Installation Manual
Contents
1. CARE AND MAINTENANCE For continuing high performance and to minimize possible equipment failure it is essential that periodic maintenance be performed on this equipment Consult your servicing contractor or User s Manual for proper frequency of maintenance Frequency of maintenance may vary depending upon geographic areas such as costal applications Leave User s Manual with homeowner Explain system operation and maintenance procedures outlined in manual AC ELECTRONIC THERMOSTAT SINGLE STAGE COOL HEAT 24 VAC HOT 24 VAC COM HEAT STAGE 1 COOL STAGE 1 ABBE SINGLE STAGE AIR FURNACE CONDITIONER AC ELECTRONIC THERMOSTAT SINGLE STAGE PF AIR COOL HEAT FAN COIL CONDITIONER 24 VAC HOT 24 VAC COM HEAT STAGE 1 COOL STAGE 1 zi INDOOR FAN INDOOR FAN s A01331 01332 THERMOSTAT SINGLE STAGE PF AIR AC THERMOSTAT COOL HEAT FAN COIL CONDITIONER SINGLE STAGE SINGLE STAGE AIR COOL HEAT FURNACE CONDITIONER 24 VAC HOT 24 VAC HOT HEAT STAGE 1 COOL STAGE 1 INDOOR FAN A01333 EP A01334 Fig 5 Typical 24v Circuit Connections 2003 Payne Heating amp Cooling 7310 W Morris St indianapolis IN 46231 6 impa1005 Catalog No 53PA 10172. SUSPENSION A94028 Fig 1 Connecting Tubing installation NOTE Check to be certain factory tubing on both indoor and outdoor unit has not been shifted during shipment Ensure tubes are not rubbing against each other or any sheet metal Pay close attention to feeder tubes making sure wires on feeder tubes are secure and tight NOTE 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 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 Arrange supporting members to adequately support unit and minimize transmission of vibration to building Consult local codes governing rooftop applications NOTE Unit must be level to within 2 3 8 in ft 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 Maintain a distance of 24 in between units Position so water snow or ice from roof or eaves cannot fall directly
3. When necessary use hanger straps which are in wide and conform to shape of tubing insulation See Fig 1 Isolate hanger straps from insulation by using metal sleeves bent to conform to shape of insulation A CAUTION DO NOT BURY MORE THAN 36 IN OF REFRIGERANT TUBING IN GROUND If any section of tubing is buried there must be a 6 in vertical rise to valve connections on outdoor unit If more than recommended length is buried refrigerant may migrate to cooler buried section during extended periods of unit shutdown causing refrigerant slugging and possible compressor damage at start up INSTALLATION PROCEDURE 1 CHECK EQUIPMENT AND JOB SITE A Unpack Unit Move 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 control box access panel It contains information needed to properly install unit Check rating plate to be sure unit matches job specifications Form iM PA10 05 Cancels IM PA10 04 Printed in U S A 3 03 Catalog No 53PA 1017 NOTE Avoid contact between tubing and structure OUTDOOR WALL INDOOR WALL CAULK Ay ut 2 LIQUID TUBE A Oy 7 L VAPOR TUBE INSULATION THROUGH THE WALL OST HANGER STRAP ROT OBE ONLY INSULATION 9 VAPOR TUBE 0 L 34 4 1 MIN LIQUID TUBE
4. Diameter Diameter Diameter Diameter 018 024 3 8 3 8 3 8 5 8 030 036 3 8 3 8 3 8 3 4 042 048 3 8 3 8 7 8 7 8 060 3 8 3 8 7 8 1 1 8 Note Tube diameters are for lengths up to 60 ft For tubing lengths greater than 60 ft consult your local distributor or Long Line Application Guidefine C Connect Control Wiring Route 24 v control wires through control wiring grommet and connect leads to control wiring See Fig 5 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 Use furnace transformer fan coil transformer or accessory transformer for control power 24 v 40 va minimum NOTE Use of available 24 v accessories may exceed the minimum 40 va power requirement Determine total transformer loading and increase the transformer capacity or split the load with an accessory transformer as required PROCEDURE 8 COMPRESSOR CRANKCASE HEATER A crankcase heater is required if refrigerant tubing is longer than 50 ft PROCEDURE 9 INSTALL ELECTRICAL ACCESSORIES Refer to the individual instructions packaged with kits or accessories when installing PROCEDURE 10 START UP A CAUTION 3 phase scroll compressors are rotation sensitive A flashing LED on phase monitor indicates reverse rotation See Fig 4 and Table 2 This will not allow contactor
5. Installation Manual Electric Air Conditioner 018 060 PA10 018 060 PA12 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 CAUTION AND NOTE 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 wh
6. e for maximum efficiency See Procedure 11 Check Charge N CAUTION To avoid valve damage while brazing service valves must be wrapped with heat sink material such as a wet cloth AIR IN 3 8 DIA TIEDOWN 7 AIR IN KNOCKOUTS AIRIN gt pe AIR DISCHARGE zie T re 414 2 3 4 B k D A01340 UNIT SIZE PA10 060 PA12 024 060 PA10 018 048 PA12 018 Fig 2 Unit Dimensions DISCONNECT PER N E C AND OR LOCAL CODES CONTACTOR FIELD POWER FIELD_GROUND ______ Z WIRING GROUND LUG 88174 Fig 3 Line Power Connections B Sweat Connection Use refrigerant grade tubing Service valves are closed from factory and ready for brazing After wrapping service valve with a wet cloth braze sweat connections using industry accepted methods and materials Consult local code requirements Refrigerant tubing and indoor coil are now ready for leak testing This check should include ail field and factory joints PROCEDURE 7 MAKE ELECTRICAL CONNECTIONS A WARNING 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
7. 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 Locate 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 and into unit control box A WARNING According to NEC ANSI NFPA 70 and local codes 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 Failure to follow this warning can result in an electric shock fire or death 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 3 cl Table 1 Refrigerant Connections and Recommended Liquid and Vapor Tube Diameters in LIQUID VAPOR UNIT SIZE Connect Tube Connect Tube
8. ich 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 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 Electrical shock can cause personal injury or death 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 and so forth where unit operation sound 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 that comes in direct contact with tubing See Fig 1 Ensure that tubing insulation is pliable and completely surrounds vapor tube e
9. l compressors the units are equipped with a phase monitor to detect if the incoming power is correctly phased for compressor operation See Fig 4 and Table 2 the phasing is correct circuit R 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 contactor and blower relay Compressor and motors stop If indoor unit is equipped with an off delay circuit the indoor blower can run up to an additional 120 sec to increase system efficiency 24VAC e N o DFF NO 24VAC UN DK FLASH PHASE PROBLEM i o J o LS L1 A00010 Fig 4 3 Phase Monitor Control Table 2 Phase Monitor LED indicators STATUS OFF No call for compressor operation FLASHING Reversed phase ON Normal PROCEDURE 11 CHECK CHARGE A Unit Charge Factory charge is shown on unit rating plate See Fig 1 Charge procedure is shown on wiring charging label located on unit A CAUTION Compressor damage may occur if system is overcharged A CAUTION Do not vent refrigerant to atmosphere Recover during system repair or final unit disposal
10. on unit On rooftop applications locate unit at least 6 in above roof surface PROCEDURE 4 OPERATING AMBIENT OUTDOOR TEMPERATURES The minimum outdoor operating ambient in cooling mode is 55 F and the maximum outdoor operating ambient in cooling mode is 125 F PROCEDURE 5 REPLACE INDOOR CHECK FLO RATER PISTON IF REQUIRED Check indoor coil piston to see if it matches the required piston shown on outdoor unit rating plate If it does not match replace indoor coil piston with piston shipped with outdoor unit The piston shipped with outdoor unit is correct for any approved indoor coil combination PROCEDURE 6 MAKE REFRIGERANT TUBING CONNECTIONS Outdoor units may be connected to indoor sections using accessory tubing package or field supplied refrigerant grade tubing of correct size and condition For tubing requirements beyond 50 ft consult Long Line Application Guideline which is available at your local distributor Connect tubing to fittings on outdoor unit vapor and liquid service valves See Table 1 If refrigerant tubes or indoor coil is exposed to atmospheric conditions for longer than 5 minutes it must be evacuated to 500 microns to eliminate contamination and moisture in system 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 charg
11. to be energized Disconnect power to unit and interchange 2 field wiring leads on unit contactor 1 When equipped with a crankcase heater energize heater a minimum of 24 hr before starting unit To energize heater only set thermostat to OFF mode and close electrical disconnect to outdoor unit A CAUTION Service valve gage ports are equipped with Schrader valves To prevent personal injury wear safety glasses and gloves when handling refrigerant 2 Fully back seated open liquid and vapor service valves 3 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 additional 1 6 turn with wrench 4 Close electrical disconnects to energize system 5 Set room thermostat at desired temperature Be sure set point is below indoor ambient temperature 6 Set room thermostat at COOL and fan ON or AUTO modes as desired Operate unit for 15 minutes Check system refrigerant charge See Check Charge section A WARNING Relieve pressure and recover all refrigerant 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 Sequence of Operation Turn on power to indoor and outdoor units Transformer is energized On a call for cooling thermostat makes circuits R Y and R G On three phase models with scrol
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