International Comfort Products Installation Manual
INSTALLATION INSTRUCTIONS
R−410A Single Package Heat Pumps
PHD524−60
Single Phase
These instructions must be read and understood completely before attempting installation
Safety Labeling and Signal Words
DANGER, WARNING, CAUTION, and NOTE
The signal words DANGER, WARNING,
CAUTION, and NOTE are used to identify levels of
hazard seriousness. The signal word DANGER is
only used on product labels to signify an immediate
hazard. The signal words WARNING, CAUTION,
and NOTE will be used on product labels and
throughout this manual and other manual that may
apply to the product.
DANGER− Immediate hazards which will result in
severe personal injury or death.
WARNING−Hazards or unsafe practices which
could result in severe personal injury or death.
CAUTION − Hazards or unsafe practices which
may result in minor personal injury or product or
property damage.
NOTE − Used to highlight suggestions which will
result in enhanced installation, reliability, or
operation.
The signal word WARNING is used throughout
this manual in the following manner:
!
WARNING
The signal word CAUTION is used throughout
this manual in the following manner:
!
CAUTION
Signal Words on Product Labeling
Signal words are used in combination with
colors and/or pictures or product labels.
!
WARNING
PERSONAL INJURY, AND/OR PROPERTY
DAMAGE HAZARD
Failure to carefully read and follow this warning
could result in equipment malfunction, property
damage, personal injury and/or death.
Installation or repairs made by unqualified
persons could result in equipment malfunction,
property damage, personal injury and/or death.
The information contained in this manual is
intended for use by a qualified service technician
familiar with safety procedures and equipped
with proper tools and test instruments.
Installation must conform with local building
codes and with the national Electrical Code
NFPA70 current edition or Canadian Electrical
Code part 1 CSA C.22.1.
518 01 2103 01 02/17/11
SAFE INSTALLATION REQUIREMENTS
FIGURE 1
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
a fire extinguisher available. Read these instructions thoroughly
and follow all warnings or cautions included in literature and
attached to the unit. Consult local building codes, the current
editions of the National Electrical Code (NEC) NFPA 70.
In Canada refer to the current editions of the Canadian electrical
Code CSA C22.1.
Recognize safety information. This is the safety−alert symbol .
When you see this symbol 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
serious injury or death. WARNING signifies a hazard which could
result in serious injury or death. CAUTION is used to identify unsafe
practices which may 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.
!
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury or
death.
Before installing or servicing system, turn off power supply to the
unit and install lockout tag. There may be more than one
disconnect switch. Turn off accessory heater power switch if
applicable.
!
UNIT OPERATION AND SAFETY HAZARD
Failure to follow this warning could result in personal injury or
equipment damage.
R−410A systems operate at higher pressures than standard
R−22 systems. DO NOT use R−22 service equipment or
components on R−410A equipment. Ensure service equipment
is rated for R−410A.
PHD5 AIR CONDITIONING UNIT
!
WARNING
WARNING
!
CUT HAZARD
Failure to follow this caution may result in personal injury.
When removing access panels (see Fig. 18) or performing
maintenance functions inside your unit, be aware of sharp
sheetmetal parts and screws. Although special care is taken to
reduce sharp edges to a minimum, be extremely careful when
handling parts or reaching into the unit.
CAUTION
INTRODUCTION
This packaged heat pump unit is fully self−contained and designed
for outdoor installation (see Fig. 1). See Fig. 4 and 5 for unit
dimensions. Standard units are shipped in a horizontal−discharge
configuration for installation on a ground level slab. Standard units
can be converted to downflow (vertical) discharge configurations
for rooftop applications.
RECEIVING AND INSTALLATION
Step 1—Check Equipment
IDENTIFY UNIT
The unit model number and serial number are stamped on the unit
information plate. Check this information against shipping papers.
INSPECT SHIPMENT
Inspect for shipping damage before removing packaging materials.
If unit appears to be damaged or is torn loose from its anchorage,
have it examined by transportation inspectors before removal.
Forward claim papers directly to transportation company.
Manufacturer is not responsible for any damage incurred in transit.
Check all items against shipping list. Immediately notify the nearest
equipment distribution office if any item is missing. To prevent loss
or damage, leave all parts in original packages until installation.
Step 2—Provide Unit Support
IMPORTANT: The unit must be secured to the curb by installing
screws through the bottom of the curb flange and into the unit base
rails. When installing large base units onto the common curb, the
screws must be installed before allowing the full weight of the unit
to rest on the curb. A minimum of six screws are required for large
base units. Failure to secure unit properly could result in an
unstable unit. See Warning near Rigging/Lifting information and
accessory curb instructions for more details.
For hurricane tie downs, contact distributor for details and PE
(Professional Engineering) Certificate if required.
Roof Curb
Install accessory roof curb in accordance with instructions shipped
with curb. See Fig. 6. Install insulation, cant strips, roofing, and
flashing. Ductwork must be attached to curb.
IMPORTANT: The gasketing of the unit to the roof curb is critical for
a water tight seal. Install gasketing material supplied with the roof
curb. Improperly applied gasketing also can result in air leaks and
poor unit performance.
Curb should be level to within ¼” (6mm) This is necessary for unit
drain to function properly. Refer to accessory roof curb installation
instructions for additional information as required.
Accessory kits are available to aid in installing a new metal base rail
unit on an old roof curb.
Accessory kit number CPADCURB001A00, (small chassis) and
accessory kit number CPADCURB002A00, (large chassis)
includes roof curb adapter and gaskets for the perimeter seal and
duct openings. No additional modifications to curb are required
when using this kit.
2
518 01 2103 01
Slab Mount
Place the unit on a solid, level concrete pad that is a minimum of
4” (102mm) thick with 2” (51mm) above grade (see Figure 2). The
slab should extend approximately 2” beyond the casing on all 4
sides of the unit. Do not secure the unit to the slab except when
required by local codes.
FIGURE 2
2"
EVAP. COILCOND. COIL
Slab Mounting Details
OPTIONAL
RETURN
AIR
OPENING
OPTIONAL
SUPPLY
AIR
OPENING
Step 3—Provide Clearances
The required minimum service clearances are shown in Fig. 4 and
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
corner or under an overhead obstruction. The minimum clearance
under a partial overhang (such as a normal house overhang) is 48
in. (1219mm) above the unit top. The maximum horizontal
extension of a partial overhang must not exceed 48 in.(1219mm).
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. (102mm) above the highest expected water
and runoff levels. Do not use unit if it has been under water.
Step 4—Rig and Place Unit
Rigging and handling of this equipment can be hazardous for many
reasons due to the installation location (roofs, elevated structures,
etc.).
Only trained, qualified crane operators and ground support staff
should handle and install this equipment.
When working with this equipment, observe precautions in the
literature, on tags, stickers, and labels attached to the equipment,
and any other safety precautions that might apply.
Training for operators of the lifting equipment should include, but
not be limited to, the following:
1. Application of the lifter to the load, and adjustment of the lifts to
adapt to various sizes or kinds of loads.
2. Instruction in any special operation or precaution.
3. Condition of the load as it relates to operation of the lifting kit,
such as balance, temperature, etc.
Follow all applicable safety codes. Wear safety shoes and work
gloves.
INSPECTION
Prior to initial use, and at monthly intervals, all rigging shackles,
clevis pins, and straps should be visually inspected for any
damage, evidence of wear, structural deformation, or cracks.
Particular attention should be paid to excessive wear at hoist
hooking points and load support areas. Materials showing any kind
of wear in these areas must not be used and should be discarded.
!
WARNING
UNIT FALLING HAZARD
Failure to follow this warning could result in personal
injury or death.
Never stand beneath rigged units or lift over people.
Rigging/Lifting of Unit
!
WARNING
UNIT FALLING HAZARD
Failure to follow this warning could result in personal
injury/death or property damage.
When straps are taut, the clevis should be a minimum of
36 in. (914 mm) above the unit top cover.
!
WARNING
UNIT FALLING HAZARD
Failure to follow this warning could result in personal
injury or death.
Large base units must be secured to common curb
before allowing full weight of unit to rest on curb. Install
screws through curb into unit base rails while rigging
crane is still supporting unit.
Lifting holes are provided in base rails as shown in Fig. 4 and 5.
1. Leave top shipping skid on the unit for use as a spreader
bar to prevent the rigging straps from damaging the unit. If
the skid is not available, use a spreader bar of sufficient
length to protect the unit from damage.
2. Attach shackles, clevis pins, and straps to the base rails
of the unit. Be sure materials are rated to hold the weight
of the unit (See Fig. 3).
3. Attach a clevis of sufficient strength in the middle of the
straps. Adjust the clevis location to ensure unit is lifted
level with the ground.
After the unit is placed on the roof curb or mounting pad, remove
the top crating.
Step 5—Select and Install Duct Connections
The design and installation of the duct system must be in
accordance with the standards of the NFPA for installation of
non−residence type air conditioning and ventilating systems, NFPA
90A or residence type, NFPA 90B and/or local codes and
ordinances.
Select and size ductwork, supply−air registers, and return air grilles
according to ASHRAE (American Society of Heating,
Refrigeration, and Air Conditioning Engineers) recommendations.
The unit has duct flanges on the supply− and return−air openings
on the side of the unit.
518 01 2103 01
3
!
WARNING
PROPERTY DAMAGE HAZARD
Failure to follow this warning could result in personal injury/death
or property damage.
For vertical supply and return units, tools or parts could drop into
ductwork. Install a 90 degree turn in the return ductwork between
the unit and the conditioned space. If a 90 degree elbow cannot
be installed, then a grille of sufficient strength and density should
be installed to prevent objects from falling into the conditioned
space. Units with electric heaters require 90 degree elbow in
supply duct.
When designing and installing ductwork, consider the following:
1. All units should have field−supplied filters or accessory filter
rack installed in the return−air side of the unit. Recommended
sizes for filters are shown in Table 1.
2. Avoid abrupt duct size increases and reductions. Abrupt
change in duct size adversely affects air performance.
IMPORTANT: Use flexible transitions 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. (610mm)
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.
FIGURE 3
Unit Corner Weight (lbs) and Rigging
CAUTION - NOTICE TO RIGGERS
PRUDENCE - AVIS AUX MANIPULATEUR
ACCESS PANELS MUST BE IN PLACE WHEN RIGGING.
PANNEAUX D'ACCES DOIT ÊTRE EN PLACE POUR MANIPULATION.
Use top skid as spreader bar. / Utiliser la palette du haut comme barre de répartition
DUCTS
MINIMUM HEIGHT: 36" (914.4 mm)
HAUTEUR MINIMUM
BANDE SCELLANT DOIT ÊTRE
EN PLACE AVANT DE PLACER
L'UNITÉ SUR LA BASE DE TOIT
50CY502286 2.0
SEE DETAIL A
VOIR DÉTAIL A
UNIT HEIGHT
HAUTEUR D'UNITÉ
DETAIL A
VOIR DÉTAIL A
SEAL STRIP MUST BE IN
PLACE BEFORE PLACING
UNIT ON ROOF CURB
IN. (mm)DIN. (mm)EIN. (mm)FIN. (mm)GIN. (mm)HIN. (mm)
47.8
(1214)
32.4 (822)
43.9
(1116)
2.7 (69)
30.6 (778)
42.2
(1072)
46.1 (1170)
518 01 2103 01
7
CONFIGURING UNITS FOR DOWNFLOW (VERTICAL)
DISCHARGE
FIGURE 7
Supply and Return Duct Openings
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before installing or servicing system, turn off the power
supply to the unit and install lockout tag. There may be
more than one disconnect switch.
1. Open all electrical disconnects and install lockout tag
before starting any service work.
2. Remove horizontal (metal) ductcovers to access vertical
(downflow) discharge duct knockouts in unit basepan.
(See Fig. 7.)
3. To remove downflow return and supply knockout covers,
break front and right side connecting tabs with a
screwdriver and hammer. Push cover down to break rear
and left side tabs.
NOTE:These panels are held in place with tabs similar to an
electrical knockout. Reinstall horizontal duct covers (Fig. 7)
shipped on unit from factory. Insure openings are air and
watertight.
NOTE:The design and installation of the duct system must be in
accordance with the standards of the NFPA for installation of
nonresidence−type air conditioning and ventilating systems,
NFPA 90A or residence−type, NFPA 90B; and/or local codes
and ordinances.
Adhere to the following criteria when selecting, sizing, and
installing the duct system:
1. Units are shipped for side shot installation.
2. Select and size ductwork, supply−air registers, and
return−air grilles according to American Society of
Heating, Refrigeration and Air Conditioning Engineers
(ASHRAE) recommendations.
3. Use flexible transition between rigid ductwork and unit to
prevent transmission of vibration. The transition may be
screwed or bolted to duct flanges. Use suitable gaskets to
ensure weather−tight and airtight seal.
4. All units must have field−supplied filters or accessory filter
rack installed in the return−air side of the unit.
Recommended sizes for filters are shown in Table 1.
5. Size all ductwork for maximum required airflow (either
heating or cooling) for unit being installed. Avoid abrupt
duct size increases or decreases or performance may be
affected.
6. Adequately insulate and weatherproof all ductwork
located outdoors. Insulate ducts passing through
unconditioned space, and use vapor barrier in accordance
with latest issue of Sheet Metal and Air Conditioning
Contractors National Association (SMACNA) and Air
Conditioning Contractors of America (ACCA) minimum
installation standards for heating and air conditioning
systems. Secure all ducts to building structure.
7. Flash, weatherproof, and vibration−isolate all openings in
building structure in accordance with local codes and
good building practices.
Horizontal Duct Covers
Basepan
Downflow
(Vertical)
Supply
Knockout
Basepan
Downflow
(Vertical)
Return
Knockout
Provide for Condensate Disposal
NOTE:Ensure that condensate−water disposal methods comply
with local codes, restrictions, and practices.
The PHD5 units dispose of condensate through a 3/4 in. NPT
female fitting that exits on the compressor end of the unit.
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. Prime the trap with water. 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 field−supplied 2 −in. (51mm) trap at the
condensate connection to ensure proper drainage. Condensate
trap is available as an accessory or is field−supplied. 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. Connect a drain tube using a minimum of
field−supplied 3/4−in. PVC or field−supplied 3/4−in. copper pipe at
outlet end of the 2−in. (51 mm) trap. (See Fig. 8) Do not undersize
the tube. Pitch the drain tube downward at a slope of at least 1 in.
(25 mm) every 10 ft (3 m) of horizontal run. Be sure to check the
drain trough for leaks. Prime the trap at the beginning of the cooling
season start−up.
FIGURE 8Condensate Trap
TRAP
OUTLET
1-in. (25 mm) min.
2-in. (51 mm) min.
8
518 01 2103 01
A
FIGURE 9Unit Leveling Tolerances
B
A-B
(6.35)
1/4
Install Electrical Connections
C
MAXIMUM ALLOWABLE
DIFFERENCE in. (mm)
B-C
(6.35)
1/4
1/4
A-C
(6.35)
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 switch box 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. 4 and 5 for acceptable
location). Remove the high voltage knockout.
See unit wiring label, Fig. 10 and Fig. 13−14, for reference when
making high voltage connections. Proceed as follows to complete
the high−voltage connections to the unit.
!
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. 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 American National Standards
Institute/National Fire Protection Association (latest
edition) (in Canada, Canadian Electrical Code CSA
C22.1) and local electrical codes.
!
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 (latest edition) and local electrical
codes governing such wiring. In Canada, all
electrical connections must be in accordance with
CSA standard C22.1 Canadian Electrical Code Part
1 and applicable local codes. Refer to unit wiring
diagram.
2. Use only copper conductor for connections between
field−supplied electrical disconnect switch and unit.
DO NOT USE ALUMINUM WIRE.
3. Be sure that high−voltage power to unit is within
operating voltage range indicated on unit rating
plate.
4. Do not damage internal components when drilling
through any panel to mount electrical hardware,
conduit, etc.
FIGURE 10
HIGH VOLTAGE
POWER LEADS
(SEE UNIT WIRING
LABEL)
1 − PHASE USES
TWO POWER
LEADS
CONTROL BOX
LOW − VOLTAGE
POWER LEADS
(SEE UNIT
WIRING LABEL)
High and Control Voltage Connections
POWER
SUPPLY
EQUIP GR
SPLICE BOX
FIELD − SUPPLIED
FUSED DISCONNECT
)
(
W2
WHT
VIO
YEL
PNK
GRN
RED
BRN
ORN
W3
(
()
Y1
Y2
(
G
(
(
R
C
(
O
(
W2
)
W3
Y1
)
Y2
)
)
)
)
G
R
C
O
Single phase units:
1. Run the high−voltage (L1, L2) and ground lead into the control
box.
2. Connect ground lead to chassis ground connection.
3. Locate the black and yellow wires connected to the line side of
the contactor.
4. Connect field L1 to black wire on connection 11 of the
compressor contactor.
5. Connect field wire L2 to yellow wire on connection 23 of the
compressor contactor.
SPECIAL PROCEDURES FOR 208−V OPERATION
HIGH−VOLTAGE CONNECTIONS
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before making any wiring changes, switch off the main
power supply to the unit and install lockout tag.
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before making any wiring changes, switch off the main
power supply to the unit. Tag the disconnect switch with
a suitable warning label. With disconnect switch open,
move black wire from transformer (3/16 in.) terminal
!
WARNING
marked 230 to terminal marked 208. This retaps
transformer to primary voltage of 208 vac.
CONTROL VOLTAGE CONNECTIONS
518 01 2103 01
NOTE: Do not use any type of power−stealing thermostat. Unit
control problems may result.
9
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