R410A Single Package Electric Cooling PAD32460

1 & 3 Phase
These instructions must be read and understood completely before attempting installation

INSTALLATION INSTRUCTIONS

Safety Labeling and Signal Words

DANGER, WARNING, CAUTION, and NOTE
The signal words DANGER, WARNING, CAUTION, and NOTE are used to identify levels of hazard seriousness. The signal word DANGER is only used on product labels to signify an immediate hazard. The signal words WARNING, CAUTION, and NOTE will be used on product labels and throughout this manual and other manual that may apply to the product. DANGER Immediate hazards which will result in severe personal injury or death. WARNING Hazards or unsafe practices which could result in severe personal injury or death. CAUTION Hazards or unsafe practices which may result in minor personal injury or product or property damage. NOTE Used to highlight suggestions which will result in enhanced installation, reliability, or operation.

Signal Words in Manuals

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

WARNING CAUTION

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

Signal Words on Product Labeling

Signal words are used in combination with colors and/or pictures or product labels.

TABLE OF CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . RECEIVING AND INSTALLATION . . . . . . . . . . . . . Step 1 Check Equipment . . . . . . . . . . . . . . . . . . . Step 2 Provide Unit Support . . . . . . . . . . . . . . . . . Step 3 Provide Clearances . . . . . . . . . . . . . . . . . . Step 4 Field Fabricate Ductwork . . . . . . . . . . . . . Step 5 Rig and Place Unit . . . . . . . . . . . . . . . . . . . Step 6 Provide for Condensate Disposal . . . . . . Step 7 Install Duct Connections . . . . . . . . . . . . . . Step 8 Install Electrical Connections . . . . . . . . . . PRESTARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 1 Check for Refrigerant Leaks . . . . . . . . . . Step 2 StartUp Cooling Section and Make Adj. Indoor Airflow Adjustments . . . . . . . . . . . . . . . . . . . Cooling Sequence of Operations . . . . . . . . . . . . . . Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . StartUp Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 2 2 3 3 3 7 7 9 11 11 11 11 12 13 17 24 27 29

WARNING

PERSONAL INJURY, AND/OR PROPERTY DAMAGE HAZARD Failure to carefully read and follow this warning could result in equipment malfunction, property damage, personal injury and/or death. Installation or repairs made by unqualified persons could result in equipment malfunction, property damage, personal injury and/or death. The information contained in this manual is intended for use by a qualified service technician familiar with safety procedures and equipped with proper tools and test instruments. Installation must conform with local building codes and with the national Electrical Code NFPA70 current edition or Canadian Electrical Code part 1 CSA C.22.1.

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SAFETY CONSIDERATIONS
Installation and servicing of this equipment can be hazardous due to mechanical and electrical components. Only trained and qualified personnel should install, repair, or service this equipment. Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations must be performed by trained service personnel. When working on this equipment, observe precautions in the literature, on tags, and on labels attached to or shipped with the unit and other safety precautions that may apply. Follow all safety codes. Installation must be in compliance with local and national building codes. Wear safety glasses, protective clothing, and work gloves. Have fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit. . Recognize safety information. This is the safetyalert 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 safetyalert 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.

FIG. 1 UNIT PAD3

INTRODUCTION
The PAD3 units are fully selfcontained and designed for outdoor installation. (See Fig. 1.) All unit sizes have discharge openings for both horizontal and downflow configurations, and are factory shipped with all downflow duct openings covered. The unit may be installed either on a rooftop or on a groundlevel cement slab. (See Fig. 6 for roof curb dimensions.)

ELECTRICAL SHOCK HAZARD

WARNING

RECEIVING AND INSTALLATION

Step 1 Check Equipment
Identify Unit The unit model number and serial number are stamped on the unit identification plate. Check this information against shipping papers. Inspect Shipment Inspect for shipping damage before removing packaging materials. If unit appears to be damaged or is torn loose from its anchorage, have it examined by transportation inspectors before removal. Forward claim papers directly to transportation company. Manufacturer is not responsible for any damage incurred in transit. Check all items against shipping list. Immediately notify the nearest equipment distributor if any item is missing. To prevent loss or damage, leave all parts in original packages until installation.

Failure to follow this warning could result in personal injury or death. Before installing or servicing system, always turn off main power to system and install lockout tag. There may be more than one disconnect switch. Turn off accessory heater power switch if applicable.

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 flowcontrol devices, including solenoid valves. 2. Federal regulations require that you do not vent refrigerant into the atmosphere. Recover during system repair or final unit disposal.

Step 2 Provide Unit Support

IMPORTANT: The unit must be secured to the curb by installing screws through the bottom of the curb flange and into the unit base rails. When installing large base units onto the common curb, the screws must be installed before allowing the full weight of the unit to rest on the curb. A minimum of six screws are required for large base units. Failure to secure unit properly could result in an unstable unit. See Warning near Rigging/Lifting information and accessory curb instructions for more details. For hurricane tie downs, contact distributor for details and PE (Professional Engineering) Certificate if required. Roof Curb Install accessory roof curb in accordance with instructions shipped with curb (See Fig. 6). Install insulation, cant strips, roofing, and flashing. Ductwork must be attached to curb. IMPORTANT: The gasketing of the unit to the roof curb is critical for a watertight seal. Install gasketing material supplied with the

!
CUT HAZARD

CAUTION

Failure to follow this caution may result in personal injury. When removing access panels or performing maintenance functions inside your unit, be aware of sharp sheet metal parts and screws. Although special care is taken to reduce sharp edges to a minimum, be extremely careful and wear appropriate clothing, safety glasses, and gloves when handling parts or reaching into the unit.

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roof curb. Improperly applied gasketing also can result in air leaks and poor unit performance. Curb should be level to within 1/4 in. (6.35 mm) (See Fig. 2). This is necessary for unit drain to function properly. Refer to accessory roof curb installation instructions for additional information as required. Accessory kits are available to aid in installing a new metal base rail unit on an old roof curb. Accessory kit number CPADCURB001A00, (small chassis) and accessory kit number CPADCURB002A00, (large chassis) includes roof curb adapter and gaskets for the perimeter seal and duct openings. No additional modifications to curb are required when using this kit. Slab Mount Place the unit on a solid, level pad that is at least 2 in. (51 mm) above grade. The slab should extend approximately 2 in. (51 mm) beyond the casing on all 4 sides of the unit. Do not secure the unit to the pad except when required by local codes.

2. Instruction in any special operation or precaution. 3. Condition of the load as it relates to operation of the lifting kit, such as balance, temperature, etc. Follow all applicable safety codes. Wear safety shoes and work gloves. INSPECTION Prior to initial use, and at monthly intervals, all rigging shackles, clevis pins, and straps should be visually inspected for any damage, evidence of wear, structural deformation, or cracks. Particular attention should be paid to excessive wear at hoist hooking points and load support areas. Materials showing any kind of wear in these areas must not be used and should be discarded. Fig. 2 Unit Leveling Tolerances

Step 3 Provide Clearances

The required minimum service clearances are shown in Fig. 4 and 5. Adequate ventilation and outdoor air must be provided. The outdoor fan draws air through the outdoor coil and discharges it through the top fan grille. Be sure that the fan discharge does not recirculate to the outdoor coil. Do not locate the unit in either a corner or under an overhead obstruction. The minimum clearance under a partial overhang (such as a normal house overhang) is 48 in. (1219 mm) above the unit top. The maximum horizontal extension of a partial overhang must not exceed 48 in. (1219 mm). IMPORTANT: Do not restrict outdoor airflow. An air restriction at either the outdoorair inlet or the fan discharge may be detrimental to compressor life. Do not place the unit where water, ice, or snow from an overhang or roof will damage or flood the unit. Do not install the unit on carpeting or other combustible materials. Slabmounted units should be at least 2 in. (51 mm) above the highest expected water and runoff levels. Do not use unit if it has been under water.
A C
MAXIMUM ALLOWABLE DIFFERENCE in. (mm) A-B 1/4 (6.35) B-C 1/4 (6.35) A-C 1/4 (6.35)

WARNING

UNIT FALLING HAZARD Failure to follow this warning could result in personal injury or death. Never stand beneath rigged units or lift over people.

WARNING

Step 4 FieldFabricate Ductwork

Secure all ducts to roof curb and building structure on vertical discharge units. Do not connect ductwork to unit. For horizontal applications, unit is provided with flanges on the horizontal openings. All ductwork should be secured to the flanges. Insulate and weatherproof all external ductwork, joints, and roof openings with counter flashing and mastic in accordance with applicable codes. Ducts passing through an unconditioned space must be insulated and covered with a vapor barrier. If a plenum return is used on a vertical unit, the return should be ducted through the roof deck to comply with applicable fire codes. See unit rating plate for any required clearances around ductwork. Cabinet returnair static shall not exceed .25 in. w.c.

PROPERTY DAMAGE HAZARD Failure to follow this warning could result in personal injury/death or property damage. When straps are taut, the clevis should be a minimum of 36 in. (914 mm) above the unit top cover. Fig. 3 Slab Mounting Detail

OPTIONAL RETURN AIR OPENING

OPTIONAL SUPPLY AIR OPENING

Step 5 Rig and Place Unit

Rigging and handling of this equipment can be hazardous for many reasons due to the installation location (roofs, elevated structures, etc.). Only trained, qualified crane operators and ground support staff should handle and install this equipment. When working with this equipment, observe precautions in the literature, on tags, stickers, and labels attached to the equipment, and any other safety precautions that might apply. Training for operators of the lifting equipment should include, but not be limited to, the following: 1. Application of the lifter to the load, and adjustment of the lifts to adapt to various sizes or kinds of loads.
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2 (50.8mm)

EVAP. COIL

COND. COIL

Fig. 4 PAD3 2 to 3 Ton Unit Dimensions

UNIT 24 30 36 Electrical Characteristics 208/230-1-60 208/230-1-60, 208/230-3-60 208/230-1-60, 208/230-3-60 460-3-60 Unit WT. LB KG 272 123.3 277 125.3 283 128.3 297 134.6 Unit HT. A 40 1018 42 1070 46 1172 46 1172 X 20-1/2 20-1/2 20-1/2 20-1/2 520.7 520.7 520.7 520.7 Center of Gravity Y Z 15-3/4 400.1 16-1/2 15-3/4 400.1 16-13/16 15-3/4 400.1 17 15-3/4 400.1 17 UNIT 24 30 36 Voltage 208/230 208/230 208/230 460 1 54.4 55.4 56.6 56.6 24.7 25.1 25.7 25.7 Corner Weight LB/KG 2 3 43.5 19.7 65.2 29.6 44.3 20.1 66.4 30.2 45.2 20.5 67.9 30.8 45.2 20.5 76.9 34.9 4 108.7 110.7 113.1 118.1 49.3 50.3 51.3 53.6

4
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419.1 427.0 431.8 431.8

Fig. 5 PAD3 3.5 to 5 Ton Unit Dimensions

Unit 42 48 60 Electrical Characteristics 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 WT. LB KG 369 167.5 383 173.8 375 170.2 389 176.6 397 180.2 411 186.5 Unit HT. A 45-3/4 1137 45-3/4 1137 46-3/4 1187 46-3/4 1187 46-3/4 1187 46-3/4 1187 X 20-1/4 20-1/4 20-1/4 20-1/4 20-1/4 20-1/4 514.4 514.4 514.4 514.4 514.4 514.4 Center of Gravity Y 17-1/2 444.5 17-1/2 444.5 17-1/2 444.5 17-1/2 444.5 17-1/2 444.5 17-1/2 444.5 Z 17-1/8 17-1/8 17-3/8 17-3/8 17-5/8 17-5/8 435 435 441 441 448 448 UNIT 42 48 60 Voltage 208/230 460 208/230 460 208/230 460 1 73.8 73.8 75.0 75.0 79.4 79.4 33.5 33.5 34.1 34.1 36.1 36.1 Corner Weight LB/KG 2 3 59.1 26.8 88.6 40.2 59.1 26.8 97.6 44.3 60.0 27.3 90.1 40.9 60.0 27.3 99.1 45.0 63.6 28.9 95.3 43.3 63.6 28.9 104.3 47.4 4 147.7 1527 150.1 155.1 158.9 163.9 67.1 69.3 68.1 70.4 72.1 74.4

5
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FIG. 6 ROOF CURB DIMENSIONS

B
HVAC unit base rails HVAC unit basepan
Dashed lines show cross support location for large basepan units.

Sealing Gasket Roofcurb

A
Anchor screw Flashing field supplied Wood nailer* Roofcurb* Insulation (field supplied)

Roofing material field supplied Cant strip field supplied

SMALL/COMMON CURB
*Provided with roofcurb

A09413

A09090

ROOF CURB DETAIL

B C G
SUPPLY AIR SMALL BASE UNIT

H F A E D
RETURN AIR

LARGE BASE UNIT

UNIT PLACEMENT ON COMMON CURB

A09094

LARGE CURB

A09415

SMALL OR LARGE BASE UNIT

UNIT SIZE Small or Large Large

CATALOG NUMBER CPRFCURB010A00 CPRFCURB011A00 CPRFCURB012A00 CPRFCURB013A00

A IN. (mm) 11 (279) 14 (356) 11 (279) 14 (356)

B (small base) IN. (mm)* 10 (254)

B (large base) IN. (mm)*

C IN. (mm)

D IN. (mm)

E IN. (mm) 32.4 (822)

F IN. (mm)

G IN. (mm) 30.6 (778)

H IN. (mm)

14 (356) 14 (356)

16 (406)

47.8 (1214) 43.9 (1116)

2.7 (69) 42.2 (1072)

46.1 (1170)

* Part Numbers CPRCURB010A00 and CPRCURB011A00 can be used on both small and large basepan units. The cross supports must be located based on whether the unit is a small basepan or a large basepan. NOTES:

1. Roof curb must be set up for unit being installed. 2. Seal strip must be applied, as required, to unit being installed. 3. Roof curb is made of 16gauge steel. 4. Attach ductwork to curb (flanges of duct rest on curb). 5. Insulated panels: 1in. (25.4 mm) thick fiberglass 1 lb. density.

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FIG. 7 RIGGING WEIGHTS

CAUTION - NOTICE TO RIGGERS PRUDENCE - AVIS AUX MANIPULATEUR

ACCESS PANELS MUST BE IN PLACE WHEN RIGGING. PANNEAUX D'ACCES DOIT TRE EN PLACE POUR MANIPULATION.

Use top skid as spreader bar. / Utiliser la palette du haut comme barre de rpartition
DUCTS

MINIMUM HEIGHT: 36" (914.4 mm) HAUTEUR MINIMUM

UNIT HEIGHT HAUTEUR D'UNIT

SEAL STRIP MUST BE IN PLACE BEFORE PLACING UNIT ON ROOF CURB

BANDE SCELLANT DOIT TRE EN PLACE AVANT DE PLACER L'UNIT SUR LA BASE DE TOIT

SEE DETAIL A VOIR DTAIL A

DETAIL A VOIR DTAIL A

50CY502286 2.0

Unit Rigging Weight

CORNER WEIGHTS (SMALL CABINET) 24 30 lb kg lb kg 279 127 284 129

36 lb 290 kg 132

Unit Rigging Weight

CORNER WEIGHTS (LARGE CABINET) 42 48 lb kg lb kg 378 171 384 174

60 lb 406 kg 184

*For 460 Volt units add 14 lb (6.35 kg) to the rigging weight. NOTE: See dimensional drawing for corner weights.

Rigging/Lifting of Unit (See Fig. 6.)

WARNING

UNIT FALLING HAZARD Failure to follow this warning could result in personal injury or death. Large base units must be secured to common curb before allowing full weight of unit to rest on curb. Install screws through curb into unit base rails while rigging crane is still supporting unit. Lifting holes are provided in base rails as shown in Fig. 4 and 5. 1. Leave top shipping skid on the unit for use as a spreader bar to prevent the rigging straps from damaging the unit. If the skid is not available, use a spreader bar of sufficient length to protect the unit from damage. 2. Attach shackles, clevis pins, and straps to the base rails of the unit. Be sure materials are rated to hold the weight of the unit. (See Fig. 7). 3. Attach a clevis of sufficient strength in the middle of the straps. Adjust the clevis location to ensure unit is lifted level with the ground. After the unit is placed on the roof curb or mounting pad, remove the top skid.

Condensate water can be drained directly onto the roof in rooftop installations (where permitted) or onto a gravel apron in ground level installations. Install a fieldsupplied 2in. (51 mm) condensate trap at end of condensate connection to ensure proper drainage. Make sure that the outlet of the trap is at least 1 in. (25 mm) lower than the drain pan condensate connection to prevent the pan from overflowing (See Fig. 8). When using a gravel apron, make sure it slopes away from the unit. Connect a drain tube using a minimum of 3/4 in. PVC or 3/4 in. copper pipe (all fieldsupplied) at the outlet end of the 2in. (51 mm) trap. Do not undersize the tube. Pitch the drain tube downward at a slope of at least 1in. (25 mm) for every 10 ft (3.1 m) of horizontal run. Be sure to check the drain tube for leaks. Prime trap at the beginning of the cooling season startup. FIG. 8 CONDENSATE TRAP
TRAP OUTLET 1-in. (25 mm) min.

2-in. (51 mm) min.

Step 6 Provide for Condensate Disposal

NOTE: When installing condensate drain connection be sure to comply with local codes and restrictions. Unit disposes of condensate water through a 3/4 in. NPT fitting which exits through the base on the evaporator coil access side. See Fig. 4 & 5 for location. 7

Step 7 Install Duct Connections

The design and installation of the duct system must be in accordance with the standards of the NFPA for installation of nonresidence type air conditioning and ventilating systems, NFPA 90A or residencetype, NFPA 90B and/or local codes and ordinances.
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Select and size ductwork, supplyair registers, and return air grilles according to ASHRAE (American Society of Heating, Refrigeration, and Air Conditioning Engineers) recommendations. The unit has duct flanges on the supply and returnair openings on the side of the unit. When designing and installing ductwork, consider the following: 1. All units should have fieldsupplied filters or accessory filter rack installed in the returnair side of the unit. Recommended sizes for filters are shown in Table 1. 2. Avoid abrupt duct size increases and reductions. Abrupt change in duct size adversely affects air performance. IMPORTANT: Use flexible connectors between ductwork and unit to prevent transmission of vibration. Use suitable gaskets to ensure weather tight and airtight seal. When electric heat is installed, use fireproof canvas (or similar heat resistant material) connector between ductwork and unit discharge connection. If flexible duct is used, insert a sheet metal sleeve inside duct. Heat resistant duct connector (or sheet metal sleeve) must extend 24in. (610 mm) from electric heater element. 3. Size ductwork for cooling air quantity (cfm). The minimum air quantity for proper electric heater operation is listed in Table 2. Heater limit switches may trip at air quantities below those recommended. 4. Seal, insulate, and weatherproof all external ductwork. Seal, insulate and cover with a vapor barrier all ductwork passing through conditioned spaces. Follow latest Sheet Metal and Air Conditioning Contractors National Association (SMACNA) and Air Conditioning Contractors Association (ACCA) minimum installation standards for residential heating and air conditioning systems. 5. Secure all ducts to building structure. Flash, weatherproof, and vibrationisolate duct openings in wall or roof according to good construction practices. Configuring Units for Downflow (Vertical) Discharge FIG. 9 SUPPLY AND RETURN DUCT OPENINGS

WARNING

ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death. Before performing service or maintenance operations on the system, turn off main power to unit and install lockout tag. 1. Open all electrical disconnects and install lockout tag before starting any service work. 2. Remove horizontal (metal) ductcovers to access vertical (downflow) discharge duct knockouts in unit basepan. (See Fig. 9.) 3. To remove downflow return and supply knockout covers, break front and right side connecting tabs with a screwdriver and hammer. Push cover down to break rear and left side tabs. NOTE: These panels are held in place with tabs similar to an electrical knockout. Reinstall horizontal duct covers (Fig. 9) shipped on unit from factory. Insure openings are air and watertight. NOTE: The design and installation of the duct system must be in accordance with the standards of the NFPA for installation of nonresidencetype air conditioning and ventilating systems, NFPA 90A or residencetype, NFPA 90B; and/or local codes and ordinances. Adhere to the following criteria when selecting, sizing, and installing the duct system: 1. Units are shipped for side shot installation. 2. Select and size ductwork, supplyair registers, and returnair grilles according to American Society of Heating, Refrigeration and Air Conditioning Engineers (ASHRAE) recommendations. 3. Use flexible transition between rigid ductwork and unit to prevent transmission of vibration. The transition may be screwed or bolted to duct flanges. Use suitable gaskets to ensure weathertight and airtight seal. 4. All units must have fieldsupplied filters or accessory filter rack installed in the returnair side of the unit. Recommended sizes for filters are shown in Table 1. 5. Size all ductwork for maximum required airflow (either heating or cooling) for unit being installed. Avoid abrupt duct size increases or decreases or performance may be affected. 6. Adequately insulate and weatherproof all ductwork located outdoors. Insulate ducts passing through unconditioned space, and use vapor barrier in accordance with latest issue of Sheet Metal and Air Conditioning Contractors National Association (SMACNA) and Air Conditioning Contractors of America (ACCA) minimum installation standards for heating and air conditioning systems. Secure all ducts to building structure. 7. Flash, weatherproof, and vibrationisolate all openings in building structure in accordance with local codes and good building practices.

Horizontal Duct Covers

Basepan Downflow (Vertical) Supply Knockout

Basepan Downflow (Vertical) Return Knockout

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Step 8 Install Electrical Connections

ELECTRICAL SHOCK HAZARD

WARNING

Failure to follow this warning could result in personal injury or death. The unit cabinet must have an uninterrupted, unbroken electrical ground to minimize the possibility of personal injury if an electrical fault should occur. This ground may consist of an electrical wire connected to the unit ground screw in the control compartment, or conduit approved for electrical ground when installed in accordance with NFPA 70 (NEC) (latest edition) (in Canada, Canadian Electrical Code CSA C22.1) and local electrical codes.

side of the contactor. 4. Connect field L1 to black wire on connection 11 of the compressor contactor. 5. Connect field wire L3 to yellow wire on connection 13 of the compressor contactor. 6. Connect field wire L2 to blue wire from compressor. FIG. 10 HIGH AND CONTROLVOLTAGE CONNECTIONS

HIGH VOLTAGE POWER LEADS (SEE UNIT WIRING LABEL) 3-PHASE SHOWN 1-PHASE USES TWO POWER EQUIP GR LEADS

POWER SUPPLY

UNIT COMPONENT DAMAGE HAZARD Failure to follow this caution may result in damage to the unit being installed. 1. Make all electrical connections in accordance with NEC NFPA 70 (latest edition) and local electrical codes governing such wiring. In Canada, all electrical connections must be in accordance with CSA standard C22.1 Canadian Electrical Code Part 1 and applicable local codes. Refer to unit wiring diagram. 2. Use only copper conductor for connections between fieldsupplied electrical disconnect switch and unit. DO NOT USE ALUMINUM WIRE. 3. Be sure that highvoltage power to unit is within operating voltage range indicated on unit rating plate. On 3phase units, ensure phases are balanced within 2 percent. Consult local power company for correction of improper voltage and/or phase imbalance. 4. Do not damage internal components when drilling through any panel to mount electrical hardware, conduit, etc. HighVoltage Connections The unit must have a separate electrical service with a fieldsupplied, waterproof disconnect switch mounted at, or within sight from the unit. Refer to the unit rating plate, NEC and local codes for maximum fuse/circuit breaker size and minimum circuit amps (ampacity) for wire sizing. The fieldsupplied disconnect may be mounted on the unit over the highvoltage inlet hole when the standard power and lowvoltage entry points are used. See Fig. 4 and 5 for acceptable location. See unit wiring label (Fig. 1217) and Fig. 10 for reference when making high voltage connections. Proceed as follows to complete the highvoltage connections to the unit. Single phase units: 1. Run the highvoltage (L1, L2) and ground lead into the control box. 2. Connect ground lead to chassis ground connection. 3. Locate the black and yellow wires connected to the line side of the contactor. 4. Connect field L1 to black wire on connection 11 of the compressor contactor. 5. Connect field wire L2 to yellow wire on connection 23 of the compressor contactor. Threephase units: 1. Run the highvoltage (L1, L2, L3) and ground lead into the control box. 2. Connect ground lead to chassis ground connection. 3. Locate the black and yellow wires connected to the line 9

CAUTION

FIELD-SUPPLIED FUSED DISCONNECT

CONTROL BOX WHT(W1) VIO (W2) YEL(Y) GRN(G) LOW-VOLTAGE POWER LEADS (SEE UNIT WIRING LABEL) RED(R) BRN(C) BLU (DH) DH GRA (Y2)
3-Phase Only

W1 W2 Y G R C THERMOSTAT (TYPICAL)

SPLICE BOX

Special Procedures for 208V Operation

WARNING

ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death. Before installing or servicing system, always turn off main power to system. Tag the disconnect switch with a suitable warning label. With disconnect switch open, move black wire from transformer (3/16 in., 4.8mm) terminal marked 230 to terminal marked 200. This retaps transformer to primary voltage of 208 vac. Control Voltage Connections NOTE: Do not use any type of powerstealing thermostat. Unit control problems may result. Use no. 18 American Wire Gage (AWG) colorcoded, insulated (35C minimum) wires to make the control voltage connections between the thermostat and the unit. If the thermostat is located more than 100 ft (30.5 m) from the unit (as measured along the control voltage wires), use no. 16 AWG colorcoded, insulated (35 C minimum) wires. Standard Connections Locate the seven (eight for 3phase) low voltage thermostat leads in 24 volt splice box. A gray wire is standard on 3phase units for connection to an economizer. See Fig 10 for connection diagram. Run the lowvoltage leads from the thermostat, through the control wiring inlet hole grommet (Fig. 4 and 5), and into the lowvoltage splice box. Provide a drip loop before running wires through panel. Secure and strain relief all wires so that they do not interfere with operation of unit. If an accessory electric heater is installed, low voltage leads from heater must be connected to factory supplied control leads from Indoor Fan Board P4 connector.
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NOTE: If the unit 24V wires do not have a matching receptacle, cut the 24V wires from the electric heater plug, strip the ends, and wire nut together to match the schematic connections. If the electric heater 24V wires do not have a matching plug, cut the 24V wires from the unit receptacle, strip the ends, and wire nut together to match the schematic connections. Factory wires are provided for electric heat staging W1 and W2 (W2 and W3 on IFB). If room thermostat has only one stage of supplemental heat, connect white and violet wires shown in Fig. 10 to second stage heat field wire. Some electric heaters have four control wires (plus common wire). Consult unit wiring diagram and electric heater wiring diagram for additional details.

Transformer Protection The transformer is of the energylimiting type, however a direct short will likely blow a secondary fuse. If an overload or short is present, correct overload condition and check for blower fuse on Indoor Fan Board. Replace fuse as required with correct size and rating. Accessory Electric Heaters Installation Electric heaters may be installed with the PAD3 units per instructions supplied with electric heater package. See unit rating plate for factoryapproved electric heater kits.

Table 1 Physical Data Unit PAD3

UNIT SIZE NOMINAL CAPACITY (ton) SHIPPING WEIGHT* lb. SHIPPING WEIGHT* (kg) COMPRESSORS Quantity REFRIGERANT (R-410A) Quantity lb Quantity (kg) REFRIGERANT METERING DEVICE OUTDOOR COIL Rows...Fins/in. Face Area (sq ft) OUTDOOR FAN Nominal Cfm Diameter in. Diameter (mm) Motor Hp (Rpm) INDOOR COIL Rows...Fins/in. Face Area (sq ft)
INDOOR BLOWER Nominal Cooling Airflow (Cfm) Size in. Size (mm.) Motor HP (RPM) HIGH-PRESSURE SWITCH (psig) Cut-out Reset (Auto) LOSS-OF-CHARGE / LOW-PRESSURE SWITCH (Liquid Line) (psig) cut-out Reset (auto) RETURN-AIR FILTERS} Throwaway Size in. Throwaway Size (mm)

24 2 279 127

30 2-1/2 284 129

36 3 290 132 Scroll 1

42 3-1/2 378 171

48 4 384 174

60 5 406 184

4.8 2.2

6.2 2.8

6.4 2.9 TXV

6.1 2.7

6.4 2.9

10.0 4.5

1...21 10.2 2800 24 610 1/5 (810) 2...17 3.7

800 10x10 254x254 1/2 (1050)

1...21 11.9 3000 24 610 1/5 (810) 3...17 3.7

1000 10x10 254x254 1/2 (1050)

1...21 15.4 3200 24 610 1/5 (810) 3...17 3.7

1...21 13.6 3600 26 660 1/5 (810) 3...17 4.7

1...21 15.5 4000 26 660 1/5 (810) 3...17 4.7

1600 11x10 279.4x254 1.0 (1075)

2...21 15.5 3200 26 660 1/5 (810) 3...17 5.7

1750 11x10 279.4x254 1.0 (1040)

1200 1400 11x10 11x10 279.4x254 279.4x254 3/4 (1000) 3/4 (1075) 650 +/- 15 420 +/- 25 20 +/- 5 45 +/- 10

20x20x1 508x508x25

20x24x1 508x610x25

24x30x1 610x762x25

24x36x1 610x914x25

*Required filter sizes shown are based on the larger of the ARI (Air conditioning and Refrigeration Institute) rated cooling airflow or the heating airflow velocity of 300 ft/minute for throwaway type or 450 ft/minute for high-capacity type. Air filter pressure drop for non-standard filters must not exceed 0.08 IN. W.C. { If using accessory filter rack refer to the filter rack installation instructions for correct filter size and quantity. } For 460 volt units, add 14 lb (6.4 kg) to the weight.

Table 2 Minimum Airflow for Reliable Electric Heater Operation (CFM)

SIZE Cfm 24 800 30 1000 36 1200 42 1400 48 1600 60 1750

513 01 3103 02

10

PRESTARTUP

WARNING

FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury, death or property damage. 1. Follow recognized safety practices and wear protective goggles when checking or servicing refrigerant system. 2. Relieve and recover all refrigerant from system before touching or disturbing compressor plug if refrigerant leak is suspected around compressor terminals. 3. Do not remove compressor plug until all electrical sources are disconnected and tagged. 4. Never attempt to repair soldered connection while refrigerant system is under pressure. 5. Do not use torch to remove any component. System contains oil and refrigerant under pressure. To remove a component, wear protective goggles and proceed as follows: a. Shut off electrical power to unit and install lockout tag. b. Relieve and reclaim all refrigerant from system using both high and lowpressure ports. c. Cut component connecting tubing with tubing cutter and remove component from unit. d. Carefully unsweat remaining tubing stubs when necessary. Oil can ignite when exposed to torch flame. Proceed as follows to inspect and prepare the unit for initial startup: 1. Remove all access panels. 2. Read and follow instructions on all DANGER, WARNING, CAUTION, and INFORMATION labels attached to, or shipped with unit. 3. Make the following inspections: a. Inspect for shipping and handling damages, such as broken lines, loose parts, disconnected wires, etc. b. Inspect for oil at all refrigerant tubing connections and on unit base. Detecting oil generally indicates a refrigerant leak. Leak test all refrigerant tubing connections using electronic leak detector, or liquidsoap solution. If a refrigerant leak is detected, see following Check for Refrigerant Leaks section. c. Inspect all field and factorywiring connections. Be sure that connections are completed and tight. d. Ensure wires do not touch refrigerant tubing or sharp sheet metal edges. e. Inspect coil fins. If damaged during shipping and handling, carefully straighten fins with a fin comb. 4. Verify the following conditions: a. Make sure that condensate drain pan and trap are filled with water to ensure proper drainage. b. Make sure that all tools and miscellaneous loose parts have been removed.

1. Locate leak and make sure that refrigerant system pressure has been relieved and reclaimed from both high and lowpressure 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 R410A refrigerant vapor to system and leaktest unit. 4. Recover refrigerant from system and evacuate to 500 microns if no additional leaks are found. 5. Charge unit with R410A refrigerant, using an accurate scale. Refer to unit rating plate for required charge.

Step 2 StartUp Cooling Section And Make Adjustments

Complete the required procedures given in the PreStartUp section before starting the unit. Do not jumper any safety devices when operating the unit. Do not operate the unit when the outdoor temperature is below 40F (4C) (unless accessory lowambient kit is installed). Do not rapid cycle the compressor. Allow 5 minutes between on cycles to prevent compressor damage. CHECKING COOLING CONTROL OPERATION Start and check the unit for proper cooling control operation as follows: 1. Place room thermostat SYSTEM switch in OFF position. 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 temperature. Observe that compressor, condenser fan, and evaporator blower motors start. Observe that compressor and outdoor fan shut down when control setting is satisfied and that indoor blower shuts down after 90 sec. fan time delay expires. IMPORTANT: Threephase, scroll compressors are direction oriented. Unit must be checked to ensure proper compressor 3phase power lead orientation. If not corrected within 5 minutes, the internal protector will shut off the compressor. The 3phase power leads to the unit must be reversed to correct rotation. When turning backwards, the difference between compressor suction and discharge pressures may be minimal. CHECKING AND ADJUSTING REFRIGERANT CHARGE The refrigerant system is fully charged with R410A refrigerant and is tested and factory sealed. NOTE: Adjustment of the refrigerant charge is not required unless the unit is suspected of not having the proper R410A charge. A subcooling charging chart is attached to the inside of the compressor access panel. The chart includes the required liquid line temperature at given discharge line pressures and outdoor ambient temperatures. An accurate thermocouple or thermistortype thermometer, and a gauge manifold are required when using the subcooling charging method for evaluating the unit charge. Do not use mercury or small dialtype thermometers because they are not adequate for this type of measurement. NOTE: Allow system to operate for a minimum of 15 minutes before checking or adjusting refrigerant charge. IMPORTANT: When evaluating the refrigerant charge, an indicated adjustment to the specified factory charge must always be very minimal. If a substantial adjustment is indicated, an abnormal condition exists somewhere in the cooling system, such as insufficient airflow across either coil or both coils.
513 01 3103 02

STARTUP
Step 1 Check for Refrigerant Leaks
Proceed as follows to locate and repair a refrigerant leak and to charge the unit:

11

Proceed as follows: 1. Remove caps from low and highpressure service fittings. 2. Using hoses with valve core depressors, attach low and highpressure gauge hoses to low and highpressure service fittings, respectively. 3. Start unit and let run until system pressures stabilize. 4. Measure and record the following: a. Outdoor ambientair temperature (5F [5C] db). b. Liquid line temperature (5F [5C]) at TXV. c. Discharge (highside) pressure (psig). d. Suction (lowside) pressure (psig) (for reference only). 5. Using Cooling Charging Charts compare outdoorair temperature (5F [5C] db) with the discharge line pressure (psig) to determine desired system operating liquid line temperature (See Fig. 18). 6. Compare actual liquid line temperature with desired liquid line temperature. Using a tolerance of +25F (+1.15C), add refrigerant if actual temperature is more than 25F (1.15C) higher than proper liquid line temperature, or remove refrigerant if actual temperature is more than 25F (1.15C) lower than required liquid line temperature. NOTE: If the problem causing the inaccurate readings is a refrigerant leak, refer to Check for Refrigerant Leaks section. AIRFLOW ADJUSTMENTS

shipped loose with vinyl caps and are located in the control box, near the interface fan board (IFB) (Fig. 11). Single Cooling Fan Speed Set-up (Dehumidification feature not used) To change cooling speed: 1. Remove the vinyl cap off of the desired speed tap wire (Refer to Table 3 for color coding). Add the wet coil pressure drop in Table 5 to the system static to determine the correct cooling airflow speed in Table 4 that will deliver the nominal cooling airflow as listed in Table 1 for each size. 2. Remove the current speed tap wire from the LOW terminal on the interface fan board (IFB) (Fig. 11) and place vinyl cap over the connector on the wire. 3. Connect the desired speed tap wire to the LOW terminal on the interface fan board (IFB). NOTE: If accessory electric heat is installed, and the electric heat fan speed is chosen to be the same as the normal cooling fan speed, the dry airflow must meet or exceed the minimum airflow speed specified in Table 2 for the specific size unit. Two Cooling Fan Speeds Set-up (Dehumidification feature used) IMPORTANT: Dehumidification control must open control circuit on humidity rise above set point. Use of the dehumidification cooling fan speed requires use of either a 24 VAC dehumidistat or a thermostat which includes control of a 24 VAC dehumidistat connection. In either case, the dehumidification control must open the control circuit on humidity rise above the dehumidification set point. Dehumidification controls are available with the reverse logic; these must not be used. 1. Using Fig. 11, move the two pin DEHUM jumper from the STD position to the DEHUM position. 2. Remove fan speed tap wire from the LOW terminal on the interface fan board (IFB) (Fig. 11). 3. Determine correct normal cooling fan speed for unit and application. Add the wet coil pressure drop in Table 5 to the system static to determine the correct cooling airflow speed in Table 4 that will deliver the nominal cooling airflow as listed in Table 1 for each size. NOTE: If accessory electric heat is installed, the dry airflow must meet or exceed the minimum airflow speed specified in Table 2 for the specific size unit. The electric heat fan speed will be the same as the normal cooling fan speed. 4. Remove the vinyl cap off of the desired speed tap wire (Refer to Table 3 for color coding) for the normal cooling fan speed and place desired speed tap wire on HIGH on the interface board. 5. Refer to airflow tables (Table 4) to determine allowable speeds for the dehumidification cooling fan speed. In Table 4, speeds that are not allowed for dehumidification cooling are shaded. 6. Remove the vinyl cap off of the desired speed tap wire (Refer to Table 3 for color coding) for the dehumidification cooling fan speed and place desired speed tap wire on the LOW connection on the interface board (IFB). Verify that static pressure is in the acceptable range for the speed tap to be used for dehumidification cooling. 7. Use any spare vinyl plugs to cap any unused speed tap wires.

CAUTION

UNIT OPERATION HAZARD Failure to follow this caution may result in unit damage. For cooling operation, the recommended airflow is 350 to 450 cfm for each 12,000 Btuh of rated cooling capacity. For heating operation, the airflow must produce a temperature rise that falls within the range stamped on the unit rating plate. NOTE: Be sure that all supplyand returnair grilles are open, free from obstructions, and adjusted properly.

WARNING

ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death. Disconnect electrical power to the unit and install lockout tag before changing blower speed. This unit is factory-set up for use with a single cooling fan speed. In addition, this unit has the field-selectable capability to run two different cooling fan speeds: The rated cooling fan speed (350~400 CFM/Ton) and an enhanced dehumidification fan speed (As low as 320 CFM/Ton) for use with either a dehumidistat or a thermostat that supports dehumidification. The cooling speed is marked LOW on the interface fan board (IFB) (Fig. 11) . The factory-shipped settings are noted in Table 4. There are 4 additional speed tap wires available for use in either electric heating or cooling (For color coding on the indoor fan motor leads, see Table 3). The additional 4 speed tap wires are

513 01 3103 02

12

Fig. 11 Interface Fan Board (IFB)

QC5
STD DEHUM

Table 3 Color Coding for Indoor Fan Motor Leads

Black = High Speed Orange = MedHigh Speed Red = Med Speed Pink = MedLow Speed Blue = Low Speed
CDM/C

HIGH

LOW
QC4

COM
QC3

KZ

KL

DCR

QCR

07

09 0L0

08

ALO

R13 C8

R11

Q1

C D2 QC1

WARNING

Q3

24VAC/R

AL2

ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death. Disconnect electrical power to the unit and install lockout tag before changing blower speed. Continuous Fan Operation When the DEHUM feature is not used, the continuous fan speed will be the same as cooling fan speed. When the DEHUM feature is used, the continuous fan will operate on IFB LOW speed when the DH control lead is not energized, or IFB HIGH speed when the DH lead is energized. (See Figure 11). COOLING SEQUENCE OF OPERATION With the room thermostat SYSTEM switch in the COOL position 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 thermostat 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 time delay relay (TDR) (through unit wire G) across the 24V 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. A set of normally open contacts on the interface fan board (IFB) are closed which energizes a circuit to the indoor fan motor (IFB). 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 a point that is slightly below the cooling control setting of the room thermostat. At this point, the thermostat breaks the circuit between thermostat terminal R to terminals Y and G. These open circuits deenergize contactor coil C and IFB. The condenser and compressor motors stop. After a 90second delay, the blower motor stops. The unit is in a standby condition, waiting for the next call for cooling from the room thermostat.

C9

C4

G1

RL 01

G2 QIL Z2 06 04 A7 R9 AB A15 C0 Z1 U1 C3 D5 D3 C7 JWZ R4 F1

RL4

R2

JW5 QCB

R3 R5 R6

P2

JW3

P4

W2 Y

W3 W3 W2 W2 C JW4

SSTZ-8

P1

W3 W2 Y2 G Y1 DH Y

Single Speed Cooling With Higher Electric Heat Speed This unit can also be configured to operate with single speed cooling and a higher speed for an accessory electric heater. 1. Using Fig. 11, move the two pin DEHUM jumper from the STD position to the DEHUM position. 2. See Table 2 for minimum airflow for electric heat operation. Add electric heater and filter pressure drop to duct system static pressure to determine total external static pressure. 3. Select speed tap from Table 4 that will achieve required airflow from Table 2. 4. Remove the vinyl cap off of the desired speed tap wire (Refer to Table 3 for color coding). 5. Connect the desired speed tap wire to the HIGH terminal on the interface fan board (IFB).

CAUTION

UNIT OPERATION HAZARD Failure to follow this caution may result in unit component damage or improper operation. To use this mode, a speed connection must be made on the HIGH terminal that meets or exceeds the minimum airflow found in Table 2.

13

3AMP

P3 SDL

513 01 3103 02

Table 4 Dry Coil Air Delivery CFM* Horizontal Discharge Unit PAD32460
UNIT PAD3 MOTOR SPEED
Low MedLow Medium1 MedHigh High Low MedLow Medium MedHigh1 High Low MedLow Medium1 MedHigh High Low MedLow Medium MedHigh1 High Low MedLow Medium1 MedHigh High MedLow Medium1 MedHigh High

WIRE COLOR
Blue Pink Red Orange Black Blue Pink Red Orange Black Blue Pink Red Orange Black Blue Pink Red Orange Black Blue Pink Red Orange Black Pink Red Orange Black CFM CFM CFM CFM CFM CFM CFM CFM CFM CFM CFM CFM CFM CFM CFM CFM CFM CFM CFM CFM CFM CFM CFM CFM CFM CFM CFM CFM CFM

0.1
754 851 941 1009 1241 741 973 1088 1140 1202 1234 1290 1354 1606 1630 1295 1345 1505 1545 1705 1402 1457 1736 2149 2344 1678 1962 2131 2461

0.2
650 777 851 917 1167 638 887 1023 1064 1140 1168 1223 1290 1546 1580 1234 1282 1452 1492 1643 1351 1404 1695 2111 2306 1635 1915 2088 2409

EXTERNAL STATIC PRESSURE (IN. W.C.) 0.3 0.4 0.5 0.6 0.7
538 675 774 840 1111 547 823 954 996 1082 1093 1154 1226 1489 1517 1182 1235 1413 1449 1607 1311 1367 1642 2062 2259 1602 1880 2065 2339 429 591 684 759 1036 415 733 881 915 1015 1021 1090 1158 1430 1463 1126 1194 1358 1411 1568 1263 1318 1601 2026 2203 1558 1843 2013 2286 475 576 667 969 665 800 840 961 961 1027 1102 1371 1407 1075 1140 1323 1362 1518 1224 1284 1553 1980 2141 1513 1794 1982 2192 479 577 881 538 723 758 881 894 977 1046 1316 1339 1016 1095 1282 1313 1483 1172 1233 1512 1945 2070 1474 1753 1941 2140 447 818 451 658 687 810 825 894 981 1258 1277 955 1027 1234 1278 1448 1136 1197 1465 1905 1991 1438 1711 1888 2062

0.8
731 563 564 732 759 828 918 1208 1210 898 974 1169 1231 1404 1080 1144 1427 1864 1902 1404 1675 1860 1968

0.9
640 461 480 631 687 762 843 1140 1131 857 921 1130 1188 1360 1041 1104 1381 1793 1803 1349 1628 1785 1874

24

30

36

42

48

60

* Air delivery values are without air filter and are for dry coil (See Wet Coil Pressure Drop table). 1 Factory-shipped cooling speed Note: Deduct field-supplied air filter pressure drop and wet coil pressure drop to obtain external static pressure available for ducting. Shaded areas indicate airflows that are not recommended for dehumidification control.

Table 4 Dry Coil Air Delivery CFM* Downflow Discharge Unit PAD32430
UNIT PAD3 MOTOR SPEED Low WIRE COLOR Blue CFM WATTS BHP CFM WATTS BHP CFM WATTS BHP CFM WATTS BHP CFM WATTS BHP CFM WATTS BHP CFM WATTS BHP CFM WATTS BHP CFM WATTS BHP CFM WATTS BHP 0.10 809 85 0.09 875 101 0.11 939 119 0.13 1026 146 0.16 1264 250 0.27 756 84 0.09 1002 144 0.15 1110 188 0.20 1160 213 0.23 1240 254 0.27 0.20 664 82 0.09 787 111 0.12 860 124 0.13 949 151 0.16 1202 261 0.28 669 90 0.10 928 155 0.17 1025 195 0.21 1091 225 0.24 1173 266 0.29 0.30 554 87 0.09 693 115 0.12 748 134 0.14 873 161 0.17 1134 274 0.29 548 96 0.10 842 161 0.17 967 205 0.22 1004 232 0.25 1110 274 0.29 EXTERNAL STATIC PRESSURE (IN. W.C.) 0.40 0.50 0.60 0.70 447 95 0.10 612 498 392 125 131 142 0.13 0.14 0.15 663 591 472 399 138 147 155 164 0.15 0.16 0.17 0.18 786 694 604 516 167 177 183 195 0.18 0.19 0.20 0.21 1070 1002 931 870 279 290 296 308 0.30 0.31 0.32 0.33 457 106 0.11 733 660 560 450 173 185 192 203 0.19 0.20 0.21 0.22 879 814 706 611 211 223 236 243 0.23 0.24 0.25 0.26 945 866 804 699 243 249 261 273 0.26 0.27 0.28 0.29 1031 966 902 821 284 295 302 315 0.30 0.32 0.32 0.34 0.80 806 319 0.34 509 255 0.27 615 285 0.31 726 327 0.35 0.90 699 328 0.35 496 291 0.31 626 331 0.35 1.0 610 332 0.36

MedLow

Pink

24

Medium

Red

MedHigh

Orange

High

Black

Low

Blue

MedLow

Pink

30

Medium

Red

MedHigh1

Orange

High

Black

513 01 3103 02

14

Table 4 Dry Coil Air Delivery CFM* Downflow Discharge Unit PAD33648
UNIT PAD3 MOTOR SPEED Low WIRE COLOR Blue CFM WATTS BHP CFM WATTS BHP CFM WATTS BHP CFM WATTS BHP CFM WATTS BHP CFM WATTS BHP CFM WATTS BHP CFM WATTS BHP CFM WATTS BHP CFM WATTS BHP CFM WATTS BHP CFM WATTS BHP CFM WATTS BHP CFM WATTS BHP CFM WATTS BHP 0.10 1277 285 0.31 1312 314 0.34 1381 358 0.38 1631 567 0.61 1681 618 0.66 1365 177 0.19 1425 197 0.21 1582 267 0.29 1623 285 0.31 1775 371 0.40 1503 225 0.24 1556 244 0.26 1861 400 0.43 2319 758 0.81 2532 1014 1.09 0.20 1215 289 0.31 1260 324 0.35 1326 365 0.39 1579 576 0.62 1633 626 0.67 1324 189 0.20 1384 210 0.23 1549 280 0.30 1586 299 0.32 1736 386 0.41 1457 233 0.25 1508 261 0.28 1822 417 0.45 2291 769 0.82 2487 1022 1.10 0.30 1147 299 0.32 1203 329 0.35 1269 375 0.40 1525 581 0.62 1575 636 0.68 1284 201 0.22 1339 223 0.24 1509 294 0.32 1553 312 0.33 1696 401 0.43 1423 246 0.26 1461 268 0.29 1786 426 0.46 2255 787 0.84 2444 1015 1.09 EXTERNAL STATIC PRESSURE (IN. W.C.) 0.40 0.50 0.60 0.70 1094 1045 992 932 305 314 319 328 0.33 0.34 0.34 0.35 1153 1095 1050 995 340 344 355 361 0.36 0.37 0.38 0.39 1212 1161 1121 1070 383 391 395 406 0.41 0.42 0.42 0.44 1477 1423 1372 1336 592 598 609 617 0.63 0.64 0.65 0.66 1526 1478 1415 1366 644 652 653 649 0.69 0.70 0.70 0.70 1233 1181 1127 1084 210 222 236 248 0.23 0.24 0.25 0.27 1301 1254 1199 1151 235 248 257 271 0.25 0.27 0.28 0.29 1469 1433 1392 1346 308 322 336 344 0.33 0.35 0.36 0.37 1511 1470 1433 1393 324 335 349 363 0.35 0.36 0.37 0.39 1660 1622 1588 1557 410 424 439 453 0.44 0.45 0.47 0.49 1374 1330 1287 1241 254 269 282 292 0.27 0.29 0.30 0.31 1432 1388 1346 1302 281 290 305 319 0.30 0.31 0.33 0.34 1758 1716 1688 1660 441 452 467 482 0.47 0.48 0.50 0.52 2230 2193 2166 2118 799 808 823 822 0.86 0.87 0.88 0.88 2391 2330 2259 2179 994 965 935 898 1.07 1.03 1.00 0.96 0.80 874 335 0.36 943 372 0.40 1019 418 0.45 1284 619 0.66 1312 642 0.69 1039 261 0.28 1104 284 0.30 1300 359 0.38 1350 378 0.41 1516 468 0.50 1199 307 0.33 1256 330 0.35 1619 492 0.53 2057 805 0.86 2111 858 0.92 0.90 826 347 0.37 889 382 0.41 974 424 0.45 1233 613 0.66 1249 627 0.67 984 269 0.29 1065 296 0.32 1249 374 0.40 1309 393 0.42 1472 483 0.52 1153 314 0.34 1221 345 0.37 1583 507 0.54 1992 780 0.84 2033 823 0.88 1.0 757 352 0.38 829 387 0.42 912 434 0.47 1166 598 0.64 1159 602 0.65 939 281 0.30 1015 305 0.33 1213 387 0.42 1261 407 0.44 1426 497 0.53 1111 329 0.35 1168 353 0.38 1539 519 0.56 1887 737 0.79 1949 786 0.84

MedLow

Pink

36

Medium1

Red

MedHigh

Orange

High

Black

Low

Blue

MedLow

Pink

42

Medium

Red

MedHigh1

Orange

High

Black

Low

Blue

MedLow

Pink

48

Medium1

Red

MedHigh

Orange

High

Black

15

513 01 3103 02

Table 4 Dry Coil Air Delivery CFM* Downflow Discharge Unit PAD360
EXTERNAL STATIC PRESSURE (IN. W.C.) 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 CFM 1479 1436 1387 1346 1298 1253 1206 1160 WATTS 224 239 247 262 270 284 300 307 Low Blue BHP 0.24 0.26 0.26 0.28 0.29 0.30 0.32 0.33 CFM 1841 1796 1761 1724 1690 1651 1616 1578 WATTS 425 434 453 460 476 485 501 508 MedLow Pink BHP 0.46 0.47 0.49 0.49 0.51 0.52 0.54 0.54 CFM 1944 1913 1872 1838 1801 1771 1731 1698 WATTS 486 501 511 529 537 554 565 578 60 Medium1 Red BHP 0.52 0.54 0.55 0.57 0.58 0.59 0.61 0.62 CFM 2178 2148 2105 2073 2036 2002 1967 1919 WATTS 674 691 703 717 733 743 758 754 MedHigh Orange BHP 0.72 0.74 0.75 0.77 0.79 0.80 0.81 0.81 CFM 2480 2432 2375 2322 2236 2161 2085 2006 WATTS 1029 1012 995 975 941 908 869 836 High Black BHP 1.10 1.09 1.07 1.05 1.01 0.97 0.93 0.90 *Air delivery values are without air filter and are for dry coil (See Wet Coil Pressure Drop table). 1 Factoryshipped cooling speed NOTE: Deduct fieldsupplied air filter pressure drop and wet coil pressure drop to obtain external static pressure available for ducting. Shaded areas indicate speed/static combinations that are not permitted. UNIT PAD3 MOTOR SPEED WIRE COLOR 0.90 1114 319 0.34 1527 525 0.56 1655 595 0.64 1845 734 0.79 1917 796 0.85 1.0 1061 330 0.35 1478 542 0.58 1613 603 0.65 1751 701 0.75 1808 751 0.81

Table 5 PAD3 Wet Coil Pressure Drop (in. W.C.)

1100 0.072 0.090 0.050 STANDARD CFM (S.C.F.M) 1200 1300 1400 0.081 0.105 0.100 0.110 0.140 0.060 0.065 0.075 0.041 0.063 0.085 1500 0.080 0.100 0.060

UNIT SIZE 24 30 36 42 48 60

600 0.030 -

700 0.037 0.037 -

800 0.044 0.044 -

900 0.053 0.053 0.055 -

1000 0.063 0.063 0.060 0.045 -

1600 0.090 0.104 0.065

1700 0.094 0.110 0.072

1800 0.110 0.120 0.077

1900 0.130 0.085

2000 0.100

Table 6 Wet Coil Air Delivery Downflow with 1in. Filter and Economizer
UNIT SIZE EXTERNAL STATIC PRESSURE (in. W.C.)

36 42 48 60 FILTER SIZE in. (mm) 20X20X1 (508X508X25) 20X24X1 (508X610x25) 24X30X1 (610X762x25) 24X36X1 (610X914X25)

0.1 1333 1612 2166 2298

0.2 1289 1569 2085 2239

Table 7 Filter Pressure Drop (in. W.C.)

1000 0.13 .11 0.06 900 0.00 0.00 0.00 0.04 0.06 1100 0.14 .13 0.07 1200 0.15 .14 0.07 0.06 1000 0.00 0.00 0.02 0.06 0.08 1300 .15 0.08 0.07 CFM 1400 .16 0.09 0.07 1100 0.00 0.02 0.04 0.08 0.09 1500 0.1 0.08 1200 0.00 0.03 0.06 0.10 0.11 1600 0.09

0.3 1256 1527 2002 2180

0.4 1214 1481 1919 2110

0.5 1152 1451 1798 2044

0.6 1118 1393 1709 1951

0.7 1076 1351 1582 1862

0.8 1035 1317 1467 1777

0.9 997 1278 1270 1697

1.0 950 1242 988 1591

500 0.05 500 0.00 0.00 0.00 0.00 0.00

600 0.07 600 0.00 0.00 0.00 0.00 0.00

700 0.08

800 0.1 .09 0.04 700 0.00 0.00 0.00 0.00 0.02

900 0.12 .10 0.05 800 0.00 0.00 0.00 0.02 0.04

1700 0.09 1300 0.02 0.05 0.07 0.12 0.13

1800 0.10

1900 0.11 1400 0.04 0.07 0.09 0.14 0.15 2300 0.10 0.11 0.11 0.13 0.14

2000 0.12 1500 0.06 0.08 0.10 0.16 0.17

2100 0.13

2200 0.14 1600 0.07 0.09 0.11 0.18 0.19 2500 0.12 0.13 0.13 0.15 0.16

2300 0.14

Table 8 Electric Heat Pressure Drop Small Cabinet: 2436 cfm

5kw 7.5 kw 10 kw 15 kw 20 kw

Electric Heat Pressure Drop (in. W.C.) Large Cabinet 4260 cfm
1400 0.01 0.02 0.02 0.04 0.05 1500 0.02 0.03 0.03 0.05 0.06 1600 0.03 0.04 0.04 0.06 0.07 1700 0.04 0.05 0.05 0.07 0.08 1800 0.05 0.06 0.06 0.08 0.09 1900 0.06 0.07 0.07 0.09 0.10 2000 0.07 0.08 0.08 0.10 0.11 2100 0.08 0.09 0.09 0.11 0.12

5kw 7.5 kw 10 kw 15 kw 20 kw

1100 0.00 0.00 0.00 0.00 0.02

1200 0.00 0.00 0.00 0.02 0.03

1300 0.00 0.01 0.01 0.03 0.04

2200 0.09 0.10 0.10 0.12 0.13

2400 0.11 0.12 0.12 0.14 0.15

513 01 3103 02

16

Fig. 12 Connection Wiring Diagram 208/230160

17

513 01 3103 02

Fig. 13 Ladder Wiring Diagram 208/230160

513 01 3103 02

18

Fig. 14 Connection Wiring Diagram 208/230360

19

513 01 3103 02

Fig. 15 Ladder Wiring Diagram 208/230360

513 01 3103 02

20

Fig. 16 Connection Wiring Diagram 460360

DANGER: ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING
IF USED

SCHEMATIC 460360
FOR WIRING WITH ELECTRIC HEATERS SEE SCHEMATIC

CCH
BLK

FIELD SUPPLY POWER UNIT ONLY MAXIMUM WIRE SIZE 2 AWG. L3

1 1

GRN BLK C

RED

L1

BLK

11

21

BLK

OFM
YEL
CAP

ON HEATER ACCESSORY.

YEL

13

23

YEL

BLK

BRN
COMPRESSOR PLUG

T1

L2 EQUIP_GND

BLU YEL
T3

COMP

FU1 5 AMP
BLK ECON PLUG

BLK

BLU

T2

SEE NOTE 8 FU2 5 AMP

RED YEL
GND GRNYEL L2 GND L1

BLK

7 6 11 10 8 2 3
BLU YEL

7
PNK BLU

ECON
RED
SAT PNK BLU

YEL BLK BLK GRN/YEL

6 11 10 8
GRY

COM

IFM

YEL

C
1

C
23

460V

230V
4

BRN
1 24 35

AUTOTRANSFORMER

2 3 4
BRN
460 460

SEE NOTE 5

& 6

RED

4 1 5 9 12

1 5 9 12
BLK YEL
24

TRAN
24

BLU

PNK

RED

BLK

ORN

BRN

BRN

RED

SEE NOTE 4

Y2

GRY

TSTAT
SEE NOTE 7

SEE NOTE 9

COM

COM

LOW

RED

HIGH

24VAC

ACCESSSORY ELECTRIC HEAT

COM

STD

FUSE

BRN

DEHUM

3A

WHT

WHT

HR1 (5 KW)
1

BRN

HR1

Y1

YEL VIO
1

BRN BRN

VIO
1

G DH W2

GRN BLU WHT

HR4

IFB

PNK

PNK

HR1,2,3

& 4 (20 KW)

HR2 GRY
1 2 3 4 5 6 7 Y
1

BRN BRN

GRY

HR1

& 2 (10 KW)

HR3
1

HR1,2

& 3 (15 KW)

Y2/DH

C Y1/Y

P2

W2

W3

W2

W2

W3

W2

W3

W3

P1

VIO

P4

BRN
C

BRN

HPS BLK

LPS

BLK

BLU

BLU

C1

C2

UNIT COMPONENT ARRANGEMENT

OUTDOOR FAN SECTION OFM

LEGEND
FIELD SPLICE

C CAP
ENERGIZED

CONTACTOR CAPACITOR CRANK CASE HEATER COMPRESSOR MOTOR DEHUMIDIFICATION MODE DEHUMIDIFICATION MODE ECONOMIZER GROUND HIGH PRESSURE SWITCH HEATER RELAY INTERFACE FAN BOARD INDOOR FAN MOTOR LOW PRESSURE SWITCH OUTDOOR FAN MOTOR STANDARD MODE TRANSFORMER

COLOR BLK BLU BRN GRY GRN

21 C 11 13

CODE BLACK BLUE BROWN GRAY GREEN ORANGE

TERMINAL (MARKED) TERMINAL (UNMARKED) SPLICE (IF USED) SPLICE (MARKED) FACTORY WIRING FIELD CONTROL WIRING FIELD POWER WIRING ACCESSORY OR OPTIONAL WIRING TO INDICATE COMMON POTENTIAL ONLY: NOT TO REPRESENT WIRING NOTES:

CCH COMP DH DEHUM ECON GND HPS HR IFB IFM LPS OFM STD TRAN

COMPRESSOR SECTION

INDOOR FAN SECTION

CONTROL BOX AREA

ORN

LPS

SINGLE PT. CONNECTION FOR ELECT.HEAT

23

PNK PINK RED RED VIO VIOLET WHT WHITE YEL YELLOW

HPS
CAP H CF COMP

IFM TRAN

1. IF ANY OF THE ORIGINAL WIRES FURNISHED ARE REPLACED, IT MUST BE REPLACED WITH TYPE 90 DEGREE C WIRE OR ITS EQUIVALENT.

IFB EQUIP. GND SEE HEATER SCHEMATIC FOR WIRING

2. SEE PRICE PAGES FOR THERMOSTAT AND SUBBASES. 3. USE 75 DEGREE COPPER CONDUCTORS FOR FIELD INSTALLATION. 4. REFER TO INSTALLATION INSTRUCTIONS FOR CORRECT SPEED SELECTION OF IFM. 5. RELOCATION OF SPEED TAPS MAY BE REQUIRED WHEN USING FIELD INSTALLED ELECTRIC HEATERS,

C S R CCH

DISCONNECT PER NEC

CONSULT INSTALLATION INSTRUCTIONS TO DETERMINE CORRECT SPEED TAP SETTING. 6. IDO NOT DISCONNECT PLUG UNDER LOAD.I 7. THIS FUSE IS MANUFACTURED BY LITTELFUSE, P/N 257003 8. THESE FUSES ARE MANUFACTURED BY COOPER BUSSMAN, P/N FNQR5

24V SPLICE BOX 24V POWER ENTRY

9. DEHUM FEATURE CANNOT BE USED WHEN ECONOMIZER IS INSTALLED. UNIT FACTORYSHIPPED IN STD MODE.

21

513 01 3103 02

Fig. 17 Ladder Wiring Diagram 460360

DANGER: ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING
L2 L1 BLK 11 BLK 21 11 IF USED RED BLK OFM BLK C S BRN R YEL GRN CCH 23 C 13 L3 YEL

G/Y

CAP

YEL

BLU
T2 T1 T3

YEL BLK

COMP

11

BLK CL G N X

YEL

13

G/Y

IFM

460V BLK RED 24V

SEE NOTE 7

TRAN

460V YEL 13

24V

RED

24VAC

G/Y

FUSE 3A
R C Y1 G DH W2 W3 Y2 RED BRN YEL GRN BLU WHT VIO VIO P21 P22 P23 P24 P11 P12 P13 P14 P15 P16 P17

IFB
IRI ICI IY1/YI IGI IY2/DHI IW2I IW3I

HPS BLK
ACCESSORY ELECTRIC HEAT

LPS BLK BLU BLU

C1 C

C2 BRN
C,TRAN

BRN P41 WHT VIO WHT VIO HR1 BRN BLK P42

HR4
HR2 BRN

ECON

P43
YEL

PNK

PNK

BRN

HARNESS

2 3 4
BRN
COM C

P44

GRY BRN LOW

SEE NOTE 9

GRY BRN

HR3

P45

5 6
PNK PNK BLU

STD DEHUM
HIGH

SAT
BLU

BLU PNK
SEE NOTE 4

1 2 3 4
5

7
C IFM

RED ORN BLK

BRN

C G/Y

BRN
RED

50VL500271
513 01 3103 02

D
22

Fig. 18 Cooling Charging Chart

23

513 01 3103 02

MAINTENANCE
To ensure continuing high performance, and to minimize the possibility of premature equipment failure, periodic maintenance must be performed on this equipment. This cooling unit should be inspected at least once each year by a qualified service person. To troubleshoot unit, refer to Table 9, Troubleshooting Chart. NOTE TO EQUIPMENT OWNER: Consult your local dealer about the availability of a maintenance contract.

For longer life, operating economy, and continuing efficiency, clean accumulated dirt and grease from the blower wheel and motor annually.

ELECTRICAL SHOCK HAZARD

WARNING

Failure to follow this warning could result in personal injury or death. Disconnect and tag electrical power to the unit before cleaning the blower motor and wheel. To clean the blower motor and wheel: 1. Remove and disassemble blower assembly as follows: a. Remove blower access panel. b. Disconnect 5 pin plug and 4 pin plug from indoor blower motor. Remove capacitor if required. c. On all units remove blower assembly from unit. Remove screws securing blower to blower partition and slide assembly out. Be careful not to tear 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, remove screws that secure motor mount brackets to housing, and slide motor and motor mount out of housing. 2. Remove and clean blower wheel as follows: a. Ensure proper reassembly by marking wheel orientation. b. Lift wheel from housing. When handling and/or cleaning blower wheel, be sure not to disturb balance weights (clips) on blower wheel vanes. c. Remove cakedon 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 flats and not on round part of shaft. Reinstall blower into unit. f. Connect 5 pin plug and 4 pin plug to indoor blower motor. Reinstall capacitor if required. g. Reinstall blower access panel. 3. Restore electrical power to unit. Start unit and check for proper blower rotation and motor speeds during cooling cycles. Fig. 19 Access Panels

PERSONAL INJURY AND UNIT DAMAGE HAZARD Failure to follow this warning could result in personal injury or death and possible unit component damage. The ability to properly perform maintenance on this equipment requires certain expertise, mechanical skills, tools and equipment. If you do not possess these, do not attempt to perform any maintenance on this equipment, other than those procedures recommended in the Owners Manual.

WARNING

ELECTRICAL SHOCK HAZARD

WARNING

Failure to follow these warnings could result in personal injury or death: 1. Turn off electrical power to the unit and install lockout tag before performing any maintenance or service on this unit. 2. Use extreme caution when removing panels and parts. 3. Never place anything combustible either on or in contact with the unit.

CAUTION

UNIT OPERATION HAZARD Failure to follow this caution may result in equipment damage or improper operation. Errors made when reconnecting wires may cause improper and dangerous operation. Label all wires prior to disconnecting when servicing. 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 for cleanliness. Clean when necessary. 3. Inspect blower motor and wheel for cleanliness each cooling season. Clean when necessary. 4. Check electrical connections for tightness and controls for proper operation each cooling season. Service when necessary. 5. Ensure electric wires are not in contact with refrigerant tubing or sharp metal edges. AIR FILTER IMPORTANT: Never operate the unit without a suitable air filter in the returnair duct system. Always replace the filter with the same dimensional size and type as originally installed. See Table 1 for recommended filter sizes. Inspect air filter(s) at least once each month and replace (throwawaytype) or clean (cleanabletype) at least twice during each cooling season and twice during the heating season, or whenever the filter becomes clogged with dust and lint. INDOOR BLOWER AND MOTOR NOTE: All motors are prelubricated. Do not attempt to lubricate these motors.
513 01 3103 02

Compressor Access Panel

Blower Access Panel

Control Access Panel

24

Fig. 20 Fan Blade Position

MOTOR

FAN GRILLE

MOTOR SHAFT
MAX DISTANCE BETWEEN TOP OF FAN GRILLE AND BOTTOM OF FAN BLADE
SIZE 24 30 36 42 48 60 A IN. 7.3 7.3 7.3 7.6 7.6 7.6 MM 185 185 185 193 193 193

Outdoor Coil, Indoor Coil, and Condensate Drain Pan Inspect the condenser coil, evaporator coil, and condensate drain pan at least once each year. The coils are easily cleaned when dry; therefore, inspect and clean the coils either before or after each cooling season. Remove all obstructions, including weeds and shrubs, that interfere 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 attachment. Be careful not to bend the fins. If coated with oil or grease, clean the coils with a mild detergent and water solution. 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 from the unit base. Inspect the drain pan and condensate drain line when inspecting the coils. Clean the drain pan and condensate drain by removing all foreign matter from the pan. Flush the pan and drain trough with clear water. Do not splash water on the insulation, motor, wiring, or air filter(s). If the drain trough is restricted, clear it with a plumbers snake or similar probe device. OUTDOOR FAN

2. Turn motor/grille assembly upside down on top cover to expose the fan blade. 3. Inspect the fan blades for cracks or bends. 4. If fan needs to be removed, loosen the setscrew and slide the fan off the motor shaft. 5. When replacing fan blade, position blade as shown in Fig. 20. 6. Ensure that setscrew engages the flat area on the motor shaft when tightening 7. Replace grille. ELECTRICAL CONTROLS AND WIRING Inspect and check the electrical controls and wiring annually. Be sure to turn off the electrical power to the unit. Remove access panels to locate all the electrical controls and wiring. Check all electrical connections for tightness. Tighten all screw connections. If any smoky or burned connections are noticed, disassemble the connection, clean all the parts, restrip the wire end and reassemble the connection properly and securely. After inspecting the electrical controls and wiring, replace the access 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 operating cycles, or if a suspected malfunction has occurred, check each electrical component with the proper electrical instrumentation. Refer to the unit wiring label when making these checkouts. NOTE: Refer to the heating and/or cooling sequence of operation in this publication as an aid in determining proper control operation REFRIGERANT CIRCUIT Inspect all refrigerant tubing connections and the unit base for oil accumulations annually. Detecting oil generally indicates a refrigerant leak.

CAUTION

UNIT OPERATION HAZARD Failure to follow this caution may result in damage to unit components. Keep the condenser fan free from all obstructions to ensure proper cooling operation. Never place articles on top of the unit. 1. Remove 6 screws holding condenser grille and motor to top cover.

25

513 01 3103 02

WARNING

3. Apply ohmmeter leads across switch. You should have continuity on a good switch. COPELAND SCROLL COMPRESSOR (R410A REFRIGERANT) The compressor used in this product is specifically designed to operate with R410A refrigerant and cannot be interchanged. The compressor is an electrical (as well as mechanical) device. Exercise extreme caution when working near compressors. Power should be shut off, if possible, for most troubleshooting techniques. Refrigerants present additional safety hazards.

EXPLOSION, SAFETY AND ENVIRONMENTAL HAZARD Failure to follow this warning could result in personal injury, death or equipment damage. This system uses R410A refrigerant which has higher operating pressures than R22 and other refrigerants. No other refrigerant may be used in this system. Gauge set, hoses, and recovery system must be designed to handle R410A. If you are unsure, consult the equipment manufacturer. If oil is detected or if low cooling performance is suspected, leaktest all refrigerant tubing using an electronic leakdetector, halide torch, or liquidsoap solution. If a refrigerant leak is detected, refer to Check for Refrigerant Leaks section. If no refrigerant leaks are found and low cooling performance is suspected, refer to Checking and Adjusting Refrigerant Charge section. EVAPORATOR AIRFLOW The heating and/or cooling airflow does not require checking unless improper performance is suspected. If a problem exists, be sure that all supply and returnair grilles are open and free from obstructions, and that the air filter is clean. When necessary, refer to Indoor Airflow and Airflow Adjustments section to check the system airflow. R410A ITEMS The indoor metering device is a TXV type device. PRESSURE SWITCHES Pressure switches are protective devices wired into the control circuit (low voltage). They shut off compressor if abnormally high or low pressures are present in the refrigeration circuit. These pressure switches are specifically designed to operate with R410A systems. R22 pressure switches must not be used as replacements for the R410A air conditioner. LOSS OF CHARGE/LOWPRESSURE SWITCH (AIR CONDITIONER ONLY) This switch is located on the liquid line and protects against low suction pressures caused by such events as loss of charge, low airflow across indoor coil, dirty filters, etc. It opens on a pressure drop at about 20 psig (957 Pa). If system pressure is above this, switch should be closed. To check switch: 1. Turn off all power to unit. 2. Disconnect leads on switch. 3. Apply ohmmeter leads across switch. You should have continuity on a good switch. NOTE: Because these switches are attached to refrigeration system under pressure, it is not advisable to remove this device for troubleshooting unless you are reasonably certain that a problem exists. If switch must be removed, remove and recover all system charge so that pressure gauges read 0 psi (0 Pa). Never open system without breaking vacuum with dry nitrogen. HIGHPRESSURE SWITCH The highpressure switch is located in the discharge line and protects against excessive condenser coil pressure. It opens at 650 psig (31.1 kPa). High pressure may be caused by a dirty condenser coil, failed fan motor, or condenser air recirculation. To check switch: 1. Turn off all power to unit. 2. Disconnect leads on switch.
513 01 3103 02

WARNING

EXPLOSION HAZARD Failure to follow this warning could result in personal injury or death and/or property damage. Wear safety glasses and gloves when handling refrigerants. Keep torches and other ignition sources away from refrigerants and oils. The scroll compressor pumps refrigerant throughout the system by the interaction of a stationary and an orbiting scroll. The scroll compressor has no dynamic suction or discharge valves, and it is more tolerant of stresses caused by debris, liquid slugging, and flooded starts. The compressor is equipped with a noise reducing shutdown device and an internal pressure relief port. The pressure relief port is a safety device, designed to protect against extreme high pressure. The relief port has an operating range between 550 (26.3 kPa) and 625 (29.9 kPa) psi differential pressure. REFRIGERANT

WARNING

EXPLOSION, ENVIRONMENTAL SAFETY HAZARD Failure to follow this warning could result in personal injury, death or equipment damage. This system uses R410A refrigerant which has higher operating pressures than R22 and other refrigerants. No other refrigerant may be used in this system. Gauge set, hoses, and recovery system must be designed to handle R410A. If you are unsure, consult the equipment manufacturer. This system uses R410A refrigerant which has higher operating pressures than R22 and other refrigerants. No other refrigerant may be used in this system. Gage set, hoses, and recovery system must be designed to handle R410A. If you are unsure, consult the equipment manufacturer. Failure to use R410A compatible servicing equipment or replacement components may result in property damage or injury. COMPRESSOR OIL The Copeland scroll compressor uses 3MAF POE oil. If additional oil is needed, use Uniqema RL323MAF. If this oil is not available, use Copeland Ultra 32 CC or Mobil Arctic EAL22 CC. This oil is extremely hygroscopic, meaning it absorbs water readily. POE oils can absorb 15 times as much water as other oils designed for HCFC and CFC refrigerants. Take all necessary precautions to avoid exposure of the oil to the atmosphere. SERVICING SYSTEMS ON ROOFS WITH SYNTHETIC MATERIALS POE (polyolester) compressor lubricants are known to cause long term damage to some synthetic roofing materials. Exposure, even if immediately cleaned up, may cause embrittlement (leading to 26

23cracking) to occur in one year or more. When performing any service that may risk exposure of compressor oil to the roof, take appropriate precautions to protect roofing. Procedures which risk oil leakage include, but are not limited to, compressor replacement, repairing refrigerant leaks, replacing refrigerant components such as filter drier, pressure switch, metering device, coil, accumulator, or reversing valve.

LIQUID LINE FILTER DRIER The filter drier is specifically designed to operate with R410A. Use only factoryauthorized components. Filter drier must be replaced whenever the refrigerant system is opened. When removing a filter drier, use a tubing cutter to cut the drier from the system. Do not unsweat a filter drier from the system. Heat from unsweating will release moisture and contaminants from drier into system. R410A REFRIGERANT CHARGING Refer to unit information plate and charging chart. Some R410A refrigerant cylinders contain a dip tube to allow liquid refrigerant to flow from cylinder in upright position. For cylinders equipped with a dip tube, charge R410A units with cylinder in upright position and a commercial metering device in manifold hose. Charge refrigerant into suctionline.

Synthetic Roof Precautionary Procedure 1. Cover extended roof working area with an impermeable polyethylene (plastic) drip cloth or tarp. Cover an approximate 10 x 10 ft (3 x 3 m) area. 2. Cover area in front of the unit service panel with a terry cloth shop towel to absorb lubricant spills, prevent runoffs, and protect drop cloth from tears caused by tools or components. 3. Place terry cloth shop towel inside unit immediately under component(s) to be serviced and prevent lubricant runoffs through the louvered openings in the unit base. 4. Perform required service. 5. Remove and dispose of any oil contaminated material per local codes.

TROUBLESHOOTING
Refer to the Troubleshooting Chart (Table 9 for troubleshooting information.

STARTUP CHECKLIST
Use the StartUp Checklist at the back of this manual.

AIR CONDITIONER WITH R410A QUICK REFERENCE GUIDE R410A refrigerant operates at 5070 percent higher pressures than R22. Be sure that servicing equipment and replacement components are designed to operate with R410A. R410A refrigerant cylinders are rose colored. S R410A refrigerant cylinders manufactured prior to March 1, 1999, have a dip tube that allows liquid to flow out of cylinder in upright position. Cylinders manufactured March 1, 1999 and later DO NOT have a dip tube and MUST be positioned upside down to allow liquid to flow. S Recovery cylinder service pressure rating must be 400 psig. DOT 4BA400 or DOT BW400. S R410A systems should be charged with liquid refrigerant. Use a commercial type metering device in the manifold hose. S Manifold sets should be minimum 700 psig highside and 180 psig lowside with 550 psig lowside retard. S Use hoses with minimum 700 psig service pressure rating. S Leak detectors should be designed to detect HFC refrigerant. S R410A, as with other HFCs, is only compatible with POE oils. S Vacuum pumps will not remove moisture from oil. S Only use factory specified liquidline filter driers with rated working pressures no less than 600 psig. S Do not install a suctionline filter drier in liquid line. S POE oils absorb moisture rapidly. Do not expose oil to atmosphere. S POE oils may cause damage to certain plastics and roofing materials. S Wrap all filter driers and service valves with wet cloth when brazing. S A R410A liquidline filter drier is required on every unit. S Do not use an R22 TXV. S Never open system to atmosphere while it is under a vacuum. S When system must be opened for service, break vacuum with dry nitrogen and replace filter driers. S Always replace filter drier after opening system for service. S Do not vent R410A into the atmosphere. S Observe all warnings, cautions, and bold text. S Do not leave R410A suction line driers in place for more than 72 hrs.

27

513 01 3103 02

Table 9 Troubleshooting Chart

SYMPTOM CAUSE Power failure Fuse blown or circuit breaker tripped Defective contactor, transformer, control relay, or highpressure, lossofcharge or lowpressure switch Insufficient line voltage Incorrect or faulty wiring Thermostat setting too low/too high Faulty wiring or circuit Loose connections in compressor Compressor motor burned out, seized, or internal overload open Defective run capacitor, overload, or PTC (positive temperature coefficient) thermistor One leg of 3phase power dead Low input voltage Threephase scroll compressor (size 030 060 unit) has a low pressure differential Scroll compressor is rotating in the wrong direction Refrigerant overcharge or undercharge Compressor cycles (other than normally satisfying) cooling/heating calls Defective compressor Insufficient line voltage Blocked outdoor coil Defective run/start capacitor, overload or start relay Faulty outdoor fan motor or capacitor Restriction in refrigerant system Dirty air filter Unit undersized for load Thermostat temperature set too low Low refrigerant charge Air in system Outdoor coil dirty or restricted Dirty air filter Dirty indoor or outdoor coil Refrigerant overcharged Air in system Indoor or outdoor air restricted or air shortcycling Low refrigerant charge Restriction in liquid tube Refrigerant overcharged Dirty air filter Low refrigerant charge Metering device or low side restricted Insufficient coil airflow Temperature too low in conditioned area Outdoor ambient below 55F (13C) Filter drier restricted REMEDY Call power company Replace fuse or reset circuit breaker Replace component Determine cause and correct Check wiring diagram and rewire correctly Reset thermostat setting Check wiring and repair or replace Determine cause Replace compressor Determine cause and replace Replace fuse or reset circuit breaker Determine cause Determine cause and correct Correct the direction of rotation by reversing the 3phase power leads to the unit Recover refrigerant, evacuate system, and recharge to capacities shown on rating plate Replace and determine cause Determine cause and correct Determine cause and correct Determine cause and replace Replace Locate restriction and remove Replace filter Decrease load or increase unit size Reset thermostat setting Locate leak, repair, and recharge Recover refrigerant, evacuate system, and recharge Clean coil or remove restriction Replace filter Clean coil Recover excess refrigerant Recover refrigerant, evacuate system, and recharge Determine cause and correct Check for leaks, repair and recharge Remove restriction Recover excess refrigerant Replace filter Check for leaks, repair and recharge Remove source of restriction Check filterreplace if necessary Reset thermostat setting Install lowambient kit Replace

Compressor and outdoor fan will not start

Compressor will not start but condenser fan runs

Compressor operates continuously

Excessive head pressure

Head pressure too low Excessive suction pressure

Suction pressure too low

513 01 3103 02

28

STARTUP CHECKLIST
(Remove and Store in Job Files) I. PRELIMINARY INFORMATION MODEL NO.: SERIAL NO.: DATE: TECHNICIAN: II. PRESTARTUP (Insert check mark in box as each item is completed) ( ) VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT ( ) REMOVE ALL SHIPPING HOLD DOWN BOLTS AND BRACKETS PER INSTALLATION INSTRUCTIONS ( ) CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS ( ) CHECK THAT INDOOR (EVAPORATOR) AIR FILTER IS CLEAN AND IN PLACE ( ) VERIFY THAT UNIT INSTALLATION IS LEVEL ( ) CHECK FAN WHEEL, AND PROPELLER FOR LOCATION IN HOUSING/ORIFICE AND SETSCREW TIGHTNESS III. STARTUP ELECTRICAL SUPPLY VOLTAGE COMPRESSOR AMPS INDOOR (EVAPORATOR) FAN AMPS TEMPERATURES OUTDOOR (CONDENSER) AIR TEMPERATURE DB RETURNAIR TEMPERATURE DB WB COOLING SUPPLY AIR DB WB PRESSURES REFRIGERANT SUCTION PSIG, SUCTION LINE TEMP* REFRIGERANT DISCHARGE PSIG, LIQUID TEMP{ ( ) VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS
* Measured at suction inlet to compressor { Measured at liquid line leaving condenser.

29

513 01 3103 02