Installation Manual
Contents
1. IMPORTANT Check to be certain factory tubing on both indoor and outdoor unit has not shifted during shipment Ensure tubes are not rubbing against each other or any sheet metal Pay close attention to feeder tubes making sure wire ties on feeder tubes are secure and tight PROCEDURE 9 MAKE ELECTRICAL CONNECTIONS A WARNING Electrical Shock Hazard Failure to follow this warning could cause death or personal injury To avoid personal injury or death do not supply power to unit with compressor terminal box cover removed Be sure field wiring complies with local and national fire safety and electrical codes and voltage to system is within limits shown on unit rating plate Contact local power company for correction of improper voltage See unit rating plate for recommended circuit protection device NOTE Operation of unit on improper line voltage constitutes abuse and could affect unit reliability See unit rating plate Do not install unit in system where voltage or phase imbalance 3 phase may fluctuate above or below permissible limits NOTE Use copper wire only between disconnect switch and unit NOTE Install branch circuit disconnect of adequate size per NEC to handle unit starting current L ocate disconnect within sight from and readily accessible from unit per Section 440 14 of NEC A Route Ground and Power Wires Remove access panel to gain access to unit wiring Extend wires from disconnect through power wiring hole provided and2. above or below 15 ft respectively A Heating Check Chart Procedure To check system operation during heating cycle refer to the Heating Check Chart on outdoor unit This chart indicates whether a correct relationship exists between system operating pressure and air temperature entering indoor and outdoor units If pressure and temperature do not match on chart system refrigerant charge may not be correct Do not use chart to adjust refrigerant charge NOTE When charging is necessary during heating season charge must be weighed in accordance with unit rating plate 0 6 oz ft of 3 8 in liquid line above or below 15 ft respectively EXAMPLE To calculate additional charge required for a 25 ft line set 25 ft 15 ft 10 ft X 0 6 oz ft 6 oz of additional charge PROCEDURE 14 FINAL CHECKS IMPORTANT Before leaving job be sure to do the following 1 Securely fasten all panels and covers 2 Tighten service valve stem caps to 1 12 turn past finger tight 3 Leave User s Manual with owner Explain system operation and periodic maintenance requirements outlined in manual 4 Fill out Dealer Installation Checklist and place in customer file CARE AND MAINTENANCE For continuing high performance and to minimize possible equipment failure periodic maintenance must be performed on this equipment Frequency of maintenance may vary depending upon geographic areas such as coastal applications 2005 Payne Heating amp Cooling 7310 W Morris St I
3. into unit control box A WARNING Electrical Shock Hazard Failure to follow this warning can result in an electric shock fire or death The unit cabinet must have an uninterrupted or unbroken ground to minimize personal injury if an electrical fault should occur The ground may consist of electrical wire or metal conduit when installed in accordance with existing electrical codes B Connect Ground and Power Wires Connect ground wire to ground connection in control box for safety Connect power wiring to contactor as shown in Fig 5 5 C Connect Control Wiring Route 24v control wires through control wiring grommet and connect leads to control wiring See Fig 6 Use No 18 AWG color coded insulated 35 C minimum wire If thermostat is located more than 100 ft from unit as measured along the control voltage wires use No 16 AWG color coded wire to avoid excessive voltage drop All wiring must be NEC Class 1 and must be separated from incoming power leads Use furnace transformer fan coil transformer or accessory transformer for control power 24v 40va minimum NOTE Use of available 24v accessories may exceed the minimum 40va power requirement Determine total transformer loading and increase the transformer capacity or split the load with an accessory transformer as required TYPICAL HEAT HP THERMOSTAT FAN COIL PUMP 24 VAC HOT 24 VAC COM HEAT STAGE 2 COOL HEAT STAGE 1 eae IF AVAILABLE A02325 Fig
4. surrounds vapor tube oOo OO N OD NO A WUN When necessary use hanger straps which are 1 in wide and conform to shape of tubing insulation See Fig 1 10 Isolate hanger straps from insulation by using metal sleeves bent to conform to shape of insulation When outdoor unit is connected to factory approved indoor unit outdoor unit contains system refrigerant charge for operation with indoor unit of the same size when connected by 15 ft of field supplied or factory accessory tubing For proper unit operation check refrigerant charge using charging information located on control box cover IMPORTANT Maximum liquid line size is 3 8 in O D for all residential applications including long line IMPORTANT Always install a liquid line filter drier on any system using an existing field service lineset and or existing indoor coil Also always use liquid line filter driers on burnout compressor replacements Refer to Spec Sheet for appropriate part number Obtain filter drier from your distributor or branch Form IM PH13 01 Cancels New Printed in U S A 1 06 Catalog No IM PH13 01 A94208 Fig 1 Connecting Tube Installation INSTALLATION PROCEDURE 1 CHECK EQUIPMENT AND J OB SITE A Unpack Unit M ove to final location Remove carton taking care not to damage unit B Inspect Equipment File claim with shipping company prior to installation if shipment is damaged or incomplete Locate unit rating plate on unit service panel It conta
5. 6 Generic Wiring Diagram See Thermostat Installation Instructions for wiring specific unit combinations A97413 D Final Wiring Check IMPORTANT Check factory wiring and wire connections to ensure terminations are secured properly Check wire routing to ensure wires are not in contact with tubing sheet metal etc PROCEDURE 10 COMPRESSOR CRANKCASE HEATER When equipped with a crankcase heater furnish power to heater a minimum of 24 hr before starting unit To furnish power to heater only set thermostat to OFF and close electrical disconnect to outdoor unit A crankcase heater is required if refrigerant tubing is longer than 50 ft PROCEDURE 11 INSTALL ELECTRICAL ACCESSORIES Refer to the individual instructions packaged with kits or accessories when installing PROCEDURE 12 START UP A CAUTION Unit Damage Personal Injury Hazard Failure to follow this caution could result in unit damage or personal injury Do not overcharge system with refrigerant Do not operate unit in a vacuum or at negative pressure Do not disable low pressure switch In scroll compressor applications Dome temperatures may be hot Z CAUTION Unit Damage Personal Injury Hazard Failure to follow this caution may result in unit damage or personal injury Wear safety glasses protective clothing and gloves when handling refrigerant and observe the following Back seating service valves are not equipped with Schrader valves Fully back seat counte
6. Installation Manual Electric Heat Pump 018 060 Single Phase 048 060 3 Phase NOTE Read the entire instruction manual before starting the installation SAFETY CONSIDERATIONS Improper installation adjustment alteration service maintenance or use can cause explosion fire electrical shock or other conditions which may cause death personal injury or property damage Consult a qualified installer service agency or your distributor or branch for information or assistance The qualified installer or agency must use factory authorized kits or accessories when modifying this product Refer to the individual instructions packaged with the kits or accessories when installing 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 and National Electrical Code NEC for special requirements Recognize safety information This is the safety alert symbol When you see this symbol on the unit and in instructions or manuals be alert to the potential for personal injury Understand the 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 ha
7. e kit for proper installation PROCEDURE 7 CHECK DEFROST THERMOSTAT Check defrost thermostat to ensure it is properly located and securely attached There is a liquid header with a brass distributor and feeder tube going into outdoor coil At the end of 1 of the feeder tubes there is a 3 8 in O D stub tube approximately 2 in long See Fig 3 The defrost thermostat should be located on stub tube Note that there is only 1 stub tube used with liquid header and on most units it is the bottom circuit 3 TABLE 1 REFRIGERANT CONNECTIONS AND RECOMMENDED LIQUID AND VAPOR TUBE DIAMETERS IN UNIT LIQUID VAPOR LONG LINE SIZE Connection Diameter Tube Diameter Connection Diameter Tube Diameter Connection Diameter Tube Diameter 018 024 3 8 3 8 5 8 5 8 5 8 3 4 030 036 3 8 3 8 3 4 3 4 3 4 718 042 048 3 8 3 8 718 718 718 1 1 8 060 3 8 3 8 718 718 1 1 8 NOTES 1 Tube Diameters are for lengths up to 50 ft horizontal or 20 ft vertical differential F or tubing lengths greater than 50 ft consult the Application Guideline and Service Manual for Air Conditioners and Heat Pumps Using R 22 Refrigerant PISTON BODY PISTON PISTON RETAINER STRAINER A97512 Fig 4 Liquid Service Valve with Sweat Adapter Tube PROCEDURE 8 MAKE PIPING CONNECTIONS WARNING Explosion Hazard Failure to follow this warning could result in death or personal injury Relieve pressure and recover all refrigera
8. een speed up terminals with a flat bladed screw driver See Fig 8 This reduces the timing sequence to 1 256th of original time CEBD430524 01A 5501A ri Q lt w N m X A02001 Fig 8 Defrost Control Aes TABLE 3 DEFROST CONTROL SPEED UP TIMING SEQUENCE MINIMUM MAXIMUM SPEED UP PARAMETER MINUTES MINUTES NOMINAL 30 minute cycle 50 minute cycle 90 minute cycle 10 minute cycle 5 minutes See Table 3 6 When you hear reversing valve change position remove screwdriver immediately otherwise control will terminate normal 10 minute defrost cycle in approximately 2 sec NOTE Length of defrost cycle is dependent on the length of time it takes to remove screwdriver from test pins after reversing valve has shifted 7 Unit will remain in defrost for remainder of defrost cycle time or until defrost thermostat reopens at approximately 80 F coil temperature of liquid line 8 Turn off power to outdoor unit and reconnect fan motor lead to OF2 on control board See Fig 8 PROCEDURE 13 CHECK CHARGE Factory charge is shown on unit rating plate To check charge in cooling mode refer to Cooling Only Procedure on unit wiring and charging label To check charge in heating mode refer to Heating Check Chart Procedure NOTE If superheat or subcooling charging conditions are not favorable charge must be weighed in accordance with unit rating plate 0 6 oz ft of 3 8 in liquid line
9. em A94025 Fig 5 Line Power Connections A Outdoor Unit Connected to Factory Approved Indoor Unit Outdoor unit contains correct system refrigerant charge for operation with indoor unit of same size when connected by 15 ft of field supplied or factory accessory tubing Check refrigerant charge for maximum efficiency B Refrigerant Tubing Connect tubing to fittings on outdoor unit vapor and liquid service valves See Table 1 Use refrigerant grade tubing Refer to appropriate section below for type of service valves installed on unit C Sweat Connection A CAUTION Unit Damage Hazard Failure to follow this caution may result in unit component damage To avoid valve damage while brazing service valves must be wrapped in a heat sinking material such as a wet cloth Remove plastic retainer holding outdoor piston in liquid service valve and connect sweat flare adapter provided to valve See Fig 6 Connect refrigerant tubing to fittings on outdoor unit vapor and liquid service valves Service valves are closed from factory and ready for brazing A fter wrapping service valve with a wet cloth tubing set can be brazed to service valve using either silver bearing or non silver bearing brazing material Do not use soft solder materials which melt below 800 F Consult local code requirements Refrigerant tubing and indoor coil are now ready for leak testing This check should include all field and factory joints D Final Tubing Check
10. ins information needed to properly install unit Check rating plate to be sure unit matches job specifications PROCEDURE 2 INSTALL ON A SOLID LEVEL MOUNTING PAD If conditions or local codes require the unit be attached to pad tie down bolts should be used and fastened through knockouts provided in unit base pan Refer to unit mounting pattern in Fig 2 to determine base pan size and knockout hole location On rooftop applications mount on level platform or frame 6 in above roof surface Place unit above a load bearing wall and isolate unit and tubing set from structure A rrange supporting members to adequately support unit and minimize transmission of vibration to building Consult local codes governing rooftop applications Roof mounted units exposed to winds above 5 mph may require wind baffles to achieve adequate defrost Consult Low A mbient Guideline for wind baffle construction NOTE Unit must be level to within 2 3 8 in ft per compressor manufacturer specifications PROCEDURE 3 CLEARANCE REQUIREMENTS When installing allow sufficient space for airflow clearance wiring refrigerant piping and service Allow 30 in clearance to service end of unit and 48 in above unit For proper airflow a 6 in clearance on 1 side of unit and 12 in on all remaining sides must be maintained M aintain a distance of 24 in between units Position so water snow or ice from roof or eaves cannot fall directly on unit On rooftop applica
11. ndianapolis IN 46231 10 imph1301 Catalog No IM PH13 01
12. nt before system repair or final unit disposal to avoid personal injury or death Use all service ports and open all flow control devices including solenoid valves A CAUTION Unit Damage Hazard Failure to follow this caution may result in unit damage DO NOT BURY MORE THAN 36 IN OF REFRIGERANT TUBING IN GROUND If any section of refrigerant tubing is buried there must be a 6 in vertical rise at service valve to avoid equipment damage Refrigerant tubing lengths up to 36 in may be buried without further special consideration For lengths above 36 in consult your local distributor A CAUTION Unit Damage Hazard Failure to follow this caution may result in unit component damage To prevent damage to unit or service valves observe the following Use a brazing shield Wrap service valves with wet cloth or use a heat sink material Outdoor units may be connected to indoor section using accessory tubing package or field supplied refrigerant grade tubing of correct size and condition For tubing requirements beyond 50 ft length or 20 ft vertical differential substantial capacity and performance losses can occur Following the recommendations in the Residential Split System Long Line A pplication Guideline will reduce these losses Refer to Table 1 for field tubing equivalent line length If refrigerant tubes or indoor coil are exposed to atmosphere they must be evacuated to 500 microns to eliminate contamination and moisture in the syst
13. rclockwise valve stem before removing gage port cap Front seating service valves are equipped with Schrader valves A CAUTION Environmental Hazard Failure to follow this caution may lead to fines or environmental impact Federal regulations require that you do not vent refrigerant to atmosphere Recover during system repair or final unit disposal 1 Fully back seat open liquid and vapor tube service valves 2 Unit is shipped with valve stem s front seated closed and caps installed Replace stem caps after system is opened to refrigerant flow Replace caps finger tight and tighten with wrench an additional 1 12 turn 3 Close electrical disconnects to energize system 4 Set room thermostat to desired temperature Be sure set point is below indoor ambient temperature 5 Set room thermostat to HEAT or COOL and fan control to ON or AUTO mode as desired Operate unit for 15 minutes Check system refrigerant charge A CAUTION e 3 phase scroll compressors are rotation sensitive To avoid equipment damage ensure that the compressor rotation is correct A flashing LED on phase monitor indicates reverse rotation See Fig 7 and Table 2 e This will not allow contactor to be energized e Disconnect power to unit and interchange 2 field wiring leads on unit contactor A Sequence of Operation With power supplied to indoor and outdoor units transformer is energized COOLING On a call for cooling thermostat makes ci
14. rcuits R O R Y and R G Circuit R O energizes reversing valve switching it to cooling position On three phase models with scroll compressors the units are equipped with a phase monitor to detect if the incoming power is correctly phased for compressor operation See Fig 9 and Table 2 If the phasing is correct circuitR Y energizes contactor starting outdoor fan motor and compressor circuit R G energizes indoor unit blower relay starting indoor blower motor on high speed NOTE If the phasing is incorrect the contactor will not be energized To correct the phasing interchange any two of the three power connections on the field side When thermostat is satisfied its contacts open de energizing the contactor and blower relay Compressor and motors should stop NOTE If indoor unit is equipped with a time delay relay circuit the blower runs an additional 90 sec to increase system efficiency HEATING On acall for heating thermostat makes circuits R Y and R G If phasing is correct circuit R Y energizes contactor starting outdoor fan motor and compressor Circuit R G energizes indoor blower relay starting blower motor on high speed A00010 Fig 7 Phase Monitor Control 7 Table 2 Phase Monitor LED Indicators LED STATUS No call for compressor operation OFF FLASHING Reversed phase ON Normal Should temperature continue to fall R W2 is made through second stage room thermostat Circuit R W2 energizes relays b
15. ringing on supplemental electric heat If outdoor thermostat is used field installed option only the first bank will be energized Remaining bank of supplemental electric heat will be energized when outdoor temperature falls below outdoor thermostat setting When thermostat is satisfied its contacts open de energizing contactor and relays All heaters and motors should stop DEFROST The defrost control is a time temperature control which includes a field selectable quick connects located at board edge time period between defrost cycles 30 50 or 90 minutes factory set at 90 minutes Defrost mode is identical to cooling mode except that outdoor fan motor stops and second stage heat is turned on to continue warming conditioned space First the defrost cycle timer starts when the contactor is energized and a 24 volt signal is present on the T1 terminal Then the defrost cycle begins when the cycle times out 30 50 90 min and the defrost thermostat is closed To initiate defrost the defrost thermostat must be closed This can be accomplished as follows 1 Turn off power to outdoor unit 2 Disconnect outdoor fan motor lead from OF2 on control board See Fig 8 Tape lead to prevent grounding 3 Restart unit in heating mode allowing frost to accumulate on outdoor coil 4 After a few minutes in heating mode liquid line temperature should drop below closing point of defrost thermostat approximately 30 F 5 Short betw
16. tions locate unit at least 6 in above roof surface PROCEDURE 4 OPERATING AMBIENT The minimum outdoor operating ambient in cooling mode is 55 F and the maximum outdoor operating ambient in cooling mode is 125 F The maximum outdoor operating ambient in heating mode is 66 F O 38D 9 53 TIEDOWN KNOCKOUTS 2 PLACES B A94199 DIMENSIONS IN UNIT MINIMUM TIEDOWN KNOCKOUT LOCATIONS SIZE MOUNTING PAD DIMENSIONS A 018 030 22 1 2 X 22 1 2 3 11 16 042 060 30 X 30 6 1 2 Fig 2 Mounting Unit to Pad FEEDER TUBE a STUB TUBE DEFROST THERMOSTAT A97517 Fig 3 Defrost Thermostat Location PROCEDURE 5 ELEVATE UNIT A CAUTION Unit Damage Hazard Failure to follow this caution may result in unit component damage Accumulation of water and ice in base pan may cause equipment damage In areas where prolonged freezing temperatures are encountered elevate unit per local climate and code requirements to provide clearance above estimated snowfall level and ensure adequate drainage of unit PROCEDURE 6 EXPANSION DEVICE A hard shutoff thermostatic expansion valve is required at the indoor section of the system for proper operation of these products If the indoor section of the system is not equipped with a hard shutoff TXV refer to Spec Sheet for the correct TX V kit to be installed Follow the instructions in th
17. zards which could result in personal injury or death CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage NOTE is used to highlight suggestions which will result in enhanced installation reliability or operation A WARNING Electrical Shock Hazard Failure to follow this warning can cause death or personal injury Before installing or servicing system always turn off main power to system There may be more than 1 disconnect switch Turn off accessory heater power if applicable INSTALLATION RECOMMENDATIONS NOTE In some cases noise in the living area has been traced to gas pulsations from improper installation of equipment 1 Locate unit away from windows patios decks etc where unit operation sounds may disturb customer Ensure that vapor and liquid tube diameters are appropriate to capacity of unit Run refrigerant tubes as directly as possible by avoiding unnecessary turns and bends Leave some slack between structure and unit to absorb vibration When passing refrigerant tubes through the wall seal opening with RTV or other pliable silicon based caulk See Fig 1 Avoid direct tubing contact with water pipes duct work floor joists wall studs floors and walls Do not suspend refrigerant tubing from joists and studs with a rigid wire or strap which comes in direct contact with tubing See Fig 1 Ensure that tubing insulation is pliable and completely
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