Payne PH3Z Series User manual

PH3Z
13 SEER SINGLE-PACKAGED HEAT PUMP SYSTEM
WITH R-22 REFRIGERANT SINGLE AND THREE PHASE
2-5 NOMINAL TONS (SIZES 024-060)
Installation Instructions
NOTE: _ Read the entire instruction manual before starting the
installation.
TABLE OF CONTENTS
PAGE
SAFETY CONSIDERATIONS ... 0.00.00 eee 2
INTRODUCTION 2.00... eee 2
RECEIVING AND INSTALLATION .......0....00.00048. 2-7
Check Equipment .. 0.0.0... 00. eee eee 2
Identify Unit 22... ene 2
Inspect Shipment ..... 0.0.0... . eee eee 2
Provide Unit Support .. 0.0.0.0... ee ee eee 2
Slab Mount 2.0. 6c 2
Ground Mount ©... eee 2
Provide Clearances 0... 0. eee 2
Place Unit 2... een ee 2
Select and Install Ductwork... 0. ee 2
Configuring Units for Downflow (Vertical) Discharge .... 3
Connect Condensate Drain ©... 0. eee 3
Install Electrical Connections ©... 0.0... eee 6
High-Voltage Connections ... 0.0.0.0... 0. eee eee 6
Routing Power Leads Into Unit ...................00- 6
Connecting Ground Lead to Unit Ground .............. 6
Routing Control Power Wires... 2... 0. ee 6
Accessory Electric Heat Wiring ............. 00000000 6
PRE-START-UP 2000 eee 7
START-UP 2. eee 8-17
Check for Refrigerant Leaks .......... 000.000 00 vee ee 8
Start-Up Cooling and Make Adjustments ................ 8
Checking Cooling and Heating Control Operation ....... 8
Refrigerant Charge»... 0.0... eee ee eee 8
No Charge... 0.0... eee eee eens 8
Low Charge Cooling .. 0.0.0... 0. eee eee eee 8
Heating Mode Charge ... 0.0.0.0... 0. cee eee eee 8
Indoor Airflow and Airflow Adjustments ................ 9
Unit Controls 2... eee 9
High-Pressure Relief Valve... 0.0... 0... eee eee ee 9
Loss-of-Charge Switch 2.0... 0.0.0. eee eee 9
Compressor Overload 2.0.0.0... 00.00 eee eee ee 10
Compressor Rotation .. 2.0... 0. eee eee 10
Sequence of Operation 2.0... 0... eee eee eee 10
Fan Operation 00... 0... eee ee eee 10
2
s
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s
WII
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Ann
A05194
Fig. 1 - Unit PH3Z
Cooling Operation... 2.0... 0... eee eee 10, 17
Heating Operation .. 0.0... . 0. eee eee 17
Continuous Fan 2.2... eee 17
Defrost... 0. eee eens 17
Electric Resistance Heating .... 0.0.0.0... 0.0 eee eee 17
MAINTENANCE . 200 een 17-20
Air Filter 2. ee eens 18
Unit Top Removal... 0... eee 18
Indoor Blower and Motor ... 2.0.0.0... 000s 18
Outdoor Coil, Indoor Coil, and Condensate Drain Pan ..... 19
Outdoor Fan 2... eee eee 19
Electrical Controls and Wiring .... 0.0.0.0... 00 eee eee ee 19
Refrigerant Circuit... 0... eee 20
Indoor Airflow 2.0.0... ee eee 20
Metering Devices .. 0.0.0.0... cee eee 20
Liquid Line Strainers... 0.0.0.0... ee eee 20
High Flow Valves .. 0.0... 0.0. cece eee 20
TROUBLESHOOTING . 2... ones 20
START-UP CHECKLIST 2.0.0.0 eee 20

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.
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 ail safety codes. Installation must be in compliance with
local and national building codes. Wear safety glasses, protective
clothing, and work gloves. Have fire extinguisher available. Read
these instructions thoroughly and follow all warnings or cautions
included in literature and attached to the unit.
Recognize safety information. This is the safety-alert symbol A.
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.
CUANDO:
ELECTRICAL SHOCK 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 tag. There may be more than one
disconnect switch. Turn off accessory heater power switch if
applicable.
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care
and wear appropriate clothing.
INTRODUCTION
The PH3Z packaged heat pump is fully self-contained and
designed for outdoor installation (See Fig. 1). Standard units are
shipped in a horizontal-discharge configuration for installation on
a ground-level slab or directly on the ground if local codes permit.
Standard units can be converted to downflow (vertical) discharge
configurations for rooftop applications with a field supplied
plenum.
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 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.
Manutacturer 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.
Step 2 — Provide Unit Support
For hurricane tie downs, contact distributor for details and PE
(Professional Engineering) Certificate, if required.
SLAB MOUNT
Place the unit on a solid, level concrete pad that is a minimum of 4
in. (102 mm) thick with 2 in. (51 mm) above grade. The slab
should extend approximately 2 in. (51 mm) 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. (152 mm) wide gravel apron should be used around the
flat surface to prevent airflow blockage by grass or shrubs. The
unit should be level within 1/4 in. (6 mm). This is necessary for the
unit drain to function properly.
GROUND MOUNT
The unit may be installed either on a slab or placed directly on the
ground if local codes permit. Place the unit on level ground
prepared with gravel for condensate discharge.
Step 3 — Provide Clearances
The required minimum service clearances are shown in Fig. 5.
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
comer 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 4 in. (102 mm) above the highest expected water
and runoff levels. Do not use unit if it has been under water.
Step 4 — Place 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 must be
level with in 1/4 in. (6 mm) 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 supports the unit.
Step 5 — Select and Install 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 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.
Use the duct flanges provided on the supply- and return-air
openings on the side of the unit. See Fig. 5 for connection sizes
and locations. The 14-in. (356 mm) 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 prior to start-up, even if they are
not used for installation.
bo

When designing and installing ductwork, consider the following:
4 CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in damage to unit
components.
When connecting ductwork to units, do not drill deeper
than 3/4 in. (19 mm) in shaded area shown in Fig. 2 or coil
may be damaged.
<@— 19.17 in. (487 mm) ——P 13.92 in.| ¢q@——__.
(100 mm}
ce] oC o oO
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Ao8003
Fig. 2 - Area Not to be Drilled More Than 3/4-in. (19 mm)
Deep
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.
Fig. 6 shows a typical duct system with PH3Z unit installed.
CONFIGURING UNITS FOR DOWNFLOW (VERTICAL)
DISCHARGE
CE UA Le:
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
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. They are not convertible
to vertical air supply. A field-supplied plenum must be used to
convert to vertical air discharge.
Step 6 — Connect Condensate Drain
NOTE: When installing condensate drain connection be sure to
comply with local codes and restrictions.
Unit removes condensate through a 1-3/64 in. (27 mm) ID hole
(using 3/4-in. (19 mm) 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 the 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. (25 mm) 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. (51 mm) trap using a 3/4-in. (19 mm) OD
tubing or pipe. (See Fig. 3 and 4.) Make sure that the outlet of the
trap is at least 1 in. (25 mm) lower than the unit drain-pan
condensate connection to prevent the pan from overflowing. Prime
the trap with water. Connect a drain tube using a minimum of
3/4-in. (19 mm) PVC, 3/4-in. (19 mm) 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. (25 mm) for every 10 ft
(3 m) of horizontal run. Be sure to check the drain tube for leaks.
Prime trap at the beginning of the cooling season. start-up.
Allowable glues for condensate trap connection are: Standard
ABS, CPVC, or PVC cement..
1” (25 mm) MIN.
TRAP
OUTLET Y
2” (51 mm) MIN.
A08004
Fig. 3 - Condensate Trap
\ TT OUTLET
4
(25
mm)
MIN.
“yo
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!
{
— 2" (61 mm) MIN.
Fig. 4 - PVC Condensate Trap

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art ELECTRICAL UNIT WT. UNIT HEIGHT CENTER OF GRAVITY NM/IN
u CHARACTERTSTICS Les. | KG. A X i z
PH3Z024 208-230-1-60 293 | 133 [| 30.13 [765] | 14.0 (356) [ 19.0 [483] | 15.0 [387]
PH3Z030 208-230-1-60 324 | 147 [| 34.13 [867] | 14.0 (356) [ 19.0 (483) | 16.0 [406]
PH3Z036 208-230-1-60 377 fit [ 42.13 toro) [14.0 (386) [19.0 (483) [| 19.8 (503)
PH3Z042 208-230-1-60 389 | 177 | 42.13 (oT) | 14.0 (356) | 19.0 (483) | 21.9 (5561
PH3Z048 208-230-1-60 3ea_[ 175 | 42.13 Trove) [4.0 (3501 [19.0 (483) [19.8 (5031 REQUIRED CLEARANCES TO COMBUSTIBLE MATL. MILLIMETERS CTH]
PH3Z060 208-230-1-60 433_[i97_[ 42.73 trove) | 44.0 (356) [ 79.0 (4831 [21.9 (556) TOP OF UNIT...... a ce
BOTTOM OF UNIT... . “0
SIDE OF UNIT WITH DUCT OPENINGS. || ‘0
SIDE OF UNIT OPPOSITE DUCT OPENINGS 8
NEC. REQUIRED CLEARANCES,
MILLIMETERS CIN]
pe 1295.0 ——_____» BETWEEN UNITS, POWER ENTRY SIDE... 2.2.00. cccs.......,. 1066.8 [42.00]
(50, 98] UNIT AND UNGROUNDED SURFACES, POWER ENTRY SIDE..........914.0 [36.00]
BOTTOM OF UNIT UNIT AND BLOCK OR CONCRETE WALLS AND OTHER
GROUNDED SURFACES, POWER ENTRY SIDE...................,1066.8 [42,00]
REQUIRED CLEARANCE FOR SERVICING
MILLIMETERS CINJ
RETURN SUPPLY TOP OF UNIT. bo eeceeeeee 914.0 [36,00]
1 SIDE OF UNIT OPPOSITE DUCT OPENINGS. Silos irs ee. 162.0 [30.00]
SIDE OF UNIT WITH POWER ENTRY..... DTT 162.0 (30.00)
q CEXCEPT FOR NEC REQUIREMENTS)
NOTE: CLEARANCES MUST BE MAINTAINED TO PREVENT RECIRCULATION OF AIR FROM
OUTDOOR FAN DISCHARGE. A REMOVABLE FENCE OR BARRICADE REQUIRES NO
4 CLEARANCE,
812.9
39]
BOTTOM OF UNIT
BE DIMENSIONS IN [1 ARE IN INCHES
TOP VIEW
153.9
(29.681
COMPRESSOR, CONTROL BOX AND 138.3
INDOOR COIL ACCESS PANEL 129.07] —= 238.3 e—— 476.7 =
19.38] (18.77)
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® C6 LOW VOLTAGE ENTRY
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| | | | [28.75]
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- | . 5 [9.75] <A .
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26.8 1.0. [1.05] 12.7 DP..501 DUCT OPENINGS
CONDENSATE DRAIN
LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW REAR VIEW
A” REY
SO0ZH500442 so

INDOOR
THERMOSTAT
power ee
SOURCE
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DISCONNECT
(UNIT AND.
ELECTRIC "=
cheer |
RUST-PROOF
BASEPAN
CONDENSATE
CONNECTION
ames Power Wiring
Contro! Wiring
»»> Condenser Airflow
ey
Evaporator Airflow
A08207
Fig. 6 - Typical Installation
Table 1 - Physical Data
UNIT SIZE 024 030 036 042 048 060
NOMINAL CAPACITY (ton) 2 2-1/2 3 3-1/2 4 5
OPERATING WEIGHT (ib) 293 324 377 389 384 433
(kg) 133 147 171 176 174 196
COMPRESSOR Scroll Ultra Tech Scroll
REFRIGERANT (R-22)
Quantity (Ib) 7.5 10.3 10.3 11.9 11.4 13.3
(kg) 3.4 4.7 4.7 5.4 5.2 6.0
REFRIGERANT METERING DEVICE AccuRater® TXV
Orifice ID (in) 0.067 0.067 0.082 0.086 - -
Orifice OD (in.) 0.049 0.057 0.059 0.063 0.070 0.073
CONDENSER COIL Copper Tubes, Aluminum Plate Fins
Rows...Fins/in. 2...27 2...27 2...27 2...27 2...27 2...27
Face Area (sq. ft.) qd 12.7 15.8 15.8 13.3 15.8
CONDENSER FAN Propeller
Nominal Cfm 2600 2600 3200 3200 3200 3300
Diameter (in.) 20 20 20 20 20 20
(mm) 508 508 508 508 508 508
Motor HP (RPM) 1/8 (825) 1/8 (825) 1/4 (4100) 1/4 (4100) 1/4 (4100) 1/2 (4100)
EVAPORATOR COIL Copper Tubes, Aluminum Plate Fins
Rows...Fins/in. 3...17 3...17 4,..17 4,..17 4,..17 4,..17
Face Area (sq. ft.) 43 49 49 6.4 49 6.4
Evaporator blower Direct Drive
Nominal Airflow (Cfm) 800 | 4000 4200 | 4400 4600 1875
Size (in.) 10x8 11x9 41x10
(mm) 254 x 203 279 x 229 279 x 254
Motor HP (RPM) 1/2 (1050) | 1/2 (1050) 3/4 (1050) | 3/4 (1050) 1 (1050) | 1 (1050)
CONNECTING DUCT SIZES Round
Supply Air (in.) 14
(mm) 356
Return Air (in.) 14
(mm) 356
Return-Air Filters* Throwaway (in.) 24 x 24 24 x 30 30 x 30
(mm) 610 x 610 610 x 762 762 x 762
*Required filter sizes shown are based on the AAI (Air conditioning & Refrigeration Institute) rated airflow at a velocity of 300 ft/min (91 m) for throwaway type or
450 ft/min (137 m) for high capacity type. Recommended filters are 1—in. (25 mm) thick.

Table 2 - Minimum Airflow for Safe Electric Heater Operation
— Minimum Airflow (CFM)
Unit Size 5kW | 7.5kW | 10kW | 15kW | 20kW
024 500 650 750 - -
030 600 B00. | 1050 - -
036 600 goo. | 1050. 1150. | 1200
042 600 goo. | 1050. | 1150. | 1200
048 600 goo. | 1050. | 1150. | 1200
060 600 goo. | 1050. | 1150. | 1200
Step 7 — Install Electrical Connections
4 WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
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 70 American National Standards Institute/
National Fire Protection Association (latest edition) (in
Canada, Canadian Electrical Code CSA C22.1) and local
electrical codes.
4 CAUTION
UNIT 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 NEC
ANSI/NFPA 70 (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.
bo . Use only copper conductor for connections between
field-supplied electrical disconnect switch and unit. DO
NOT USE ALUMINUM WIRE.
. 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.
an
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. 6 and 7 for acceptable
location.
Operation of unit on improper line voltage constitutes abuse and
may cause unit damage that could affect warranty.
ROUTING POWER LEADS INTO UNIT
Use only copper wire between disconnect and unit. The
high-voltage leads should be in a conduit until they enter the unit;
conduit termination at the unit must be watertight. Run the
high-voltage leads through the hole on the control box side of the
unit (See Fig. 7). When the leads are inside the unit, run leads to
the control box (See Fig. 8). For single-phase units, connect leads
to the black and yellow wires (See Fig. 9).
CONNECTING GROUND LEAD TO UNIT GROUND
Connect the ground lead to the chassis using the unit ground in the
control box (See Fig. 8 and 9).
ROUTING CONTROL POWER WIRES (24-V)
Form a drip-loop with the thermostat leads before routing them
into the unit. Route the thermostat leads through grommeted hole
provided in unit into unit control box (See Fig. 7). Connect
thermostat leads and unit power leads as shown in Fig. 9, 10 and
11.
Route thermostat wires through grommet providing a drip-loop at
the panel. Connect low-voltage leads to the thermostat as shown in
Fig. 10 & 11.
The unit transformer supplies 24-v power for complete system
including accessory electrical heater. Transformer is factory wired
for 230-v operation.
ACCESSORY ELECTRIC HEAT WIRING
Refer to accessory electric heat installation instructions for
information on installing accessory electric heat. Accessory electric
heat wiring is shown in Fig. 17 and 18.
LOW-VOLTAGE WIRING
ENTRY HOLE
HIGH-VOLTAGE POWER
WIRING ENTRY HOLE
(grommet hole)
A08407
Fig. 7 - Unit Electrical Connection

HEATER LOW
VOLTAGE PLUG
A05388
Fig. 8 - Control Box Wiring
UNIT GROUND
GROUND
-~Teap [
SINGLE-PHASE |; ___ _ | RK
3-PHASE CONNECTIONS
CONNECTIONS |TODISCONNECT), = ~R_veL
TO DISCONNECT |PER NEC L YEL~
PER NEC
bin nanny - 7 Blu-
co0012
Fig. 9 - Line Power Connections
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Lie
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GRN
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YEL
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ORN
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The
Thermostat
and subbase
cf VIO
Unit Controi
Power
A05207
Fig. 10 - Control Connections (Sizes 024-042)
Thermostat
and subbase
Unit Control
ower
A05208
Fig. 11 - Control Connections (Sizes 048-060)
PRE-START-UP
CUANDO:
FIRE, EXPLOSION, ELECTRICAL SHOCK
HAZARD
Failure to follow this warning could result in personal
injury or death and/or property damage.
1. Follow recognized safety practices and wear protective
goggles when checking or servicing refrigerant system.
bo . Relieve and recover all refrigerant from system before
touching or disturbing anything inside terminal box 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 ail 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 flame.
Proceed as follows to inspect and prepare the unit for initial
start-up:
1. Remove all access panels.
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
Check for Refrigerant Leaks section.

c. Inspect all field- and factory-wiring connections. Be
sure that connections are completed and tight.
d. Ensure wires do not touch refrigerant tubing or sharp
sheet metal edges.
e. Inspect coil fins. If damaged during shipping and
handling, carefully straighten fins with a fin comb.
4. Verity the following conditions:
a. Make sure that outdoor-fan blade is correctly positioned
in fan orifice. Top edge of blade should be 3.125 in.(79
mm) down from outdoor coil outlet grille (size
024-048, See Fig. 19) or hub should be 0.708-in. (18
mm) away from motor end bell (size 060, See Fig. 19).
See Outdoor Fan Adjustment section.
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 and miscellaneous loose parts
have been removed.
START-UP
Step 1 — 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 accepted practices.
NOTE: Install a filter drier whenever the system has been opened
for repair.
Step 2 — Start-Up Cooling and Make Adjust-
ments
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 (4.4°C) (unless
accessory low-ambient kit is installed). Do not rapid cycle the
compressor, Allow 5 min. between “on” cycles to prevent
compressor damage.
CHECKING COOLING
OPERATION
Start and check the unit for proper cooling control operation as
follows:
1. Place room thermostat SYSTEM switch in OFF position.
Observe that blower motor starts when FAN switch is
placed 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.
. Place SYSTEM switch in COOL position and FAN switch
in AUTO position. Set control below room temperature.
Observe that compressor, outdoor fan, and indoor blower
motors start and that reversing valve shifts. Observe that
cooling cycle shuts down when control setting is satisfied.
Reversing valve (RV) remains energized.
AND HEATING CONTROL
bo
3. Place system switch 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 mode when
temperature control is set to call for Cooling (below room
temperature), and unit operates in Heating mode when
temperature control is set to call for Heating (above room
temperature).
Step 3 — Refrigerant Charge
Refrigerant Charge — Amount of refrigerant charge is listed on
unit nameplate 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 Refrigerant Service Techniques. Use standard
evacuating techniques. After evacuating system, weigh in the
specified amount of refrigerant (refer to Table 1).
LOW CHARGE COOLING
024-042 units:
1. Measure suction line pressure by attaching a gauge to the
service port.
bo . Measure the suction 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. Locate the measured suction line pressure in the top row of
Table 5 and the measured outdoor ambient temperature in
the left column 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:
1. Measure discharge line pressure by attaching a gauge to the
service port.
bo . 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 Tables 3 to find the
required subcooling based on the model size and the
outdoor ambient temperature.
5. Interpolate if the outdoor temperature lies in between the
table values. Extrapolate if the temperature lies beyond the
table range.
6. Find the pressure value corresponding to the measured
pressure on 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
liquid line temperature value in the table.
9, Add charge using the service connection on the suction line
of the compressor.
HEATING MODE CHARGE
Do not attempt to adjust charge by cooling methods while in heat
pump heating mode. Recover refrigerant and weigh in according to
unit data plate refrigerant data.

Table 3 — Required Subcooling
Required Subcooling FCC} Required Liquid Line Temperature for a Specific Subcooling (R-22)
Outdoor Ambient Temperature Required Subcooling (°F) Required Subcooling (C}
Model Size Pressure Pressure
75 (24) 82 (28) 85 (29) 95 (35) 105 (44) (psig) 5 10 15 20 (kPa) 3 § 8 Z|
048 18 (10) | 1719.4) | 17 (9.4) | 16 (8.9) | 14 (7.8) 134 7 66 61 56 924 34 39 19 16
049 24 (13.3) | 23 (42.8) 22 (12.23 22 (12.2) 20 (11.7) 141 14 69 64 59 972 26 23 21 18
060 21 (i1.7)] 21 (11.7) | 20 (41.1) | 19 (10.6) | 16 (8.9) 156 80 15 10 65 1075 30 27 24 2]
163 83 18 73 68 1124 31 28 26 23
170 86 81 16 V1 1172 33 30 27 24
Vat 89 84 79 14 1220 34 31 29 26
184 91 86 81 76 1268 36 33 30 27
. 194 94 89 84 19 1307 37 34 3] 29
Charging Procedure (CHARGE SYSTEM IN HIGH CAPACITY)
1- Measure bot line pressure by attaching a gauge to the “8 5 s 88 8 He i 7 si 5s
2- Measure the Liquid line temperature by attaching a
temperature sensing device to it. eet ie 88 a4 88 ised 43 a0 3 34
3- Insalate the temperature sensing device se that the Outdoor . .
Ambient doesn’t affect the reading. 229 106 101 96 31 1579 44 4 38 36
4- Refer to the required Subcooling in the table to find the 237 108 103 98 93 1634 45 42 40 37
required Subcooling based on the model size and the 245 WW 106 101 96 1689 47 44 4] 38
Outdoor Ambient temperature. 253 113 108 103 98 1744 48 45 42 40
5- Interpolate if the Outdoor temperature lies in between the
table values. 262 116 i 106 101 1806 49 46 44 44
6- Find the Pressure Value corresponding to the measured 271 118 113 108 103 1868 54 48 44 42
Pressure on the Compressor Discharge line. 280 121 116 111 106 1930 52 49 46 44
7- Read across from the Pressure reading to obtain the Liquid 289 123 118 113 108 1992 53 51 48 45
line temperature for a required Subcooling
8- we Charge if the measured temperature is higher than the 298 125 120 115 110 2054 55 52 49 46
iqaid line temperature value in the table &
9- Add Charge using the service connection on the Suction line 307 168 1¢3 118 M3 21g 36 28 90 a8
of the Compressor 317 130 125 120 115 2185 57 54 52 49
10-Remove charge if the measured temperature is lower than the get 132 tel tee a eeo4 98 96 33 58
liquid line temperature in the table.
337 135 130 125 120 2323 60 57 54 52
347 137 132 127 122 2392 61 58 56 53
357 139 134 129 124 246) 62 60 57 54
367 142 137 132 127 2530 64 61 58 95
DRAWING RUMBER REY
50ZH500375 5.0
A08406
Step 4 — Indoor Airflow and Airflow Adjust-
ments
NOTE: | For cooling operation, the recommended airflow is 350
to 450 cfm for each 12,000 Btuh of rated cooling capacity.
Table 4 shows dry coil air delivery for horizontal discharge units.
Tables 6-8 show pressure drops.
NOTE: Be sure that all supply- and return-air grilles are open,
free from obstructions, and adjusted properly.
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Disconnect electrical power to the unit and install lockout
tag before changing blower speed.
Airflow can be changed by changing the lead connections at the
blower motor. To change motor speeds, reposition wire at fan
motor speed terminals labeled 1-2-3-4 (refer to Fig. 12).
Remove the speed tap connector labeled 1 through 5 on the motor.
While looking at the connector end that is inserted into the motor,
gently pry the locking tab outward and remove the wire from the
connector. Insert the wire into the desired tap until it locks into
place. Be sure new airflow meets the range noted above and
minimum electric heat CFM, if equipped. Refer to Table 2 and 4.
All model sizes are factory wired or rated airflow operation.
Fig. 12 - Motor Speed Selection
FOR 208/230V BLOWER MOTORS
The motor lead speed connections are as follows:
I
WU G&@OoOO!
SIZE RATED AIRFLOW HIGH AIRFLOW
024 Tap 1 Tap 3
030 Tap 2 Tap 4
036 Tap 1 Tap 3
042 Tap 2 Tap 4
RATED AIRFLOW HIGH AIRFLOW
SIZE Low High Low High
Stage Stage Stage Stage
048 Tap 1 Tap 3 Tap 2 Tap 4
060 Tap 1 Tap 3 Tap 2 Tap 4

Step 5 — Unit Controls
All compressors have the following internal-protection controls.
HIGH-PRESSURE RELIEF VALVE
This valve opens when the pressure differential between the low
and high side becomes excessive.
LOSS OF CHARGE 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 either the
current or internal temperature become excessive, and
automatically resets when the internal temperature drops to a safe
level.
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.
Step 6 — 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 service gages to suction and discharge pressure
fittings.
2, Energize the compressor.
3. The suction pressure should drop and the discharge pressure
should rise, as is normal on any start-up.
If the suction pressure does not drop and the discharge pressure
does not rise to normal levels:
1. Turn off power to the unit and tag disconnect.
2. Reverse any two of the unit power leads.
3. Turn on power to the unit.
The suction and discharge pressure levels should now move to
their normal start-up levels.
NOTE: When the compressor is rotating in the wrong direction,
the unit makes an elevated level of noise and does not provide
cooling.
Step 7 — Sequence of Operation
FAN OPERATION
The FAN switch on the thermostat controls indoor fan operation.
When the FAN switch is placed in the ON position, the IFR
(indoor-fan relay) is energized through the G terminal on the
thermostat. 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.
When the FAN switch is set to AUTO, the thermostat 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
is equipped with accessory electric heat, the indoor-fan motor will
also run while the accessory electric heat is energized.
NOTE: Some units are equipped with a time-delay relay. On
these units, the indoor fan remains on for 30 seconds 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.
COOLING OPERATION (SIZES 048 AND 060)
These units utilize a 2 stage indoor thermostat. 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 of an initial start-up) starting the compressor (low
stage) and the outdoor fan motor. If the low stage operation cannot
satisfy the cooling demand, the second stage cooling (Y2)
energizes switching the compressor into high stage cooling through
energizing an internal solenoid valve inside the scroll compressor
and switching the indoor fan into high stage. When second stage
cooling is satisfied, Y2 de-energizes switching the compressor and
the indoor fan into low stage cooling. When the low stage cooling
demand is met, Y1 de-energizes shutting the compressor, indoor
fan and the outdoor fan.
HEATING OPERATION (SIZES 024-042)
With a call for heating (Y1), the indoor fan Gow stage) 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. If Y/Y2 cannot satisfy the heating demand, the
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
demand is met, W3, W2 and Y/Y2 sequentially de-energize
shutting the compressor, indoor fan and the outdoor fan.
HEATING OPERATION (SIZES 048 AND 060)
With a first stage call for heating (Y1), the indoor fan (low stage)
energizes immediately whereas the contactor energizes after a 5
minute time delay (in case of initial start-up) starting the
compressor (low stage) and the outdoor fan motor. If the low stage
oepration 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 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 demand is satisfied, W3, W2 and Y2 sequentially
de-energize switching the compressor and the indoor fan into low
stage heating. When the low stage heating demand is met, Y1
de-energizes shutting the compressor, indoor fan and the outdoor
fan.
CONTINUOUS FAN
With the continuous Indoor fan option selected on the thermostat,
G is continuously energized. In case of 024-042 units, the selected
airflow setting is provided. In case of 048 and 060 units, the
system runs low stage (Y1) airflow for continuous fan operation.
DEFROST
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 timer and defrost cycle start only when contactor is
energized and defrost thermostat (DFT) is closed.
Defrost mode is identical to Cooling mode. The outdoor fan motor
stops because of “OF1” and “OF2” contacts opening on the defrost
board, a bank of optional electric heat turns on to warm air
supplying the conditioned space.
ELECTRIC RESISTANCE HEATING
If accessory electric heaters are installed, on a call for second stage
or emergency heat, the thermostat energizes W which energizes the
heater relay and in turn energizes the electric heaters. The blower
motor is energized, unless already running in heat pump heating
mode. If the heaters are staged, W2 is energized when the second
stage of heating is required. When the need for heating is satisfied,
the heater and IFM are de-energized.
10

FIELD SCHEMATIC
CCH
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DIP SWITCH OEMS
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—_ cc tt
LEGEND Wel iL
a FIELD SPLICE FIELD SELECTABLE OPTIONS FoR pe PERIOD
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a = 47 = GRD GROUND DEFROST WILE TERMINATE iM 30 SEC. IF DFT OPER
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GARD POTENTIAL ONLY TFM INDOOR FAN MOTOR
BOARD NOT TO REPRESENT WIRING [ps LOW PRESSURE SWITCH
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OFM OUTDOOR FAN MOTOR
RVS. REVERSING VALVE SOLENOID
TRAN TRANSFORMER
NOTES:
EQUIP.
COMP 7 1. IF ANY OF THE ORIGINAL WIRES FURRHED ARE REPLACED, i CTD (11,72) COMPRESSOR DELAY
GND IT MUST BE REPLACED WITH TYPE 90 DEGREE C WIRE OR cA SEOUENCE
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PER NEC 3. USE 75 DEGREE COPPER CONDUCTORS FOR FIELD INSTALLATION. & Ci Cl
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8 SUPPLIED 93022 TSA
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WHEN USING FIELD INSTALLED ELECTRIC HEATERS,
CONSULT INSTALLATION INSTRUCTIONS
DETERMINE CORRECT SPEED TAP sirtiNe
$. "BO NOT DISCONNECT PLUG UNDER LOAD."
[sormso0411 9.0)
A08209
Fig. 13 - Typical Single-Phase Unit Electrical Diagram (Sizes 024-042)
11

UNIT COMPONENT ARRANGEMENT
QUTBOOR FAN
SECTION
men mon
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CONTROL BOX AREA
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CONSULT INSTALLATION
LEGEND
CONTACTOR:
CAPACITOR
CIRCUIT BREAKER
S Fieto splice
TERMINAL (MARKED)
© TERMINAL (UNMARKED?
IF ANY OF THE ORIGINAL WIRES FURNISHED ARE REPLACED,
IT MUST BE REPLACED WITH TYPE 90 DEGREE C WIRE OR
IT'S EQUIVALENT
it PRICE PAGES FOR THERMOSTAT AND SUBBASES.
SE 75 OEGREE COPPER urs For ay INSTALLATION
RELOCATION OF SPEED TAPS MAY SE
WHEN USING FIELD INSTALLED cuca HEATERS.
ERSTRUCTION ST
DETERMINE CORRECT SPEED TAP seria.
"DO NOT DISCONNECT PLUG UNDER LOAD. ©
FIELD cH SCHEMATIC
PPLY :
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DIP SWITCH SETTINGS
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30 MINUTES 60 MINUTES 96 MINUTES 120 MINETES
¢ ———3RN
FIELD SELECTABLE OPTIONS FOR TIME PERIOD
BETWEEN DEFROST CYCLES (MINUTES?
THE COMPRESSOR WILE “SHUT OFF FOR 30 SEC
cen & INITEATHON AND TERWIKATION TW THE "QUIET SHEFT*
° EAKER Ost ION
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NO! TO. REPRESENT WIRING Te pk ter eehat eer rca
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OFM = OUTDOOR FAN NOT
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TRAN TRANSFORMER
FAN SEQUENCE CTD {71,12} COMPRESSOR DELAY
8 y 1490 o .5StC 7 TH MIN
6 6 G a
ENERGIZED — DE-ENERGIZED CLOSES gpens
TSAT
50ZH500374 |t0.
ot DEEAOsT
Fig. 14 - Typical Single-Phase Unit Electrical Diagram (Sizes 048-060)
A06405

FIELD con SCHEMATIC
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(DEFAULT)
30 MINUTES 60 MINUTES 90 MINUTES 120 MINUTES On
¢ ———arn T23] [eta] fp2a] faa Th
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LEGEND of
UNIT COMPONENT ARRANGEMENT
OUTDOOR FAN CONTROL BOK AREA
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} rievo spcice
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2 Re vy Se SRMRE Rta
© SPLICE (HARKED) COMP COMPRESSOR MOTOR
FACTORY WIRING CTD COMPRESSOR TINE DELA
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AFIELD
Power
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DEF
BEEROST
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T= ACCESSORY éF ROS
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RYS REVERSING VALVE SOLE
TRAN TRANSFORMER
NOTES
1, IF ANY OF THE GRIGINAL WIRES FUMSHED ARE REPLACED,
TT MUST BE REPLACED WITH TYPE 90 DEGREE € WIRE OR
IT'S EQUIVALENT
2. SEE PRICE PAGES FOR THERMOSTAT AND SUBBASES
3. USE 75 DEGREE COPPER CONDUCTORS FOR FIELD INSTALLATION
4, FACTORY WIRING FOR SPEED SELECTOR PLUG EN
02421
63022
03621
oder
5. RELOCATION OF SPEED TAPS MAY BE REQUIRE
WHEN USING FIELD INSTALLED ELEC Tae sHEATE,
CONSULT INSTALLATION INSTRUCTIONS
DETERMINE CORRECT SPEED Ta? urtine.
6. "DO NOT DISCONNECT PLUG UNDER LOAD."
FIELD SELECTABLE OPTIONS FOR TIME PERIOD
BETWEEN DEFROST CYCLES <WINUTES?
THE COMPRESSOR WILL SHUT OFF FOR 30, SEC. O DEFROST
TALTIAEION AnD TEMEAATION I THE "QUIET SeIet™
sees} JUMPERED TEST PINS {USE METAL OBJECT?
e AMS eth Ue RE
1) MOMENTARILY SHORT PERS AND RELEASE TO BYPASS
COMPRESSOR OFF DELA\
2) SHORT FOR 5+ SEC. AND RELEASE FOR FORCED DEFROST
3) PERMANENT SHORT WiLL BE IGNORED
y
DEFROST WILE TERMINATE IN 30 SEC. 1F DFT OPEN
DEFROST WILE TERMINATE NORMALLY IF DFT IS CLOSED
NOID
FAN SEQUENCE CTD {11,12} COMPRESSOR DELAY
Q b 7460 0.5 SEC 1 T+5 MIN,
: ‘i t a ¢
ERGIZED DE-ENERGIZED CLOSES opens
TSAT
902H500453 43.0
A06325
Typical Three-Phase Unit Electrical Diagram (Sizes 030-042)

FIELD SCHEMATIC
vont
DR
@
DB
208/230-3-60
UNIT
ONLY
BLI
TA
Het
ml
ss
TP
\
a OFM
MAXIMUM. WIRE
SIZE
2
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=
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FOR WRIG WITH == .
ELECTRIC HEATERS rex 1 an ve GRN-YEL
SEE SCHEMATIC Pe A
ON HEATER AccessoRY. |= L— = = T; 1! rh
i4 | I BLK G30) Gd) cy [ft
l | | SEE NOTE #6
; I BRN
TRANT “ 3.2 AM
| MANUAL RESET
I (a)
|
|
| | |
DEFROST BOARD 1 DB)
J
6 GRN
R RE
al YEL
9 ‘ORN
we WHT
Y¥2 ———PNK
w3-———V 10
¢ ———BRN
LEGEND
A view speice
ACCESSSORY ELECTRIC HTN
HRI «5 KW) BRN
WHT wm (HR BRN
HRI,2,3 8 4 (20 Kif BRN
PSs
PK ———____|
HR1,2 8 3 095 KW)
GRY
VIO
HRI & 2 (10 KW)
BRN
DIP SWITCH SETTINGS
«DEF AULT)
30 MIMGTES $0 MIBUTES $0 MINUTES 120 MINUTES ‘ou
123 123 123 123 123
CU ° Ui " WU . in ill
OFF
FIELD SELECTABLE OPTIONS FOR TIME PERIOD
FSi
z
BEIWEER DEFROST CYCLES (MINUTI
——erore SERMON cides gr HEE Pa eR E Bal h o enge
gyrase CONTROL 80% o, Si ce, RCH cute msi
= =aSo Cp SPLICE (MARKED? OMP COMPRESSOR MOTOR sPeED JUNBERED TEST PINS (USE METAL OBJECT?
$84 FSse FACTORY WIRING CTD COMPRESSOR TINE OFLAY FIED SPEED-UP CELE
ce. 0 OS Be — FIELD CONTROL WIRING © DB DEFROST BOARD 1 (AOENTARILY SHORT, PINS ARD RELEASE TO BYPASS
Bae mm a 7 TTELO POWER WIRING vr aeeost Resta 2) SRORT FOR 5+ SEC. AKD RELEASE FOR FORCED DEFROST.
Sao of BR === ACCESSORY OR OPFTONAL OI 3) PERMANENT SHORT WILL BE IGNORED
2°R 3 @ WIRING CB FAN CONTROL BOARD
DEFROST] | Faw KD © GROURD DEFROST WILL TERMINATE IN 36 SEC, IF DFT PEN
BOARD CONTROL —— 10 INDICATE COMMON BR HEATER RELAY DEFROST WILL TERMINATE NORMALLY IF DFT IS CLOSED.
~ BOARD POTENTIAL ONLY: TFM INBOOR FAN MOTOR
cap NOT TO REPRESENT WIRING | ps LOW PRESSURE SWITCH
“/ HPS HIGH PRESSURE SWITCH
OFM OUTDOOR FAN MOTOR
RVS «REVERSING VALVE SOLENOIO
TRAN TRANSFORMER
EQuIe NOTES
COMP :
GND 1. [EF ANY OF THE ORIGINAL WIRES FURNISHED ARE REPLACED, FAN SEQUENCE CID (T4,72) COMPRESSOR DELAY
TT MUST BE REPLACED WITH TYPE 90 DEGREE ¢ WIRE OR
DISCONNECT IT’S EGUIVALENT
PER NEC 2. SEE PRICE PAGES FOR THERMOSTAT AND SUBBASES 0 T1490 o.5 SEC 7 Te5 MIN
3. USE 75 DEGREE COPPER CONDUCTORS FOR FIELD INSTALLATION 6 6 cl a
FIELD 4. RELOCATION OF SPEED TAPS MAY BE REOUIRED ENERGIZED DE-ENERGIZED CLOSES PENS
c SUPPLIED WHEN USING FIELD INSTALLED ELECTRIC HEATERS, TSAT OPENS
Soe NLS
oO epee POWER ENTRY 5. "DO NOT DISCONNECT PLUG UNDER LOAD, *
50ZH500454 43.0
A06326
Fig. 16 - Typical Three-Phase Unit Electrical Diagram (Sizes 048-060)
14

UNIT FAN Lv
CONTROL PLUG
BOARD CEP BRN = FE
STEP 4 Ga waT — — — — — => 5-775 I
@4pvie ------------- 1 '
. WSR enk — —-—-—----—---- = 1 |
Ss f i I
STEP
al
bers
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UNIT POWER ——5LK pa bl 1
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: OS On —— o-| ko BLK YEL
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ry BB io RELAY 2 |
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SINGLE POINT KIT. ) RELAY 3 I
L-~4---f6“;-o]-sen-4¢ EL3 AUTO LIMIT
|
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lo“ -O4 ---- —sBren-
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o-| fo BLK YEL
wa PUNK
STEP 2m VIOLET
wi ae
sree | tre
we
BROWN
c
TO UNIT CONTROL
WHREING 2aVAC
Fig. 17 - Single-Phase Accessory Electric Heater Wiring
>!
| HRS
TO UNIT POWER
WIRING
BLUE
YELLOW
BLACK
cai
|
aul
it
*
BLUE
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Fig. 18 - Three-Phase Accessory Electric Heater Wiring
A05209
bi
be
L3
A06327

Table 4 - Dry Coil Air Delivery* Horizontal Discharge
(Deduct 10 percent for 208 Volt Operation)
230 VOLT HORIZONTAL DISCHARGE
UNIT SPEED AIR EXTERNAL STATIC PRESSURE (IN. WC)
SIZE TAP DELIVERY 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Watts — 99 700 118 7130 742 — — — —
' CFM — 848 793 757 698 632 — — — —
024 Watts — — — — — 222 233 244 257 260
2 CFM — — — — — 970 918 861 795 729
Watts — 755 146 157 170 — — — — —
2 CFM — 4108 995 951 884 — — — — —
030 Watts — — — — — 261 275 286 291 3715
3 CFM — — — — — 1117 7053 7074 980 877
Watts 780 166 179 197 204 216 — — — —
' CFM 1344 72715 1172 1136 7095 7054 — — — —
036 Watts — — — 261 276 290 301 316 329 342
2 CFM — — — 1343 7304 4272 4234 7190 1148 77100
Watts 269 283 305 321 336 349 360 — — —
3 CFM 1440 7404 1369 1333 7301 1273 1239 — — —
042 Watts — — 418 432 450 465 480 490 503 518
4 CFM — — 1572 7543 7504 1475 1444 14718 1380 41332
Watts — 204 209 216 229 236 249 — — —
' CFM — i129 1087 1027 994 932 884 — — —
Watts — — 233 245 254 266 276 289 — —
2 CFM — — 1164 4122 1066 7025 954 906 — —
048 Watts 386 398 409 418 425 435 438 444 451 —
3 CFM 1680 7652 7625 7583 7555 75715 1477 1444 7403 —
Watts — 440 448 457 462 469 477 480 485 486
4 CFM — 1745 1717 1684 1654 16712 1573 1537 7508 1470
Watts 224 235 251 266 277 291 298 — — —
' CFM 1334 1288 1259 7224 1181 1157 1117 — — —
Watts — — 286 301 317 325 333 344 370 —
2 CFM — — 1333 1296 1261 4232 1199 4170 7062 —
060 Watts 608 626 643 660 668 685 697 — — —
3 CFM 4931 7900 1878 1844 1817 1789 1755 — — —
Watts 737 755 770 787 799 817 826 812 782 —
4 CFM 2093 2067 2028 2001 1971 7934 1899 7850 1757 —
*Air delivery values are based on operating voltage of 230v, wet coil, 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 coil frosting may occur at air-
flows below this point.
2. Dashes indicate portions of table that are beyond the blower motor capacity or are not recommended.
16

Table 5 — Cooling Charging Chart
SUCTION LINE TEMPERATURE (°F)
Suction Line Pressure (PSIG)
oD Cy 52 54 56 59 61 64 67 7o | 73 | 76 | 79 | 82 | 85 | 89 92
45 51 55 60 64 69 —_— —_— —_— —_ —_ _— —_— —_— —_ —_—
55 — — 53 57 62 66 70 —_— —_— —_— —_ —_ _— —_— —_—
65 — — — —_— 53 57 62 66 71 75 —_— —_— —_— —_ —_
75 _ _ _ _ _ _ —_ 56 61 | 66 | 71 7 | — | — —
85 — — — — — — — —_— 53 58 63 67 72 —_— —_—
95 —_— — — — — — — — —_— 50 54 58 62 66 —_—
105 — — — — — — — — — — 50 53 57 60 64
115 — — — — — — — — — — 49 52 55 58 61
125
_ _ —
—_—
—
— — — —
—
—
50
53
56
59
SUCTION LINE TEMPERATURE (°C)
Suction Line Pressure (kPa)
Pee) P. 361 370 387 405 423 442 462 482 502 523 544 566 589 612 636
7 11 13 15 18 21 —_— —_— —_— —_ —_ _— —_— —_— —_— —_—
13 —_ —_ 12 14 16 19 24 —_ —_ — f—f/—f—f]— —_
18 — — — —_— 12 14 17 19 21 24 —_— —_— —_— —_ —_
24 _ _ _ _ _ _ —_ 13 16 49 | 22 | 24 | — | — —
29 _ _ _ = _ = = — 12 14 | 17 | 20 | 22 | — —
35 _ _ — |— ;,— — — — — io | 12 | 14 | 17 | 19 —
a _ _— — |— ;,— — — — — |— | 10 | 12 | 14 | 16 18
46 —_— — — — — — — — — —_— 9 11 13 14 16
52
_ _
_
— —
—
— —
—
— —
10
11
13
15
MAINTENANCE
To ensure continuing high performance, and to minimize the
possibility of premature equipment failure, periodic maintenance
must be performed on this equipment. This 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.
NOTE TO EQUIPMENT OWNER: Consult your local dealer
about the availability of a maintenance contract.
PERSONAL
HAZARD
Failure to follow this warning could result in personal
injury or death and possible unit component damage.
INJURY AND UNIT 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.
The minimum maintenance requirements for this equipment are as
follows:
1. Inspect air filter(s) each month. Clean or replace when
necessary.
bo . 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.
CUANDO:
ELECTRICAL SHOCK HAZARD
Failure to follow these warnings could result in personal
injury or death:
1. Turn off electrical power to the unit before performing
any maintenance or service on this unit.
. Use extreme caution when removing panels and parts.
Ww
be
. Never place anything combustible either on or in contact
with the unit.
Step 1 — 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.
Step 2 — Unit Top Removal
NOTE: When performing maintenance or service procedures that
require removal of the unit top, be sure to perform ail of the routine
maintenance procedures that require top removal, including coil
inspection and cleaning, and condensate drain pan inspection and
cleaning.
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Disconnect and tag electrical power to the unit before
removing top.
17

Only qualified service personnel should perform maintenance and 2. Remove the blower wheel from the housing:
service procedures that require unit top removal. a. Loosen the set screw which secures the wheel to the
Refer to the following top removal procedures: motor shaft.
1. Remove screws on unit top cover surface. (Save all screws.) b. Loosen the three mounting legs of the motor by
2. Remove screws on unit top cover flange. (Save all screws.) removing the bolts that fasten themounting legs to the
3. Lift top from unit carefully. Set top on edge and make sure housing.
that
top
is
supported
by
unit
side
that
is
opposite
duct
(or
c.
Slide
out
the
motor
assembly
(motor,
belly
band
and
the
plenum) side. 3 mounting legs) from the hub of the wheel.
4. Carefully replace and secure unit top to unit, using screws d. Remove the filler panel at the discharge end of the
removed in Steps 1 and 2, when maintenance and/or service blower housing by removing the two screws that fasten
procedures are completed. it to the housing.
Step 3 — Indoor Blower and Motor e. Remove the wheel form the housing.
3. Remove the caked on dirt from the wheel and the motor
For longer life, operating economy, and continuing efficiency :
; , : using a brush.
clean accumulated dirt and grease from the blower wheel and
motor annually. 4. Remove lint and dirt accumulations from the wheel and
housing with a vacuum cleaner, using a soft brush
attachment.
yIN WARNING 5. Remove grease and oil with a mild solvent.
ELECTRICAL
SHOCK
HAZARD
6,
Reassemble
a.
Slip
the
wheel
back
in
the
housing
with
the
hub
set
screw parented in the correct direction.
Failure to follow this warning could result in personal
injury or death.
Disconnect and tag electrical power to the unit before b. Install the filler panel.
cleaning and lubricating the blower motor and wheel. c. Reinsert the motor assembly in the wheel hub and align
the mounting legs with the housing mounting hold
locations.
To clean the blower wheel: . , .
d. Tighten the mounting bolts to fasten the motor assembly
1. Remove the blower housing: with the housing
a. Remove the screws on the external side of the duct
. . e. Center the wheel in the housing by sliding it, align the
panel that fasten the housing to the duct panel assembly.
flat end of the shaft with the set screw and tighten the
b. Remove the side access panel and unscrew the set screw.
mounting bracket that fastens the blower housing to the t
. ae . . Slide back the blower housing into the mounting rails in
internal partition panel fo the control box assembly.
the duct panel and install the mounting bracket back in
c. Make sure that the blower housing is supported by hand its position.
before completely removing the mounting bracket. g. Install the screws on the external side of the duct panel
d. Slide the blower housing from the rails of the duct panel to fasten duct panel with the housing.
and place it outside the unit. h. Replace the side access panel.
Table 6 — Wet Coil Pressure Drop
UNIT STANDARD CFM (S.C.F.M.)
SIZE 600 700 800 900 7000 77100 7200 7300 7400 7500 7600 41700 7800 7900 2000
024 .027 034 040 .047 .053 - - - - - - - - - -
030 - .036 .042 .050 .055 .063 .072 084 - - - - - - -
036 - - - .050 .055 .063 .072 084 .090 .097 - - - - -
042 - - - - .042 .049 .052 .059 .065 074 .078 .085 094 - -
048 - - - - - - .072 084 .090 .097 .108 120 129 .139 -
060 - - - - - - - - - 074 .078 .085 094 .098 114
Table 7 — Filter Pressure Drop (in. we)
FILTER CFM
unit size | SIZE in.
(mm) | 300 | 600 | 700 | 800 | 900 |1000 |1100 |1200 |1300 |1400 |1500 |1600 |1700 |1800 | 1900 [2000 |2100 |2200 |2300
024-036 eon oro 0.06 | 0.07 |0.08 0.08 0.09 0.09 0.09 0.10011 Jorz2fo14foisf — | — | — | — f — | — | —
30 x 30
042-060 | ora | — | — | — | — | — | — | — | — ]0.08 0.09 Jo.t0 | 0.11 }0.12 0.18 J0.14 0.45 0.16 | 0.17 Jo.18
Table 8 — Accessory Electric Heat Pressure Drop (in. we)
HEATER CFM
kw 600 800 4000 4200 7400 71600 71800 2000 2200
5-20 0.06 0.08 0.10 0.13 0.15 0.18 0.20 0.23 0.25
18

Step 4 — Outdoor Coil, Indoor Coil, and
Condensate Drain Pan
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
air filter(s). If the drain trough is restricted, clear it with a
“plumbers snake” or similar probe device.
Step 5 — Outdoor Fan
4& CAUTION
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
unit.
1. Shut off unit power supply and install lockout tag.
bo . Remove outdoor-fan assembly (grille, motor, motor cover,
and fan) by removing screws and flipping assembly onto
unit top cover.
an . Loosen fan hub setscrews.
. Adjust fan height as shown in Fig. 19.
a . Tighten setscrews.
on . Replace outdoor-fan assembly.
<
N wenn (12mm)
A08004
Fig. 19 - Outdoor Fan Adjustment
Step 6 — 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 panel to locate all the electrical controls and wiring.
Check ail 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 and reassemble 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 sheet metal edges.
After inspecting the electrical controls and wiring, replace all the
panels. Start the unit, and observe at least one complete cooling
cycle to ensure proper operation. If discrepancies are observed in
operating cycle, or if a suspected malfunction has occurred, check
each electrical component with the proper electrical
instrumentation. Refer to the unit wiring label when making these
checks.
Step 7 — Refrigerant Circuit
Inspect all refrigerant tubing connections and the unit base for oil
accumulation annually. Detecting oil generally indicates a
refrigerant leak.
If oil is detected or if low performance is suspected, leak test all
refrigerant tubing using an electronic leak detector, 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 performance is suspected,
refer to Checking and Adjusting Refrigerant Charge section.
Step 8 — Indoor Airflow
The heating and/or cooling airflow does not require checking
unless improper performance 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.
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
assembly.
Step 10 — 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 11 — High Flow Valves
High flow valves are located on the compressor hot gas and suction
tubes. Large black plastic caps distinguish 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 Chart (Table 9) for troubleshooting
information.
START-UP CHECKLIST
Use the Start-Up Checklist at the back of this manual.
19

)
ACCUMULATOR
COMPRESSOR
Check Valves
OUTDOOR COIL
=
@)
|
i
ft
|
See FS strainer]
A Open
B Closed
C Open
D Closed
LEGEND
Les Loss of Charge Switch
A
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
Acutrol Metering Device
Check Valve (Arrow indicates direction of flow)
HEATING CYCLE
metering device on each circuit.
)
ACCUMULATOR
COMPRESSOR
Check Valves
Fig. 20 - Typical Heat Pump Operation, Heating Mode
©
INDOOR COIL
Eh
Eh
ERA
ERA
Ou
ao
3. Each circuit evaporates the refrigerant and the circuits are com-
bined in the outdoor header with some of the circuits flowing through
the check vaive.
4, The refrigerant then flows through the 4-way valve, accumulator,
and back to the compressor.
OUTDOOR COIL
E
@)
(
it
A Closed
B Open
C Closed
D Open
LEGEND
Les Loss of Charge Switch
el
1. Hot gas from compressor flows through the 4-way valve and is
directed to the heating liquid line check vaive. [tis then con-
densed and subcooled through converging circuits. Refrigerant leaves
the outdoor coil by way of the strainer and the check vaive in the
cooling liquid line,
Acutrol Metering Device
Check Valve (Arrow indicates direction of flow)
COOLING CYCLE
2, The refrigerant then feeds the indoor coil through the Acultrol
metering device on each circuit.
Fig. 21 - Typical Heat Pump Operation, Cooling Mode
20
Dd)
DG
|
24
IK
Dd
pene
©)
3. Each circuit evaporates the refrigerant and the circults are com-
bined in the indoor coil header with some of the circuits flowing
through the check vaive,
4. The refrigerant then flows through the 4-way valve, accumulator,
and back to the compressor.
C95045
INDOOR COIL
—
2 A
Ol
{_
C95044