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INSTALLATION INSTRUCTIONS

R--410A Single Package Electric Cooling

PAD324--60

1 & 3 Phase

These instructions must be read and understood completely before attempting installation

Safety Labeling and Signal Words

DANGER, WARNING, CAUTION, and NOTE

The signal words

DANGER, WARNING

,

CAUTION

, and

NOTE

are used to identify levels

of hazard seriousness. The signal word

DANGER

is only used on product labels to signify an

immediate hazard. The signal words

WARNING

,

CAUTION

, and

NOTE

will be used on product

labels and throughout this manual and other

manual that may apply to the product.

DANGER

-- Immediate hazards which will result in

severe personal injury or death.

WARNING

--Hazards or unsafe practices which

could result in severe personal injury or death.

CAUTION

-- Hazards or unsafe practices which

may result in minor personal injury or product or

property damage.

NOTE

-- Used to highlight suggestions which will

result in enhanced installation, reliability, or

operation.

!

WARNING

Signal Words in Manuals

The signal word

WARNING

is used throughout

this manual in the following manner:

The signal word

CAUTION

is used throughout

this manual in the following manner:

!

CAUTION

Signal Words on Product Labeling

Signal words are used in combination with

colors and/or pictures or product labels.

SAFETY CONSIDERATIONS

2

. . . . . . . . . . . . . . . . .

RECEIVING AND INSTALLATION

2

. . . . . . . . . . . . .

Step 1 -- Check Equipment

2

. . . . . . . . . . . . . . . . . . .

Step 2 -- Provide Unit Support

2

. . . . . . . . . . . . . . . . .

Step 3 -- Provide Clearances

3

. . . . . . . . . . . . . . . . . .

Step 4 -- Field Fabricate Ductwork

3

. . . . . . . . . . . . .

Step 5 -- Rig and Place Unit

3

. . . . . . . . . . . . . . . . . . .

Step 6 -- Provide for Condensate Disposal

7

. . . . . .

Step 7 -- Install Duct Connections

7

. . . . . . . . . . . . . .

Step 8 -- Install Electrical Connections

9

. . . . . . . . . .

PRE--START--UP

11

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

START--UP

11

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 1 -- Check for Refrigerant Leaks

11

. . . . . . . . . .

Step 2 -- Start--Up Cooling Section and Make Adj. 11
Indoor Airflow Adjustments

12

. . . . . . . . . . . . . . . . . . .

Cooling Sequence of Operations

13

. . . . . . . . . . . . . .

Wiring Diagram

15

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance

22

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting

25

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start--Up Checklist

27

. . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

!

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.

513 01 3103 00

04/21/10

Summary of Contents for PAD324

Page 1: ...roduct Labeling Signal words are used in combination with colors and or pictures or product labels SAFETY CONSIDERATIONS 2 RECEIVING AND INSTALLATION 2 Step 1 Check Equipment 2 Step 2 Provide Unit Support 2 Step 3 Provide Clearances 3 Step 4 Field Fabricate Ductwork 3 Step 5 Rig and Place Unit 3 Step 6 Provide for Condensate Disposal 7 Step 7 Install Duct Connections 7 Step 8 Install Electrical Co...

Page 2: ...ns require that you do not vent refrigerant into the atmosphere Recover during system repair or final unit disposal WARNING CUT HAZARD 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 extreme...

Page 3: ... 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 use...

Page 4: ... 1 16 13 16 427 0 36 208 230 1 60 208 230 3 60 283 128 3 46 1172 20 1 2 520 7 15 3 4 400 1 17 431 8 460 3 60 297 134 6 46 1172 20 1 2 520 7 15 3 4 400 1 17 431 8 UNIT Voltage Corner Weight LB KG 1 2 3 4 24 208 230 54 4 24 7 43 5 19 7 65 2 29 6 108 7 49 3 30 208 230 55 4 25 1 44 3 20 1 66 4 30 2 110 7 50 3 36 208 230 56 6 25 7 45 2 20 5 67 9 30 8 113 1 51 3 460 56 6 25 7 45 2 20 5 76 9 34 9 118 1 5...

Page 5: ...1187 20 1 4 514 4 17 1 2 444 5 17 3 8 441 60 208 230 1 60 208 230 3 60 397 180 2 46 3 4 1187 20 1 4 514 4 17 1 2 444 5 17 5 8 448 460 3 60 411 186 5 46 3 4 1187 20 1 4 514 4 17 1 2 444 5 17 5 8 448 UNIT Voltage Corner Weight LB KG 1 2 3 4 42 208 230 73 8 33 5 59 1 26 8 88 6 40 2 147 7 67 1 460 73 8 33 5 59 1 26 8 97 6 44 3 1527 69 3 48 208 230 75 0 34 1 60 0 27 3 90 1 40 9 150 1 68 1 460 75 0 34 1...

Page 6: ...UMBER A IN mm B small base IN mm B large base IN mm C IN mm D IN mm E IN mm F IN mm G IN mm H IN mm Small or Large CPRFCURB010A00 11 279 10 254 14 356 16 406 47 8 1214 32 4 822 2 7 69 30 6 778 46 1 1170 CPRFCURB011A00 14 356 Large CPRFCURB012A00 11 279 14 356 43 9 1116 42 2 1072 CPRFCURB013A00 14 356 Part Numbers CPRCURB010A00 and CPRCURB011A00 can be used on both small and large basepan units The...

Page 7: ...terials 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 Step 6 Provide for Condensate Disposal NOTE When installing condensate drain connection be sure to comply with local cod...

Page 8: ...or maintenance operations on the system turn off main power to unit and install lockout tag WARNING 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 ...

Page 9: ...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 Three phase units 1 Run the high voltage 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 side of ...

Page 10: ...1 21 11 9 1 21 15 4 1 21 13 6 1 21 15 5 2 21 15 5 OUTDOOR FAN Nominal Cfm Diameter in Diameter mm Motor Hp Rpm 2800 24 610 1 5 810 3000 24 610 1 5 810 3200 24 610 1 5 810 3600 26 660 1 5 810 4000 26 660 1 5 810 3200 26 660 1 5 810 INDOOR COIL Rows Fins in Face Area sq ft 2 17 3 7 3 17 3 7 3 17 3 7 3 17 4 7 3 17 4 7 3 17 5 7 INDOOR BLOWER Nominal Cooling Airflow Cfm Size in Size mm Motor HP RPM 800...

Page 11: ...refrigerant vapor to system and leak test unit 4 Recover refrigerant from system and evacuate to 500 microns if no additional leaks are found 5 Charge unit with R 410A refrigerant using an accurate scale Refer to unit rating plate for required charge Step 2 Start Up Cooling Section And Make Adjustments Complete the required procedures given in the Pre Start Up section before starting the unit Do n...

Page 12: ...cation 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 o...

Page 13: ...ging blower speed WARNING 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 switc...

Page 14: ...tic pressure available for ducting Shaded areas indicate airflows that are not recommended for dehumidification control Table 5 PAD3 Wet Coil Pressure Drop in W C UNIT SIZE STANDARD CFM S C F M 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 24 0 030 0 037 0 044 0 053 0 063 30 0 037 0 044 0 053 0 063 0 072 0 081 0 105 36 0 055 0 060 0 090 0 100 0 110 0 140 42 0 045 0 050 0 0...

Page 15: ...TION OF SPEED TAPS MA WHEN USING FIELD INSTALLED CONSULT INSTALLATION INSTRU DETERMINE CORRECT SPEED TAP 6 DO NOT DISCONNECT PLUG UND 7 THIS FUSE IS MANUFACTURED B 8 UNIT FACTORY SHIPPED IN STD ACCESSSORY ELECTRIC HEAT HR1 5 KW HR1 2 10 KW HR1 2 3 15 KW HR1 2 3 4 20 KW HR3 HR2 HR4 1 3 HR1 1 3 BRN BRN BRN BRN BRN RED BLK YEL FIELD SUPPLY POWER UNIT ONLY MAXIMUM WIRE SIZE 2 AWG 1 1 OFM COMPRESSOR PL...

Page 16: ...L C G Y BLK RED BRN YEL GRN WHT VIO P1 7 P1 5 P1 6 P1 4 P1 3 P1 2 P1 1 P2 4 P2 3 P2 2 P2 1 C C1 C2 HR1 HR4 HR2 HR3 BRN BRN BRN BRN WHT VIO PNK GRY 2 5 4 3 1 BLU PNK RED BLK G Y HIGH C P4 4 P4 3 P4 2 P4 1 P4 5 IFB RED 24VAC IF USED ACCESSORY ELECTRIC HEAT G Y RED BRN WHT VIO PNK GRY R C Y G W2 W3 Y YEL ORN SEE NOTE 4 50VL500269 DANGER ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING BLU C ...

Page 17: ...DISCONNECT PLUG UNDER LOAD I 7 THIS FUSE IS MANUFACTURED BY LITTELFUSE P N 257003 8 DEHUM FEATURE CANNOT BE USED WHEN ECONOMIZER IS INSTALLED UNIT FACTORY SHIPPED IN STD MODE HR3 HR2 HR4 HR1 BRN BRN BRN BRN BRN RED BLK YEL FIELD SUPPLY POWER UNIT ONLY MAXIMUM WIRE SIZE 2 AWG 1 1 SCHEMATIC 230 3 60 OFM COMPRESSOR PLUG EQUIP_GND 1 1 1 1 1 WHT VIO PNK GRY BRN WHT VIO PNK GRY BRN BRN IFB 24V SPLICE DI...

Page 18: ...2 4 P2 3 P2 2 P2 1 HR1 HR4 HR2 HR3 BRN BRN BRN BRN WHT VIO PNK GRY 2 5 4 3 1 BLU PNK RED BLK HIGH P4 4 P4 3 P4 2 P4 1 P4 5 IFB RED 24VAC IF USED ACCESSORY ELECTRIC HEAT G Y RED BRN WHT VIO PNK GRY R C Y1 G W2 W3 50VL500270 YEL L2 DANGER ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING TRAN BRN C C2 Y C 13 FUSE 3A BRN C SEE NOTE 7 3 5 6 4 2 8 7 ECON HARNESS GRY Y2 YEL RED BLK PNK BLU PNK B...

Page 19: ...R LOAD I 7 THIS FUSE IS MANUFACTURED BY LITTELFUSE P N 257003 8 THESE FUSES ARE MANUFACTURED BY COOPER BUSSMAN P N FNQ R 5 9 DEHUM FEATURE CANNOT BE USED WHEN ECONOMIZER IS INSTALLED UNIT FACTORY SHIPPED IN STD MODE ACCESSSORY ELECTRIC HEAT HR1 5 KW HR1 2 10 KW HR1 2 3 15 KW HR1 2 3 4 20 KW HR3 HR2 HR4 1 3 HR1 1 3 BRN BRN BRN BRN BRN RED BLK YEL FIELD SUPPLY POWER UNIT ONLY MAXIMUM WIRE SIZE 2 AWG...

Page 20: ...P2 1 HR1 HR4 HR2 HR3 BRN BRN BRN BRN WHT VIO PNK GRY 2 5 4 3 1 BLU PNK RED BLK G Y HIGH C P4 4 P4 3 P4 2 P4 1 P4 5 IFB RED 24VAC IF USED ACCESSORY ELECTRIC HEAT G Y RED BRN WHT VIO PNK GRY R C Y1 G W2 W3 50VL500271 YEL L2 ORN SEE NOTE 4 DANGER ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING TRAN BRN C C2 Y C 13 FUSE 3A BRN C BRN SEE NOTE 7 C1 3 5 6 4 2 8 7 ECON HARNESS VIO Y2 YEL RED BLK...

Page 21: ...21 513 01 3103 00 Fig 18 Cooling Charging Chart ...

Page 22: ...e 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 throwaway type or clean cleanable type 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 pre lubricated Do not attempt ...

Page 23: ...ser fan free from all obstructions to ensure proper cooling operation Never place articles on top of the unit CAUTION 1 Remove 6 screws holding condenser grille and motor to top cover 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...

Page 24: ...ondenser air recirculation 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 COPELAND SCROLL COMPRESSOR R 410A REFRIGER ANT The compressor used in this product is specifically designed to operate with R 410A refrigerant and cannot be interchanged The compressor is an electrical as well as mecha...

Page 25: ...Refer to the Troubleshooting Chart Table 9 for troubleshooting information START UP CHECKLIST Use the Start Up Checklist at the back of this manual AIR CONDITIONER WITH R 410A QUICK REFERENCE GUIDE R 410A refrigerant operates at 50 70 percent higher pressures than R 22 Be sure that servicing equipment and replacement components are designed to operate with R 410A R 410A refrigerant cylinders are r...

Page 26: ...ate Defective compressor Replace and determine cause Insufficient line voltage Determine cause and correct Blocked outdoor coil Determine cause and correct Defective run start capacitor overload or start relay Determine cause and replace Faulty outdoor fan motor or capacitor Replace Restriction in refrigerant system Locate restriction and remove Compressor operates continuously Dirty air filter Re...

Page 27: ...S 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 START UP ELECTRICAL SUPPLY VOLTAGE COMPRESSOR AMPS INDOOR EVAPORATOR FAN AMPS TEMPERATURES OUTDOOR CONDENSER AIR TEMPERATURE DB RETURN AIR TEMPERATURE DB WB COOLING SUPPLY AIR DB WB PRESSURES REFRIGERANT SUCT...

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