Payne PYIP024060, PY1P024040, PYIP030060, PY1P030040, PYIP030080 Installation, Start-up And Service Instructions Manual

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CONTENTS

Page

SAFETY CONSIDERATIONS ...................... 1-5

I. General ................................... 1

RECEIVING AND INSTALLATION ................. 6 15

I. Step 1 -- Check Equipment .................. (3

II. Step 2 -- Provide Unit Support ............... (3

III. Step 3 -- Field Fabricate Ductwork ............ (3

IV. Step 4 -- Provide Clearances ................. 6

V. Step 5 -- Rig and Place Unit ................. 6

VI. Step 6 -- Connect Condensate Drain .......... 9

VII. Step 7 -- Install Flue Hood ................... 9

VIII. Step 8 -- Install Gas Piping .................. 9

IX. Step 9 -- Install Duct Connections ........... 11

X. Step 10 -- Install Electrical Connections ...... 13

PRE-START-UP ................................. 1(3

START-UP .................................... 16 29

I. Check for Refrigerant Leaks ................. 1(3

II. Start-Up Heating Section and

Make Adjustments ......................... 17

III. Start-Up Cooling Section and

Make Adjustments ......................... 20

MAINTENANCE ................................ 3043

I. Air Filter .................................. 30

II. Unit Top Removal .......................... 30

III. Evaporator Blower and Motor ................ 30

IV. Flue Gas Passageways ..................... 31

V. Combustion-Air Blower ..................... 31

VI. Limit Switch .............................. 31

VII. Burner Ignition ............................ 31

VIII. Main Burners ............................. 32

IX. Condenser Coil, Evaporator Coil, and

Condensate Drain Pan ..................... 32

X. Condenser Fan ............................ 33

XI. Electrical Controls and Wiring ............... 33

Xll. Refrigerant Circuit ......................... 33

Xlll. Gas Input ................................. 33

XlV. Evaporator Airflow ......................... 33

XV. Metering Device -- Acutrol TM Device .......... 33

XVI. Liquid Line Strainer ........................ 33

TROUBLESHOOTING ........................... 34-3(;

START-UP CHECKLIST .......................... CL 1

NOTE TO INSTALLER -- Before the installation, READ

THESE INSTRUCTIONS CAREFULLY AND COMPLETELY.

Also, make sure the User's Manual and Replacement Guide are left with tile unit after installation. The furnace is NOT

to be used for temporary heating of buildings or structures under constrttction.

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can be hazardous due to system pressure and electrical compo

nents. Only trained and qualified personnel should install, repair, or service air conditioning equipment.

Cancels: II PY1P 18 1 II PY1P 18 2

9/1/98

Fig. 1 -- Unit PY1P

Untrained personnel can perform basic maintenance flmc- tions of cleaning coils and filters. All other operations should be performed by trained service personnel. When working on

air conditioning equipment, observe precautions in the lit erature, tags and labels attached to the unit, and other safety

precautions that may apply. Follow all safety codes. Wear safety glasses and work gloves.

Use quenching cloth for unbrazing operations. Have fire ex- tinguisher available for all brazing operations.

I. GENERAL

The PY1P units (see Fig. 1) are fidly self-contained, combi- nation Category I gas heating/electric cooling units designed

for outdoor installation. See Fig. 2 5 (pages 2 5) for unit di- mensions. All unit sizes have discharge openings for both hori

zontal and downflow configurations, and are factory shipped with all 4 duct openings covered. Units may be installed ei-

ther on a rooftop or a groundqevel cement slab. See Fig. 6 for roof curb dimensions.

/-COND COIL

- 4 13/16" ()22.2) 43 11116"

4ll0B.B)

B/16 °

(312.?)

BLOWER ACCESS BURNER AND CONTROL 30X

PANEL RIGHT SIDE VIEW ACCESS PANEL

REQ'D CLEARANCES FOR SERVICING in (mm)

Duct panel ............................. 0

Unit top ........................... 36 (914)

Side opposite ducts ..................... 36 (914)

Compressor access ..................... 36 (914)

(Except for NEC requirements) REQ'D CLEARANCES TO COMBUSTIBLE MAT'L in. (mm)

Maximum extension of overhangs ............... 48 (1219)

Unit top ........................... 14 (356)

Duct side of unit ........................ 2 (51)

Side opposite ducts ..................... 14 (356)

Bottom of unit ........................... 0

Flue panel ......................... 36 (914)

NEC REQ'D CLEARANCES in. (mm)

Between units, control box side ................ 42 (1067)

Unit and ungrounded surfaces, control box side ......... 36 (914)

Unit and block or concrete walls and other grounded

surfaces, control box side .................. 42 (1067)

49 9116"

(1259.3)

COIL

RETURN

AIR OPENING

(281,4) I

l? l/1B'_

(433,9)

LOPT_ONAL SUPPLY

AIR OPENING

14 ?liB"

(365.9)

(52,63

10 9116"

(263.R)

7/3" (22.2) BIA,

CONTROL ENTRY_

t (203.2)

€

I 1/8" (2B.6) DIA,

POWER ENTRY

_ (90.51 i

i !

_-I 5/E _ 441,3) OIA.

GASENTRY

1/2 _ - 14 NPT

GASCONNECTION

REAR VIEW

i w (58.O)

! I

(29.6)

FLUE PANEL

FLUE HOOD

0 ?/3" 422.23)

ALTERNATE LV ENTRY

EVAP COIL ACCESS

LEFT SIDE VIEW

I W4" (31.75)

_,ALTERNATE POWER ENTRY

I ?/16 -2 3/18"

(39.3) 455.6)

COMPRE330R ACCES5 PANEL

3/4" NPT (13,0)

DRAIN OUTLET

FRONT VIEW

UNIT

PYIP180040 PY1P024040 PYIP024060 PY1P030040

PYIP030060/080 PYIP036060/080 PYIP036100/120 PYIP042060/080

PYIP042100/120

ELECTRICAL

CHARACTERISTICS

208/230-1-60 208/230-1-60

208/230-1-60 208/230-1-60, 208/230-3-60 208/230-1-60, 208/230-3-60

208/230-1-60, 208/230-3-60, 460-3-60 208/230-1-60, 208/230-3-60, 460-3-60

UNIT WEIGHT

Ib kg

272 123 303 138 315 143 320 145

332 149 336 153 348 158 375 170

387 176

CORNER WEIGHT UNIT HEIGHT

(Ib/kg) (in./mm)

A B C D E

81/37 82/28 78/35 53/24 24 1/813

97/44 43/20 123/56 40/18 241/813 100/45 46/21 128/57 43/20 241/813 100/45 47/21 128/57 47/21 241/813

103/46 50/22 129/58 50/23 24 1/813

86/39 76/35 111/50 63/29 24 1/813

89/40 79/36 114/52 66/30 24 1/613

95/43 86/39 119/54 75/34 28 1/714

98/45 89/40 122/55 78/35 28 1/714

UNIT

PYIP018040

PY1P024040 PY1P024060 PY1P030040

PY1P030060/080 PY1P036060/080 PY1P036100/120

PYIP042060/080 PY1P042100/120

in./mm

169½d420 7

209½d522 3

in./mm

18/5½6/481 0

22/5½6/5826

CENTER OF GRAVITY in./mm

X Y Z

2507/637 20.59/523 2707/688 23.35/593 2698/685 23.27/591 2671/678 23.46/598 10.85/278

2715/689 22.38/568 2750/698 22.48/571 2740/696 22.44/570

2701/686 22.44/570

127/321

2694/684 22.44/570

LEGEND

CG -- Center of Gravity MAT'L -- Materiat COND -- Condenser NEC -- National Electrical Code

LV -- Low Voltage REQ'D -- Required

NOTES:

1. Clearances must be maintained to prevent recirculation of airfrom outdoor- fan discharge.

2 Adequate clearance around air openings into combustion chamber must

be provided.

Fig. 2 -- PYIP018-042 Without Base Rail, Unit Dimensions

--2--

SLOWER ACCESS

PANEL

BURNER ANS CONTROL BOX

RIGHT _IDE VIEW ACCESS PANEL

REQ'D CLEARANCES FOR SERVICING. in. (mm)

Duct panel ............................. 0

Unit top ........................... 36 (914)

Side opposite ducts ..................... 36 (914)

Compressor access ..................... 36 (914)

(Except for NEC requirements) REQ'D CLEARANCES TO COMBUSTIBLE MAT'L. in (ram)

Maximum extension of overhangs ............... 48 (1219)

Unit top ........................... 14 (356)

Duct side of unit ........................ 2 (51)

Side opposite ducts ..................... 14 (356)

Bottom of unit ........................... 0

Ftue panel ......................... 36 (914)

NEC REQ'D CLEARANCES. in. (ram)

Between units, control box side ................ 42 (1067)

Unit and ungrounded surfaces, control box side ......... 36 (914)

Unit and block or concrete walls and other grounded

surfaces, control box side .................. 42 (1067)

7/8" (22,2) OIA. I I/8" (28.6) GIA, C(:_ITROL ENTRY POWER ENTRY

1A_/B:TR(41.3) OI A. /

I/2" - 14 NPT FLUE PANEL

GAS CONNECTION

REARVIEW

FLUE HOOD

18 I/

(458

(142.

1 S/It

(29,S) (253.8)

1 9/16"

52"

(1320_8)

-45 I/2"

COND COIL (115E,7)

43 11/16 °

(II08.B)

3 5/1G_

(84,1) I

1 1/4"

(31,75)

ALTERNATE POWER ENTRY

EVAP COIL ACCESS

OPTIONAL RETURN

/ AIROPENING /

(368.9)

(52. S)

GUPPLY 10 9/16"

(268, 9)

_1 11/16" (48,2)

(43.21

-OPTIONALSUPRLY

AIR OPENING

COMPRESSOR ACCESS PANEL

(325.4)

1 3/4 ° NPT (19.0)

(34,S) SRAIN OUTLET

LEFT SIDE VIEW 2 3/16" FRONT VIEW

(SS.6)

UNIT

PYIP018040 PYIP024040 PYIP024060 PYIP030040

PYIP030060/080 PYIP036060/080 PYIP036100/120 PYIP042060/080

PYIP042100/120

ELECTRICAL

CHARACTERISTICS

208/230-1-60 208/230-1-60 208/230-1-60

208/230-1-60, 208/230-3-60

208/230-1-60, 208/230-3-60 208/230-1-60, 208/230-3-60, 460-3-60 208/230-1-60, 208/230-3-60, 460-3-60

208/230-1-60, 208/230-3-60, 460-3-60 208/230-1-60, 208/230-3-60, 460-3-60

UNIT WEIGHT

Ib kg

296 135 327 149 339 155 344 157

356 162 360 164 372 169 399 181

411 187

CORNER WEIGHT UNIT HEIGHT

(Ib/kg) (in,/rnm)

A B C D E

87/40 68/31 82/37 59/27 274/697 103/47 49/22 129/59 46/21 274/697 106/48 52/24 132/60 49/22 274/697 106/48 53/24 132/60 53/24 274/697

102/46 71/32 123/56 60/27 274/697

92/42 82/37 117/53 69/31 274/697

95/43 85/39 120/55 72/33 274/697 101/46 92/42 125/57 81/37 31.4/798

104/47 95/43 128/58 84/38 31.4/798

UNIT

PYIP018040

PY1P024040 PY1P024060 PY1P030040

PY1P030060/080 PY1P036060/080 PY1P036100/120

PYIP042060/080 PY1P042100/120

F G

in./mm in./mm

19%/5048 22¼/5654

23%/6064 26¼/6668

CENTER OF GRAVITY in./mm

25.04/636

26.90/683.3

26.82/681.2

26.57/674.9

26.93/684

27.31/693.7

27.23/691.6

26.87/682.5

26.81/681

Y Z

2272/577 2017/5123 2022/5136 201 /5093 13.16/334.3

211 /5354 210 /5326 210 /5331

210 /5331

14.96/380

210 /5337

LEGEND

CG -- Center of Gravity MAT'L -- Material COND -- Condenser NEC -- NationaI Electrical Code

LV -- Low Voltage REQ'D -- Required

NOTES:

1 Clearances must be maintained to prevent recirculation of air from outdoor-

fan discharge

2. Adequate clearance around air openings into combustion chamber must be provided

Fig. 3 -- PYIP018-042 With Optional Base Rail, Unit Dimensions

--3--

(19,0)

(55,B) DRAIN OUTLET

FRONT VIEW

RETURN

AIR OPENING

14 71IS"

(365.91

l _'2 1/lS"

(52,6)

10 9/16 °

(268,9)

FLUE HOOD

18 1/16

(458,8)

(E8,0)

t 3116 _

129.GI

0 7/8" (22.23) 1 1/4" (31.?51

ALTERNATELV ENTRY ALTERNATEPOWERENTRY

EVAPCOIL ACCESg

(292. I ) 1325.4) (36, 3)

(253,81

LEFTSIDE VIEW

REQ'D CLEARANCES FOR SERVICING. in (ram)

Duct panel ............................. 0

Unit top ........................... 36 (914)

Side opposite ducts ..................... 36 (914)

Compressor access ..................... 36 (914)

(Except for NEC requirements) REQ'D CLEARANCES TO COMBUSTIBLE MAT'L. in (ram)

Maximum extension of overhangs ............... 48 (1219)

Unit top ........................... 14 (356)

Duct side of unit ........................ 2 (51)

Side opposite ducts ..................... 14 (356)

Bottom of unit ........................... 0

Flue panel ......................... 36 (914)

NEC REQ'D CLEARANCES. in (ram)

Between units, control box side ................ 42 (1067)

Unit and ungrounded surfaces, control box side ......... 36 (914)

Unit and block or concrete walls and other grounded

surfaces, control box side .................. 42 (1867)

718" (22.2)DIA, I I18"(28.6)OIA. CONTROLENTRY POWERENTRY

28 15/16

1734 ' I I

1 5/9" (41.9) OIA,_-_

GAS ENTRY

I/2"- 14 NPT

GASOONNECT!0N

FLUE PANEL

UNIT

ELECTRICAL

CHARACTERISTICS

PY1PO48080 208/230-1-60, 208/230-3-60,460-3-60 PY1P048100/120/140 208/230-1-60, 208/230-3-60,460-3-80 PY1P060080 208/230-1-60, 208/230-3-60,460-3-80

PYIP060100/120/140 208/230-1-60, 208/230-3-60,460-3-80

UNIT

PYIP048080

PYIP048100/120/140 PYIP060O80 PYIP060100/120/140

CENTER OF GRAVITY (in./mm)

UNIT WEIGHT

Ib kg

414 188 426 193 453 206

465 211

107/49 110/50 117/53

120/55

CORNER WEIGHT

(Ib/kg)

B C

83/38 158/72 86/39 159/72 93/42 167/76

96/44 167/76

LEGEND

CG -- Center of Gravity MAT'L -- MateriaI

X Y

28.76/731 2346/596

28.42/722 2342/595

28.36/720 2327/591

27.95/710 2323/590

D 66/30 71/32 76/35

82/37

1535/390 1535/390

COND -- Condenser NEC -- National Electrical Code

LV -- Low Voltage REQ'D -- Required NOTES:

1. Clearances must be maintained to prevent recircutation of air from outdoor- fan discharge.

2 Adequate clearance around air openings into combustion chamber must

be provided.

Fig. 4 -- PYIP048,060 Without Base Rail, Unit Dimensions

--4--

GIG"

(23, B)

+45 1/2"

CON0 C0IL (115B,71

43 11/16"

1110B.8)

(281,4)

(433+a1

AIR OPENING

14 ?/16"

(355.9)

t L2 1116"

(52,6)

10 BilE"

(268.91

5/B"

:39B,91

BLOWER ACCESS BURNER ANO CONTROL BOX

PANEL RIGHT SIDE VIEW ACCESS PANEL

ACCESB PANEL

13/15"

3/4" NPT {15.0)

DRAIN OUTLET

J 3115"

(55,B1 FRONT VIEW

FLUE HO00

1B 1/15

(458.8)

L__

B 518"

(142.9)

1B/16: _lO "_

(29.5) (253.5)

I 114"

(31,7G3

ALTERNATE POWER ENTRY

EVAP COIL ACCEBB

/16"

REQ'D CLEARANCES FOR SERVICING. in. (ram)

Duct panel ............................. 0

Unit top ........................... 36 (914)

Side opposite ducts ..................... 36 (914)

Compressor access ..................... 36 (914)

(Except for NEC requirements) REQ'D CLEARANCES TO COMBUSTIBLE MAT'L. in (ram)

Maximum extension of overhangs ............... 48 (1219)

Unit top ........................... 14 (356)

Duct side of unit ........................ 2 (51)

Side opposite ducts ..................... 14 (356)

Bottom of unit ........................... 0

Flue panel ......................... 36 (914)

NEC REQ'D CLEARANCES. in. (ram)

Between units, controt box side ................ 42 (1867)

Unit and ungrounded surfaces, control box side ......... 36 (914)

Unit and block or concrete walls and other grounded

surfaces, control box side .................. 42 (1067)

2 1116"

(G2.3) _

?%Nf&2 NT ¢7

1 13116'

29 7/8"

32 1/4" (287.3)

,8,B.B)I

4_I t18" (2B.G) OIA+

POWER ENTRY

, /

1 B/B" (41=31 OIA.

GAS ENTRY

I/2" - 14 NPT FLUE PANEL

GAS CONNECTION

UNIT

ELECTRICAL

CHARACTERISTICS

PYIP048080 208/230-1-60,208/230-3-60,460-3-60 PY1P048100/120/140 208/230-1-60,208/230-3-60,460-3-60 PYIP060OBO 208/230-1-60,208/230-3-60,460-3-60

PYIP060100/120/140 208/230-1-60,208/230-3-60,460-3-60

UNIT WEIGHT

Ib kg

438 199 450 205 477 217

489 222

A 113/51 116/53

123/56 126/57

CORNER WEIGHT

(Ib/kg)

B C

89/40 164/75 92/42 165/75 99/45 173/79

182/46 173/79

D 72/33 77/35 82/37

88/40

UNIT

PY1P048080 PY1P048100/120/140

PY1P060080 PY1P060100/120/140

CENTER OF GRAVITY (in./mm)

X Y Z

28.54/7249 2000/508 1766/4486

28.22/7168 2005/5093 1766/4486

28.18/7156 2019/5128 1766/4486

27.79/7059 2023/5138 1766/4486

LEGEND

CG -- Center of Gravity MAT'L -- Material COND -- Condenser NEE -- National Electrical Code

LV -- Low Voltage REQ'D -- Required NOTES:

1.Clearances must be mahTtained to prevent redrculation of air from outdoor- fan discharge

2. Adequate clearance around air openings into combustion chamber must be provided.

Fig. 5 -- PYIP048,060 With Optional Base Rail, Unit Dimensions

--5--

RECEIVING AND INSTALLATION

I. STEP 1 -- CHECK EQUIPMENT

A. Identify Unit

The unit model nmnber and serial number are stamped on unit identification plate. Check this information against ship

ping papers and job data.

B. Inspect Shipment

Inspect for" shipping damage while unit is still on shipping pallet. If unit appears to be damaged or is torn loose fl'om its

anchorage, have it examined by transportation inspectors be- fore removal. Fm_vard claim papers directly to transporta-

tion company. Manufacturer is not responsible for any darn age incnrred in transit.

Check all items against shipping list. hnmediately notify your representative if any item is missing.

To prevent loss or damage, leave all parts in original pack ages until installation.

II. STEP 2 -- PROVIDE UNIT SUPPORT

A. Roof Curb

Install accessory roof curb in accordance with instructions shipped with curb. See Fig. 6 for roof curb dimensions. In

stall insulation, cant strips, roofing, attd flashing. Ductwork must be attached to curb.

IMPORTANT: The gasketing of the unit to the roof curb is critical for a watertight seal. Install gasketing material sup-

plied with the roof curb. hnproperly applied gasketing can also result in air leaks and poor" unit performance.

Curb should be level to within 1/4inch. This is necessa W for unit drain to flmction properly. Refer to accessory roof curb

installation instructions for additional information as required.

B. Slab Mount

Place the unit on a solid, level concrete pad that is a mini mmn of 4 in. thick with 2 in. above grade. The slab should be flush on the front of the unit (to allow condensate drain in-

stallation) and should extend 2 in. on the three remaining sides of the unit. See Fig. 7. Install a 6tin. gravel apron in

fl'ont of condenser air inlets to prevent obstrtiction of airflow by grass or shrubs. Do not secure the unit to the slab exc'u_t

when required by local codes.

C. Flush Mount

Place side of unit with duct panel flush against transition. On units with optional base rails, the skirt on duct-panel side of unit cat] be removed or relocated to allow unit to be mounted

flush against transitions that extend below basepan of trait, To move skirt, proceed as follows:

1. Remove 4 screws holding skirt to base rail. Retain screws.

2. Remove skirt or slide skirt inwards until alternate clear ance holes align with base rails.

3. Secure with screws removed in Step 1. Holes align with base rails.

To remove wood support under unit (with base rail only), loosen 4 screws above rigging holes and slide assembly out through

rectangular hole.

III. STEP 3 -- FIELD FABRICATE DUCTWORK

Secure all ducts to roof curb and building structure on verti- cal discharge units. Do [rot cczmect chlctwork to unit. For hori-

zontal applications, unit is provided with flanges on the hori zontal openings. All ductwork should be secured to the flanges.

Insulate attd weatherproof all external ductwork, joints, attd roof openings with counter flashing and inastic in accordance with applicable codes.

Ducts passing through an unconditioned space must be in- sulated and covered with a vapor barrier.

If a plenmn return is used on a vertical unit, the return should be ducted through the roof deck to comply with applicable fire codes.

A minimum clearance is not required around ductwork. Cabi- net return air static shall not exceed -.25 in. wg.

IV. STEP 4 -- PROVIDE CLEARANCES

The required n_inimunt operating and service clearances are shown in Fig. 2-5. Adequate combustion, ventilation, and cot]-

denser air must be provided, in accordance with section 5.3, Air for Combustion and Ventilation, of the National Fuel Gas Code ANSI (American National Standards Association) Z223.1

(in Canada, sections 7.2, 7.3 or 7.4 or Can/CGA [Canadian

Gas Association] B 149 Installation Codes), or applicable pro- visions of local building code.

The condenser fat] pushes air through the condenser coil and discharges it through the bank of louvers in the top cover,

the decorative grille on the right side of the unit, and the con> presser access panel. Be sure that the fan discharge does not

recirculate to the condenser coil. Do not locate the unit in ei- ther a corner or tinder an overhead obstruction. The mini-

mum clearance under a partial overhang (such as a normal house overhang) is 48-in. above the unit top. The maximunl

horizontal extension of a partial overhang must not exceed 48 inches.

Do not place the unit where water, ice, or snow fl'om an over- hang or roof will damage or flood the unit. Do not install the

unit on carpeting, tile, or other combustible materials. The unit may be installed on wood flooring or on Class A, B, or C

roof covering materials.

V. STEP 5 -- RIG AND PLACE UNIT

Use spreader bars or crate top when rigging the unit. The units must be rigged for lifting as shown in Fig. 8 and 9. Re-

fer to Table 1 for operating weight attd to Fig. 2 5 for" corner weights. U[se extreme c'ozlticzr to pz'eveirt ct_moge wheir mov

ing tire zmib U)rit must ['emoin in on zqJz'(ght [rositio:r dzlz'inq

oH ['{qgd/_,_ and moviz\_ OlreZ'ation.s. The unit Intist be level for

proper condensate drainage; therefore, the groundqevel pad or accessory roof curb must be level before setting the unit it]

place. When a field fabricated support is used, be sure that the support is level and properly supports the unit.

--6--

FLAT

CURB

PART NUMBER

CPRFCURB001A01 CPRFCURB002A01 CPRFCURB003A01

_A_

8" [203]

11" [279]

14" [356]

POWER AND

GAS ENTRY

5UPPLY AIR

[SEE DETAIL "A "j

17!

[44E]

SUPPLY AIR

OPENING

RETURN AIR

OPENING

[279 (406]

3G 3/4".

[1010]

[13]

SCREW DLEARANOE

SEAL

(_PPLIED WITH CURB)

FOR UNITS WITH

BASE RAILS)

(FIELD SUPPLIED)

=FING FELT

(FIELD SUPPLIED)

MATERIAL

(FIELD SUPPLIED)

THIS BRACKET MUST BE REMOVED

BEFORE iNSTALLATION

MUST BE REMOVED

BEFORE INBTALLATION

IGIO INSULATION

(FIELD SUPPLIED)

DETAIL "A"

33 7/8"

[858]

NOTES:

1. Roof curb must be set up for unit being installed.

2. SeaI strip must be applied as required for unit being installed.

3. Dimensions in [ ] are in millimeters.

4. Roof curb is made of 16 gage steel.

5. Attach ductwork to curb (flanges of duct rest on curb).

6. Service clearance 4 ft on each side.

7. [_ Direction of airflow.

8. Insulated panels: 1-in. thick fiberglass 1 Ib density.

Fig. 6 -- Roof Curb Dimensions

--7--

2,0'z,,

FLUSHWITHSLAB_ _F2. 0-

//i ! I

/ J

/ ,

/ b

// I I

/ I I

L. ...... J

, _

r "1

I I I i

I I

I t I t

L J

......U.......... ;_7.........20,,

CONCRETESLAB

Fig. 7 -- Slab Mounting Details

SEEDETAILA"_

SEAL STRIP MUST BE IN PLACE BEFORE PLACING

UNIT ON ROOF CURB "1

914-1371 / (36"- 54") /

_'_ DUCT END l\

SECURESCREW

AGAINSTBASEPAN

TO HOLDLIFTING

BRACKETINPLACE

DETAIL A

NOTICE TO RIGGERS

Hook rigging shackles through holes in lifting brackets, as shown in De- tail "A." Lifting brackets to be centered around the unit center of gravity. Use wooden top skid when rigging, to prevent rigging straps from dam- aging unit.

UNIT MAX A B C

PYIP WEIGHT

Size Ib kg in. mm in. mm in. mm

018 332 150 24.3 618 24.85 631 024 375 170 22.4 570 24.85 631 030 384 174 22.3 585 24.85 631 036 408 185 49.4 !255 22.0 559 24.85 631 042 447 203 22.5 571 28.85 733 048 486 220 21.0 533 34.85 885 060 525 238 21.5 545 34.85 885

Fig. 8 -- Suggested Rigging for Units Without

Base Rail

S 4-1371 UNIT ON ROOF CURB

BEE DETAIL A

NOTICE TO RIGGERS

Hook rigging shackles through holes in lifting brackets, as shown in De- tail "A." Lifting brackets to be centered around the unit center of gravity. Use wood top skid when rigging, to prevent rigging straps from damag- ing unit. Remove 4 screws to slide wood support through rectangular

hole in rail.

UNIT MAX PYIP WEIGHT

Size Ib kg

018 320 145

024 363 165 030 380 172 036 396 180 042 435 !97 048 474 215 060 5!3 233

in,

49.4

mm in.

24.4

22.6

22.5

1255 22.2

22.6 2! .2

21.6

619 574 571 563 574 538 549

in, mm

28.2 715

32.2 816

38.2 969

Fig. 9 -- Suggested Rigging for Units With

Optional Base Rail

A. Units Without Base Rail

If accessory rigging brackets are to be used for rigging, in- stall them as follows:

1. Position brackets as close to the corners of unit as pos- sible. Be sure brackets are well outside of center of grav-

ity. See Fig. 2 and 4.

2. Position paint protectors and foam strips between screws and painted surface of unit. Tighten screws until they

make contact with the paint protectors.

3. Secure device or hook of sufficient strength to hole in bracket as shown in detail "A" of Fig. 8.

4. If wood top is available, use it for a spreader bar to pre-

vent straps fl'om damaging unit. If wood top is not avail-

able, use spreader bars of sufficient length.

--8--

B. Units With Optional Base Rail

Lifting holes are provided in optional base rail as shown in Fig. 9. Operating weights are shown in Table 1. Refer to rig-

ging instructions on unit. Protective wood support must be removed from unit before

unit is mounted to curb. Remove 4 screws that secure sup port above rigging holes in rails. Slide support out through

rectangular hole in rail. See Fig. 9.

Vl. STEP 6 -- CONNECT CONDENSATE DRAIN

NOTE: When installing condensate drain connection be sure to comply with local codes and restrictions.

Model PY1P disposes of condensate water through a 3/4 in. NPT fitting which exits through the compressor access panel.

See Fig. 2 5 for location. Condensate water can be drained directly onto the roof in roof

top installations (where permitted) or onto a gravel apron in groundqevel installations. Install a field-supplied conden-

sate trap at end of condensate connection to ensure proper drainage. Make sure that the outlet of the trap is at least

1 in. lower than the drain pan condensate connection to pre

vent the pan fi'om overflowing. See Fig. 10. Prime the trap with water. When using a gravel apron, make sure it slopes

away fl'om the unit. If the installation requires draining the condensate water away

fi'om the unit, install a 2-in. trap at the condensate connec- tion to ensure proper drainage. See Fig. 10. Make sure that

the outlet of the trap is at least 1 in. lower than the drain- pan condensate connection to prevent the pax] fi'om overflow

ing. Prime the trap with water. Connect a drain tube using a minimum of 3/4 in. PVC or 3/4 in. copper pipe (all field

supplied) at the outlet end of the 2-in. trap. Do not undersize the tube. Pitch the drain tube downward at a slope of at least

one in. for every 10 ft of horizontal run. Be sure to check the drain tube for leaks.

1" MIN,

Fig. 10 -- Condensate Trap

VIII, STEP 7 -- Install Flue Hood The flue hood assembly is shipped screwed to the control box

in the burner compartment. Remove the burner access panel to locate the assembly.

Fox" units being installed in California Air Quality Manage ment Districts which require NO x emissions of 40 nanograms/

joule or less, kit CRLOWNOX001A00 must be installed.

Install the flue hood as follows:

1. This installation must conform with local building codes and with the National Fuel Gas Code (NFGC), ANSI Z223.1 (in Canada, CAN/CGA B149.1, and B149.2), or

NFPA (National Fire Protection Association) latest re vision. Refer to Provincial and local plumbing or waste-

water codes and other" applicable local codes.

2. Remove fl'om shipping location. Place vent cap assem bly over fine panel. Orient screw holes in vent cap with

holes in the fine panel.

3. Secure flue hood to flue panel by inserting a single screw on the right side, the left side, and the top of the hood.

VIII. STEP 8 -- INSTALL GAS PIPING

The gas supply pipe enters the unit through the access hole provided. The gas connection to the unit is made to the 1/d in.

FPT gas inlet on the manual shutoff or gas valve. Install a gas supply line that runs to the heating section. Re

fer to Table 2 and the NFGC for" gas pipe sizing. Do not zl.se ca.st iron pipe. It is recommended that a black iron pipe is

used. Check the local utility fox" recommendations concern- ing existing lines. Size gas supply piping fox" 0.5 in. wg maxi-

mum pressure drop. Never" zLse pipe _smaller than tire _/z-hr. FPT go_s hrlet on tire unit ga_s valve.

For natural gas applications, the gas pressure at unit gas cox]- nection must not be less than 4.0 in. wg or greater than

13 in. wg while the unit is operating. For propane applica-

tions, the gas pressure must not be less than 4.0 in. wg or greater than 13 in. wg at the unit connection.

An l/a-in. NPT plugged tapping accessible for test gage cox]- nection must be installed immediately upstream of the gas

supply connection to the furnace. When installing the gas supply line, observe local codes per

raining to gas pipe installations. Refer to the NFGC ANSI Z223.1-1988 NFPA latest edition (in Canada, CAN/CGA B 149.1,

(2) M86). In the absence of local building codes, adhere to the

following pertinent recommendations:

1. Avoid low spots in long runs of pipe. Grade all pipe V4 inch in every 15 ft to prevent traps. Grade all hori-

zontal runs downward to risers. Use risers to connect to

heating section and to meter.

2. Protect all segments of piping system against physical and thermal damage. Support all piping with appropri-

ate straps, hangers, etc. Use a minimum of one hanger every 6 ft. Fox" pipe sizes larger than _?z in., follow rec

ommendations of national codes.

3. Apply joint compound (pipe dope) sparingly and only to

male threads of joint when making pipe connections. Use

only pipe dope that is resistant to action of liquefied petroleum gases as specified by local and/or national codes.

Newt u_se Teflon talre.

4. Install sediment trap in riser" leading to heating section per Fig. 11. This drip leg functions as a trap for" dirt and

condensate.

5. Install an accessible, external, manual main shutoffvalve

in gas supply pipe within 6 ft of heating section.

6. Install groundOoint union close to heating section be- tween unit manual shutoff and external manual main

shutoff valve.

7. Pressure test all gas piping in accordance with local and

national plumbing and gas codes before connecting pip- ing to unit.

NOTE: Pressure test the gas supply system a/terthe gas sup- ply piping is connected to the gas valve. The supply piping

must be disconnected from the gas valve during the testing of the piping systems when test pressure is in excess of

0.5 psig. Pressure test the gas supply piping system at pres- sures equal to or less than 0.5 psig. The unit heating section

must be isolated from the gas piping system by closing the external main manual shutoff valve and slightly opening the

groundOoint union.

--9--

Table I -- Physical Data -- Unit PYIP

UNIT SIZE PYIP

NOMINAL CAPACITY (ton) OPERATING WEIGHT (Ib)

Without Base Rail With Optional Base Rail

COMPRESSORS

Quantity

REFRIGERANT (R-22)

Charge (Ib)

REFRIGERANT METERING DEVICE

Orifice ID (in,)

CONDENSER COIL

Rows,..Fins/in, Face Area (sq ft)

CONDENSER FAN

Nominal Cfm Diameter (in.)

Motor Hp (Rpm)

EVAPORATOR COIL

Rows Fins/in. Face Area (sq ft)

EVAPORATOR FAN

Nominal Airflow (Cfm) Size (in.)

FURNACE SECTION*

Burner Orifice (Qty.,.drilt size)

Natural Gas

Burner Orifice (Qty._drill size)

Propane Gas

RETURN-AIR FILTERS (in.)t

Throwaway

018040 024040 024060 030040 030060 030080 036060

11/2 2 2 2//z 2 Y, 2i/, 3

036080

036100

036120

272 303 315 320 332 332 336 336 348 348 296 327 339 344 356 356 360 360 372 372

Rotary Reciprocating

1 1

260 2.75 2.75 3.40 I 3.40 340 430 430 4.30 430

Acutror M Device

.030 030 030 030 030 .030 .032 .032 032 .032

1.17 1..17 1..17 2..17 2..17 2.17 2.17 595 5.95 5.95 5.95 5.95 595 595

1700 1700 1700 1900 1900 1900 1900

18 18 18 18 18 18 18

1A(850) V_(850) V_(850) V8(850) V8(850) _A(850) ¼ (1050)

3.15 3..15 3..15 3..15 3..15 3.15 3.15 183 2.29 2.29 2.29 2.29 229 306

Direct Drive

600 800 800 1000 1000 1000 1200

10 x 10 10 x 10 10 x 10 10 x 10 10 x 10 10 x 10 10 x 10

1.32 1..32 2..32 1..32 2..32 2.32 2.32

1.41 1..41 2..47 1..41 2..47 2.42 2.47

20 x 20 20 x 20 20 x 20 20 x 24 20 x 24 20 x 24 20 x 24

2.17 595

1900

_(1050)

3.15 306

1200

10 x 10

2.32

2. 42

20 x 24

2..17

5.95

1900

1A(1050)

3..15

3.06

1200

10 x 10

2..32

2..40

20 x 24

2.17 595

1900

¼ (1050)

3.15 306

1200

10 x 10

3.32

3 .42

20 x 24

UNIT SIZE PYIP 042060 042080 042100 042120 048080 048100 048120 048140 060080 060100 060120 060140 NOMINAL CAPACITY (ton) 3 ½ 3½ 3 ½ 34½ 4 4 4 4 5 5 5 5

OPERATING WEIGHT (tb)

Without Base Rail 375 375 387 387 414 426 426 426 453 465 465 465 With Optional Base Rail 399 399 411 411 438 450 450 450 477 489 489 489

COMPRESSORS Reciprocating Hermetic Scroll

Quantity 1 1

REFR,GERANT(R-22,I I I I

Charge (Ib) 520 520 520 520 650 650 650 650 700 7.00 7.00 7.00

REFRIGERANT METERING Acutrot Device

DEVICE

Orifice ID (in.) .034 .034 .034 .034 .030 .030 .030 .030 .030 030 030 030

CONDENSER COIL

Rows...Fins/in. 2.17 2.17 2.17 2.17 2.17 2.17 2.17 2.17 2.17 2...17 2..17 2..17 Face Area (sq ft) 704 704 704 704 867 867 867 867 867 8.67 8.67 8.67

CONDENSER FAN

Nominal Cfm 1900 1900 1900 1900 2400 2400 2400 2400 2400 2400 2400 2400 Diameter (in.) 18 18 18 18 20 20 20 20 20 20 20 20

Motor Hp (Rpm) _¼(1050) _¼(1050) _¼(1050) _¼(1050) % (1050) % (1050) % (1050) % (1050) % (1050) _/J(1050) _/J(1050) _/J (1050)

EVAPORATOR COIL

Rows Fins/in. 3.15 3.15 3.15 3.15 3..15 3..15 3..15 3..15 4..15 4..15 4..15 4..15 Face Area (sq ft) 333 333 333 333 444 444 444 4.44 4.44 4.44 4.44 4.44

EVAPORATOR FAN Direct Drive

Nominal Airflow (Cfm) 1400 1400 1400 1400 1600 1600 1600 1600 1995 1995 1995 1995

Size (in.) 10 x 10 10 x 10 10 x 10 10 x 10 10 x 10 10 x 10 10 x 10 10 x 10 10 x 10 10 x 10 10 x 10 10 x 10

FURNACE SECTION*

Burner Orifice (Qty...drill size) 2.32 2.32 2.32 3.32 2.32 2.32 3.32 3..32 2..32 2..32 3..32 3..32

Natural Gas

Burner Orifice (Qty...drill size) 2.47 2.42 2.40 3.42 2.42 2.40 3.42 3..40 3..42 2..40 3..42 3..40

Propane Gas

RETURN-AIR FILTERS (in.)t

Throwaway 24 x 24 24 x 24 24 x 24 24 x 24 24 x 30 24 x 30 24 x 30 818"* 24 x 30 24 x 30 24 x 30 960**

*Based on altitude of 0-2000 feet.

tRequired filter sizes shown are based on the larger of the ARI (Air Conditioning & Refrigeration Institute) rated

cooling airflow or the heating airflow at a velocity of 300 ft/min for throwaway type or 450 ft/min for high-capacity

type. For non-standard air filters, air filter pressure drop must not exceed 0.08 in. wg

**Sq inch Fitter is mounted external to unit.

--]0--

A. Configuring Units for Downflow (Vertical) Discharge

8. Check for gas leaks at the field installed and factory installed gas lines after all piping connections have been

completed. Use soap-and-water solution (or method speci- fied by local codes and/or regulations).

--] d_..1_ TEE

/ NtPPLE

_,_ CAP

Fig. 11 -- Sediment Trap

IX. STEP 9 -- INSTALL DUCT CONNECTIONS

The unit has duct flanges on the supply and return air open ings on the side and bottom of the unit. See Fig. 2 5 for con

nection sizes and locations.

Open all electrical disconnects before starting any serv

ice work.

Remove return duct covet" located on duct panel.

Figure 12 shows duct covet" removed. Save duct cover

and screws.

3. Locate lances in basepan insulation that are placed over the perimeter of the vertical duct opening covet"

(Fig. 13).

4. Using a straight edge and sharp knife, cut and remove the insulation around the perimeter of the cover. Re-

move and save 5 screws securing the cover to the base- pan and slide out the covet'. Discard the cover (Fig. 14).

5. Remove supply duct covet" located on duct panel.

Figure 12 shows duct cover removed. Save duct covet"

and screws. Remove and discard 2 screws which secure vertical dis

charge opening cover to basepan (Fig. 15). Slide covet" forward to disengage, then tilt and remove cover through

vertical discharge opening in bottom of unit. Discard

duct covet" (Fig. 16).

7. If unit ductwork is to be attached to vertical opening flanges on the unit basepan 0ackstand applications only),

do so at this time.

8. It is recommended that the basepan insulation around the perimeter of the vertical return air opening be se

cured to the basepan with aluminum tape. Applicable local codes may require aluminum tape to prevent ex-

posed fiberglass.

9. Covet" both horizontal duct openings with the duct coy ers fi'om Steps 2 and 5. Make sure opening is air- and

watertight.

10. After completing unit conversion, perform all safety checks and power up unit.

NOTE: The design and installation of the duct system must be in accordance with the standards of the NFPA for instal-

lation of nonresidence-type air conditioning and ventilating systems, NFPA 90A or residence type, NFPA 90B; and/or lo

cal codes and residence type, NFPA 90B; and/or local codes and ordinances.

--11--

Table 2 -- Maximum Gas Flow Capacity*

NOMINAL INTERNAL LENGTH OF PIPE, FTI"

IRON PIPE, DIAMETER

SIZE

(in.) (in.) 10 20 30 40 50 60 70 80 90 100 125 150 175 200

I/2 .622 175 120 97 82 73 66 61 57 53 50 44 40 -- --

3/4 .824 360 250 200 170 15! 138 125 118 !10 103 93 84 77 72

1 1.049 680 465 375 320 285 260 240 220 205 195 175 160 145 !35

11/4 1.380 1400 950 770 600 580 530 490 460 430 400 360 325 300 280 11/2 1.610 2100 !460 1180 990 900 8!0 750 690 650 620 550 500 460 430

*Capacity of pipe in cu ft of gas per hr for gas pressure of 0.5 psig or less. Pressure drop of 0.5-in. wg (based on

a 0.60 specific gravity gas). Refer to Table C-4, National Fire Protection Association NFPA 54.

1-This length includes an ordinary number of fittings.

SUPPLY DUCT OPENING RETURN DUCT OPENING

Fig. 12 -- Supply and Return Duct Openings

Fig. 14 -- Vertical Duct Cover Removed

Fig. 13 -- Lance Location for Vertical Duct

Opening Cover

Fig. 15- Removal of Vertical Discharge

Opening Cover

--12--

-- X.STEP10 -- INSTALL ELECTRICAL CONNECTIONS

Fig. 16 -- Vertical Discharge Cover Removed

Adhere to the following criteria when selecting, sizing, and installing the duct system:

1. Units are shipped with all 4 duct openings covered. Re- move appropriate panels for intended 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) recmnmendations.

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 gas kets to ensure weathertight and airtight seal.

4. All units must have field supplied filters or accesso W fil ter rack installed in the return air side of the unit. Rec

ommended sizes for filters are shown in Table 1.

5. Size all ductwork for maxinlmn 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 uncon-

ditioned space, and use vapor barrier in accordance with latest issue of Sheet Metal and Air Conditioning Contractors National Association (SMACNA) and Air Con

ditioning Contractors of America (ACCA) minimum in- stallation 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.

1. Make all electrical connections in accordance with NEC ANSI/NFPA (latest edition) and local electrical codes gov

erning such wiring. In Canada, all electrical connec- tions 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 coi)perconductor 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 oper ating voltage range indicated on unit rating plate.

4. Do not damage internal components when drilling through any panel to mount electrical hardware, conduit, etc. On

3 phase units, ensure phases are balanced within 2%. Consult local power company for correction of improper

voltage and/or phase imbalance.

A. 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 for maxL mum fllse/circuit breaker size and minimum circuit amps (am- pacity) for" wire sizing. See Table 3 for electrical data.

The field supplied disconnect switch box may be mounted on the unit over the high voltage inlet hole when tire standard

power and low-voltage entry points are used. See Fig. 2-5 for" acceptable location.

Standard Power Enti T Proceed as follows to complete the high-voltage connections

to the unit:

1. Connect ground lead to chassis ground connection when using separate ground wire.

2. Run high-voltage leads into unit control box.

3. Locate black and yellow wires connected to line side of

contactor.

4. Cut wires at partition where they exit control box.

5. Strip back leads and connect to high voltage leads. On 3 phase units, blue wire is provided stripped back and

ready to connect to high voltage lead. See unit wiring label and Fig. 17.

--13--

Table 3 -- Electrical Data -- Unit PYIP

UNIT VOLTAGE SIZE V-PH-Hz RANGE

PY1P Min Max

018 208/230-1-60 187 253

024 208/230-1-60 187 253

208/230-1-60 187 253

030

208/230-3-60 187 253 208/230-1-60 187 253

036 208/230-3-60 187 253

460-3-60 4!4 506

208/230-1-60 187 253

042 208/230-3-60 187 253

460-3-60 414 506

208/230-1-601- 187 253

208/230-1-60"* 187 253

048 208/230-3-601- 187 253

208/230-3-60"* 187 253

460-3-601- 414 506

460-3-60** 4!4 506

298/230-1-60 187 253

060 208/230-3-60 187 253

460-3-60 414 506

COMPRESSOR OUTDOOR-FAN

MOTOR

RLA LRA FLA

8.3 45.0 0.7

!2.4 6! .0 0.7

14.4 82.0 1.4

9.4 66.0 1.4

18.0 96.0 1.4

11.7 75.0 1.4

5.6 40.0 0.8

20.4 104.0 1.4

14.0 9! .0 1.4

6.4 42.0 0.8

21.8 124.0 2.!

26.4 129.0 2.1 !2.8 93.0 2.!

15.0 99.0 2.1

6.4 46.5 ! .1

8.2 50.0 1.!

32.1 169.0 2.! !9.3 123.0 2.!

19.0 62.0 ! .1

INDOOR-FAN POWER SUPPLY

MOTOR

FLA MCA MOCP*

1.8 12.9 15

2.0 18.2 30

2.3 2! .4 30

2.0 15.1 25

2.8 28.7 40

2.8 18.8 30

1.4 9.2 10

4.0 30.9 50

4.0 22.9 35

2.0 10.8 15

5.0 40.1 60

5.0 40.1 69

5.0 25.9 40

5.0 25.9 49

2.3 !3.7 29

2.3 13.7 20

6.8 49.0 60

6.8 33.0 50

3.2 !6.8 25

AWG 60 C

MIN WIRE

SIZE

14 12 10 12 10 12 14

8 10 14

6 10 10 !4 14

8 !2

MAX WIRE

LENGTH (ft)

75 8O

100

8O 9O

85 100 100

85 100 100 100

100 100 100

9O 100

LEGEND

AWG -- American Wire Gage

FLA -- Full Load Amps HACR -- Heating, Air Conditioning and

Refrigeration

LRA -- Locked Rotor Amps MCA -- Minimum CircuitAmps

MOCP -- Maximum Overcurrent Protection RLA -- Rated Load Amps

*Fuse or HACR Breaker.

1-Carrier Scroll Compressor. **CopeIand Scroll Compressor.

0Q°s

NOTES:

1. In compliance with NEC (National Electrical Code) requirements for multimotor and combination load equipment (refer to NEC Articles 430 and 440), the overcurrent protective device for the unit shall be fuse or HACR breaker. The CGA (Canadian Gas Associa- tion) units may be fuse or circuit breaker.

2. Minimum wire size is based on 60 C copper wire. If other than 60 C wire is used, or if length exceeds wire length in table, deter-

mine size from NEC.

3. Unbalanced 3-Phase Supply Voltage

Never operate a motor where a phase imbalance in supply voltage is greater than 2%. Use the following formula to determine the percent-

age of voltage imbalance.

% Voltage imbalance

= !00 x max voltage deviation from average voltage

average voltage

Example: Supply voltage is 460-3-60.

A a C AB = 452 v

BC = 464 v

(_ AC = 455 v

Average Voltage =

452 + 464 + 455

= 1371

= 457

Determine maximum deviation from average voltage. (AB) 457 - 452 = 5 v (BC) 464 - 457 = 7 v (AC) 457 - 455 = 2 v

Maximum deviation is 7 v. Determine percent of voltage imbalance.

% Voltage Imbalance = 100 x --

457

= 1.53%

This amount of phase imbalance is satisfactory as it is below the maxi- mum allowable 2%.

IMPORTANT: If the supply voltage phase imbalance is more than 2 Yo, contact your local electric utility company immediately.

--14--

THERMOSTAT (TYPICAL)

1,¢o,,¢,¢91

t S J g, g

_-I _jI Z Cl I Z z I wl rr I m I r¢l

I SPLICE BOX

GND LOW-VOLTAGE POWER LEADS (SEE UNIT

WIRING LABEL)

__%K[

_-4L..U-E

]""- "_ _ '-- POWER

]_ --._q ._TI SUPPLY

----1"--S--- FIELD-SUPPLIED

FUSED DISCONNECT

LEGEND

.... Field Control-Voltage Wiring

.... Field High-Voltage Wiring

NOTE: Use blue wire for 3-phase units only.

Fig. 17 -- High- and Control-Voltage Connections

Alternate Power Entry

1. Remove knockouts in fixed compressor panel located on duct panel side of unit.

2. Route high-voltage leads into high-voltage terminal box.

3. Connect ground wire to green yellow wire using field supplied splice.

4. Connect power wires to unit high-voltage leads.

5. On 3 phase units, locate blue wire projecting fi'om corn pressor junction box. Cut wire at partition and route into

high voltage junction box through grommet in back of

junction box.

6. On 3-phase units, strip back blue lead and connect to third leg of the power wires.

B. Special Procedures for 208-v Operation

1. Disconnect the orange transformer-primary lead from the contactor. See unit wiring label.

2. Remove the tape and wirenut fi'om the terminal on the end of the red transformer-prhnm T lead.

3. Save the wirenut.

4. Connect the red lead to the contactor terminal fi'om which the orange lead was disconnected.

5. Using the wirenut removed fi'om the red lead, insulate the loose terminal on the orange lead.

6. Wrap the cover with electrical tape so that the metal terminal cannot be seen.

C. Control Voltage Connections

Locate the roon] thermostat on an inside wall in the space to be conditioned, where it will not be subjected to either a cool-

ing or heating source or direct exposure to sunlight. Mount tire thermostat 4 to 5 ft above the floor.

NOTE: Do not use any type of power stealing thermostat. Unit control problems may result.

Use no. 18 American Wire Gage (AWG) color-coded, insu- lated (35 C mininmm) wires to make the control voltage con-

nections between the thermostat and the unit. If the thermo- stat is located more thai] 100 ft from the unit (as measured along the control voltage wires), use no. 16 AWG color" coded,

insulated (35 C minimum) wires. Standard Connection

Remove knockout hole located in the flue panel adjacent to the control access panel. See Fig. 2-5. Remove the rubber groin

met fl'om the installer's packet (included with unit) and in- stall grommet in the knockout opening. Provide a drip loop

before running wire through panel. Run the low voltage leads from the thermostat, through the

inlet hole, and into unit low-voltage splice box. Locate five 18-gage wires leaving control box. These low-

voltage connection leads can be identified by the colors red, green, yellow, brown, and white. (See Fig. 17.) Ensure the leads

are long enough to be routed into the low-voltage splice box

(located below right side of control box). Stripped yellow wire

is located in connection box. Route leads through hole in bot- tom of control box and make low voltage connections as shown

in Fig. 17. Secure all cut wires, so that they do not interfere with operation of unit.

Alternate Connection Remove knockout in compressor fixed panel located below high

voltage knockout. Remove the rubber grommet fl'om the in staller's packet (included with unit) and install grommet in

the knockout opening. Route thermostat wires through grom- met providing drip loop at panel, Connect low voltage leads

as shown in Fig. 17.

D. Heat Anticipator Setting

The rooin thei'nmstat heat anticipator nmst be properly ad-

justed to ensure proper heating performance. Set the heat

anticipator, using an ammeter between the W and R termi nals to determine the exact required setting.

NOTE: For thermostat selection purposes, use 0.18 amp for" the approximate required setting.

Failure to make a proper heat anticipator adjustment will result in improper operation, discomfort to the occupants of

the conditioned space, and inefficient energy utilization; how- ever, the required setting may be changed slightly to provide

a greater degree of comfort for a particular installation.

E. Transformer Protection

The unit transformer protection may be one of 2 types.

The ill-st t,"on_sfoFmez"(ype may contain an auto. reset over

current protector for control circuit protection. If this device trips, it may reset without warning, starting the heating or

cooling section of this product. Use caution when servicing; if overcurrent protector continues to trip, there is a problem in

the low voltage electrical circuit, such as an electrical short, ground, or transformer overload. Disconnect power, correct

the condition, and check for normal unit operation.

The _seconct rfon_stbrmel" type is of the energy limiting type. It

is set to withstand a 30 second overload or shorted second ary condition.

--15--

PRE-START-UP

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 WARNING, CAU- TION, and INFORMATION labels attached to, or shipped

with, unit.

3. Make the following inspections: a. Inspect for shipping and handling dan]ages such as

broken lines, loose parts, disconnected wires, etc.

b. Inspect for oil at all refi'igerant tubing connections

and on unit base. Detecting oil generally indicates a refi'igerant leak. Leak-test all refrigerant tubing con

nections using electronic leak detector, halide torch, or liquid soap solution. If a refi'igerant leak is de-

tected, see Check for Refi'igerant Leaks section on this page.

c. Inspect all field and factm T wiring connections. [3e

sure that connections are completed and tight.

d. Inspect coilfins. Ifdamaged during shipping and han-

dling, carefiflly straighten fins with a fin comb.

4. Verify the following conditions:

a. Before lighting the unit for the first time, perform

the following: If the gas supply pipe was not purged before connecting the unit, it will be full of air. It is

recommended that the ground joint union be loos- ened, and the supply line be allowed to purge until

the odor of gas is detected. Never purge gas lines into a combustion chamber, hnmediately upon detection

of gas odor, retighten the union. Allow 5 minutes to elapse, then light unit.

b. Make sure that condenser-fan blade is correctly po-

sitioned in fan orifice. Leading edge of condenser fan blade should be '/z in. maximum fl'om plastic fan ori

rice (see Fig. 18).

c. Make sure that air filter(s) is in place. d. Make sure that condensate drain trap is filled with

water to ensure proper drainage.

e. Make sure that all tools and miscellaneous loose parts

have been removed.

_i_ -,-1/2 IN, MAX

]_ / MOTOR SHAFT

Fig. 18 -- Fan Blade Clearance

START-UP

I. CHECK FOR REFRIGERANT LEAKS

Proceed as follows to locate and repair a refrigerant leak and to charge the unit:

f. Locate leak and make sure that refrigerant system pres-

sure has been relieved and reclaimed fi'om 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.

3. Add a small charge of R 22 refi'igerant vapor to system and leak test unit.

4. Evacuate and reclaim refrigerant from refrigerant sys- tem if additional leaks are not found.

5. Charge unit with R-22 refi'igerant, using a volumetric charging cylinder or accurate scale. Re[ki" to tlnit Foth\q

piote [bF r'_quiF_(t c'hofge. Be sure to add extra refriger-

ant to compensate for internal volume of filter drier.

--16--

II. START UP HEATING SECTION AND MAKE ADJUSTMENTS

Do not jumper any safety devices when operating the unit. Make sure that burner orifices are properly aligned. Un

stable operation may occur when the burner orifices in the manifold are misaligned.

Follow the lighting instructions on the heating section opera tion label (located inside the burner or blower access door) to

start the heating section.

NOTE: Make sure that gas supply has been purged, and that all gas piping has been checked for leaks.

A. Check Heating Control

Start and check the unit for proper heating control operation as follows. (See furnace lighting instructions located inside

burner or blower access panel.)

1. Place the room thermostat SYSTEM switch in the HEAT position and the fan switch in the AUTO. position.

2. Set the heating temperature control of the thermostat above rooIn temperature.

3. The induced-draft motor will start.

4. After a call for heating, the main burner should light within 5 seconds. If the burners do not light, there is a

22 second delay before another 5 second try. If the burn- ers still do not light, this sequence is repeated. If the

burners do not light within 15 minutes from the initial call for heat, there is a lockout. To reset the control, break

the 24 v power to W.

5. The evaporator fan will turn on 45 seconds after the flame has been established. The evaporator fan will turn off

45 seconds after the thermostat has been satisfied.

B. Check Gas Input

Check gas input and manifold pressure after unit start-up (see Table 4). If adjustment is required proceed as follows.

The rated gas inputs shown in Table 4 are for altitudes from sea level to 2000 ft above sea level. These inputs are based

on natural gas with a heating value of 1050 Btu/ft :_ at 0.65 specific gravity, or propane gas with a heating value of

2500 Btu/ft :_ at 1.5 specific gravity. For elevations above 2000 ft, reduce input 4% for each 1000 ft above sea level. When

the gas supply being used has a different heating value or specific gravity, refer to national and local codes, or contact

your distributor to determine the required orifice size.

C. Adjust Gas Input

The gas input to the unit is determined by measuring the gas flow at the meter or by measuring the manifold pressure.

Measuring the gas flow at the meter is recommended for natu- ral gas units. The manifold pressure must be measured to

determine the input of propane gas units. Measure Gas Flow (Natural Gas Units)

Minor adjustment to the gas flow can be made by changing the manifold pressure. The manifold pressure must be main

rained between 3.4 and 3.6 in. wg. If larger adjustments are required, change main burner orifices following the recom

mendations of national and local codes. NOTE: All other appliances that use the same meter must

be turned off when gas flow is measured at the meter. Proceed as follows:

1. Turn off gas supply to unit.

2. Remove pipe plug on manifold (see Fig. 19), then con- nect manometer at this point. Turn on gas to unit.

3. Record number of seconds for gas meter test dial to make one revolution.

4. Divide number of seconds in Step 3 into 3600 (number of seconds in one hour).

5. Multiply result of Step 4 by the number of cuft shown for one revolution of test dial to obtain cuft of gas flow

per hour.

6. Multiply result of Step 5 by Btu heating value of gas to obtain total measured input in Btuh. Compare this value

with heating input shown in Table 4. Consult the local gas supplier if the heating value of gas is not known.

EXAMPLE: Assume that the size of test dial is 1 cuft, one revolution takes 30 seconds, and the heating value of the gas

is 1050 Btu/ft:L Proceed as follows:

1. 30 seconds to complete one revolution.

2. 3600 + 30 = 120.

3. 120 x 1 = 120 ft:*of gas flow/hr.

4. 120 x 1050 = 126,000 Btuh input.

If the desired gas input is 120,000 Btuh, only a minor change in the manifold pressure is required.

Observe manifold pressure and proceed as follows to adjust gas input:

1. Remove covet" screw over regulator adjustment screw on gas valve.

2. Turn regulator adjustment screw clockwise to increase gas input, or turn regulator adjustment screw counter

clockwise to decrease input. Manifold pressure must be between 3.4 and 3.6 in. wg.

3. Replace cover screw cap on gas valve.

4. Turn off gas supply to unit. Remove manometer from pressure tap and replace pipe plug on gas valve. Turn

on gas to unit and check for leaks.

--17--

Table 4 -- Rated Gas Inputs at Indicated Manifold Pressures

UNIT PY1P

018040, 024040, 030040 024060, 030060, 036060, 042060 030080, 036080, 042080,

048080, 060080

036100, 042100, 048100, 060100 036120, 042120, 048120, 060120 048140, 060140

NUMBER

ORIFICES

2 2 2

3 3

GAS SUPPLY PRESSURE

(in. wg)

Natural Propane

Min Max Min Max

4.0 13.0 4.0 !3.0

4.0 13.0 4.0 13.0

4.0 13.0 4.0 !3.0

MANIFOLD

NATURAL GAS PROPANE*

PRESSURE

(in, wg)

Natural Propane

3.5 3.1

3.5 3.3

3.5 3.4

3.5 3.7

3.5 3.5

3.5 3.4

Orifice Heating

Drill Input

Size (Btuh)t

32 40,000 32 58,000

32 80,000 32 95,000

32 120,000 32 138,000

Orifice

Drill

Size

41 47

42 4O

Heating

Input

(Btuh)t

40,000 54,000

80,000 95,000

115,000

!33,000

*When a unit is converted to propane, different size orifices must be used. See separate natural-to-propane conversion kit

instructions.

1-Based on altitudes from sea level to 2000 ft above sea level. For altitudes above 2000 ft, reduce input rating 4% for each

additional 1000 ft above sea level. In Canada, from 2000 ft above sea level to 4500 ft above sea level, derate the unit

10%.

MANIFOLD PIPE PLUG

Fig. 19- Burner Assembly

Measure Manifold Pressure (Propane Units) The main burner orifices on a propane gas unit are sized for

the unit rated input when the manifold pressure reading matches tire level specified in Table 4.

Proceed as follows to adjust gas input on a propane gas unit:

1. Turn off gas to unit.

2. Remove pipe plug on manifold (see Fig. 19), then con nect manometer at this point.

3. Turn on gas to unit.

4. Remove cover screw over regulator adjustment screw on

gas valve.

5. Adjust regulator adjustment screw to the correct mani fold pressure, as specified in Table 4. Turn adjusting

screw clockwise to increase manifold pressure, or turn adjusting screw counterclockwise to decrease manifold

pressure.

6. Replace cover screw.

7. Turn offgas to unit. Remove manometer fl'om pressure

tap. Replace pipe plug on gas valve, then turn on gas to unit. Check for leaks.

D. Check Burner Flame

With burner access panel removed, observe tire unit heating operation. Watch the burner flames to see if they are light

blue and soft in appearance, and that the flames are approxi- mately tire same for each burner. Propane will have blue flame

with yellow tips. See Fig. 20. Refer to Maintenance section for" information on burner removal.

E. Airflow and Temperature Rise

The heating section for" each size unit is designed and ap proved for heating operation within the temperature-rise range

stamped on the unit rating plate. Table 5 shows the approved temperature rise range for each

heating input, and the air delivery cfln at various tempera ture rises. The heating operation airflow must produce a tem-

perature rise that falls within the approved range. Refer" to Evaporator Airflow and Airflow Adjustments section

on page 24 to adjust heating airflow when required.

--18--

Table 5 -- Air Delivery (Cfm) at Indicated Temperature Rise and Rated Heating Input

HEATING TEMPERATURE RISE °F

INPUT (Btuh) 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90

40,000 1389 1111 926 794 694 617 556 ........

56,000 2083 1667 1389 1190 1042 926 833 758 .......

80,000 2778 2222 1852 1587 1389 1235 1111 1010 926 855 794 ....

95,000 3472 2778 2315 1984 1736 1543 1389 1263 1157 1068 992 926 868 -- -- 120,000 4167 3333 2778 2381 2083 !852 1667 1515 1389 1282 1190 1111 1042 980 928 136,000 5037 4029 3358 2878 25!8 2238 20!4 1831 1679 1549 1439 1343 !259 1185 !119

NOTE: Dashed areas do not fall within the approved temperature rise range of the unit.

BURNERFLAME

°°

Fig. 20 -- Monoport Burners

F. Heating Sequence of Operation See Fig. 21-23 and unit wiring label.

On a call for heating, terminal "W" of the thermostat is en- ergized, starting the induced draft motor. When the hall

effect sensor on the induced draft motor senses that it has reached the required speed, the burner sequence begins. This

flmction is performed by the integrated gas control (IGC). The evaporator-fan motor is energized 45 seconds after flame is

established. When the thermostat is satisfied and "W" is deen ergized, tire burners stop firing and the evaporator fan motor

shuts off after" a 45 second time off delay. A LED (light-emitting diode) indicator is provided on the con-

trol board to monitor operation. The control board is located by removing the burner access panel. During normal opera tion, the LED is continuously on. See Table 6 for error codes.

Table 6 -- LED Indications

ERROR CODE LED INDICATION

Normal Operation On Hardware Failure Off

Fan On/Off Delay Modified 1 Flash Limit Switch Fault 2 Flashes

Flame Sense Fault 3 Flashes Four Consecutive Limit Switch Faults 4 Flashes

Ignition Lockout Fault 5 Flashes Induced-Draft Motor Fault 8 Flashes

RolIout Switch Fault 7 Flashes

Internal Control Fault 8 Flashes

NOTES:

1. There is a 3-second pause between error code displays.

2. If more than one error code exists, all applicable error codes will be displayed in numerical sequence.

3. This chart is on the wiring diagram located inside the burner access panel.

G. Limit Switches

Normally-closed limit switch (LS) completes the control cir- cuit through the thermostat R circuit. Should the leaving-air

temperature rise above the maximum allowable tempera- ture, the limit switch opens and the R control circuit "breaks."

Any interruption in the R control circuit instantly closes the gas valve and stops gas flow to the burners and pilot. The

blower motor continues to run until LS resets. When the air temperature at the limit switch drops to the

low-temperature setting of the limit switch, the switch closes and completes tire R control circuit. The electric-spark igni

tion system cycles and the unit returns to normal heating operation.

H. Auxiliary Limit Switch -- Rollout

The function of the switch is to close the main gas valve in the event of flame rollout. The switch is located above the

main burners. When the temperature at the auxiliary switch reaches the maximum allowable temperatm'e, the R control

circuit trips, closing the gas valve and stopping gas flow to the burners. The indoor (evaporator) fan motor (IFM) and in

duced draft motor continue to run tmtil switch is reset.

--19--

III. START UP COOLING SECTION AND MAKE ADJUSTMENTS

A superheat charging label is attached to the inside of the compressor access door. The label includes a "Superheat Charg-

ing Table" and a "Required Suction-Tube (F) Temperature" chart.

An accurate superheat, thermocouple, or thermistor type ther monmter, a sling psychrometer, and a gage manifold are re

quired when using the superheat charging method for evalu ating the unit charge. Do not u,se me['c'rHy or small Hial-(ype

themlome_ers bec'ouse they ore not oclequa_e _bz"this _ype of

measzmemenb

A. Checking Cooling Control Operation

Start and check the unit for" proper cooling control operation as follows:

1. Place room thermostat SYSTEM switch in OFF posL tion. Observe that blower motor starts when FAN switch

is placed in ON position and shuts down when FAN switch is placed in AUTO, position.

2. Place SYSTEM switch in COOL position and FAN switch in AUTO. position. Set cooling control below room tem-

perature. Obsexwe that compressor, condenser fan, and evaporator blower motors start. Observe that cooling

cycle shuts down when control setting is satisfied. The evaporator fan will continue to run for"30 seconds.

3. When using an auto. changeover room thermostat, place both SYSTEM and FAN switches in AUTO. positions.

Observe that unit operates in heating mode when tern perature control is set to "call for heating" (above room

temperature) and operates in cooling mode when tem- perature control is set to "call for" cooling" (below room

temperature).

IMPORTANT: Three phase, scroll compressor units (sizes 048,060) are direction-oriented. These units must be checked to ensure proper compressor 3-phase power lead orientation.

If not corrected within 5 minutes, the internal protector will shut off the compressor. The 3 phase power leads to the unit

must be reversed to correct rotation. When turning back

wards, scroll compressors emit elevated noise levels, and the

difference between compressor suction and discharge pres- sures may be dramatically lower than normal.

B. Checking and Adjustment Refrigerant Charge

The refrigerant system is fully charged with R-22 refriger- ant, tested, and factory sealed.

NOTE: Adjustment of the refl'igerant charge is not required unless the unit is suspected of not having the proper" R-22

charge.

Proceed as follows:

1. Remove caps fl'om low and high pressure service fittings.

2. Using hoses with valve core depressors, attach low- and high-pressure gage hoses to low- and high-pressure serw

ice fittings, respectively.

3. Start unit in cooling mode and let unit run until system

pressures stabilize.

4. Measure and record the following: a. Outdoor ambient air temperature (F db).

b. Evaporator inlet-air temperature (F wb). c. Suction tube temperature (F) at low side service

fitting.

d. Suction (low-side) pressure (psig).

5. Using "Superheat Charging Table," compare the out- door entering air temperature with indoor air tempera- rare to determine desired system operating superheat

temperature. See Tables 7A 7H.

6. Using "Required Suction-Tube (F) Temperature" table, compare desired superheat temperature with suction (lmw side) operating pressure (psig) to determine proper suction-

tube temperature. See Table 8.

7. Compare actual suction-tube temperature with proper suction-tube temperature. Using a tolerance of _+3° F, add refl'igerant if actual temperature is more than 3 ° F

higher than proper suction tube temperature, or re move refrigerant if actual temperature is more than

3° F lower than required suction-tube temperature.

NOTE: If the problem causing the inaccurate readings is a refl'igerant leak, refer to Check for" Refl'igerant Leaks section

on page 16.

VOLT OPERATIONREVERSEREDANDGRN LEADSONTRANSFORMER.

COOLINGFANLOGIC

BR I

I I I

0 T T+30 6 6

ENERGIZED DE'ENERGIZED

HEATING FAN LOGIC

I I I I

o 45 T T÷3O

W BR W BR

ENERGIZEDENERGIZEDI_'-Eh_R61ZEDDE-ENERGIZED

SINGLE STAGE HEAT _ 5Iit;LE STAGE

COOL THERMOSTAT ¢TYP)

RE_D RED_BRN i

)ISCONNEO COMPONENT

! --" I

Irnl

CAP I g 2

J_ I

_NATE

YEL BR I

24V

)TRAN

)

AWG

C CAP

CH COMP CR EQUIP

FL FS

FU GND GVR

HS HV TRAN --

IDM IFM IGC

MGV

NEC

OFM

LEGEND

American Wire Gage PWR --

Btower ReIay QT -- Contactor RS --

Capacitor TRAN -- Crankcase Heater

Compressor Motor Combustion Relay

Equipment Fuse Link 4_ Flame Sensor

Fuse O Ground

Gas Valve Relay • Hall Effect Sensor

High-Voltage Transformer Ignitor

Induced-Draft Motor Indoor-Fan Motor

Integrated Gas Control internal Protector Limit Switch

Main Gas Vatve National Electrical Code Outdoor-Fan Motor

Power

Quadruple Terminal

Rollout Switch

Transformer

Field Sptice

Terminal (Marked) Terminal (Unmarked) Splice

Splice (Marked)

Factory Wiring Field Control Wiring Field Power Wiring

Accessory or Optionat Wiring To Indicate Common Potential Onty, Not to Represent Wiring

NOTES:

1 If any of the original wire furnished must be replaced, it must be replaced

with type 90 C wire or its equivalent

2 Use copper conductors onty

Fig. 21 -- 208/230-1-60 Wiring Diagram, Units PYIP018-060

--2]--

MAXIMUM WIRE } ,_UP-I_,_Y----a_-,,--YEL

S,ZE2AWG -- U

EQUIP 6ND

230 VOLT OPERATION A5 SHOWN. FOR 20B

VOLT OPERATION REVERSE RED AND ORN

LEADSON TRANSFORMER.

CO(_..INOFAN LOGIC

BR I I ..... i

I I I

0 T T+30 G 6

ENERGIZED DE-ENERGIZED

HEATING FAN LOGIC

I I I I

O 45 T T+30

W BR W BR

ENERGIZEDENERGIZEO_-ENEROIZED BE-ENERGIZED

i i

FAN -- --

I I _ I

I R

" "3

SINGLE5TA_ ItEATg 5INGLESTAGE I

COOLTHERMOSTAT(TYP)

CONNON

RED

-- WHT'

-- GRN

-- RED

_ --YEL-

_ - BRN-

24V SPLICE

BOX

I COMPONENT

ARRANGEMENT

24v GAS SECTION

IGC

ALTERNA_

__BRN--

YEL BRN--

I BRN--

BRN--

LEGEND

AWG -- Amedcae Wire Gage PWR -- BR -- Blower Relay QT --

C -- Contactor RS -- CAP -- Capacitor TRAN --

CH -- Crankcase Heater COMP -- Compressor Motor _[[_

CR -- Combustion Relay

EQUIP -- Equipment FL -- Fuse Link <_ FS -- FIame Sensor

FU -- Fuse 0 GND -- Ground

GVR -- Gas Valve Relay HS -- Hail Effect Sensor

HV TRAN -- High-Voltage Transformer

I -- Ignitor

IDM -- Induced-Draft Motor IFM -- Indoor-Fan Motor

IGC -- Integrated Gas Control IP -- Internal Protector

LS -- Limit Switch MGV -- Main Gas Valve NEC -- National Electrical Code i

OFM -- Outdoor-Fan Motor

Power Quadruple Terminal

Roltout Switch Transformer

Field Splice

Terminal (Marked) Terminal (Unmarked) Splice

Splice (Marked)

Factory Wiring Field Control Wiring Field Power Wiring

24V

TRAN

Accessory or Optional Wiring To Indicate Common Potential Only, Not to Represent Wiring

NOTES:

1 If any of the original wire furnished must be replaced, it must be replaced

with type 90 C wire or its equivalent

2 Use copper conductors only.

Fig. 22 -- 208/230-3-60 Wiring Diagram, Units PYIP030-060

--22--

L?_-_p

EQUIP GND

COOLING FAN LOGIC

BR I

I I I

0 T T+3O G G

ENERGIZED DE-ENERGIZED

HEATING FAN LOGIC

i I I I

0 45 T T+3O

W BR W BR

ENERGIZEDENERGIZEDI_E-ENERGIZEOOE-ENERGIZED

BLK. BLK,_--- l

_---YELTL

BLK

LBLU

BLK,

BLK

(G.E.

,BLK

YED OFM

CAP2

BLI_ COMP

YEL

JGH (036 & 042 ONLY)

CAP

--vIo _VIO--

f_L GVR

_,t1-11-.

I o

IFM

_LU--------7

3L_

2LN I :

6RN-YEL--------_

NtN_

_P GROUNDED THRU STANDOFF

YEL BRN--W

t--BRN--d

i BRN--

IDM

BRN-- C

24V TRAN

QT -- Quadruple Terminal RS -- Rollout Switch

TRAN -- Transformer

Field Splice

LEGEND

AWG -- American Wire Gage BR -- Blower Relay

C -- Contactor CAP -- Capacitor

CH -- Crankcase Heater

COMP -- Compressor Motor CR -- Combustion ReIay

EQUIP -- Equipment FS -- Flame Sensor

FU -- Fuse GND -- Ground

GVR -- Gas Valve Relay HS -- HalI Effect Sensor

HV TRAN -- High-VoItage Transformer 1 -- Ignitor

IDM -- Induced-Draft Motor IFM -- Indoor-Fan Motor

IGC -- Integrated Gas Controt LS -- Limit Switch

MGV -- Main Gas Valve NEC -- NationaI Electrical Code

OFM -- Outdoor-Fan Motor PWR -- Power

4_ TerminaI (Marked)

O Terminal (Unmarked)

• Splice Splice (Marked)

Factory Wiring Field Control Wiring Field Power Wiring Accessory or Optional Wiring

To Indicate Common PotentiaI Only, Not to Represent Wiring

NOTES:

1 If any of the original wire furnished must be replaced, it must be replaced

with type 90 C wire or its equivalent

2 Use copper conductors onty

Fig. 23 --460-3-60 Wiring Diagram, Units PYIP036-060

--23--

C.Evaporator Airflow and Airflow Adjustments

Table 5 shows the temperature rise at various airflow rates. Tables 9 and 10 show both heating and cooling airflows at

various external static pressures. Refer to these tables to de-

termine the airflow for the system being installed. See Table 11 for wet coil pressure drop.

NOTE: Be sure that all supply and return-air grilles are open, free from obstructions, and adjusted properly.

Airflow can be changed by changing the lead connections of the blower motor.

Unit PYIP two- or 3-speed motors (except size 030) are fac- tory wired for low speed operation. Unit PY1P is factory wired

for medium speed. For 208/230-v and A.O. Smith 460-v Blower Motors

The motor leads are color-coded as follows:

3 SPEED 2 SPEED

black = high speed black = high speed blue = medium speed red = low speed

red = low speed

To change the speed of the blower motor, remove the fan mo- tor speed leg lead fl'om the blower relay (BR). This wire is

attached to terminal BM for single-phase and 3-phase units. To change the speed, remove and replace with lead for de-

sired blower motor speed. In_sulare tire remowH leaH m avoicl

c'onract with c'hassis /raz'r_s.

For 460-v GE Motors The motor leads are color coded as follows:

3 SPEED 2 SPEED

black = high black = high blue = jumper blue = jumper orange = medium red = low red = low

To change the speed of the blower motor, remove fan motor speed lead from the blower relay (BR) and replace with the

lead for the desired blower motor speed. The motor speed lead is attached to terminal BM. [n.sul_r_ remov_ct leact end ro avoid

contact with c'ha.ssLs Darts. On 3-speed motors only, connect

orange lead to terminal BM of BR. To select high speed on 460 v GE motors, separate the black (female QC) fi'om the blue lead (male QC) and connect the black lead to the BR.

[n_sulare tire blue leact go avoiH contact with ar_y c'hasMs parr&

D. Cooling Sequence of Operation

With the room thermostat SYSTEM switch in the COOL po- sition and the FAN switch in the AUTO. position, the cooling

sequence of operation is as follows: When the room temperature rises to a point that is slightly

above the cooling control setting of the thermostat, the ther mostat completes the circuit between thermostat terminal R

to terminals Y and G. These completed circuits through the thermostat connect contactor coil (C) (through unit wire Y)

and blower relay coil (BR) (through unit wire G) across the 24 v secondary of transformer (TRAN).

The normally-open contacts of energized contactor (C) close and complete the circuit through compressor motor (COMP)

to condenser (outdoor) fan motor (OFM). Both motors start instantly.

The set of normally-open contacts of energized relay BR close and complete the circuit through evaporator blower (indoor)

fan motor (IFM). The blower motor starts instantly. NOTE: Once the compressor has started and then has stopped,

it should not be started again until 5 minutes have elapsed. The cooling cycle remains "on" until the room temperature

drops to point that is slightly below the cooling control set ting of the room thermostat. At this point, the thermostat

"breaks" the circuit between thermostat terminal R to termb nals Y and G. These open circuits deenergize contactor coil C

and relay coil BR. The condenser and compressor motors stop. After a 30-second delay, the blower motor stops. The unit is

in a "standby" condition, waiting for the next "call for cool ing" fl'om the room thermostat.

TEMP (F)

OUTDOOR ENTERING

AIR 54

65 SPH 17.3 70 SPH 13.8

75 SPH 10.2 80 SPH 8.2

85 SPH 8.1 90 SPH *

95 SPH *

100 SPH * 105 SPH *

110 SPH * 115 SPH *

LEGEND

Ewb -- Entering Wet Bulb

Table 7A- Superheat Charging Table, PY1P018

INDOOR AIR -- CFM

600

Indoor Air -- Ewb (F)

56 58 60 62 64 66 68 70 72 74 76

!8.5 19.6 20.8 24.2 27.7 28.5 29.3 29.3 29.3 29.3 29.3 !4.9 16.1 !7.3 20.7 24.1 25.7 27.3 27.3 27.3 27.3 27.3

!1.4 12.5 !3.7 17.! 20.6 22.9 25.2 25.2 25.2 25.2 25.2

8.8 9.5 10.2 13.6 17.0 20.1 23.1 23.9 24.1 25.4 26.1

6.2 6.5 6.6 10.0 13.5 17.3 21.1 22.6 24.1 25.6 27.1 * * 5.0 8.1 11.4 15.2 19.0 20.5 22.0 23.5 25.0

* * * 6.2 9.4 13.2 17.0 18.5 20.0 21.5 23.0 * * * 7.3 1! .1 14.9 17.2 !9.5 21.7 24.0

* * * 5.3 9.1 12.9 15.9 18.9 21.9 24.9 * * * 6.7 10.8 13.8 16.8 19.8 22.8

* * * 8.8 1! .8 14.8 !7.8 20.8

*Do not attempt to charge system under these conditions -- refrigerant

slugging may occur.

SPH -- Superheat at Compressor (F)

TEMP (F)

OUTDOOR ENTERING

AIR 54

65 SPH 18.2 70 SPH 17.1

75 SPH 16.0 80 SPH 14.8

85 SPH 13.7 90 SPH 1! .1

95 SPH 8.5

100 SPH 7.3

105 SPH 6.2 110 SPH *

115 SPH *

LEGEND

Ewb -- Entering Wet Bulb

Table 7B -- Superheat Charging Table, PYIP024

INDOOR AIR -- CFM

800

Indoor Air -- Ewb (F)

56 58 60 62 64 66 68 70 72 74 76

!9.0 19.9 20.7 22.5 24.2 25.! 25.9 26.6 27.2 27.9 28.6 !7.6 18.1 !8.6 20.4 22.1 23.0 23.9 24.9 26.0 27.1 28.1

16.2 16.4 !6.6 18.3 20.1 21.0 2! .8 23.3 24.8 26.2 27.7

14.7 14.6 !4.5 16.3 18.0 19.7 2!.3 22.4 23.5 24.6 25.8 !3.3 12.9 !2.5 14.3 16.0 18.4 20.7 21.5 22.3 23.1 23.8

!0.9 10.7 !0.4 12.2 13.9 16.3 18.7 !9.9 21.0 22.2 23.4

8.4 8.4 8.4 10.1 11.9 14.3 16.6 18.2 !9.8 21.4 23.0

7.5 7.7 7.9 8.9 9.9 12.2 14.6 16.6 !8.6 20.6 22.6

6.6 6.9 7.3 7.6 7.8 10.2 12.5 14.9 17.3 19.7 22.1 * * 5.3 5.5 5.8 8.1 10.5 13.3 16.1 18.9 21.7

* * 6.1 8.4 1! .6 14.9 !8.1 21.3

*Do not attempt to charge system under these conditions -- refrigerant

slugging may occur.

SPH -- Superheat at Compressor (F)

TEMP (F)

OUTDOOR ENTERING

AIR 54

65 SPH 14.2 70 SPH 13.6 75 SPH 13.0

80 SPH 10.9 85 SPH 8.9

90 SPH 8.3 95 SPH 7.8

100 SPH 7.3

105 SPH 6.7 110 SPH

115 SPH

LEGEND

Ewb -- Entering Wet Bulb

Table 70 -- Superheat Charging Table, PYIP030

INDOOR AIR -- CFM

1000

Indoor Air -- Ewb (F)

56 58 60 62 64 65 68 70 72 74 76

!5.1 16.1 !7.1 19.2 2!.3 23.3 24.7 25.9 27.2 27.8 28.5 !4.1 14.6 !5.0 17.! 19.2 21.3 22.8 24.2 25.7 26.3 26.9 !3.0 13.0 !3.0 15.! 17.2 19.2 20.9 22.6 24.2 24.8 25.4

!1.0 11.0 !0.9 13.6 16.1 18.7 20.1 21.4 22.7 23.6 24.4

8.9 8.9 8.9 12.0 15.! 18.2 19.2 20.2 21.2 22.4 23.5

8.4 8.4 8.3 10.9 13.6 16.2 17.7 19.2 20.8 21.6 22.5

7.8 7.8 7.8 9.9 12.0 14.1 16.! 18.2 20.2 20.9 21.7

7.3 7.3 7.3 9.3 11.4 13.6 15.6 17.6 !9.7 20.2 20.7

6.7 6.7 6.7 8.8 10.9 13.0 15.0 17.1 !9.1 19.4 19.8

6.7 8.9 10.9 13.0 15.0 17.1 !8.0 18.9 * 6.8 8.9 10.9 13.0 15.0 16.5 !8.0

*Do not attempt to charge system under these conditions -- refrigerant

slugging may occur.

SPH -- Superheat at Compressor (F)

--25--

Table 7D -- Superheat Charging Table, PYIP036

INDOOR AIR -- CFM

1200

Indoor Air -- Ewb (F)

TEMP (F)

OUTDOOR ENTERING

AIR 54 56 58 60 62 64 66 68 70 72 74 76 65 SPH 8.4 8.4 8.4 8.4 12.5 16.7 18.7 20.7 22.0 23.4 24.8 26.1 70 SPH 5.0 5.0 5.0 5.0 9.0 13.! 15.9 18.6 20.0 21.3 22.7 24.0

75 SPH * * 5.4 9.6 13.! 16.6 17.9 19.3 20.6 22.0

80 SPH * * 6.0 10.3 14.5 15.9 17.3 !8.6 20.0 85 SPH * * * 7.5 12.5 13.9 !5.2 16.5 17.9

90 SPH * * * 5.4 10.4 12.5 !4.6 16.8 18.8 95 SPH * * * 8.4 11.3 14.1 17.0 19.8

100 SPH * * * 6.4 10.0 13.5 17.1 20.7

105 SPH .... 8.7 13.0 17.3 21.7

110 SPH .... 9.3 12.4 15.6 18.7

115 SPH .... 10.0 11.9 13.8 15.8

LEGEND *Do not attempt to charge system under these conditions -- refrigerant

Ewb -- Entering Wet Bulb slugging may occur.

SPH -- Superheat at Compressor (F)

Table 7E -- Superheat Charging Table, PYIP042

TEMP (F) INDOOR AIR -- CFM

OUTDOOR 1400 ENTERING Indoor Air -- Ewb (F)

AIR 54 56 58 60 62 64 66 68 70 72 74 76 65 SPH 11.O 1! .0 11 .O !4.0 17.0 20.0 22.0 24.0 26.0 26.0 27.7 28.6 70 SPH 7.5 7.5 7.5 !0.4 13.4 16.4 18.9 21.4 24.0 25.0 26.1 27.1

75 SPH * * 6.9 9.9 12.9 15.9 18.9 21.9 232 24.4 25.7 80 SPH * * 5.9 8.4 10.8 13.8 16.8 19.8 21.3 22.8 24.9

85 SPH * * 5.0 6.9 8.8 1! .8 !4.8 17.8 19.5 21.1 22.8

90 SPH * * 6.0 6.8 10.2 !3.7 17.3 18.6 20.0 2!.4 95 SPH * * * 5.0 8.7 !2.7 16.7 17.8 18.9 20.0

100 SPH * * * 6.5 10.5 14.6 16.4 !8.2 20.0

105 SPH .... 8.4 12.6 15.1 17.6 20.0

110 SPH .... 8.0 12.0 14.2 16.4 18.6

115 SPH .... 7.7 11.5 13.4 15.3 17.2

LEGEND *Do not attempt to charge system under these conditions -- refrigerant

Ewb -- Entering Wet Bulb slugging may occur.

SPH -- Superheat at Compressor (F)

Table 7F -- Superheat Charging Table, PYIP048 (Carrier Scroll Compressor)

TEMP (F) INDOOR AIR -- CFM

OUTDOOR 1600 ENTERING Indoor Air -- Ewb (F)

AIR 54 56 58 60 62 64 66 68 70 72 74 76

65 SPH 15.5 15.5 15.6 15.6 17.6 19.6 21.6 22.8 24.0 25.2 25.2 25.3 70 SPH 11.7 1!.8 11.8 1!.8 13.9 16.0 !8.0 20.1 22.2 24.3 24.3 24.3 75 SPH 8.0 8.0 8.0 8.0 10.2 12.3 !4.5 17.4 20.4 23.3 23.3 23.3

80 SPH 6.0 6.0 6.0 6.0 8.7 11.3 13.9 16.3 !8.6 20.9 21.5 22.0 85 SPH 7.2 10.3 13.4 15.1 !6.8 18.5 19.7 20.8

90 SPH 5.6 7.7 9.9 12.4 !5.0 17.6 18.7 19.8 95 SPH * 5.2 6.3 9.8 13.2 16.7 17.7 18.8

100 SPH * * 5.8 9.1 12.5 15.8 17.! 18.4 105 SPH * * 5.2 8.4 11.7 14.9 16.5 18.!

110 SPH * * 6.2 8.8 11.4 14.0 15.9 17.8 115 SPH * * 7.1 9.1 11.1 13.1 15.3 17.5

LEGEND

Ewb -- Entering Wet Bulb

SPH -- Superheat at Compressor (F)

*Do not attempt to charge system under these conditions -- refrigerant

slugging may occur.

--26--

Table 7G -- Superheat Charging Table, PYIP048 (Copeland Scroll Compressor)

INDOOR AIR -- CFM

1600

Indoor Air -- Ewb (F)

58 60 62 64 66 68 70 72 74 76

19.0 !9.0 21.7 24.3 26.0 27.7 27.9 28.2 28.4 28.8

15.4 !5.4 18.! 20.8 22.5 24.1 25.1 28.1 27.1 28.1

11.9 !1.9 14.6 17.2 18.9 20.6 22.3 24.0 25.8 27.5

8.4 8.4 11.0 13.7 15.4 17.0 19.5 22.0 24.5 27.0

5.0 5.0 7.5 10.! 11.8 13.5 16.7 20.0 23.2 28.4 * * 6.6 9.0 11.4 14.7 17.9 21.1 24.4

* * 6.2 9.4 12.6 15.9 !9.1 22.3 * * 7.3 10.6 13.8 !7.0 20.3

* * 5.3 8.5 !1.8 15.0 !8.2 * * 6.9 !1.2 15.5 !9.8

* * 5.3 10.6 !6.0 21.3

*Do not attempt to charge system under these conditions -- refrigerant

slugging may occur.

TEMP (F)

OUTDOOR ENTERING

AIR 54 56 65 SPH 19.0 !9.0 70 SPH 15.4 !5.4

75 SPH 1! .9 !1.9 80 SPH 8.4 8.4

85 SPH 5.0 5.0 90 SPH * *

95 SPH * *

100 SPH * * 105 SPH * *

110 SPH * * 115 SPH * *

LEGEND

Ewb -- Entering Wet Bulb

8PB -- Superheat at Compressor (F)

TEMP (F)

OUTDOOR ENTERING

AIR 54

65 SPH 20.1 70 SPH 16.5

75 SPH 13.0 80 SPH 10.9

85 SPH 8.9 90 SPH 6.9

95 SPH 5.0

100 SPH * 105 SPH *

110 SPH * 115 SPH *

LEGEND

Ewb -- Entering Wet Bulb

Table 7H -- Superheat Charging Table, PYIP060

INDOOR AIR -- CFM

1995

Indoor Air -- Ewb (F)

56 58 60 62 64 66 68 70 72 74 76

20.1 20.1 20.1 20.1 20.1 22.6 25.2 25.6 26.1 26.6 27.0

16.5 16.5 !6.5 17.3 18.0 20.6 23.1 24.0 24.8 25.6 26.5

13.0 13.0 !3.0 14.5 16.0 18.5 2!.1 22.3 23.5 24.7 25.9 !0.9 10.9 !0.9 12.4 13.9 16.5 19.0 20.6 22.2 23.8 25.4

8.9 8.9 8.9 10.4 11.9 14.4 17.0 18.9 20.9 22.9 24.9

6.9 6.9 6.9 8.4 9.9 12.4 14.9 17.3 !9.6 22.0 24.3

5.0 5.0 5.0 6.3 7.8 10.3 12.9 15.6 !8.3 21.1 23.8 * * * 5.8 8.3 10.8 13.9 !7.0 20.1 23.2

* * * 6.2 8.8 12.3 15.7 19.2 22.7 * * * 6.7 10.6 14.4 18.3 22.2

* * * 8.9 13.1 !7.4 21.6

*Do not attempt to charge system under these conditions -- refrigerant

slugging may occur.

SPH -- Superheat at Compressor (F)

--27--

Table 8 -- Required Suction-Tube Temperature (F)*

SUPERHEAT SUCTION PRESSURE AT SERVICE PORT (psig)

TEMP (F) 61.6 64.2 67.1 70,0 73.0 76.0 79,2 82.4 86.7

0 35 37 39 4! 43 45 47 49 51

2 37 39 41 43 45 47 49 51 53 4 39 41 43 45 47 49 5! 53 55 6 41 43 45 47 49 51 53 55 57

8 43 45 47 49 51 53 55 57 59 10 45 47 49 51 53 55 57 59 61 12 47 49 51 53 55 57 59 6! 63 14 49 51 53 55 57 59 61 63 65 16 5! 53 55 57 59 61 63 65 67 18 53 55 57 59 61 63 65 67 69

20 55 57 59 8! 83 65 67 89 71 22 57 59 61 83 85 67 69 71 73 24 59 61 63 85 87 69 7! 73 75 26 81 63 65 87 89 71 73 75 77 28 83 65 67 89 71 73 75 77 79 30 85 67 69 71 73 75 77 79 81 32 87 69 71 73 75 77 79 81 83 34 89 71 73 75 77 79 8! 83 85 36 7! 73 75 77 79 81 83 85 87 38 73 75 77 79 81 83 85 87 89 40 75 77 79 8! 83 85 87 89 91

*Temperature at su_ion service valve.

Table 9 -- Dry-Coil Air Delivery* -- Horizontal Discharge at 230 and 460 V -- Unit PYIP

(Deduct 10% from Cfm and Watts for 208 V Operation)

UNIT MOTOR AIR EXTERNAL STATIC PRESSURE (in. wg) PY1 P SPEED DELIVERY 0,0 0.1 0.2 0.3 0.4 0.6 0.6 0,7 0.8 0.9 1.0

Watts 230 225 220 210 195 170 t _ _ _ t

Low

Cfm 760 745 725 695 640 540 t t t t t

018

Watts t t t t 270 235 200 t t t t

High Cfm t ? t ? 850 700 450 t ? t ?

Watts 275 275 273 269 260 257 249 ? ? ? ?

Low

Cfm 857 835 802 782 745 717 663 t ? _ ?

024, Med Watts 371 368 360 349 345 326 319 304 293 ? 030 Cfm 1079 1063 1027 996 978 919 865 783 726 _

Watts 5!4 493 476 460 443 425 40! 378 344 _

High Cfm !409 1383 1324 1282 1223 1!56 1068 984 857 _

Watts 473 447 427 418 395 367 346 337 323 _

Low

Cfm !253 1253 1172 1130 1047 946 865 829 768 _

Watts 5!9 500 478 459 439 410 377 357 340 _

036 Med

Cfm !414 1366 1287 1234 1162 !074 920 829 743 _

Watts 667 634 609 593 564 541 506 469 436 422

High Cfm 1734 1639 1563 1461 1370 !292 1157 960 829 743

Watts 678 635 604 580 550 520 493 455 430 _

Low

Cfm !540 15!5 1475 1430 1375 !280 1225 1128 1020 _

042

Watts t 820 785 750 700 680 649 612 570 _

High Cfm t 1825 1750 1685 1610 1525 1485 !355 12!5 _

Watts t t 854 786 744 706 64! 606 557 511

Low

Cfm t t 2026 1905 1830 1752 1603 !513 1367 1228

048

Watts t t _ 905 846 824 804 748 683 637

High Cfm t t _ 2025 1905 1830 1752 1603 1398 1228

Watts !104 !093 1072 1029 986 938 89! 830 769 733 697

Low

Cfm !876 1865 !840 1803 1765 1710 1641 !533 1425 !345 1264

Watts 1351 !295 1245 1197 1148 1096 1053 994 936 871 812

060 Med

Cfm 2249 2209 2157 2097 2036 1959 1882 !781 1679 1542 1405

Watts t t 1391 1343 1296 1247 1!91 !129 !067 1002 936

High Cfm t t 2299 2231 2152 2060 !975 1859 !746 1591 1441

*Air delivery values are without air filter and are for dry coil. See

Table 1! for wet coil pressure drop. Deduct field-supplied air filter pres-

sure drop and wet coil pressure drop to obtain external static pressure available for ducting.

tUnit air delivery is outside of operating range.

NOTE: 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 icing may occur at airflows below this point. Water blow-off may occur at airflows above 450 cfm per 12,000 Btuh of rated cooling capacity.

--28--

Table 10 -- Dry-Coil Air Delivery* -- Downflow Discharge at 230 and 460 V -- Unit PYIP

(Deduct 10% from Cfm and Watts for 208 V Operation)

UNIT MOTOR AIR EXTERNAL STATIC PRESSURE (in. wg) PYIP SPEED DELIVERY 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0,7 0.8 0.9 1.0

Watts t 295 251 223 201 176 149 !24 t t

Low

Cfm t 821 817 753 665 536 343 164 t t

018

Watts 401 376 346 322 294 272 250 229 219 t

High Cfm !334 1253 1128 996 816 658 461 246 167 t

Watts t 285 284 282 278 274 270 261 251 244 230

Low

Cfm t 798 76! 727 682 634 581 525 450 37! 304

024, Med Watts t 378 371 368 362 357 343 332 315 301 283 030 Cfm t !01! 982 948 906 858 771 703 597 492 387

Wafts t 520 51! 487 472 451 431 411 385 362 341

High Cfm t 1342 !309 1237 1181 1106 1007 892 745 610 471

Wafts t 460 439 423 398 379 349 322 297 270 246

Low

Cfm t !19! 1136 1081 !005 907 795 687 579 47! 349

Watt t 511 492 470 450 420 392 364 332 308 275

036 Med

Cfm t 1316 1244 !178 1104 1005 891 784 657 535 389

Watts _ 655 631 603 584 552 522 492 459 433 398

High Cfm ? !54! 1458 !367 1292 1178 1053 920 806 662 509

Wafts _ 637 612 587 560 526 493 455 t t t

Low

Cfm _ !500 1450 1405 1350 1290 1200 1105 t t t

042

Wafts _ 790 750 700 679 639 608 574 547 t t

High Cfm _ 1750 1675 !604 1509 1421 1323 1221 1094 t t

Watts _ 847 784 746 708 646 609 563 516 t t

Low

Cfm _ 1995 1901 !822 1730 1580 1477 1319 1!78 t t

048

Watts _ t 909 852 820 801 751 687 639 t t

High Cfm _ t 2018 !896 18!4 1729 1582 1380 1270 t t

Wafts _ 983 950 923 885 845 804 751 697 665 633

Low

Cfm _ 1838 1808 1755 1702 !628 1553 1446 1339 1257 1175

Wafts ? 1115 1083 !045 1006 964 921 872 823 783 742

060 Med

Cfm ? 2067 2023 !957 1891 !807 1723 1612 150! 1392 !282

Watts ? 1284 1201 1166 !131 !092 1053 1001 950 907 864

High Cfm ? 2167 2108 2038 1968 1882 1796 1676 1555 1437 !318

*Air delivery values are without air filter and are for dry coil. See

Table 11 for wet coil pressure drop. Deduct field-supplied air filter pressure drop and wet coiI pressure drop to obtain external static

pressure available for ducting.

1-Unit air delivery is outside of operating range.

NOTE: 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 icing may occur at airflows below this point. Water blow-off may occur at airflows above 450 cfm per 12,000 Btuh of rated cooling capacity.

Table 11 -- Wet Coil Pressure Drop

UNIT SIZE PYIP

018

024

030

036

042

O48

060

AIRFLOW(cfm)

600 700

8OO 900

600 700 8OO

900 900

1000 1200

1400 1600

1000 1200

1400 1600 1400

1600 1800

1700

1900 2100 2300

PRESSURE DROP (in. wg)

0.069

0.082

0.102

0.116

0.039

0.058

0.075

0.088

0.095

0.123

0.068

0.088

0.108

0.123

0.048

0.069

0.088

0.102

0.068

0.075

0.088

0.082

0.095

0.108

0.123

--29--

MAINTENANCE

To ensure continuing high performance, and to minimize the possibility of premature equipment failure, periodic mainte-

nance must be performed on this equipment. This combina tion heating/cooling unit should be inspected at least once each

year by a qualified service person. To troubleshoot heating or

cooling of units, refer to tables at the back of the book. NOTE TO EQUIPMENT OWNER: Consult your local dealer

about the availability of a maintenance contract.

The minimum maintenance requirements for"this equipment are as follows:

1. Inspect air filter(s) each month. Clean or replace when necessary.

2. Inspect indoor coil, drain pan, and condensate drain each cooling season fox"cleanliness. Clean when necessary.

3. Inspect blower motor and wheel fox"cleanliness and check lubrication each heating and cooling season. Clean and

lubricate (if required) when necessary. For" first heating season, inspect blower wheel bimonthly to determine

proper cleaning fi'equency.

4. Check electrical connections for tighmess and controls fox"proper operation each heating and cooling season.

Service when necessary.

5. Check and inspect heating section before each heating season. Clean and adjust when necessm T.

6, Check flue hood screen and remove any obstructions if

necessary.

7. Check vent screen and clean if necessary.

I. AIR FILTER

Inspect air filter(s) at least once each month and replace

(throwaway type) or clean (cleanable type) at least twice dur

ing each heating and cooling season or whenever the filter(s) becomes clogged with dust and lint.

II. UNIT TOP REMOVAL NOTE: When performing maintenance or service procedures

that require removal of the unit top, be sure to perform all of the routine maintenance procedures that require top re-

moval, including: inspection of the heat exchanger area, coil inspection and cleaning, and condensate drain pan inspec

tion and cleaning. Only qualified service personnel should perform mainte-

nance and service procedures that require unit top removal. Refer to the following top removal procedures:

1. Turn off gas supply, then turn off electric power to unit.

2. Remove all screws that secure unit top, including screws around 4 sides and those on top that screw into internal

divider panels. Save all screws.

3. Lift top fi'om unit carefully. Set top on edge.

4. Carefully replace and secure unit top to unit, using screws removed in Step 2, when maintenance and/or service pro

cedures are completed. (Be sure to use original screws that have rubber washers to seal out water when secur

ing top to internal divider panels.)

III. EVAPORATOR BLOWER AND MOTOR NOTE: Motors without oilers are prelubricated. Do not at-

tempt to lubricate these motors. For longer life, operating economy, and continuing efficiency,

clean accumulated dirt and grease from the blower wheel and motor annually.

Lubricate the motor every 5 years if the motor is used inter mittently (thermostat FAN switch in AUTO. position), or ev

eW 2 years if the motor is used continuously (thermostat FAN switch in ON position).

To clean and lubricate the blower motor and wheel:

1. Remove and disassemble blower assembly as follows: a. Remove blower access door.

b. Disconnect motor lead fi'om blower relay (BR). Dis-

connect yellow lead fi'om terminal L2 of the contactor.

--30--

c. Remove blower assembly fl'om unit. Remove screws

securing blower to gas partition and slide assembly out. Be carefld not to teal" insulation in blower

compartment.

d. Ensure proper reassembly by marking blower wheel

and motor in relation to blower housing before disassembly.

e. Loosen setscrew(s) that secures wheel to motor shaft,

relnove screws that secure ii-!otor inoun{ brackets to housing, and slide motor and motor mount out of

housing.

2. Lubricate motor as follows: a. Thoroughly clean all accumulations of dirt or grease

from motor housing.

b. Remove dust caps or plugs from oil ports located at

each end of motor.

c. Use a good grade of SAE 20 nondetergent motor oil

and put one teaspoon (3/,_ oz. or 16 to 25 drops) in each oil port.

d. Allow time for oil to be absorbed by each bearing, then

wipe excess oil fl'om motor housing.

e. Replace dust caps or plugs in oil ports.

3. Remove and clean blower wheel as follows: a. Ensure proper reassembly by marking wheel

orientation.

b. Lift wheel fl'om housing. When handling and/or clean-

ing blower wheel, be sure not to disturb balance weights (clips) on blower wheel vanes.

c. Remove caked-on dirt from wheel and housing with

a brush. Remove lint and/or dirt accumulations from

wheel and housing with vacuum cleaner, using soft

brush attachment. Remove grease and oil with mild solvent.

d. Reassemble wheel into housing. e. Reassemble motor into housing. Be sure setscrews are

tightened on motor shaft fiats and not on round part of shaft.

f. Reinstall blower access door.

4. Restore electrical power, then gas supply to unit. Start unit and check for proper blower rotation and motor speeds

during heating and cooling cycles,

IV. FLUE GAS PASSAGEWAYS

To inspect the flue collector box and upper areas of the heat exchanger:

1. Remove the combustion blower wheel and motor assem bly according to directions in Combustion Air Blower sec

tion on this page.

2. Remove tile 3 screws holding the blower housing to the title collector box cover (see Fig. 24).

3. Remove the 12 screws holding the title collector box cover

(Fig. 24) to the heat exchanger assembly. Inspect the heat

exchangers.

4. Clean all surfaces as required using the wire brush.

FLUE COLLECTOR BOX

INDUCED DRAFT MOTOR MOUNTING PLATE

BLOWER HOUSING

BURNER RACK

MOUNTING SCREW

Fig. 24 -- Blower Housing and Flue Collector Box

V. COMBUSTION-AIR BLOWER

Clean periodically to assure proper airflow and heating effi- ciency. Inspect blower wheel every fall and periodically dur

ing heating season. For the first heating season, inspect blower wheel bimonthly to determine proper cleaning fl'equency.

To inspect blower wheel, remove draft hood assembly. Shine a flashlight into opening to inspect wheel. If cleaning is re

quired, remove motor and wheel as follows:

1. Remove burner access panel. (See Fig. 25.)

2. Remove the 7 screws that attach induced-draft motor mounting plate to blower housing. (See Fig. 24.)

3. Slide the motor and blower wheel assembly out of the

blower housing. (See Fig. 26.) Clean the blower wheel.

If additional cleaning is required, continue with Steps 4

and 5.

4. To remove blower, remove 2 setscrews. See Fig. 26.

5. To remove motor, remove 4 screws that hold blower hous- ing to mounting plate. Remove the motor cooling fan by removing one setscrew. Remove nuts that hold motor to

mounting plate.

6. To reinstall, reverse the procedure outlined above.

Vl. LIMIT SWITCH

Remove blower panel. Limit switch is located on the gas partition.

VII. BURNER IGNITION

Unit is equipped with a direct spark ignition 100% lockout system. Ignition module is located in the control box. Module

contains a selfdiagnostic LED. During servicing, refer to la- bel diagram for LED interpretation.

If lockout occurs, unit may be reset by either momentarily interrupting power supply to unit, or turning selector switch

to OFF position at the thermostat.

--31--

ONkN_EOFTHU_PA_L

BURNER

""_""_ACCESS

PANEL

Fig. 25 -- Burner Access Panel

BLOWER HOUSING

2 SETSCREWS (HIDDEN)

Fig. 26 -- Removal of Motor and Blower Wheel

VIII. MAIN BURNERS

At the beginning of each heating season, inspect for deterio- ration or blockage due to corrosion or other causes. Observe

the main burner flames and adjust if necessary.

A. Removal of Gas Train

1. Shut off manual gas valve.

2. Shut off power to unit.

3. Remove burner access panel. (See Fig. 25.)

4. Disconnect gas piping at unit gas valve.

5. Remove wires connected to gas valve. Mark each wire.

6. Remove ignitor and sensor wires at the ignitor module.

7. Remove the mounting screw that attaches the burner rack to the basepan. (See Fig. 24.)

8. Slide the burner rack out of the unit. (See Fig. 24 and 27.)

9. To reinstall, reverse the procedure outlined above.

Fig. 27 -- Burner Rack Removed

IX. CONDENSER COIL, EVAPORATOR COIL, AND CONDEN- SATE DRAIN PAN

Inspect the condenser coil, evaporator coil, and condensate drain pan at least once each year. Proper inspection and clean-

ing requires the removal of the unit top. See Unit Top Re moval section on page 30.

The coils are easily cleaned when dry; therefore, inspect and clean the coils either before or after each cooling season. Re- move all obstructions, including weeds and shrubs, that in

terfere 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 attach- ment. Be careful not to bend the fins. If coated with oil or

grease, clean the coils with a mild detergent and water solu tion. 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 fl'om the unit base. Inspect the drain pan and condensate drain line when in-

specting the coils. Clean the drain pan and condensate drain by removing all foreign matter fi'om the pan. Flush the pan

and drain tube with clear water. Do not splash water on the insulation, motor, wiring, or air filter(s). If the drain tube is

restricted, clear" it with a "plumbers snake" or similar probe device. Ensure that the auxiliary drain port above the drain

tube is also clear.

--32--

X. CONDENSER FAN

1. Remove 2 screws at bottom and 2 screws along sides of condenser air intake grille and remove plastic grille.

2. Inspect the fan blades for cracks or bends.

3. If fan needs to be removed, loosen the setscrew and slide the fan off the motor shaft.

4. When replacing fan blade, position blade so that lead- ing edge is 1/z in. in front of fan orifice. See Fig. 18.

5. Ensure that setscrew engages the fiat area on the me tar shaft when tightening.

6. Replace grille.

XI. ELECTRICAL CONTROLS AND WIRING

Inspect and check the electrical controls and wiring annu ally. Be _szlr'ere turn off'the ga_s _supIrl_ and then tire electrical

power re tire zmfr.

Remove the control, blower, and compressor compartment ac- cess panels to locate all the electrical controls and wiring. Check

all electrical connections fox"tightness. Tighten all screw con nections. If any smoky or burned connections are noticed, dis-

assemble the connection, clean all the parts, restrip the wire end, and reassemble the connection properly and securel N

After inspecting the electrical controls and wiring, replace all the panels. Start the unit, and observe at least one complete

heating cycle and one complete cooling cycle to ensure proper operation. If discrepancies are observed in either or both op-

erating cycles, or if a suspected malflmction has occurred, check each electrical component with the proper electrical instru

mentation. Refer to the unit wiring label when making these checkouts.

NOTE: Refer to the heating and/or cooling sequence of op eration in this publication as an aid in determining proper control operation.

XII. REFRIGERANT CIRCUIT

Inspect all refrigerant tubing connections and the unit base fox"oil accumulations annually. Detecting oil generally indi

cares a refl'igerant leak. If oil is detected or if low cooling performance is suspected,

leak-test all refrigerant tubing using an electronic leak- detector, halide torch, or liquid soap solution. If a refrigerant

leak is detected, refer to Check for Refl'igerant Leaks section on page 16.

If no refrigerant leaks are found and low cooling perfor- mance is suspected, refer to Checking and Adjusting Refrig-

erant Charge section on page 20.

XIII. GAS INPUT

The gas input does not require checking unless improper heat- ing performance is suspected. If a problem exists, refer to

Start Up section on page 16.

XIV. EVAPORATOR AIRFLOW

The heating and/or cooling airflow does not require checking unless improper performance is suspected. [ta problem ex-

isr_s, be sure that oH _sUi)lrlF- and retzmn-ah" gz'illes are open

and bee O'om ob.stfuctions, and that tire oh" i/ire1"ZscJean.When necessary, refer to Evaporator Airflow and Airflow Adjust

ments section on page 24 to check the system airflow.

XV, METERING DEVICE- ACUTROL TM DEVICE

This metering device is a fixed orifice and is located in the header to the evaporator coil.

XVI. LIQUID LINE STRAINER

The liquid line strainer (to protect metering device) is made of wire mesh and located in the liquid line on the inlet side of

the metering device.

TROUBLESHOOTING

Cooling

SYMPTOM CAUSE REMEDY

Compressor and Power failure Call power company. condenser fan will Fuse blown or circuit breaker tripped Replace fuse or reset circuit breaker.

not start.

Defective thermostat, contactor, transformer, Replace component. or control relay

Insufficient line voltage Determine cause and correct. Incorrect or faulty wiring Check wiring diagram and rewire correctly.

Thermostat setting too high Lower thermostat setting below room temperature.

Compressor will not Faulty wiring or loose connections in Check wiring and repair or replace. start but condenser compressor circuit

fan runs. Compressor motor burned out, seized, or Determine cause. Replace compressor.

internal overload open Defective run/start capacitor, overload, Determine cause and replace.

start relay One leg of 3-phase power dead

Three-phase scroll compressor (Unit sizes 048,060 only)

makes excessive noise, and there

may be a low pres- sure differential.

Compressor cycles (other than normally satisfying

thermostat).

Scroll compressor is rotating in the wrong direction

Replace fuse or reset circuit breaker. Determine cause.

Correct the direction of rotation by reversing the 3-phase power leads to the unit. Shut down unit to allow pressures to equalize.

Refrigerant overcharge or undercharge Recover refrigerant, evacuate system, and

recharge to capacities shown on nameplate.

Defective compressor Replace and determine cause.

Insufficient line voltage Determine cause and correct.

Blocked condenser Determine cause and correct. Defective run/start capacitor, overload Determine cause and replace.

or start relay Defective thermostat Replace thermostat.

Faulty condenser-fan motor or capacitor Replace. Restriction in refrigerant system Locate restriction and remove.

Compressor Dirty air filter Replace filter. operates Unit undersized for load Decrease load or increase unit size.

continuously. Thermostat set too low Reset thermostat.

Low refrigerant charge Locate leak, repair, and recharge. Leaking valves in compressor Replace compressor.

Air in system Recover refrigerant, evacuate system, and recharge.

Condenser coil dirty or restricted Clean coil or remove restriction. Excessive head Dirty air filter Replace filter. pressure. Dirty condenser coil Clean coil.

Refrigerant overcharged Recover excess refrigerant. Air in system Recover refrigerant, evacuate system, and recharge. Condenser air restricted or air short-cycling Determine cause and correct.

Head pressure too Low refrigerant charge Check for leaks, repair and recharge. low. Compressor valves leaking Replace compressor.

Restriction in liquid tube Remove restriction.

Excessive suction High heat load Check for source and eliminate. pressure. Compressor valves leaking Replace compressor.

Refrigerant overcharged Recover excess refrigerant.

Suction pressure Dirty air filter Replace filter. too low. Low refrigerant charge Check for leaks, repair and recharge.

Metering device or low side restricted Remove source of restriction.

Insufficient evaporator airflow increase air quantity. Check filter -- replace if

necessary. Temperature too low in conditioned area Reset thermostat. Outdoor ambient below 40 F install low-ambient kit.

Field-installed filter-drier restricted Replace.

--34--

SYMPTOM

Burners will not ignite.

Inadequate heating.

Poor flame characteristics.

Heating

CAUSE

Water in gas line

No power to furnace No 24-v power supply to control

circuit

Miswired or loose connections Burned-out heat anticipator in

thermostat

Broken thermostat wire Misaligned spark electrodes

No gas at main burners

Dirty air filter

Gas input to furnace too low

Unit undersized for application Restricted airflow

Blower speed too low

Limit switch cycles main burners

incomplete combustion results in:

Aldehyde odors, carbon monox-

ide, sooting flame, floating flame

REMEDY

Drain. install drip leg. Check power supply fuses, wiring, or circuit breaker.

Check transformer. NOTE: Some transformers have internal overcurrent protection that requires a cool-down period to reset.

Check all wiring and wirenut connections.

Replace thermostat.

Run continuity check. Replace wire if necessary.

Check flame ignition and sense electrode positioning. Adjust as necessary.

1. Check gas line for air. Purge as necessary. NOTE: After purging gas line of air, wait at least

5 minutes for any gas to dissipate before attempt- ing to light unit.

2. Check gas valve. Clean or replace filter as necessary. Check gas pressure at manifold. Match with that on

unit nameplate.

Replace with proper unit or add additional unit. Clean or replace filter. Remove any restriction. Use faster speed tap if available, or install alternate

motor. Check rotation of blower, thermostat heat antic-

ipator settings, temperature rise of unit. Adjust as necessary.

1. Tighten all screws around burner compartment.

2. Cracked heat exchanger. Replace.

3. Unit overfired. Reduce input (change orifices or

adjust gas line or manifold pressure).

4. Check burner alignment.

--35--

LED Troubleshooting -- Error Code

SYMPTOM CAUSE REMEDY

Hardware failure. Loss of power to control module Check 5 amp fuse on IGC, power to unit, 24-v circuit (LED OFF) (IGC). breaker, and transformer. Units without a 24-v circuit

breaker have an internal overload in the 24-v trans- former. If the overload trips, allow 10 minutes for au-

tomatic reset.

Limit switch fault. High temperature limit switch is Check the operation of the indoor (evaporator) fan (LED 2 flashes) open. motor. Ensure that the supply-air temperature rise is

in accordance with the range on the unit nameplate.

Flame sense fault. The IGC sensed flame that Reset unit. If problem persists, replace control board. (LED 3 flashes) should not be present.

4 consecutive limit switch Inadequate airflow to unit. Check operation of indoor (evaporator) fan motor and

faults, that supply-air temperature rise agrees with range on

(LED 4 flashes) unit nameplate information. Ignition lockout. Unit unsuccessfully attempted Check ignitor and flame sensor electrode spacing,

(LED 5 flashes) ignition for 15 minutes, gaps, etc. Ensure that flame sense and ignition wires

are properly terminated. Verify that unit is obtaining proper amount of gas.

Induced-draft motor fault. IGC does not sense that induced- Check for proper voltage. If motor is operating, check (LED 6 flashes) draft motor is operating, the speed sensor plug/IGC Terminal J2 connection.

Proper connection: PiN 1 -- White, PIN 2 -- Red, PIN 3 -- Black.

Rollout switch fault. Rollout switch has opened. Rollout switch will automatically reset, but IGC will (LED 7 flashes) continue to lockout unit. Check gas valve operation.

Ensure that induced-draft blower wheel is properly secured to motor shaft. Reset unit at unit disconnect.

Internal control fault. Microprocessor has sensed an If error code is not cleared by resetting unit power, (LED 8 flashes) error in the software or hardware, replace the IGC.

IMPORTANT: Refer to Heating troubleshooting chart for additional troubleshooting analysis.

LEGEND

IGC -- Integrated Gas Unit Controller LED -- Light-Emitting Diode

--36--

PACKAGED SERVICE TRAINING

Our packaged service training programs provide an excellent way to increase your kalowledge of the equipment discussed in this manual. Product progralns cover:

• Unit Familiarization • Maintenance

• Installation Overview • Operating Sequence

A large selection of product, theory, and skills programs is available. All pro m'ams include a video cassette and/or slides and a companion booklet. Use these for self teaching or to conduct full training sessions.

For a free Service Training Material Catalog (STM), call 1-800-962-9212. Ordering instructions are included.

--37--

Payne PYIP024060, PY1P024040, PYIP030060, PY1P030040, PYIP030080 Installation, Start-up And Service Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual