blower speed.
The high stage cooling fan speed of the unit is connected to the
"HIGH" terminal on the interface fan board (IFB) (See Fig.ll ).
The low stage cooling fan speed of the unit is connected to the
"LOW" terminal on the interface fan board (IFB) (See Fig. 11).
The unit is factory-shipped with fan speeds as noted in Table 4.
There are 3 additional speed tap wires available for use (For color
coding on the indoor fan motor leads, see Table 3). The additional
3 speed tap wires are shipped loose with vinyl caps and are located
in the control box, near the IFB.
To change the fan speed, remove the vinyl cap off of the desired
speed tap wire (Refer to Table 3 for color coding). Remove the
current speed tap wire from the "HIGH" or "LOW" terminal on the
interface fan board (IFB) (Fig. 11) and place vinyl cap over the
connector on the wire. Connect the desired speed tap wire to the
"HIGH" or "LOW" terminal on the IFB. For optimum
performance, add the wet coil pressure drop in Table 5to the
system static to determine the correct cooling airflow speed in
Table 4 that will deliver the nominal cooling airflow as listed in
Table 1 for each size.
NOTE: For cooling operation, the recommended airflow is 350 to
450 CFM for each 12,000 Btuh of rated cooling capacity.
NOTE: If accessory electric heat is installed in the unit, the dry
airflow must meet or exceed the minimum airflow specified in
Table 2 for the specific size. Use Table 4 to determine dry airflow
for a known external static pressure. Electric heat fan speed is the
same as high stage cooling fan speed.
Continuous Fan Operation
The continuous fan operates at the same fan speed as low stage
cooling fan operation.
Fig. 11 - Interface Fan Board (IFB)
A12006
12

Table 4-Dry Coil Air Delivery* - Horizontal and Downflow Discharge -
Unit PA5G--A24-60
Unit
(Voltage) Wire Color
Motor
Speed
Low 1
Med-Low
Medium 2
Med-High
High
Low 1
Med-Low
Medium
Med-High 2
High
Low 1
Med-Low
Medium 2
Med-High
High
Low 1
Med-Low
Medium 2
Med-High
High
External Static Pressure (IN. W.C.)
0.1
659
726
907
953
1179
921
1019
1272
1321
1478
1201
1419
1678
1916
2093
1320
1351
1824
2001
2292
0.2
551
625
837
870
1118
740
849
1203
1258
1426
1159
1364
1635
1881
2051
1256
1295
1782
1958
2238
0.3
440
537
759
807
1061
448
603
1150
1212
1387
1101
1318
1602
1846
2024
1211
1258
1742
1923
2158
0.60.4 0.5
335 ---
407 ---
679 588
718 652
996 942
479 ---
1097 1054
1168 1114
1334 1292
1062 1004
1258 1214
1558 1513
1810 1761
1967 1947
1142 1096
1212 1170
1711 1673
1883 1831
2049 1935
0.7 0.8 0.9
Blue CFM
Pink CFM ............
PA5G--A24 Red CFM 474 343 ......
(208/230-1-60) Orange CFM 528 443 ......
Black CFM 864 794 718 619
Blue CFM ............
Pink CFM ............
PA5G--A36 Red CFM 996 937 881 841
(208/230-1-60) Orange CFM 1075 1009 856 904
Black CFM 1247 1212 1148 1108
Blue CFM 957 897 852 793
Pink CFM 1160 1118 1053 1009
PA5G--A48 Red CFM 1474 1438 1404 1349
(208/230-1-60) Orange CFM 1722 1681 1647 1600
Black CFM 1907 1854 1826 1749
Blue CFM 1028 973 903 835
Pink CFM 1124 1080 1036 992
PA5G--A60 Red CFM 1641 1607 1563 1490
(208/230-1-60) Orange CFM 1776 1705 1624 1538
Black CFM 1840 1732 1635 1513
*Air delivery values are without air filter and are for dry coil (See PA5G Wet Coil Pressure Drop Table).
1 Factory-shipped low stage cooling speed
2 Factory-shipped high stage cooling speed, Electric heat speed (If electric heat is installed).
NOTE: Deduct field-supplied air filter pressure drop and wet coil pressure drop to obtain external static pressure available for ducting.
UNIT
SIZE
24
36
48
60
600 700 800 900 1000
0.005 0.007 0.010 0.012 0.015
0.019 0.023
Table 5-PA5G--AWetCoil Pressure Drop (IN.W.C.)
STANDARD CFM (S.C.EM)
1100 1200 1300 1400 1500
0,027 0,032 0,037 0,042 0,047
0.027 0.032 0.036 0.041
0.029
1600
0.046
0.032
1700
0.052
0.036
1800
0.057
0.040
1900
0.063
0.045
2000
0.068
0.049
2100
0.053

FilterSize
Inches(mm)
20X20X1
(508X508X25)
24X30X1
(610X762x25)
24X36X1
(610X914X25)
5OO
0.05
Table 6-Filter Pressure Drop (IN. W.C.)
CFM
600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000
0.07 0.08 0.1 0.12 0.13 0.14 0.15
0.05 0.06 0.07 0.07 0.08 0.09 0.1
0.06 0.07 0.07 0.08 0.09 0.09 0.10 0.11 0.12
2100
0.13
2200
0.14
2300
0.14
5kw
7.2 kw
10kw
15kw
5kw
7.2kw
10kw
15kw
20kw
500
0.00
0.00
0.00
0.00
1100
0.00
0.00
0.00
0.00
0.02
1200
0.00
0.00
0.00
0.02
0.03
600
0.00
0.00
0.00
0.00
1300
0.00
0.01
0.01
0.03
0.04
700
0.00
0.00
0.00
0.00
800
0.00
0.00
0.00
0.02
Table 7 -Electric Heat Pressure Drop (IN. W.C.)
900
0.00
0.00
0.00
0.04
Small Cabinet: 24 CFM
1000 1100
0.00 0.00
0.00 0.02
0.02 0.04
0.06 0.08
1200
0.00
0.03
0.06
0.10
1300
0.02
0.05
0.07
0.12
Electric Heat Pressure Drop Table (in. W.C.) -Large Cabinet 36-60 CFM
1400
0.01
0.02
0.02
0.04
0.05
1500
0.02
0.03
0.03
0.05
0.06
1600
0.03
0.04
0.04
0.06
0.07
1700
0.04
0.05
0.05
0.07
0.08
1800
0.05
0.06
0.06
0.08
0.09
1900
0.06
0.07
0.07
0.09
0.10
2000
0.07
0.08
0.08
0.10
0.11
2100
0.08
0.09
0.09
0.11
0.12
2200
0.09
0.10
0.10
0.12
0.13
1400
0.04
0.07
0.09
0.14
1500
0.06
0.08
0.10
0.16
2300
0.10
0.11
0.11
0.13
0.14
2400
0.11
0.12
0.12
0.14
0.15
1600
0.07
0.09
0.11
0.18
2500
0.12
0.13
0.13
0.15
0.16

DANGER ELECTRICAL SHOCK HAZARD DISCONNECT POWERBEFORE
FIELD
SUPPLY
POWER UNIT ONLY J L| BLH
MAXIMUM WIRE_ .....
SIZE 2 AWO. YEL"
EQUIP_GND ---
T-STAT
G--GIN --
R --RED --
¥| --YEL --
W2 --WNT i
UNIT COMPONENT ARRANGEMENT
OUTN®R FAN
SECTION
Y2 --PN_--
CONPRESSOR
SECTION
F_q
F_
iCONP
R
i
INDOOR FAN
SECTION
_,__=_ =_
24V POWER
-- ENTRY
CONTROLBOX AREA
SZNGLEPT.
CONNECTION
FOS
ELEC,SEAT
]I _--
24V SPLICEBOX
F-
RED
+
BLK
I
IFB
NOTE8
ELECTRIC HEATER
CONNECTOR FACCESSORY
ELECTRIC HEAT
<_BRN- n
I0- - _ -BRN-
-ORN-
<RI RY-- - RN-
LEGEND
NOTES:
H
FIELRRPLICE C CONTACTOR
TERMINAL(HARKED) CAP CAPACITOR
oTERMIHAL{U_MAR_ER) CB CIRCUITBREAKER
OOH CRANECA_EHEATER
oSPLICE ROMP COMPRESSOR_OTOR
_SPL_RE (MAR_ED) CTD COMPRESSORTIME RELAY
i fACTORY_IRIHR FEB FAR CONTROLBOARD
----FIELRCONTROLWEREH_ _HR _ROO_D
J- FIELDPOMERWIRIER BPE SIRE PRESSURESWITCH
---- ACCESSORYOR OPTIONAL BR BEATERRELAY
WIRIH_ IFR INDOORFAN BOARD
iTO INDICATECOMMON ErR INDOORFAN ROTOR
POTENTIALOHLY: LPS LOW PRESSURESWITCH
HOTTO REPR_ERT WEREH_ OFM OVTROORFAN MOTOR
TI_H TI_H_FOIMEN
T-RTRT _EIMOETAT
I, IF ANY OF THE ORIGINAL WIRES FURNISHED ARE REPLACED,
IT MUST BE REPLACED WITH TYPE 90 DEGREE C WIRE OR
IT'S EQUIVALENT.
2. USE 75 DEGREE COPPER CONDUCTORS FOR FIELD INSTALLATION,
3. REFER TO INSTALLATION INSTRUCTIONS
FOR CORRECT SPEED SELECTION OF IFM.
4. REL_ATION OF SPEED TAPS MAY BE REQUIRED
WHEN USING FIELD INSTALLED ELECTRIC BEATERS,
CONSULT INSTALLATION INSTRUCTIONS TO
DETERMINE CORRECT SPEED TAP SETTING.
5. 'DO NOT DISCONNECT PLUG UNDER LOAD.'
6. THIS FUSE IS MANUFACTURED BY LITTELFUSE, PIN 25700_.
7, UNIT FACTORY-SHIPPED IN STD MODE.
Fig. 12 -Connection Wiring Diagram 208/230-1-60
A12007
15

DANGER' ELECTRICAL SHOCK HAZARD DISCONNECT POWERBEFORE SERVICING
T'STAT
R - -_RED-
__z]_BR N_
C _ _z___yE L_
Y1
G - -Z_GRN-
Y2- -_-PNK-
W2- -_WHT-
W3- -Z_L--vIO-
LI I USE COPPER CONDUCTORS ONLY EOUI_ GND IL2
BLK YEL
11
11
11
FIELD SUPPLY _.L
208/230 VAC, 60 HZ, 1PH =
IF USED-----x.
C 21 _k CCH I23
----4 _--( )------BLK---o---BLK----_ _ FBLK-J
LGRN--m T
,4
21 _-----BLK" _C` R/_| Y_L
)._JBRN YIEL/_7 I
°-
_LK _x YEL
SEEIFB FUSE/
NOTE 8_ 3AMP
-C)PI-I"R"
0P1-2"0"
OP1-3"YI"
-0 P1-4"G"
P1-5'Y2'
"0 P1-6'W2'
-C) P1-7'w3'
"Y"C--
P2-1"C"C
P2-2"y"C
P2-3"W2"0
PZ-4"R"O
LOWC
HIGHC
P3-1"SOL" C
PS-2"SOL" C
24VACIR
P4-1CY--'--
P4- 20--"--
P4- 30-----
P4- 4O'-'--
P4- :_>""--
230 TRAN COM
208
-BLK "_
RED__-%L7 G/Y
YEL-
--BRN
-YEL
-WHT
-RED
HPS1 LPS
-.-_L[F_BLU/PN_-O._3----BLU/PN_--_YEL/PNK-_-O--YEL/PNK-4_LU_BRN--
SEE NOTE5 [ ___LO__r-m__f---_
--PNK ,FM
--ORN---'I "_ l--k /
--BLK_
--RED FTT--RED---_COMP SOLENOID
--B LK------,--RED_o-------- RED------_,_BLK_B LK----J
ELECTRIC HEATER BPS2 _-- ACCESSORY
CONNECTOR _. ELECTRIC HEAT
r"i
"--IF-"
_R_ _l< _ "BRN-- "_
-----4VNT-.!<,<2 _VHT- -C_- -BRN- "_
iV_ _< _ -VlO- -C_R4_- -BRN- .4
A
v
-----GRY--!<<s4RY - -_ -BRN- J
_<'<z
23
23
IFB
)IFB-COM
)IFB-C
50EZ500t59
Fig. 12 Cont. -Ladder Wiring Diagram 208/230-1-60
F
A12008
16

i
=
_r_
=-
=;
,I
=
_r_
=-
=;
Model
Size
24
36
48
60
REQUIRED SUBCOOLING °F_=}.
Outdoor Ambient Tem pe,rature °F(.__
__ 75 24 ____
16 (8,9) 15 (8.3) 14 (7.8) 14 (7,8) 13 (7,2)
18 (10) 17 (9.4) 17 (9.4) 17 (9.4) 17 (9.4)
15 (8.3) 15 (8.3) 14 (7.8) 14 (7.8) 14 (7.8)
Char imq_.qProcedure
1- Measure Discharge line pressure by attaching a gauge to the service port.
2= Measure the Liquid line temperature by attaching a temperature sensing
device to it.
3= Insulate the temperature sensing device so that the Outdoor Ambient
doesn't affect the reading.
4= Refer to the required Subcooling in the table based on the model size and
the Outdoor Ambient temperature.
5= Interpolate if the Outdoor ambient temperature lies in between the table
values,
8- Find the Pressure Value in the table corresponding to the the measured
Pressure of the Compressor Discharge line.
7= Read across from the Pressure reading to obtain the Liquid line
temperature for a required Subcooling
8= Add Charge if the measured temperature is higher than the table value.
9 - Remove charge if the measured temperature is lower than the table value.
Pressure
(psig)
189
196
263
210
217
224
231
238
245
252
260
268
276
284
292
300
309
318
327
336
345
354
364
374
384
394
404
4t4
424
434
444
454
464
474
484
494
504
514
524
534
5
61
83
66
68
76
72
74
76
77
79
81
83
85
87
89
91
93
95
97
99
I61
103
I05
107
108
t16
112
!14
t16
118
119
121
123
!24
126
127
!29
131
I32
134
Required Liquid Line Temperature for a Specific Subcoolin_ IR-41OA!
Required Subcooiing (°F) Required Subcooling !°C)
Pressure
10 15 20 25 (kPa) 36 8 11
56 5t 46 41 1303 t6 13 11 8
58 53 48 43 1351 17 15 12 9
61 56 51 46 1399 t9 16 13 10
63 58 53 48 1448 20 17 14 1I
65 66 55 56 1496 21 18 15 13
67 62 57 52 1544 22 19 16 14
69 84 59 54 1593 23 20 18 15
71 66 61 56 1641 24 21 t9 16
72 67 62 57 1689 25 22 26 17
74 69 64 59 1737 26 23 21 18
76 71 66 61 1792 27 25 22 19
78 73 68 63 1848 29 26 23 26
86 75 76 65 1903 30 27 24 21
82 77 72 67 1958 31 28 25 22
84 79 74 69 2613 32 29 26 23
86 81 76 7t 2668 33 30 27 24
88 83 78 73 2130 34 31 28 26
00 85 88 75 2192 35 32 29 27
92 87 82 77 2254 36 33 31 28
94 89 84 79 2316 37 34 32 29
96 9I 86 8t 2378 38 35 33 30
98 93 88 83 2440 30 36 34 31
100 95 90 85 2509 40 38 35 32
102 97 02 87 2578 41 30 36 33
103 98 93 88 2647 42 40 37 34
105 100 95 96 2716 44 41 38 35
107 t02 97 92 2785 45 42 39 36
100 104 99 94 2854 46 43 40 37
111 t06 101 98 2923 47 44 41 38
113 168 103 98 2992 48 45 42 39
114 109 104 99 3061 48 46 43 40
116 111 166 101 3130 49 47 44 41
118 113 108 103 3199 50 48 45 42
119 114 lg9 t04 3268 51 48 46 43
121 118 111 106 3337 52 49 47 44
122 117 112 107 3406 53 58 47 45
124 119 114 109 3475 54 51 48 46
t26 121 116 111 3544 55 52 49 46
127 122 117 112 3812 56 53 50 47
129 124 119 1t4 3681 56 54 51 48
14
5
6
8
g
16
11
12
13
14
15
16
17
19
20
2t
22
23
24
25
26
27
28
29
36
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
45
o_
o

H
MAINTENANCE
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 Table 8, Troubleshooting Chart.
NOTE TO EQUIPMENT OWNER: Consult your local dealer
about the availability of a maintenance contract.
PERSONAL INJURY AND UNIT DAMAGE
HAZARD
Failure to follow this warning could result in personal
injury or death and possible unit component damage.
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 on this equipment,
other than those procedures recommended in the Owner's
Manual.
ELECTRICALSHOCK HAZARD
Failure to follow these warnings could result in personal
injury or death:
1. Turn off electrical power to the unit and install lockout
tag before performing any maintenance or service on this
unit.
2. Use extreme caution when removing panels and parts.
3. Never place anything combustible either on or in contact
with the unit.
[]NIT OPERATION HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
Errors made when reconnecting wires may cause improper
and dangerous operation. Label all wires prior to
disconnecting when servicing.
The minimum maintenance requirements for this equipment are as
follows:
1. Inspect air filter(s) each month. Clean or replace when
necessary.
2. Inspect indoor coil, drain pan, and condensate drain each
cooling season for cleanliness. Clean when necessary.
3. Inspect blower motor and wheel for cleanliness each
cooling season. Clean when necessary.
4. Check electrical connections for tightness and controls for
proper operation each cooling season. Service when
necessary.
5. Ensure electric wires are not in contact with refrigerant
tubing or sharp metal edges.
AIR FILTER
IMPORTANT: Never operate the unit without a suitable air filter
in the return-air duct system. Always replace the filter with the
same dimensional size and type as originally installed. See Table 1
for recommended filter sizes.
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
whenever the filter becomes clogged with dust and lint.
INDOOR BLOWER AND MOTOR
NOTE: All motors are pre-lubricated. Do not attempt to lubricate
these motors.
For longer life, operating economy, and continuing efficiency,
clean accumulated dirt and grease from the blower wheel and
motor annually.
ELECTRICALSHOCK HAZARD
Failure to follow this warning could result in personal
iniury or death.
Disconnect and install lockout tag on electrical power to the
unit before cleaning the blower motor and wheel.
To clean the blower motor and wheel:
1. Remove and disassemble blower assembly as follows:
a. Remove blower access panel (see Fig. 15).
b. Disconnect 5 pin plug and 4 pin plug from indoor
blower motor. Remove capacitor if required.
c. On all units remove blower assembly from unit.
Remove screws securing blower to blower partition and
slide assembly out. Be careful not to tear insulation in
blower compartment.
d. Ensure proper reassembly by marking blower wheel and
motor in relation to blower housing before disassembly.
e. Loosen setscrew(s) that secures wheel to motor shaft,
remove screws that secure motor mount brackets to
housing, and slide motor and motor mount out of
housing.
2. Remove and clean blower wheel as follows:
a. Ensure proper reassembly by marking wheel orientation.
b. Lift wheel from housing. When handling and/or
cleaning blower wheel, be sure not to disturb balance
weights (clips) on blower wheel vanes.
c. Remove caked-on dirt from wheel and housing with a
brush. Remove lint and/or dirt accumulations from
wheel and housing with vacuum cleaner, using soft
brush attachment. Remove grease and oil with mild
solvent.
d. Reassemble wheel into housing.
e. Reassemble motor into housing. Be sure setscrews are
tightened on motor shaft flats and not on round part of
shaft. Reinstall blower into unit.
f. Connect 5 pin plug and 4 pin plug to indoor blower
motor. Reinstall capacitor if required.
g. Reinstall blower access panel (see Fig. 15).
3. Restore electrical power to unit. Start unit and check for
proper blower rotation and motor speeds during cooling
cycles.
18

1
A
MOTOR FAN GRILLE
X_MOTOR SHAFT
MAX DISTANCE BETWEEN TOP OF FAN GRILLE AND BOTTOM OF FAN BLADE
SIZE
24
36
48
6O
IN.
7.3
7.3
7.6
7.6
Fig. 14 - Fan Blade Position
"A"
MM
185
185
193
193
A08505 !1
air filter(s). If the drain trough is restricted, clear it with a
"plumbers snake" or similar probe device.
OUTDOOR FAN
Filter Access
Panel For Accessory
Filter Rack
Compressor Access
Panel
Blower Access
Panel
Fig. 15 - Unit Access Panels
OUTDOOR COIL, INDOOR COIL AND
CONDENSATE DRAIN PAN
Control Access
Panel
Al1632
Inspect the condenser coil, evaporator coil, and condensate drain
pan at least once each year.
The coils are easily cleaned when dry; therefore, inspect and clean
the coils either before or after each cooling season. Remove all
obstructions, including weeds and shrubs, that interfere with the
airflow through the condenser coil.
Straighten bent fins with a fin comb. If coated with dirt or lint,
clean 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 water, using a garden hose. Be careful not to
splash water on motors, 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 inner condenser coil, be sure to clean
between the coils. Be sure to flush all dirt and debris from the unit
base.
Inspect the drain pan and condensate drain line when inspecting
the coils. Clean the drain pan and condensate drain by removing all
foreign matter from the pan. Flush the pan and drain trough with
clear water. Do not splash water on the insulation, motor, wiring, or
UNIT OPERATION HAZARD
Failure to follow this caution may result in damage to unit
components.
Keep the condenser fan free from all obstructions to ensure
proper cooling operation. Never place articles on top of the
unit.
1. Remove 6 screws holding condenser grille and motor to top
cover.
2. Turn motor/grille assembly upside down on top cover to
expose the fan blade.
3. Inspect the fan blades for cracks or bends.
4. If fan needs to be removed, loosen the setscrew and slide the
fan off the motor shaft.
5. When replacing fan blade, position blade as shown in Fig.
14.
6. Ensure that setscrew engages the flat area on the motor shaft
when tightening
7. Replace grille.
ELECTRICAL CONTROLS AND WIRING
Inspect and check the electrical controls and wiring annually. Be
sure to turn off the electrical power to the unit.
Remove access panels (see Fig. 15) 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, restrip
the wire end and reassemble the connection properly and securely.
After inspecting the electrical controls and wiring, replace the
access panels (see Fig. 15). Start the unit, and observe at least one
complete heating cycle and one complete cooling cycle to ensure
proper operation. If discrepancies are observed in either or both
operating cycles, or if a suspected malfunction has occurred, check
each electrical component with the proper electrical
19

instrumentation.Refertotheunitwiringlabelwhenmakingthese
checkouts.
NOTE:Refertotheheatingand/orcoolingsequenceofoperation
in thispublicationasanaidin determiningpropercontrol
operation
REFRIGERANT CIRCUIT
Inspect all refrigerant tubing connections and the unit base for oil
accumulations annually. Detecting oil generally indicates a
refrigerant leak.
EXPLOSION, SAFETY AND ENVIRONMENTAL
HAZARD
Failure to follow this warning could result in personal
injury, death or equipment damage.
This system uses R-410A refrigerant which has higher
operating pressures than R-22 and other refrigerants. No
other refrigerant may be used in this system. Gauge set,
hoses, and recovery system must be designed to handle
R-410A. If you are unsure, consult the equipment
manufacturer.
If oil is detected or if low cooling performance is suspected,
leak-test all refrigerant tubing using an electronic leak-detector,
halide torch, or liquid-soap solution. If a refrigerant leak is
detected, refer to Check for Refrigerant Leaks section.
If no refrigerant leaks are found and low cooling performance is
suspected, refer to Checking and Adjusting Refrigerant Charge
section.
EVAPORATOR AIRFLOW
The heating and/or cooling air-flow does not require checking
unless improper pert\_rmance is suspected. If a problem exists, be
sure that all supply- and return-air grilles are open and free from
obstructions, and that the air filter is clean. When necessary, refer to
Indoor Airflow and Airflow Adjustments section to check the
system airflow.
R-410A ITEMS
The indoor metering device is aTXV type device.
PRESSURE SWITCHES
Pressure switches are protective devices wired into the control
circuit (low voltage). They shut off compressor if abnormally high
or low pressures are present in the refrigeration circuit, These
pressure switches are specifically designed to operate with R-410A
systems. R-22 pressure switches must not be used as replacements
for the R-410A air conditioner.
LOSS OF CHARGE/LOW-PRESSURE SWITCH
(AIR CONDITIONER ONLY)
This switch is located on the liquid line and protects against low
suction pressures caused by such events as loss of charge, low
airflow across indoor coil, dirty filters, etc. It opens on a pressure
drop at about 20 psig (957 Pa). If system pressure is above this,
switch should be closed.
To check switch:
1. Turn off all power to unit.
2. Disconnect leads on switch.
3. Apply ohmmeter leads across switch. You should have
continuity on a good switch.
NOTE: Because these switches are attached to refrigeration
system under pressure, it is not advisaMe to remove this device for
troubleshooting unless you are reasonaMy certain that a problem
exists. If switch must be removed, remove and recover all system
charge so that pressure gauges read 0 psi (0 Pa). Never open system
without breaking vacuum with dry nitrogen,
HIGH-PRESSURE SWITCH
The high-pressure switch is located in the discharge line and
protects against excessive condenser coil pressure. It opens at 650
psig (31.1 kPa). High pressure may be caused by adirty condenser
coil, failed fan motor, or condenser air recirculation.
To check switch:
1. Turn off all power to unit.
2. Disconnect leads on switch.
3. Apply ohmmeter leads across switch. You should have
continuity on a good switch.
COPELAND SCROLL COMPRESSOR (R-410A
REFRIGERANT)
The compressor used in this product is specifically designed to
operate with R-410A refrigerant and cannot be interchanged.
The compressor is an electrical (as well as mechanical) device.
Exercise extreme caution when working near compressors. Power
should be shut off, if possible, for most troubleshooting techniques.
Refrigerants present additional safety hazards.
EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury or death and/or property damage.
Wear safety glasses and gloves when handling refrigerants.
Keep torches and other ignition sources away from
refrigerants and oils.
The scroll compressor pumps refrigerant throughout the system by
the interaction of a stationary and an orbiting scroll. The scroll
compressor has no dynamic suction or discharge valves, and it is
more tolerant of stresses caused by debris, liquid slugging, and
flooded starts. The compressor is equipped with a noise reducing
shutdown device and an internal pressure relief port. The pressure
relief port is a safety device, designed to protect against extreme
high pressure. The relief port has an operating range between 550
(26.3 kPa) and 625 (29.9 kPa) psig differential pressure.
REFRIGERANT
EXPLOSION,
HAZARD ENVIRONMENTAL SAFETY
Failure to follow this warning could result in personal
injury, death or equipment damage.
This system uses R-410A refrigerant which has higher
operating pressures than R-22 and other refrigerants. No
other refrigerant may be used in this system. Gauge set,
hoses, and recovery system must be designed to handle
R-410A. If you are unsure, consult the equipment
manufacturer.
This system uses R-410A refrigerant which has higher operating
pressures than R-22 and other refrigerants. No other refrigerant
may be used in this system. Gage set, hoses, and recovery system
must be designed to handle R-410A. If you are unsure, consult the
equipment manufacturer. Failure to use R-410A compatible
servicing equipment or replacement components may result in
property damage or iniury.
COMPRESSOR OIL
The Copeland scroll compressor uses 3MAF POE oil. If additional
oil is needed, use Uniqema RL32-3MAF. If this oil is not
available, use Copeland Ultra 32 CC or Mobil Arctic EAL22 CC.
2O