ICP PAK042K000A, PAK036K000A Owner’s Manual

Installation Instructions

Single Package Air Conditioners

Electric Cool / Electric Heat (Optional)

1. Safety Labeling and Signal Words .... 2

Danger, Warning and Caution ............... 2

Signal Words .............................. 2

Signal Words in Manuals ................ 2

Product Labeling ........................... 2

Danger Label .......................... 2

Warning Label ......................... 2

Caution Label ......................... 2

Unit Dimensions ...................... 3

2. Safe Installation Requirements ...... 4

3. Locating The Unit ................... 4

Access Panels ............................. 4

Clearances ................................ 4

Minimum Clearances to Combustible

Construction ........................ 5

Installation ................................. 6

Ground Level Installation ................ 6

Rooftop Installation ..................... 6

Hoisting ................................... 6

Downflow Conversion ....................... 7

Condensate Drain ...................... 7

4. Electrical Wiring .................... 7

Low Voltage Wiring ......................... 7

Low Voltage Wiring With

Economizer Option ................... 7

Thermostat ................................ 7

Unit Without Economizer ................ 7

Unit With Economizer .................. 7

Ground Connections ........................ 8

Line Voltage Wiring ......................... 8

Converting 230V Units to 208V ............... 8

Field Installed Equipment ............... 8

Final Electrical Check ....................... 8

5. Air Distribution System .............. 9

Ductwork .................................. 9

Ductwork Insulation .................... 9

Ductwork Connections .................. 9

Filters ..................................... 9

6. Economizer Accessory .............. 9

Theory of Operation ......................... 9

Sequence of Operation ..................... 10

7. Start-up Procedures ............... 10

Circulating Air Blower ...................... 10

Determining Blower Speed ............. 10

Speed Taps ............................... 11

Cooling Only ......................... 11

Cooling and Heating ................... 11

Check Before Starting ...................... 11

Circulating Air Blower .................. 11

Cooling .............................. 11

Heating .............................. 11

8. Operation ......................... 12

Scroll Anti-cycle Timer ..................... 12

Cooling .............................. 12

Turning The Unit Off ....................... 12

Thermostat Fan Switch Operation ............ 12

Adjusting Room Temperatures ............... 12

9. Maintenance ....................... 12

Monthly Maintenance and Inspection Checks ., 12

Air Filters ............................ 12

Refrigeration Access Ports .................. 12

Cooling Season Checks (Monthly) ........... 13

Condenser Coil ....................... 13

Condensate Drain ..................... 13

Annual Maintenance and Inspection .......... 13

Condenser Fan Motor ................. 13

Blower Motor Access ....................... 13

Method 1 and Method 2 ................ 13

Motor Removal Using Method 1 ......... 13

Motor Removal Using Method 2 ......... 13

Blower Wire Color Identification .............. 14

Circulating Air Blower .................. 14

10. Rigging Instructions .............. 15

51901 100200 11/1/01

I Installation Instructions Single Package Air Conditioners ]

1. Safety Labeling and Signal Words

Danger,Warning and Caution

The signal words DANGER, WARNING and CAUTION are used
to identify levels of hazard seriousness. The signal word DAN-
GER is only used on product labels to signify an immediate haz-

ard. The signal words WARNING and CAUTION will be used on
product labels and throughout this manual and other manuals that

may apply to the product.

SignalWords

DANGER - immediate hazards which WILL result in severe per-

sonal injury or death.

WARNING - Hazards or unsafe practices which COULD result in
severe personal injury or death.

CAUTION - Hazards or unsafe practices which COULD result in
minor personal injury or product or property damage.

Danger Label

White lettering on a black background except the word DANGER
which is white with a red background.

Warning Label

White lettering on a black background except the word WARN-
ING which is black with an orange background.

Signal Words in Manuals

The signal word WARNING is used throughout this manual in the
following manner:

The signal word CAUTION is used throughout this manual inthe
following manner:

CAUTION

ProductLabeling

Signal words are used in combination with colors and/or pictures
on product labels. Following are examples of product labels with

explanations of the colors used.

Caution Label

White lettering on a black background except the word CAUTION
which is black with a yellow background.

_iJ 519 01 1002 O0

I Single Package Air Conditioners Installation Instructions I

UNIT DIMENSIONS

3-5 TON MODELS

DM INCHES MILLIMETERS

A 36" 9/4
B 47 38" / 203
C 73" /854

D 4 58" 1/ 7
E /5" 38/
F E2" 307
G 18 3,4" 476

H 18 3,4" 476

I E2" 305

J 102
K N/A

L 4 1_4" /08
M 5 _t4 rr /33

N [2 1_4" 31/
P /9" 483
Q 15" 38E
R 19" 483
S 12 I '4" 3/ /

• 16 7'8" 429

I
I

I

Note: Above dimensions are in inches

ROOF CURB FOR

3-5 TON MODELS

DM NCHES

A 67 34"
B 64 34"
C 23"

D 23"
E 2 /,2"
F 42 314"
G 39 3.4"

H 23"

I /2'r

JK_< /4"

E2"

MILLIMETERS

/721
/645

E086
10/0

* Roof curbs are also available in 8" I203mm) and 24" (610mm) heiqhts IK dimension).

LOW VOLTAGE

1_2" CONDUIT

584
584

64

584
305

305
356

ELECTRIC HEAT POWER
1", 1-1/2", 2" CONDUIT

UNIT ELECTRICAL POWER

3/4", 1", 1-1/4" CONDUIT

,,÷j

UNIT BASE SHOWN SEPARATELY

TO ILLUSTRATE BOTTOM

DUCT OPENINGS

80 10 14

519 01 1002 00

I Installation Instructions

2. Safe Installation Requirements

Installation or repairs made by unqualified per-
sons can result in hazards to you and others.

Installation MUST conform with local building
codes or, in the absence of local codes, with the

National Electrical Code NFPA70-1990 or current
edition or in Canada CSA C22.1 - Canadian Elec-
trical Code Part 1 or current edition.

The information contained in this manual is in-
tended for use by a qualified service technician

familiar with safety procedures and equipped
with the proper tools and test instruments.

Failure to carefully read and follow all instruc-
tions in this manual can result in unit malfunction,

property damage, personal injury and/or death.

3. Locating The Unit

Single Package Air Conditioners I

• Seal supply and return air ducts.

• Check to see that filters are installed correctly and
are the proper type and size.

NOTE: It is the personal responsibility and obligation of the cus-
tomer to contact aqualified installer to ensure that the installation

is adequate and conforms to governing codes and ordinances.

The unit is designed for outdoor installation only. The unit may be

installed on a concrete slab (or other adequate platform) at
ground level, or on a rooftop with an adequate platform or a roof
curb. Typical installations are shown in FIGURE 3 through

FIGURE 5.

AccessPanels

CAUTION

Unit will NOT operate properly without all access pan-
els in place. Unit MUST NOT be moved unless all ac-
cess panels are in place.

See FIGURE 1 be!ow for a generalview of unit and location of ac-
cess panels.

FIGURE 1 Access Panels

er Access Panel I

J

Pane, 1" .....

Clearances

The location MUSTallow for minimum clearances and should not

be adjacent to a patio or other area where the unit's operating
sound level might be objectionable. Local codes MUST be

observed.

Minimum clearances, as specified below and in FIGURE 2,
MUST be maintained from adjacent structures to provide ade-

quate air circulation and room for service personnel.

While minimum clearances are acceptable for safety reasons,
they may not allow adequate air circulation around the unit for

proper operation in the cooling mode. Whenever possible, it is de-
sirable to allow additional clearance, especially around the con-
denser inlet and discharge openings.

Do NOT install the unit in a location that will permit discharged air

from the condenser to recirculate to the condenser inlet.

CAUTION

Do NOT operate unit in a corrosive atmosphere con-

taining chlorine, fluorine, or any other corrosive chem-
icals.

Minimum Clearancesto CombustibleConstruction

Supply and Return Air Ducts ...................... 0"

Duct Connection Side (no economizer)

...... 0" (2" (50mm) on 4 & 5 ton models)

Duct Connection Side (with economizer) . 48" (1220mm)

Condenser Access Panel Side .......... 30" (762mm)

Blower Access Panel Side .............. 30" (762mm)

Electrical Access Panel Side ............ 30" (762mm)

Clearance between 3 Ft. Overhang

and Top of Unit ............ 30" (762mm)

Combustible Base

(Wood or Class A, B or C

roof covering material) ................. 0"

519 01 1002 00

I Single Package Air Conditioners Installation Instructions

Minimum Clearances

FIGURE 2 I

(914mm) 0"

J 30" 30"

(762mm) (762mm)

(Typical 2 to 31/2 ton unit shown)

0" (2" (50mm) on 4 & 5 ton units

48" (1220mm) on all units with
economizer

(762mm)

(762mn

80-00-01

30"

Installation

CAUTION

Unit will NOT operate properly unless it is installed lev-
el front to rear and side to side. The slope MUST NOT

be greater than 1/8"per foot (lOmm per meter). For side
to side leveling, the control box side MUST always be

lower.

Support for the unit MUST be level and strong enough to
carry unit weight, The support may consist of a platform or
a combination of platform and roof beams or curb.

The platform may be constructed of pressure treated wood
and may be covered with Class A, B or C roof covering.

Platform MUST allow for proper condensate trap installa-

tion and drainage. See FIGURE 8 and associated text for
more information about condensate drainage.

See Hoisting section below for hoisting instructions.

See FIGURE 4 and FIGURE 5 for illustrations of typical rooftop
installations.

NOTE: Cardboard covers on horizontal supply and return
duct openings MUST be removed before starting unit.

Hoisting

NOTE: All access panels MUST be secured in place before hoist-

ing.

The unit should be hoisted with two lifting slings. Attach the slings
to rigging shackles that have been hooked through holes in the

base rail.

Two spreader bars MUST be placed on top of the unit to protect
the unit from damage from the pressure exerted by the slings.

Make sure that all equipment is adequate to handle the weight of
the unit and that the slings will not allow the unit to shift.

Refer to FIGURE 17 on the back cover of this manual for illus-

trated rigging instructions and weight chart,

GroundLevel Installation

Ground level platform requirements:

The unit MUST be situated to provide safe access for serv-

icing.
Platform may be made of either concrete or pressure

treated wood and MUST be level and strong enough to
support unit weight.

Position platform separate from building foundation.
Install in well-drained area, with top surface of platform

above grade level.

Platform MUST be high enough to allow for proper conden-

sate trap installation and drainage. See Figure 9 and
associated text for more information about condensate

drainage.

See FIGURE 3 for illustration of a typical ground level installation.

RooftopInstallation

Rooftop platform requirements:

The unit MUST be situated to provide safe access for serv-

icing.

The existing roof structure MUST be adequate to support
the weight of the unit or the roof MUST be reinforced.

Check the weight of the unit in relation to the roof structure

and local building codes or ordinances and reinforce roof
structure if necessary, See FIGURE 17 on the back cover
of this manual for unit weights and corner weights.

FIGURE 3 I Typical Installation (Ground Level)

519 01 1002 00

_ Installation Instructions

Single Package Air Conditioners I

FIGURE 4 I Typical Installation (Roof Curb)

I

/

FIGURE 5 | Typical Installation (Pitched Roof)

1

4-5 ton unit shown

codes and ordinances and instructions contained herein, as well
as instructions included with accessory items when instal ling unit.

It is the installer's personal responsibility to locate directions for

installation of this unit and any or all accessories. Manufacturer is
NOT responsible for improper installation practices.

3. Position and install appropriate roof curb.

4. Install unit on roof curb.

FIGURE 6

Blockoff Plate

(Return Air Compartment)

D0wnfl0wConversion

These units are shipped ready for horizontal operation but are
adaptable to downflow use. To convert to downflow use, follow

these steps:

1. Remove the blockoff plates found in the return air compart-
ment and the supply air compartment. See FIGURE 6 and

FIGURE 7,

NOTE: Blockoff plate in the supply air compartment only contains
one screw. If reinstalling plate, back part of plate MUST fit into
mating dimples of downflow flange. To reinstall, slant plate into

dimples, then put plate into position and fasten with screw.

2. Install the removed plates on the horizontal return and sup-
ply air openings.

NOTE: Itis the installer's personal responsibility to follow all local

Blockoff Plate Removed

FIGURE 7 (Return Air Compartment)

Condensate Drain

The condensate drain outlet is a 3/4" (19.1 mm) threaded female

PVC connection located at the bottom of the unit to the left of the

electrical access panel (see FIGURE 8). Condensate drain outlet
MUST be held with wrench when installing trap and drain line.

The circulating blower and the condenser fan create a negative
pressure on the condensate drain line that will prevent the con-

densate from draining properly without atrap. To combat this neg-
ative pressure, a field supplied condensate trap that will allow a

standing column of water of at least 2" (50.8mm) MUST be
installed. Top of outlet from trap MUST be at least 1" (25.4mm)

below top of outlet from unit. Install the trap as near to the unit

as possible for proper drainage.

L_J 519 01 1002 00