Payne PA3A, PA4A, R-22 PA4R Installation Instructions Manual

Installation Instructions

PA3A, PA4A

R--410A SPLIT--SYSTEM

AIR CONDITIONER

1--1/2 -- 5 TONS (018--060)

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service, maintenance,
or use can cause explosion, fire, electrical shock, or other
conditions which may cause death, personal injury, or property
damage. Consult a qualified installer, service agency, or your
distributor or branch for information or assistance. The qualified
installer or agency must use factory--authorized kits or accessories
when modifying this product. Refer to the individual instructions
packaged with the kits or accessories when installing.

Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Use quenching cloth for brazing operations.
Have fire extinguisher available. Read these instructions
thoroughly and follow all warnings or cautions included in
literature and attached to the unit. Consult local building codes and
National Electrical Code (NEC) for special requirements.

Recognize safety information. This is the safety--alert symbol
When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal injury. Understand
these signal words: DANGER, WARNING, and CAUTION. These
words are used with the safety--alert symbol. DANGER identifies
the most serious hazards which will result in severe personal injury
or death. WARNING signifies hazards which could result in
personal injury or death. CAUTION is used to identify unsafe
practices which may result in minor personal injury or product and
property damage. NOTE is used to highlight suggestions which
will result in enhanced installation, reliability, or operation.

!

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal
injury or death.

Before installing, modifying, or servicing system, main
electrical disconnect switch must be in the OFF position.
There may be more than 1 disconnect switch. Lock out
and tag switch with a suitable warning label.

!

UNIT OPERATION AND SAFETY HAZARD

Failure to follow this warning could result in personal injury
or equipment damage.

R--410A refrigerant systems operate at higher pressures than
standard R--22 systems. Do not use R--22 service equipment
or components on R --410A refrigerant equipment.

WARNING

WARNING

GENERAL

INSPECT NEW UNIT

After uncrating unit, inspect thoroughly for hidden damage. If
damage is found, notify the transportation company immediately
and file a concealed damage claim.

LOCATION

Check local codes for regulations concerning zoning, noise,
platforms, and other issues.

Locate unit away from fresh air intakes, vents, or bedroom
windows. Noise may carry into the openings and disturb people
inside.

Locate unit in a well drained area, or support unit high enough so
that water runoff will not enter the unit.

!

!

Locate unit away from areas where heat, lint, or exhaust fumes will
be discharged onto unit (as from dryer vents).

Locate unit away from recessed or confined areas where
recirculation of discharge air may occur (refer to CLEARANCES
section of this document).

Roof--top installation is acceptable providing the roof will support
the unit and provisions are made for water drainage and
noise/vibration dampening.

NOTE: Roof mounted units exposed to wind may require wind
baffles. Consult the manufacturer for additional information.

CLEARANCES

When installing, allow sufficient space for airflow clearance,
wiring, refrigerant piping, and service. Allow 30 in. (762 mm)
clearance to service end of unit and 48 in. (1219 mm) above unit.
For proper airflow, a 6 in. (152 mm) clearance on 1 side of unit and
12 in. (305 mm) on all remaining sides must be maintained.
Maintain a distance of 24 in. (610 mm) between units or 18 in.
(457 mm) if no overhang within 12 ft. (7.3 m). Position so water,
snow, or ice from roof or eaves cannot fall directly on unit.

On rooftop applications, locate unit at least 6 in. (152 mm) above
roof surface.

Do not install unit under roof overhangs unless gutters are present.
A minimum vertical clearance of 48 inches (1219 mm) is required
to the overhang.

Inside corner locations on single story structures require
evaluation. Large overhanging soffit may cause air recirculation in
a corner area even though recommended minimum clearances are
maintained. As a guide, locate the unit far enough out so that half
of the discharge grille is out from under the soffit.

When placing two or more units side-- by--side, provide a minimum
of 18 inches (457 mm) between units.

Provide minimum service clearance of 24 inches (610 mm) from
control box corner and side service panel.

UNIT SUPPORT

NOTE: Unit must be level ± 2 degrees (3/8 inch rise or fall per

foot of run) or compressor may not function properly.

Ground Level

Installation

The unit must be level and supported above grade by beams,
platform, or a pad. Platform or pad can be of open or solid
construction but should be of permanent materials such as
concrete, bricks, blocks, steel, or pressure-- treated timbers
approved for ground contact. Soil conditions must be considered
so that the platform or pad does not shift or settle and leave the unit
partially supported. Minimum pad dimensions are shown in Fig.

1.

If beams or an open platform are used for support, it is
recommended that the soil be treated or area be graveled to reduce
the growth of grasses and weeds.

To minimize vibration or noise transmission, it is recommended
that supports not be in contact with the building structure.
However, slabs on grade constructions with an extended pad are
normally acceptable.

Roof Top

Installation

This type of installation is not recommended on wood frame
structures where low noise levels are required.

Supporting structure or platform for the unit must be level. If
installation is on a flat roof, locate unit minimum 6 inches 152
mm) above roof level.

Place the unit over one or more load bearing walls. If there are
several units, mount them on platforms that are self--supporting
and span several load bearing walls. These suggestions are to
minimize noise and vibration transmission through the structure. If
the structure is a home or apartment, avoid locating the unit over
bedrooms or study.

NOTE: When unit is to be installed on a bonded guaranteed roof,
a release must be obtained from the building owner to free the
installer from all liabilities.

Fastening Unit

down

If conditions or local codes require the unit be attached in place,
remove the knockouts in the base pan and install tie down bolts
through the holes (refer to Fig. 1).

Contact local distributor for hurricane hold--down details and the
P.E. (Professional Engineer) certification, when required.

!

CAUTION

PROPERTY DAMAGE HAZARD

Failure to follow this caution may result in property
damage.
Inadequate unit support may cause excessive vibration,
noise, and/or stress on the refrigerant lines, leading to
refrigerant line failure.

3/8” Dia. Tie Down Knockouts

In Base Pan (2 places)

VIEW

FROM

A

Base Pan Width x

Depth

in. (mm)

25---3/4 x 26---5/16

(654 x 668)

31---3/16

(792)

35 x 36---9/16

(889 x 923)

TOP

Base Pan Width

Tie Down

Knockouts in. (mm)

A B C

4 --- 7 / 8

(124)

6 --- 9 / 1

9 --- 1 / 8

(232)

6

(167)

6-- 9/16

(167)

21---1/4

(540)

24--11/16

(627)

28--7/16

(722)

Mounting Pad

31---1/2 x 32 ---1/2

Depth

C

B

Minimum

Dimensions

in. (mm)

26 x 26--1/2
(660 x 673)

(800 x 826)

35 x 36--1/2
(889 x 927)

Base

Pan

A07586f

Fig. 1 --- Tie Down Knockouts

REFRIGERATION SYSTEM

A. COMPONENT MATCHES

Check to see that the proper system components are in place,
especially the indoor coil.

R--410A outdoor units can only be used with R --410A specific
indoor coils. If there is a refrigerant mis-- match, consult the indoor
coil manufacturer to determine if a refrigerant conversion kit is
available for the indoor coil.

This outdoor unit is designed for use only with indoor coils that
utilize a hard shut--off TXV refrigerant metering device. If any
other type of metering device is installed on the indoor coil, consult
the indoor coil manufacturer to determine if a hard shut--off TXV
conversion kit is available.

!

PRODUCT DAMAGE HAZARD

Failure to follow this caution may result in product damage.

Indoor coil and outdoor unit must be listed as a certified
combination (match) in the ARI Unitary Directory of
Certified Products. Indoor coil must have R --410A specific,
hard shut--off TXV refrigerant metering device.

CAUTION

2

When installing a hard shut--off TXV on an indoor coil, follow the
instructions provided with the new TXV.

A typical hard shut--off TXV installation is shown in Fig. 2.

INDOOR

SUCTION

TUBE

COIL

SUCTION
TUBE

LIQUID
TUBE

STRAP

A07587

EQUALIZER
TUBE

SENSING
BULB

HARD
SHUT OFF
TXV

SENSING BULB
(EITHER SIDE)

8 O’CLOCK 4 O’CLOCK

Fig. 2 --- Typical TXV Installation

B. REFRIGERANT LINE SETS

The refrigerant line set must be properly sized to assure maximum
efficiency and proper oil circulation. Select line set tube diameters
as specified in Table 1.

NOTE: Total line set length must not exceed 200 feet (61 m).

NOTE: A crankcase heater must be used when the refrigerant line

length exceeds 80 feet (24 m).

If outdoor unit is more than 10 feet (3 m) higher than the indoor
coil, refer to the Extended Length Refrigeration Piping Manual for
instructions.

NOTE: When the outdoor unit is higher than the indoor coil, the
vertical separation must not exceed 100 feet (31 m).

NOTE: When the outdoor unit is lower than the indoor coil, the
vertical separation must not exceed 50 feet (15 m).

If it is necessary to add refrigerant line in the field, use dehydrated
or dry, sealed, deoxidized, copper refrigeration tubing. Do not use
copper water pipe.

Do not remove rubber plugs or caps from copper tubing until
connections are ready to be made.

Be extra careful when bending refrigeration tubing. Tubing can
“kink” easily, and if this occurs, the entire length of tubing must be
replaced.

Table 1—R-- 410A Line Set Tube Diameter

(Liquid Tube Always 3/8” Dia.)

SERVICE VALVE

FITTINGS

MODEL SIZE

18 (12 ton)

24 (2 ton)

30 (22 ton)

36 (3 ton)

42 (32 ton)

48 (4 ton)
60 (5 ton) 7/8 1 --- 1 / 8 1 --- 1 / 8

NOTE: If the line set length exceeds 80 feet (24 m), also refer to Long Line

Application Guide for additional information.

(IN.)

Liquid Suction

5/8 5/8 3/4

3/8

3/4 3/4 7/8

7/8 7/8 1 --- 1 / 8

LINE SET

< 80 FEET

(24 M) LONG

Suction Line

Diameter

LINE SET

80 --- 200 FEET

( 2 4 --- 6 1 M )

LONG

Suction Line

Diameter (in.)

!

WARNING

PERSONAL INJURY and ENVIRONMENTAL

HAZARD

Failure to relieve system pressure could result in personal
injury and/or death.

1.Relieve pressure and recover all refrigerant before
servicing existing equipment, and before final unit
disposal. Use all service ports and open all flow--control
devices, including solenoid valves.

2.Federal regulations require thatyou do not vent refrigerant
into the atmosphere. Recover during system repair or
final unit disposal.

!

CAUTION

UNIT OPERATION HAZARD

Failure to follow this caution may result in improper
product operation.

Do not leave system open to atmosphere any longer than
absolutely required for installation. Internal system
components -- especially refrigerant oils -- are extremely
susceptible to moisture contamination. Keep ends of tubing
sealed during installation until the last possible moment.

C. ROUTING AND SUSPENDING REFRIGERANT LINES

Run refrigerant lines as straight and direct as possible, avoiding
unnecessary bends and turns. Always insulate the entire suction
line. Both lines should be insulated when routed through an attic or
when routed through an underground raceway.

When routing refrigerant lines through a foundation or wall, do not
allow refrigerant lines to come in direct contact with the building
structure. Make openings large enough so that lines can be
wrapped with extra insulation. Fill all gaps with RTV caulk. This
will prevent noise transmission between the tubing and the
foundation or wall.

Along floor or ceiling joists, suspend refrigerant lines so that they
do not contact the building structure, water pipes, or ductwork. Use
insulated or suspension type hangers. Metal straps must be at least
1” wide to avoid cutting into the tube insulation. Keep the liquid
and suction lines separate. Refer to Fig. 3.

OUTDOOR WALL INDOOR WALL

CAULK

INSULATION

HANGER STRAP

(AROUND SUCTION

TUBE ONLY)

1” MIN

THROUGH THE WALL

SUSPENSION

LIQUID TUBE

SUCTION TUBE

JOIST

INSULATION

SUCTION TUBE

LIQUID TUBE

A07588

Fig. 3 --- Routing and Suspending Refrigerant Lines

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