Installation guide

ManualsBrandsPayne ManualsHeating & cooling combined unitOfficial Payne central package

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.

Summary of content (38 pages)

PAGE 1
Cancels: II PY1P 18 1 II PY1P 18 2 9/1/98 CONTENTS Page SAFETY CONSIDERATIONS ...................... I. General ................................... RECEIVING AND INSTALLATION 1-5 1 ................. 6 15 I. II. Step Step 1 -2 -- Check Equipment .................. Provide Unit Support ............... (3 (3 III. IV. Step Step 3 -4 -- Field Fabricate Ductwork ............ Provide Clearances ................. (3 6 V. VI. Step Step 5 -6 -- Rig and Connect 6 9 VII. VIII.
PAGE 2
/-COND - 4 13/16" ()22.2) B/16 (312.?) COIL 43 11116" 4ll0B.B) ° COIL RETURN OPENING AIR \ BLOWER ACCESS PANEL BURNER RIGHT SIDE VIEW AND ACCESS CONTROL PANEL 30X 49 9116" (1259.3) REQ'D CLEARANCES FOR SERVICING Duct panel ............................. Unit top ........................... Side opposite ducts ..................... Compressor access ..................... (Except for NEC requirements) REQ'D CLEARANCES 0 36 (914) 36 (914) 36 (914) TO COMBUSTIBLE MAT'L 10 9116" (263.
PAGE 3
-45 I/2" COND COIL o (115E,7) 43 11/16 ° (II08.B) 1 9/16" OPTIONAL / / RETURN AIROPENING 7" SLOWER ACCESS PANEL BURNER RIGHT _IDE VIEW ANS CONTROL ACCESS PANEL BOX 52" (1320_8) REQ'D CLEARANCES FOR SERVICING. in. (mm) (368.9) Duct panel ............................. Unit top ........................... Side opposite ducts ..................... Compressor access .....................
PAGE 4
0 7/8" (22.23) 1 1/4" (31.?51 ALTERNATE LV ENTRY ALTERNATE POWER ENTRY FLUE HOOD EVAPCOIL ACCESg RETURN AIR OPENING 18 1/16 (458,8) 14 71IS" (365.91 (E8,0) l _'2 1/lS" (52,6) 10 9/16 ° (268,9) t 3116 _ 129.GI (292. I ) (253,81 REQ'D CLEARANCES 1325.4) (36, 3) LEFTSIDE VIEW FOR SERVICING. in (ram) Duct panel ............................. Unit top ........................... Side opposite ducts ..................... Compressor access .....................
PAGE 5
+45 CON0 C0IL 1/2" (115B,71 ALTERNATE I 114" (31,7G3 POWER ENTRY / 43 11/16" 1110B.8) (23, B) FLUE AIR EVAP COIL HO00 ACCEBB \, \ OPENING \ /16" 1B 1/15 (458.8) 14 ?/16" (355.9) L__ 1, B 518" (142.9) t L2 r- 1116" (52,6) 10 BilE" (268.91 1B/16: (29.5) _lO "_ (253.5) REQ'D CLEARANCES FOR SERVICING. in. (ram) Duct panel ............................. Unit top ........................... Side opposite ducts ..................... Compressor access .....................
PAGE 6
RECEIVING AND INSTALLATION Insulate attd weatherproof roof openings with counter with applicable codes. I. STEP 1 -- CHECK EQUIPMENT all external ductwork, joints, attd flashing and inastic in accordance 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.
PAGE 7
PART NUMBER _A_ CPRFCURB001A01 FLAT CURB 8" [203] CPRFCURB002A01 11" [279] CPRFCURB003A01 14" [356] POWER AND GAS ENTRY 6 SUPPLY AIR OPENING 17! [44E] "0 RETURN AIR OPENING [SEE 5UPPLY DETAIL "A "j [279 AIR (406] 3G 3/4". [1010] THIS BRACKET MUST BE REMOVED BEFORE iNSTALLATION \ SEAL (_PPLIED WITH CURB) FOR UNITS RAILS) BASE SCREW MUST BE REMOVED BEFORE INBTALLATION WITH (FIELD SUPPLIED) =FING FELT (FIELD SUPPLIED) (FIELD SUPPLIED) (FIELD MATERIAL SUPPLIED) 33 7/8" [858] I
PAGE 8
2,0'z,, FLUSH WITH SLAB_ _F2. 0- ! S 4-1371 UNIT BEE DETAIL / // / , / //i / ON ROOF CURB A J , ! I b I I I L. ...... I J NOTICE TO RIGGERS Hook rigging shackles through holes in lifting brackets, as shown in Detail "A." Lifting brackets to be centered around the unit center of gravity. Use wood top skid when rigging, to prevent rigging straps from damaging unit. Remove 4 screws to slide wood support through rectangular hole in rail. _ r "1 I I I i I I I I t t L J ......U .
PAGE 9
B. Units With Optional Base Rail 2. Lifting holes are provided in optional base rail as shown in Fig. 9. Operating weights are shown in Table 1. Refer to rigging instructions on unit. Protective wood support must be unit is mounted to curb. Remove port above rigging holes in rails. rectangular hole in rail. See Fig. 3. Secure on the removed from unit before 4 screws that secure sup Slide support out through 9. Vl.
PAGE 10
Table I -- Physical Data -- Unit PYIP UNIT SIZE PYIP NOMINAL 018040 CAPACITY 11/2 (ton) OPERATING WEIGHT (Ib) Without Base Rail With Optional Base Rail COMPRESSORS Quantity 272 296 024040 024060 030060 030080 036060 036080 036100 036120 2 2 030040 2//z 2 Y, 2 i/, 3 3 3 3 303 327 315 339 320 344 332 356 332 356 336 360 336 360 348 372 348 372 430 430 4.30 430 .032 .032 032 .032 Rotary 1 Reciprocating 1 i RETURN-AIR Throwaway FILTERS 260 2.75 2.75 3.40 I .
PAGE 11
A. Configuring 1. Units for Downflow (Vertical) Discharge Open all electrical ice work. 2. Remove return Figure 12 shows and screws. disconnects duct duct 3. Locate lances in basepan the perimeter of the (Fig. 13). covet" before starting located on covet" removed. Save any serv duct duct panel. cover insulation that are placed over vertical duct opening covet" 4. Using a straight edge and sharp knife, cut and remove the insulation around the perimeter of the cover.
PAGE 12
Table 2 -- Maximum Gas Flow Capacity* NOMINAL IRON PIPE, SIZE (in.) INTERNAL DIAMETER LENGTH OF PIPE, FTI" (in.) 10 20 40 50 100 125 150 175 200 I/2 .622 175 120 30 97 82 73 60 66 70 61 80 57 90 53 50 44 40 -- -- 3/4 1 .824 1.049 360 680 250 465 200 375 170 320 15! 285 138 260 125 240 118 220 !10 205 103 195 93 175 84 160 77 145 72 !35 11/4 11/2 1.380 1.
PAGE 13
-- X. STEP10 -- when selecting, sizing, CONNECTIONS 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 connections must be in accordance with CSA standard C22.1 Canadian Electrical Code Part 1 and applicable local codes. Refer to unit wiring diagram. Fig. 16 -- Vertical Discharge Cover Removed Adhere to the following criteria installing the duct system: INSTALL ELECTRICAL and 1.
PAGE 14
Table 3 -- Electrical Data -- Unit PYIP UNIT SIZE PY1P V-PH-Hz VOLTAGE RANGE Min Max COMPRESSOR OUTDOOR-FAN MOTOR INDOOR-FAN MOTOR MOCP* AWG 60 C MIN WIRE SIZE POWER SUPPLY RLA LRA FLA FLA MCA MAX WIRE LENGTH (ft) 018 208/230-1-60 187 253 8.3 45.0 0.7 1.8 12.9 15 14 024 208/230-1-60 187 253 !2.4 6! .0 0.7 2.0 18.2 30 12 8O 208/230-1-60 187 253 14.4 82.0 1.4 2.3 2! .4 30 10 100 208/230-3-60 187 253 9.4 66.0 1.4 2.0 15.
PAGE 15
NOTE: Do not use any type of power control problems may result. THERMOSTAT (TYPICAL) 1,¢o, ,¢,¢91 _jI wl Z rr I Cl I m I Z r¢l __%K[ / ]""- "_ I _ '-- Standard POWER ]_ --._q SPLICE BOX ._TI SUPPLY Run the low voltage leads from the thermostat, inlet hole, and into unit low-voltage splice box. LOW-VOLTAGE POWER LEADS (SEE UNIT WIRING LABEL) Field Control-Voltage Wiring Field High-Voltage Wiring NOTE: Use blue wire for 3-phase units only. Fig.
PAGE 16
PRE-START-UP 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 loosened, 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.
PAGE 17
II. START UP HEATING SECTION AND MAKE ADJUSTMENTS C. Adjust Gas Input The gas input gas flow at the Measuring the ral gas units. determine the Measure Do not Make jumper sure any that safety devices burner when orifices stable operation may occur manifold are misaligned. are when operating properly the burner Follow the lighting tion label (located instructions on the heating inside the burner or blower start section. the NOTE: all gas A.
PAGE 18
Table 4 -- NUMBER OF ORIFICES UNIT PY1 P Rated Gas Inputs at Indicated Manifold GAS SUPPLY PRESSURE (in. wg) Pressures MANIFOLD PRESSURE (in, wg) NATURAL GAS PROPANE* Heating Input (Btuh)t 40,000 Orifice Drill Size Natural Propane 018040, 024040, 030040 1 4.0 13.0 4.0 !3.0 3.5 3.1 Orifice Drill Size 32 41 Heating Input (Btuh)t 40,000 024060, 030060, 036060, 042060 2 4.0 13.0 4.0 !3.0 3.5 3.3 32 58,000 47 54,000 030080, 036080, 042080, 048080, 060080 2 4.0 13.0 4.
PAGE 19
Table 5 -- Air Delivery (Cfm) at Indicated Temperature HEATING INPUT (Btuh) 40,000 TEMPERATURE 20 1389 25 1111 30 926 35 794 40 694 45 617 50 556 Rise and Rated Heating Input RISE °F 55 ........ 60 ....... 65 70 75 ....
PAGE 20
III. START UP COOLING ADJUSTMENTS SECTION AND MAKE A superheat compressor charging label is attached access door. The label includes ing Table" chart. and An accurate a "Required superheat, Suction-Tube thermocouple, monmter, a sling psychrometer, quired when using the superheat ating the unit themlome_ers measzmemenb A.
PAGE 21
VOLT OPERATION REVERSEREDAND GRN LEADSON TRANSFORMER. \ COOLINGFAN LOGIC BR I 0 6 ENERGIZED I I T T+30 6 DE'ENERGIZED I RE_D RED_BRN HEATING FAN i LOGIC BR ! I I I I o 45 T T÷3O W BR W BR ENERGIZED ENERGIZED I_'-Eh_R61ZEDDE-ENERGIZED I L J_ I SINGLE STAGE HEAT _ 5Iit;LE COOL THERMOSTAT ¢TYP) STAGE c 24V YEL BR I ) I )ISCONNEO )TRAN c COMPONENT L LEGEND _NATE ! --" I I rnl CAP I g 2 NOTES: 1 If any of the original wire furnished must be replaced, with type 90 C wire or its equiv
PAGE 22
MAXIMUM WIRE } ,_UP-I_,_Y---a_-,,--YEL S,ZE2 AWG -- U EQUIP 6ND 230 VOLT OPERATION A5 SHOWN. FOR 20B VOLT OPERATION REVERSE RED AND ORN LEADS ON TRANSFORMER. CO(_..INO FAN LOGIC BR I I 0 G ENERGIZED I .....
PAGE 23
,BLK BLK. YED BLK,_--- l OFM CAP2 L?_-_p BLK LBLU _---YELTL EQUIP GND BLI_ YEL COMP BLK, BLK J GH (036 & 042 ONLY) (G.E. IFM COOLING FAN LOGIC BR I I 0 G ENERGIZED I I T T+3O G DE-ENERGIZED IDM HEATING FAN LOGIC i i I I I 0 45 T T+3O W BR W BR ENERGIZED ENERGIZED I_E-ENERGIZEO OE-ENERGIZED BR BRN-- C l J2 _LU-------7 3L_ R5 --vIo _VIO-f_L GVR _, t1-11-.
PAGE 24
C. Evaporator Airflow and Airflow Adjustments Table the 5 shows Tables various temperature 9 and 10 show external static termine the airflow Table 11 for wet coil rise at various airflow both heating and cooling pressures. Refer to these for the pressure system drop. being 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.
PAGE 25
Table 7A- Superheat Charging INDOOR AIR -- CFM TEMP (F) OUTDOOR ENTERING AIR 600 54 Indoor Air -- Ewb (F) 64 66 27.7 28.5 65 SPH 17.3 56 !8.5 58 19.6 60 20.8 62 24.2 70 75 SPH SPH 13.8 10.2 !4.9 !1.4 16.1 12.5 !7.3 !3.7 20.7 17.! 24.1 20.6 80 85 SPH SPH 8.2 8.1 8.8 6.2 9.5 6.5 10.2 6.6 13.6 10.0 90 95 SPH SPH * * * * * * 5.0 * 8.1 6.
PAGE 26
Table 7D -- Superheat Charging PYIP036 INDOOR AIR -- CFM TEMP (F) OUTDOOR ENTERING AIR Table, 1200 Indoor Air -- Ewb (F) 64 66 68 54 56 58 60 62 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 75 SPH SPH 5.0 5.0 5.0 * 5.0 * 9.0 5.4 13.! 9.6 15.9 13.! 18.6 16.6 20.0 17.9 21.3 19.3 22.7 20.6 24.0 22.0 80 85 SPH SPH * * * * 6.0 * 10.3 7.5 14.5 12.5 15.9 13.9 17.3 !5.2 !8.6 16.5 20.0 17.9 90 95 SPH SPH * * * * * * 5.
PAGE 27
Table 7G -- Superheat Charging Table, PYIP048 54 56 SPH 19.0 !9.0 58 19.0 60 !9.0 62 21.7 70 75 SPH SPH 15.4 1! .9 !5.4 !1.9 15.4 11.9 !5.4 !1.9 18.! 14.6 20.8 17.2 80 85 SPH SPH 8.4 5.0 8.4 5.0 8.4 5.0 8.4 5.0 11.0 7.5 90 95 SPH SPH * * * * * * * * 100 105 SPH SPH * * * * * * * * 110 115 SPH SPH * * * * * * * * --- LEGEND Entering Wet Bulb Superheat at Compressor 68 27.7 70 27.9 72 28.2 74 28.4 76 28.8 22.5 18.9 24.1 20.6 25.1 22.3 28.1 24.0 27.1 25.
PAGE 28
Table 8 -- Required Suction-Tube SUPERHEAT TEMP (F) SUCTION 67.1 82.4 86.
PAGE 29
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 PYIP MOTOR SPEED Low 018 High Low 024, 030 Med High Low 036 Med High Low 042 High Low 048 High Low 060 Med High AIR DELIVERY 0.0 0.1 0.2 EXTERNAL STATIC PRESSURE 0.3 0.4 0.5 0.6 0.8 0.
PAGE 30
MAINTENANCE I. AIR FILTER To ensure continuing high performance, and to minimize the possibility of premature equipment failure, periodic maintenance 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.
PAGE 31
c. Remove blower assembly securing out. Be blower carefld to gas partition not to teal" fl'om unit. Remove screws and slide assembly insulation in blower FLUE COLLECTOR BOX compartment. d. Ensure proper and motor disassembly. e. Loosen relnove and 2. Lubricate slide motor Thoroughly clean from housing. motor c.
PAGE 32
6. Remove ignitor and sensor 7. Remove the mounting rack to the basepan. 8. Slide the and 27.) 9. To reinstall, ONkN_EOFTHU_PA_L burner reverse wires at the ignitor screw that attaches (See Fig. 24.) rack the out of the procedure unit. outlined the (See module. burner Fig. 24 above. BURNER ""_""_ACCESS PANEL Fig. 25 -- Burner Access Panel BLOWER HOUSING Fig. 27 -- Burner Rack Removed 2 SETSCREWS IX.
PAGE 33
X. CONDENSER FAN NOTE: eration control Refer to the heating and/or cooling sequence in this publication as an aid in determining operation. XII. REFRIGERANT 2. Inspect the fan blades for cracks or bends. 3. If fan needs to be removed, loosen the setscrew the fan off the motor shaft. 6.
PAGE 34
TROUBLESHOOTING Cooling SYMPTOM Compressor condenser not start.
PAGE 35
Heating SYMPTOM Burners will not ignite. CAUSE Water in gas line No power No 24-v circuit supply or loose Burned-out thermostat Broken connections No gas at main Check in Check Adjust burners Unit undersized Restricted Blower Limit switch incomplete too low for application airflow speed main combustion check. flame ignition as necessary. Replace and sense wire if necessary. electrode or replace positioning. at manifold.
PAGE 36
LED Troubleshooting SYMPTOM -- Error Code CAUSE Hardware failure. (LED OFF) Loss of power (IGC). REMEDY to control module Check 5 amp fuse on IGC, power to unit, 24-v circuit breaker, and transformer. Units without a 24-v circuit breaker have an internal overload in the 24-v transformer. tomatic Limit (LED switch fault. 2 flashes) High temperature open. Flame sense fault. (LED 3 flashes) 4 consecutive limit faults, (LED 4 flashes) The IGC sensed flame should not be present.
PAGE 37
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.