Installation and servicing of this equipment can behazardous due to mechanical and electrical components.Only trained and qualified personnel should install, repair,or service this equipment.
Untrained personnel can perform basic maintenancefunctions such as cleaning and replacing air filters. All otheroperations must be performed by trained servicepersonnel. When working on this equipment, observeprecautions in the literature, on tags, andon labels attachedto or shipped with the unit and other safety precautions thatmay apply.
Follow all safety codes. Installation must be in compliancewith local and national building codes.Wear safety glasses,protective clothing, andwork gloves. Have fire extinguisheravailable. Read these instructions thoroughly and follow allwarnings or cautions included in literature and attached tothe unit.
Recognize safety information. This is the safety--alertsymbol . When you see this symbol in instructions ormanuals, be alert to the potential for personal injury.
Understand the signal words DANGER, WARNING,CAUTION, and NOTE. These words are used with thesafety--alert symbol. DANGER identifies the most serioushazards which will result in serious injury or death.WARNING signifies a hazard which could result in seriousinjury or death. CAUTION is used to identify unsafepractices which may result in minor personal injury orproduct and property damage. NOTE is used to highlightsuggestions which will result in enhanced installation,reliability, or operation.
These instructions cover minimum requirements andconform to existing national standards and safety codes. Insome instances, these instructions exceed certain localcodes and ordinances, especially those that may not havekept up with changing residential construction practices.
We require these instructions as a minimum for a safeinstallation.
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personalinjury or death.
Before installing or servicing system, turn off powersupply to the unit and install lockout tag. There may bemore than one disconnect switch. Turn off accessoryheater power switch if applicable.
! WARNING
INTRODUCTIONThe PAN3 packaged air conditioner is fully self--containedanddesigned for outdoor installation (seeFig. 1). SeeFig. 3and 4 for unit dimensions. All unit sizes have dischargeopenings for both horizontal and downflow configurationsand are factory shipped with all downflow duct openingscovered. The unit may be installed either on a rooftop or atground level.
RECEIVING AND INSTALLATIONStep 1—Check Equipment
IDENTIFY UNITThe unit model number and serial number are stamped onthe unit information plate. Check this information againstshipping papers.INSPECT SHIPMENT
Inspect for shipping damage while unit is still on shippingpallet. If unit appears to be damaged or is torn loose fromits anchorage, have it examined by transportationinspectors before removal. Forward claimpapers directly totransportation company. Manufacturer is not responsiblefor any damage incurred in transit. Check all items againstshipping list. Immediately notify the nearest equipmentdistribution office if any item is missing. To prevent loss ordamage, leave all parts in original packages untilinstallation.
Step 2—Provide Unit Support
For hurricane tie downs, contact distributor for details andPE (Professional Engineering) Certificate if required.
ROOFCURB
Install accessory roof curb in accordance with instructionsshippedwith curb. Install insulation, cant strips, roofing, andflashing. Ductwork must be attached to curb.
IMPORTANT: The gasketing of the unit to the roof curb iscritical for a water tight seal. Install gasketing materialsupplied with the roof curb. Improperly applied gasketingalso can result in air leaks and poor unit performance.
Curb should be level to within 1/4 in. (6mm). This isnecessary for unit drain to function properly. Refer toaccessory roof curb installation instructions for additionalinformation as required.
SLAB MOUNT
Place the unit on a solid, level concrete pad that is aminimum of 4 in. (102mm) thick with 2 in. (51mm) abovegrade (See Fig. 2). The slab should extend approximately
!
3
2 in. beyond the casing on all 4 sides of the unit. Do notsecure the unit to the slab except when required by localcodes.
OPTIONALRETURN
AIROPENING
OPTIONALSUPPLY
AIROPENING
EVAP. COIL COND. COIL
2"
FIGURE 2 Slab Mounting Details
ADDITIONAL GROUND LEVEL PLATFORMREQUIREMENTSThe unit MUST be situated to provide safe access forservicing.The unit must be level and supported above grade bybeams, platform, or a pad.Platform or pad can be of open or solid construction butshould be of permanentmaterials such as concrete, bricks,blocks, steel, or pressure--treated timbers approved forground contact. Soil conditions must be considered so thatthe platform or pad does not shift or settle and leave the unitpartially supported.Position platform separate from building foundation.Install in well--drained area, with top surface of platformabove grade level.Platform must be high enough to allow for propercondensate trap installation and drainage.
Step 3—Provide Clearances
The requiredminimumserviceclearancesareshown inFig.3 and 4. Adequate ventilation and outdoor air must beprovided.Theoutdoor fandrawsair through theoutdoor coiland discharges it through the top fan grille. Be sure that thefandischargedoesnot recirculate to theoutdoor coil.Donotlocate the unit in either a corner or under an overheadobstruction. The minimum clearance under a partialoverhang (such as a normal house overhang) is 48 in.(1219mm) above the unit top. The maximum horizontalextension of a partial overhang must not exceed 48in.(1219mm).
IMPORTANT: Do not restrict outdoor airflow. An airrestriction at either the outdoor--air inlet or the fan dischargemay be detrimental to compressor life.
Do not place the unit where water, ice, or snow from anoverhang or roof will damage or flood the unit. Do not installthe unit on carpeting or other combustible materials.Slab--mounted units should be at least 4 in. (102mm) abovethe highest expected water and runoff levels. Do not useunit if it has been under water.
Step 4—Field Fabricate Ductwork
Secure all ducts to roof curb and building structure onvertical discharge units. Do not connect ductwork to unit.
For horizontal applications, unit is provided with flanges onthe horizontal openings. All ductwork should be secured tothe flanges. Insulate and weatherproof all externalductwork, joints, and roof openings with counter flashingand mastic in accordance with applicable codes.
Ducts passing through an unconditioned space must beinsulated and covered with a vapor barrier.
If a plenum return is usedonavertical unit, the return shouldbe ducted through the roof deck to comply with applicablefire codes.
A minimum clearance is not required around ductwork.Cabinet return--air static shall not exceed --.25 in. wc.
Step 5—Rig and Place Unit
Rigging and handling of this equipment can be hazardousfor many reasons due to the installation location (roofs,elevated structures, etc.).
Only trained, qualified crane operators and ground supportstaff should handle and install this equipment.
When working with this equipment, observe precautions inthe literature, on tags, stickers, and labels attached to theequipment, and any other safety precautions that mightapply.
Training for operators of the lifting equipment shouldinclude, but not be limited to, the following:1. Application of the lifter to the load, and adjustment ofthe lifts to adapt to various sizes or kinds of loads.
2. Instruction in any special operation or precaution.3. Condition of the load as it relates to operation of thelifting kit, such as balance, temperature, etc.
Follow all applicable safety codes. Wear safety shoes andwork gloves.
INSPECTION
Prior to initial use, and at monthly intervals, all riggingbrackets and straps should be visually inspected for anydamage, evidence of wear, structural deformation, orcracks. Particular attention should be paid to excessivewear at hoist hooking points and load support areas.Brackets or straps showing any kind of wear in these areasmust not be used and should be discarded.
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personalinjury or death.
Before installing or servicing system, always turn offmain power to system. There may be more than onedisconnect switch. Turn off accessory heater powerswitch if applicable. Tag disconnect switchwith a suitablewarning label.
! WARNING
UNIT FALLING HAZARD
Failure to follow this warning could result in personalinjury or death.
Never stand beneath rigged units or lift over people.
! WARNING
4
PROPERTY DAMAGE HAZARD
Failure to follow this warning could result in personalinjury/death or property damage.
Rigging brackets for one unit use only. Whenremoving a unit at the end of its useful life, use a new setof brackets.
! WARNING
USE OF RIGGING BRACKETNOTE: Rigging brackets are factory installed on 3--phaseunits only. Single--Phase units require accessory kitNPLIFTBK003A10.
Field Installation of RiggingBracket (if not already installed)1. Remove unit from shipping carton. Leave top shippingskid on the unit for use as a spreader bar to prevent therigging straps from damaging the unit. If the skid is notavailable, use a spreader bar of sufficient length toprotect the unit from damage.
2. Remove 4 screws in unit corner posts.3. Attach each of the 4 metal rigging brackets under thepanel rain lip (See Fig. 5). Use the screws removed instep 2 above to secure the brackets to the unit.
PROPERTY DAMAGE HAZARD
Failure to follow this warning could result in personalinjury/death or property damage.
Rigging bracket MUST be under the rain lip to provideadequate lifting.
! WARNING
PROPERTY DAMAGE HAZARD
Failure to follow this warning could result in personalinjury/death or property damage.
Do not strip screws when re--securing the unit. If a screwis stripped, replace the stripped onewith a larger diameterscrew (included). When straps are taut, the clevis shouldbe a minimum of 36 (914mm) inches above the unit topcover.
! WARNING
Rigging/Lifting of Unit
1. Bend top of brackets down approximately 30 degreesfrom the corner posts.
2. Attach straps of equal length to the rigging brackets atopposite ends of the unit. Be sure straps are rated tohold the weight of the unit (See Fig. 5).
3. Attach a clevis of sufficient strength in themiddle of thestraps. Adjust the clevis location to ensure unit is liftedlevel with the ground.
4. After unit is securely in place detach rigging straps.Remove corner posts screws, and rigging bracketsthen reinstall screws.
After the unit is placed on the roof curb or mounting pad,remove the top crating.
5
FIGURE 3 PAN324--36 DIMENSIONS
REQUIRED CLEARANCE FOR OPERATION AND SERVICINGINCHES [mm]
EVAP. COIL ACCESS SIDE............................................................36.00 [914.0]POWER ENTRY SIDE....................................................................42.00 [1066.8](EXCEPT FOR NEC REQUIREMENTS)UNIT TOP .......................................................................................48.00 [1219.2]SIDE OPPOSITE DUCTS ..............................................................36.00 [914.0]DUCT PANEL .................................................................................12.00 [304.8] *
*MINIMUM DISTANCES: IF UNIT IS PLACED LESS THAN 304.8 [12.00] FROM WALL SYSTEM, THEN SYSTEM PERFORMANCE MAYBE COMPROMISE.
REQUIRED CLEARANCE TO COMBUSTIBLE MATL.
INCHES [mm]TOP OF UNIT...................................................................................14.00 [355.6]DUCT SIDE OF UNIT.........................................................................2.00 [50.8]SIDE OPPOSITE DUCTS ................................................................14.00 [355.6]BOTTOM OF UNIT .............................................................................0.50 [12.7]
NEC. REQUIRED CLEARANCES.INCHES [mm]
BETWEEN UNITS, POWER ENTRY SIDE ....................................42.00 [1066.8]UNIT AND UNGROUNDED SURFACES, POWER ENTRY SIDE .36.00 [914.0]UNIT AND BLOCK OR CONCRETE WALLS AND OTHERGROUNDED SURFACES, POWER ENTRY SIDE.........................42.00 [1066.8]
(Refer to Maximum Operating Clearances)
*Minimum distances: if unit is placed less than 304.8 (12.00) from wallsystem, then systerm performance may be compromised.
REQUIRED CLEARANCE FOR OPERATION AND SERVICINGINCHES [mm]
EVAP. COIL ACCESS SIDE............................................................36.00 [914.0]POWER ENTRY SIDE....................................................................42.00 [1066.8](EXCEPT FOR NEC REQUIREMENTS)UNIT TOP .......................................................................................48.00 [1219.2]SIDE OPPOSITE DUCTS ..............................................................36.00 [914.0]DUCT PANEL .................................................................................12.00 [304.8] *
*MINIMUM DISTANCES: IF UNIT IS PLACED LESS THAN 304.8 [12.00] FROM WALL SYSTEM, THEN SYSTEM PERFORMANCE MAYBE COMPROMISE.
REQUIRED CLEARANCE TO COMBUSTIBLE MATL.
INCHES [mm]TOP OF UNIT...................................................................................14.00 [355.6]DUCT SIDE OF UNIT.........................................................................2.00 [50.8]SIDE OPPOSITE DUCTS ................................................................14.00 [355.6]BOTTOM OF UNIT .............................................................................0.50 [12.7]
NEC. REQUIRED CLEARANCES.INCHES [mm]
BETWEEN UNITS, POWER ENTRY SIDE ....................................42.00 [1066.8]UNIT AND UNGROUNDED SURFACES, POWER ENTRY SIDE .36.00 [914.0]UNIT AND BLOCK OR CONCRETE WALLS AND OTHERGROUNDED SURFACES, POWER ENTRY SIDE.........................42.00 [1066.8]
(Refer to Maximum Operating Clearances)
*Minimum distances: if unit is placed less than 304.8 (12.00) from wallsystem, then systerm performance may be compromised.
*Required filter sizes shown are based on the larger of the ARI (Air Conditioning and Refrigeration Institute) rated cooling airflowor the heating airflow velocity of 300 ft/minute for throwaway type. For permanent filters, follow filter manufacturer’srecommendations for filter size based on allowable face velocity. Air filter pressure drop for non--standard filters must not exceed0.08 in. wc.
lb kg lb kg lb kg lb kg lb kg lb kgUnit OnlyWeight 318 144 330 150 335 152 Unit Only
Weight 412 187 442 200 446 202
CornerWeight 1 60 27 69 31 72 33 Corner
Weight 1 74 34 88 40 88 40
CornerWeight 2 42 19 50 23 41 19 Corner
Weight 2 56 25 59 27 61 28
CornerWeight 3 80 36 71 32 80 36 Corner
Weight 3 107 49 110 50 112 51
CornerWeight 4 136 62 140 64 142 64 Corner
Weight 4 175 79 185 84 185 84
RiggingWeight 328 149 340 154 345 156 Rigging
Weight 427 194 457 207 461 209
ShippingWeight 358 162 370 368 375 170 Shipping
Weight 472 214 502 228 506 230
8
Step 6—Connect Condensate Drain
NOTE: When installing condensate drain connection besure to comply with local codes and restrictions.
The PAN3 disposes of condensate water through a 3/4 in.NPT fitting which exits through the base on the evaporatorcoil access side. See Fig. 3 & 4 for location.
Condensate water can be drained directly onto the roof inrooftop installations (where permitted) or onto a gravelapron in ground level installations. Install a field--supplied2--in. condensate trap at the end of condensate connectionto ensure proper drainage. Make sure that the outlet of thetrap is at least 1 in. lower than the drain--pan condensateconnection toprevent thepan fromoverflowing (SeeFig. 6).Prime the trapwithwater.Whenusing a gravel apron,makesure it slopes away from the unit.
Connect a drain tube using a minimum of 3/4--in. PVC or3/4--in. copper pipe (all field--supplied) at the outlet end ofthe 2--in. (51mm) trap. Do not undersize the tube. Pitch thedrain tube downward at a slope of at least 1--in. (25mm) forevery 10 ft (3048mm) of horizontal run. Be sure to check thedrain tube for leaks.
FIGURE 6 Condensate Drain
TRAPOUTLET
2" min.
1" min.
Step 7—Select and Install Duct Connections
The design and installation of the duct system must be inaccordance with the standards of the NFPA for installationof non--residence type air conditioning and ventilatingsystems, NFPA 90A or residence type, NFPA 90B and/orlocal codes and ordinances.
Select and size ductwork, supply--air registers, and returnair grilles according to ASHRAE (American Society ofHeating, Refrigeration, and Air Conditioning Engineers)recommendations.Theunit hasduct flangeson thesupply--and return--air openings on the side of the unit.
When designing and installing ductwork, consider thefollowing:1. All units should have field--supplied filters or accessoryfilter rack installed in the return--air 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 airperformance.
IMPORTANT: Use flexible transitions between ductworkand unit to prevent transmission of vibration. Use suitablegaskets to ensure weather tight and airtight seal. Whenelectric heat is installed, use fireproof canvas (or similarheat resistant material) connector between ductwork andunit discharge connection. If flexible duct is used, insert a
sheet metal sleeve inside duct. Heat resistant ductconnector (or sheet metal sleeve) must extend 24--in. fromelectric heater element.
3. Size ductwork for cooling air quantity (cfm). Theminimum air quantity for proper electric heateroperation is listed in Table 2. Heater limit switches maytrip at air quantities below those recommended.
4. Seal, insulate, and weatherproof all external ductwork.Seal, insulate and cover with a vapor barrier allductwork passing through conditioned spaces. Followlatest Sheet Metal and Air Conditioning ContractorsNational Association (SMACNA) and Air ConditioningContractors Association (ACCA) minimum installationstandards for residential heating and air conditioningsystems.
5. Secure all ducts to building structure. Flash,weatherproof, and vibration--isolate duct openings inwall or roof according to good construction practices.
CONFIGURING UNITS FOR DOWNFLOW (VERTICAL)DISCHARGE
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personalinjury or death.
Before installing or servicing system, turn off the powersupply to the unit and install lockout tag. There may bemore than one disconnect switch.
! WARNING
1. Open all electrical disconnects before starting anyservice work.
2. Remove return duct cover located on duct panel bybreaking four (4) connecting tabs with screwdriver anda hammer (see Fig. 7 & 8).
3. To remove supply duct cover, break front and right sideconnecting tabs with a screwdriver and a hammer.Push louver down to break rear and left side tabs (seeFig. 7 & 8).
4. If unit ductwork is to be attached to vertical openingflanges on the unit base (jackstand applications only),do so at this time. Collect ALL screws that wereremoved. Do not leave screws on rooftop, aspermanent damage to the roof may occur.
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in propertydamage.
Collect ALL screws that were removed. Do not leavescrews on rooftop as permanent damage to the roofmay occur.
CAUTION!
5. It is recommended that the base insulation around theperimeter of the vertical return--air opening be securedto the base with aluminum tape. Applicable local codesmay require aluminum tape to prevent exposedfiberglass.
6. Cover both horizontal duct openings with the providedduct covers. Ensure opening is air and water tight.
7. After completing unit conversion, perform all safetychecks and power up unit.
9
NOTE: The design and installation of the duct systemmustbe in accordance with the standards of the NFPA forinstallation of nonresidence--type air conditioning andventilating systems, NFPA 90A or residence--type, NFPA90B; and/or local codes and ordinances.
FIGURE 7 Supply and Return Duct Opening
SUPPLYDUCTOPENING
RETURNDUCTOPENING
VENT HOODSHIPPINGLOCATION
FIGURE 8 Vertical Duct Cover Removed
DUCT COVERS REMOVED
Adhere to the following criteria when selecting, sizing, andinstalling the duct system:1. Units are shipped for horizontal duct installation (byremoving duct covers).
2. Select and size ductwork, supply--air registers, andreturn--air grilles according to American Society ofHeating, Refrigeration and Air Conditioning Engineers(ASHRAE) recommendations.
3. Use flexible transition between rigid ductwork and unitto prevent transmission of vibration. The transitionmaybe screwed or bolted to duct flanges. Use suitablegaskets to ensure weather--tight and airtight seal.
4. All units must have field--supplied filters or accessoryfilter rack installed in the return--air side of the unit.Recommended sizes for filters are shown in Table 1.
5. Size all ductwork for maximum required airflow (eitherheating or cooling) for unit being installed. Avoid abruptduct size increases or decreases or performance maybe affected.
6. Adequately insulate and weatherproof all ductworklocated outdoors. Insulate ducts passing throughunconditioned space, and use vapor barrier inaccordance with latest issue of Sheet Metal and AirConditioning Contractors National Association(SMACNA) and Air Conditioning Contractors ofAmerica (ACCA) minimum installation standards forheating and air conditioning systems. Secure all ductsto building structure.
7. Flash, weatherproof, and vibration isolate all openingsin building structure in accordancewith local codes andgood building practices.
Step 8—Install Electrical Connections
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personalinjury or death.
The unit cabinet must have an uninterrupted, unbrokenelectrical ground. This ground may consist of anelectrical wire connected to the unit ground screw in thecontrol compartment, or conduit approved for electricalground when installed in accordance with NEC,ANSI/NFPA American National StandardsInstitute/National Fire Protection Association (latestedition) (in Canada, Canadian Electrical Code CSAC22.1) and local electrical codes.
! WARNING
UNIT COMPONENT DAMAGE HAZARD
Failure to follow this caution may result in damage to theunit being installed.
1. Make all electrical connections in accordance withNEC ANSI/NFPA (latest edition) and local electricalcodes governing such wiring. In Canada, allelectrical connections must be in accordance withCSA standard C22.1 Canadian Electrical Code Part1 and applicable local codes. Refer to unit wiringdiagram.
2. Use only copper conductor for connections betweenfield--supplied electrical disconnect switch and unit.DO NOT USE ALUMINUM WIRE.
3. Be sure that high--voltage power to unit is withinoperating voltage range indicated on unit ratingplate.
4. Do not damage internal components when drillingthrough any panel to mount electrical hardware,conduit, etc.
! CAUTION
HIGH--VOLTAGE CONNECTIONS
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personalinjury or death.
Before making any wiring changes, make sure the gassupply is switched off first. Then switch off the powersupply to the unit and install lockout tag.
! WARNING
10
The unit must have a separate electrical service with afield--supplied,waterproofdisconnect switchmountedat, orwithin sight from the unit. Refer to the unit rating plate, NECand local codes for maximum fuse/circuit breaker size andminimum circuit amps (ampacity) for wire sizing.
The field--supplied disconnect switch box may be mountedon the unit over the high--voltage inlet hole when thestandardpower and low--voltageentry pointsare used (SeeFig. 3 and 4 for acceptable location).
If the unit has an electric heater, a second disconnect maybe required. Consult the Installation, Start--Up, and ServiceInstructions provided with the accessory for electricalservice connections.
Operationof unit on improper line voltage constitutesabuseand may cause unit damage that could affect warranty.
Proceed as follows to complete the high--voltageconnections to the unit.
Single phase units:1. Run the high--voltage (L1, L2) and ground lead into thecontrol box.
2. Connect ground lead to chassis ground connection.3. Locate the black and yellowwires connected to the lineside of the contactor.
4. Connect field L1 to black wire on connection 11 of thecompressor contactor.
5. Connect field wire L2 to yellowwire on connection 23 ofthe compressor contactor.
SPECIAL PROCEDURES FOR 208--V OPERATION1. Disconnect the black primary lead from thetransformer. See unit wiring label (see Fig. 9).
2. Connect the black primary lead to the transformerterminal labeled 208--v.
Indoor blower--motor speeds may need to be changed for208--v operation. Refer to indoor airflow and airflowadjustments section.
CONTROL VOLTAGE CONNECTIONS
Donot use any type of power--stealing thermostat. Unitcontrol problems may result.
Use no. 18 American Wire Gage (AWG) color--coded,insulated (35°Cminimum)wires tomake the control voltageconnections between the thermostat and the unit. If thethermostat is locatedmore than100 ft (30.5m) from theunit(as measured along the control voltage wires), use no. 16AWG color--coded, insulated (35° C minimum) wires.
STANDARD CONNECTION
Remove knockout hole located in the electric heat paneladjacent to the control access panel. See Fig. 3 & 4.Remove the rubber grommet from the installer’s packet(included with unit) and install grommet in the knockoutopening. Provide a drip loop before running wire throughpanel.
Run the low--voltage leads from the thermostat, through theinlet hole, and into unit low--voltage splice box.
Locate 18--gage wires leaving control box. Theselow--voltage connection leads can be identified by thecolors red, green, yellow, brown (See Fig. 9).
NOTE:If auxiliary electric heat is installed, there may beadditional low voltage control wires.
Ensure the leads are long enough to be routed into thelow--voltage splice box (located below right side of controlbox). Route leads through hole in bottom of control box andmake low--voltage connections (See Fig. 9). Secure all cutwires, so that they do not interfere with operation of unit.
TRANSFORMER PROTECTION
The transformer is of the energy--limiting type. It is set towithstand a 30--second overload or shorted secondarycondition. If an overload or short is present, correctoverload condition and check for blower fuse on controlboard. Replace fuse as required with correct size andrating.
Failure to follow this warning could result in personalinjury or death.1. Follow recognized safety practices and wearprotective goggles when checking or servicingrefrigerant system.
2. Relieve and recover all refrigerant from systembefore touching or disturbing anything insideterminal box if refrigerant leak is suspected aroundcompressor terminals.
3. Never attempt to repair soldered connection whilerefrigerant system is under pressure.
4. Do not use torch to remove any component. Systemcontains oil and refrigerant under pressure.
5. To remove a component, wear protective gogglesand proceed as follows:
a. Shut off electrical power to unit and installlockout tag.
b. Relieve and reclaim all refrigerant fromsystem using both high-- and low--pressureports.
c. Cut component connecting tubing with tubingcutter and remove component from unit.
d. Carefully unsweat remaining tubing stubswhen necessary. Oil can ignite when exposedto torch flame.
! WARNING
Use the Start--Up Checklist supplied at the end of this bookand proceed as follows to inspect and prepare the unit forinitial start--up:1. Remove access panel.2. Read and follow instructions on all DANGER,WARNING, CAUTION, and INFORMATION labelsattached to, or shipped with unit.
3. Make the following inspections:a. Inspect for shipping and handling damage, such asbroken lines, loose parts, disconnected wires, etc.
b. Inspect for oil at all refrigerant tubing connectionsand on unit base. Detecting oil generally indicatesa refrigerant leak.
c. Leak--test all refrigerant tubing connections usingelectronic leak detector, or liquid--soap solution. Ifa refrigerant leak is detected, see following Checkfor Refrigerant Leaks section.
d. Inspect all field-- and factory--wiring connections.Be sure that connections are completed and tight.
e. Ensure wires do not touch refrigerant tubing orsharp sheet metal edges.
f. Inspect coil fins. If damaged during shipping andhandling, carefully straighten fins with a fin comb.
4. Verify the following conditions:a. Make sure that condenser--fan blade is correctlypositioned in fan orifice. Top 1/3 of condenser--fanblade should be within fan orifice venturi.
b. Make sure that condensate drain pan and trap arefilled with water to ensure proper drainage.
c. Make sure that all tools and miscellaneous looseparts have been removed.
FIGURE 10 Fan Blade Clearance
FAN GRILLEMOTOR
1/8" MAX BETWEENMOTOR AND FAN HUB MOTOR SHAFT
1/2ý
START--UP
Step 1—CHECK FOR REFRIGERANT LEAKS
Proceed as follows to locate and repair a refrigerant leakand to charge the unit:1. Locate leak and make sure that refrigerant systempressure has been relieved and reclaimed from bothhigh-- and low--pressure ports.
2. Repair leak following accepted practices.
NOTE: Install a filter drier whenever the system has beenopened for repair.
3. Add a small charge of R--22 refrigerant vapor to systemand leak--test unit.
4. Recover refrigerant from refrigerant system andevacuate to 500 microns if no additional leaks arefound.
5. Charge unit with R--22 refrigerant, using a volumetriccharging cylinder or accurate scale. Refer to unit ratingplate for required charge. Be sure to add extrarefrigerant to compensate for internal volume of filterdrier.
STEP 2—START--UP ADJUSTMENTS
Complete the required procedures given in thePre--Start--Up section before starting the unit. Do notjumper any safety devices when operating the unit. Do notoperate the unit in cooling mode when the outdoortemperature is below 40°F (unless accessory low--ambientkit is installed). Do not rapid cycle the compressor. Allow 5min. between “on” cycles to prevent compressor damage.
CHECK COOLING CONTROL
Start and check the unit for proper cooling operation asfollows:1. Place room thermostat SYSTEM switch in OFFposition. Observe that blower motor starts when FANswitch is placed in ON position and shuts down within60 sec. when FAN switch is placed in AUTO position.
2. Place SYSTEM switch in COOL position and FANswitch in AUTO position. Set control below roomtemperature. Observe that cooling cycle shuts downwhen control setting is satisfied.
12
FIGURE 11 PAN324--60 Wiring Diagram
13
CHECKING AND ADJUSTING REFRIGERANT CHARGE
The refrigerant system is fully charged with R--22refrigerant and is tested and factory sealed. Allow systemto operate a minimum of 10 minutes before checking oradjusting charge.
The refrigerant system is fully charged with R--22refrigerant and is tested and factory sealed.NOTE: Adjustment of the refrigerant charge is not requiredunless the unit is suspected of not having the proper R--22charge.
A refrigerant charging label is attached to the outside of theservice access panel.
The charging label and tables shown refer to systemtemperatures and pressures in cooling mode only.
NOTE: Allow system to operate for a minimum of 10minutes before checking or adjusting refrigerant charge.
IMPORTANT: When evaluating the refrigerant charge, anindicated adjustment to the specified factory charge mustalways be very minimal. If a substantial adjustment isindicated, an abnormal condition exists somewhere in thecooling system, such as insufficient airflow across eithercoil or both coils.
The charging chart (see Table 4) includes the requiredsuction line temperature at given suction line pressuresandoutdoor ambient temperatures.
An accurate thermocouple or thermistor--type thermometerand a gauge manifold are required when using thesuperheat charging method for evaluating the unit charge.Do not use mercury or small dial--type thermometersbecause they are not adequate for this type ofmeasurement.
Proceed as follows:1. Remove caps from low-- and high--pressure servicefittings.
2. Using hoses with valve core depressors, attach low--and high--pressure gauge hoses to low-- andhigh--pressure service fittings, respectively.
3. Start unit and let run until system pressures stabilize.4. Measure and record the following:
a. Outdoor ambient--air temperature (°F (°C) db).b. Suction--tube temperature (°F (°C)) at low--sideservice fitting.
c. Suction (low--side) pressure (psig).5. Using Cooling Charging Charts compare outdoor--airtemperature (°F (°C) db) with the suction line pressure(psig) to determine desired system operating suctionline temperature (See Table 5A).
6. Compareactual suction--tube temperaturewithdesiredsuction--tube temperature. Using a tolerance of ±3°F(±1.7°C), add refrigerant if actual temperature is morethan 3°F (1.7°C) higher than proper suction--tubetemperature, or remove refrigerant if actualtemperature is more than 3°F (1.7°C) lower thanrequired suction--tube temperature.
NOTE: If the problem causing the inaccurate readings is arefrigerant leak, refer to Check for Refrigerant Leakssection.
INDOOR AIRFLOW AND AIRFLOW ADJUSTMENTS
NOTE: For cooling operation, the recommended airflow is350 to 450 cfm for each 12,000 Btuh of rated coolingcapacity.
Table 6 shows cooling airflows at various external staticpressures.Refer to this table to determine the airflow for thesystem being installed.
NOTE: Be sure that all supply-- and return--air grilles areopen, free from obstructions, and adjusted properly.
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personalinjury or death.
Disconnect electrical power to the unit and install lockouttag before changing blower speed.
! WARNING
Airflow can be changed by changing the lead connectionsof the blower motor.
All PAN3 units are factory wired for low speed, except sizes030 through 048 which are wired for medium speed.
FOR 208/230V
For color coding on the 208/230Vmotor leads, see Table 3.
Table 3—Color Coding for 208/230V Motor LeadsBlack = High SpeedBlue = Medium SpeedRed = Low Speed
To change the speed of the indoor fan motor (IFM), removethe fan motor speed leg lead from the time delay relay(TDR). To change the speed, remove and replace with leadfor desired blower motor speed. Insulate the removed leadto avoid contact with chassis parts.
COOLING SEQUENCE OF OPERATION
With the room thermostat SYSTEM switch in the COOLposition and the FAN switch in the AUTO position, thecooling sequence of operation is as follows:
When the room temperature rises to a point that is slightlyabove the cooling control setting of the thermostat, thethermostat completes the circuit between thermostatterminal R to terminals Y and G. These completed circuitsthrough the thermostat connect contactor coil (C) (throughunit wire Y) and time delay relay (TDR) (through unit wireG)across the 24--v secondary of transformer (TRAN).
The normally open contacts of energized contactor (C)close and complete the circuit through compressor motor(COMP) to condenser (outdoor) fan motor (OFM). Bothmotors start instantly.
The set of normally open contacts of energized relay TDRclose and complete the circuit through evaporator blower(indoor) fan motor (IFM).
NOTE: Once the compressor has started and then hasstopped, it should not be started again until 5 minutes haveelapsed.The cooling cycle remains on until the room temperaturedrops to a point that is slightly below the cooling controlsetting of the room thermostat. At this point, the thermostat
14
breaks the circuit between thermostat terminal R toterminals Y and G. These open circuits deenergizecontactor coil C and relay coil TDR. The condenser andcompressor motors stop. After a 30--second delay, the
blower motor stops. The unit is in a standby condition,waiting for the next call for cooling from the roomthermostat.
Table 4—Cooling Charging Chart
Table 5—PAN3 Wet Coil Pressure Drop (in. wc)UNITSIZE
*Air delivery values are without air filter and are for dry coil (see Wet Coil Pressure Drop table).1Factory--shipped cooling speedNote: Deduct field--supplied air filter pressure drop and wet coil pressure drop to obtain external static pressure available forducting.
MAINTENANCE
To ensure continuing high performance and tominimize thepossibility of premature equipment failure, periodicmaintenance must be performed on this equipment. Thisunit should be inspected at least once each year by aqualified service person. To troubleshoot unit, refer to Table8, Troubleshooting Chart.
NOTETOEQUIPMENTOWNER:Consult your local dealerabout the availability of a maintenance contract.
PERSONAL INJURY AND UNIT DAMAGE HAZARD
Failure to follow this warning could result in personalinjury or death and unit component damage.
The ability to properly perform maintenance on thisequipment requires certain expertise, mechanical skills,tools and equipment. If you do not possess these, do notattempt to perform any maintenance on this equipment,other than those procedures recommended in theOwner’s Manual.
! WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow these warnings could result in personalinjury or death:1. Turn off power supply to unit and insstall lockout tagbefore performing any maintenance or service onthis unit.
2. Use extreme caution when removing panels andparts.
3. Never place anything combustible either on or incontact with the unit.
! WARNING
UNIT OPERATION HAZARD
Failure to follow this caution may result in improperoperation.
Errors made when reconnecting wires may causeimproper and dangerous operation. Label all wires priorto disconnecting when servicing.
CAUTION!
The minimum maintenance requirements for thisequipment are as follows:1. Inspect air filter(s) each month. Clean or replace whennecessary.
16
2. Inspect indoor coil, drain pan, and condensate draineach cooling season for cleanliness. Clean whennecessary.
3. Inspect blower motor and wheel for cleanliness at thebeginning of each heating and cooling season. Cleanwhen necessary.
4. Check electrical connections for tightness and controlsfor proper operation each heating and cooling season.Service when necessary.
5. Ensure electric wires are not in contact with refrigeranttubing or sharp metal edges.
AIR FILTER
IMPORTANT: Never operate the unit without a suitable airfilter in the return--air duct system. Always replace the filterwith the same dimensional size and type as originallyinstalled. 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 twiceduring each cooling season and twice during the heatingseason, or whenever the filter becomes clogged with dustand lint.
INDOOR BLOWER AND MOTOR
NOTE: All motors are pre--lubricated. Do not attempt tolubricate these motors.
For longer life, operating economy, and continuingefficiency, clean accumulated dirt and grease from theblower wheel and motor annually.
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personalinjury or death.
Disconnect and tag electrical power to the unit beforecleaning the blower motor and wheel.
! WARNING
To clean the blower motor and wheel:1. Remove and disassemble blower assembly as follows:
a. Remove unit access panel.b. Disconnect motor lead from time delay relay(TDR). Disconnect yellow lead from terminal L2 ofthe contactor.
c. On all units remove blower assembly from unit.Removescrewssecuringblower to blower partitionand slide assembly out. Be careful not to tearinsulation in blower compartment.
d. Ensure proper reassembly by marking blowerwheel and motor in relation to blower housingbefore disassembly.
e. Loosen setscrew(s) that secures wheel to motorshaft, remove screws that secure motor mountbrackets to housing, and slide motor and motormount out of housing.
2. Remove and clean blower wheel as follows:a. Ensure proper reassembly by marking wheelorientation.
b. Lift wheel from housing. When handling and/orcleaning blower wheel, be sure not to disturbbalance weights (clips) on blower wheel vanes.
c. Remove caked--on dirt from wheel and housingwith abrush.Remove lint and/or dirt accumulationsfrom wheel and housing with vacuum cleaner,using soft brush attachment. Remove grease andoil with mild solvent.
d. Reassemble wheel into housing.e. Reassemble motor into housing. Be suresetscrews are tightened on motor shaft flats andnot on round part of shaft.
f. Reinstall unit access panel.3. Restore electrical power to unit. Start unit and check forproper blower rotation and motor speeds duringheating and cooling cycles.
OUTDOOR COIL, INDOOR COIL, AND CONDENSATEDRAIN PAN
Inspect the condenser coil, evaporator coil, andcondensate drain pan at least once each year.
The coils are easily cleaned when dry; therefore, inspectand clean the coils either before or after each coolingseason. Remove all obstructions, including weeds andshrubs that interfere with the airflow through the condensercoil.
Straighten bent finswith a fin comb. If coatedwith dirt or lint,clean the coils with a vacuum cleaner, using the soft brushattachment. Be careful not to bend the fins. If coated with oilor grease, clean the coils with a mild detergent and watersolution. Rinse coils with clear water, using a garden hose.Be careful not to splash water onmotors, insulation, wiring,or air filter(s). For best results, spray condenser coil finsfrom inside to outside the unit. On units with an outer andinner condenser coil, be sure to clean between the coils. Besure to flush all dirt and debris from the unit base.
Inspect the drain pan and condensate drain line wheninspecting the coils. Clean the drain pan and condensatedrain by removing all foreignmatter from the pan. Flush thepan and drain trough with clear water. Do not splash wateron the insulation, motor, wiring, or air filter(s). If the draintrough is restricted, clear it with a “plumbers snake” orsimilar probe device.
OUTDOOR FAN
UNIT OPERATION HAZARD
Failure to follow this caution may result in damage tounit components.
Keep the condenser fan free from all obstructions toensure proper cooling operation. Never place articleson top of the unit.
CAUTION!
1. Remove 6 screws holding outdoor grille and motor totop cover.
2. Turnmotor/grille assembly upside downon top cover toexpose fan blade.
3. Inspect the fan blades for cracks or bends.4. If fan needs to be removed, loosen setscrew and slidefan off motor shaft.
17
5. When replacing fan blade, position blade so that thehub is 1/8 in. (3mm) away from the motor end (1/8 in.(3mm) of motor shaft will be visible) (See Fig. 12).
6. Ensure that setscrew engages the flat area on themotor shaft when tightening.
7. Replace grille.ELECTRICAL CONTROLS AND WIRING
Inspect and check the electrical controls and wiringannually. Be sure to turn off the electrical power to the unit.
Remove access panel to locate all the electrical controlsand wiring. Check all electrical connections for tightness.Tighten all screw connections. If any smoky or burnedconnections are noticed, disassemble the connection,clean all the parts, re--strip thewire end and reassemble theconnection properly and securely.
After inspecting the electrical controls and wiring, replaceall the panels. Start the unit, and observe at least onecomplete cooling cycle to ensure proper operation. Ifdiscrepancies are observed in operating cycle, or if asuspected malfunction has occurred, check each electricalcomponentwith theproper electrical instrumentation.Referto the unit wiring label when making these checks.
REFRIGERANT CIRCUIT
Inspect all refrigerant tubing connections and the unit basefor oil accumulation annually. Detecting oil generallyindicates a refrigerant leak.
EXPLOSION, PERSONAL INJURY, EVIRONMENTALHAZARD
Failure to follow this warning could result in propertydamage, personal injury or death.
System under pressure. Relieve pressure and recoverall refrigerant before system repair or final unit disposal.Use all service ports and open all flow--control devices,including solenoid valves.
! WARNING
If oil is detected or if lowperformance is suspected, leak testall refrigerant tubing using an electronic leak detector, orliquid--soap solution. If a refrigerant leak is detected, referto Check for Refrigerant Leaks section.
If no refrigerant leaks are found and low performance issuspected, refer to Checking and Adjusting RefrigerantCharge section.
INDOOR AIRFLOW
The cooling airflow does not require checking unlessimproper performance is suspected. If a problem exists, besure that all supply-- and return--air grilles are open and freefrom obstructions, and that the air filter is clean.
METERING DEVICES--PISTON
Refrigerant metering device is a fixed orifice and is locatedin the distributor assembly to the indoor coil.
There is a liquid header with a brass distributor and feedertube going into outdoor coil. At the end of one of the feedertubes, there is a 3/8--in. OD stub tube approximately 3 in.long (seeFig. 21). Thedefrost thermostat should be locatedon this stub tube. Note that there is only one stub tube usedwith liquid header, and on most units it is the bottom circuit.
TROUBLESHOOTING
Refer to the Troubleshooting Chart (Table 9) fortroubleshooting information.
START--UP CHECKLIST
Use the Start--Up Checklist at the back of this manual.
18
Table 7—Troubleshooting Chart
SYMPTOM CAUSE REMEDY
Compressor and outdoor fan will notstart
Power failure Call power companyFuse blown or circuit breaker tripped Replace fuse or reset circuit breakerDefective contactor, transformer, control relay, orhigh--pressure, loss--of--charge or low--pressureswitch
Replace component
Insufficient line voltage Determine cause and correctIncorrect or faulty wiring Check wiring diagram and rewire correctlyThermostat setting too low/too high Reset thermostat setting
Compressor will not start but condenserfan runs
Faulty wiring or circuitLoose connections in compressor Check wiring and repair or replace
Compressor motor burned out, seized, or Determine causeinternal overload open Replace compressorDefective run capacitor, overload, or PTC (posi-tive temperature coefficient) thermistor Determine cause and replace
One leg of 3--phase power dead Replace fuse or reset circuit breakerDetermine cause
Low input voltage (20 percent low) Determine cause and correct
Compressor cycles (other than normallysatisfying) cooling/heating calls
Refrigerant overcharge or underchargeRecover refrigerant, evacuate system, andrecharge to capacities shown on ratingplate
Defective compressor Replace and determine causeInsufficient line voltage Determine cause and correctBlocked outdoor coil Determine cause and correctDefective run/start capacitor, overload or startrelay Determine cause and replace
Faulty outdoor fan motor or capacitor ReplaceRestriction in refrigerant system Locate restriction and remove
Compressor operates continuously
Dirty air filter Replace filterUnit undersized for load Decrease load or increase unit sizeThermostat temperature set too low Reset thermostat settingLow refrigerant charge Locate leak, repair, and recharge
Air in system Recover refrigerant, evacuate system, andrecharge
Outdoor coil dirty or restricted Clean coil or remove restriction
Excessive head pressure
Dirty air filter Replace filterDirty indoor or outdoor coil Clean coilRefrigerant overcharged Recover excess refrigerant
Air in system Recover refrigerant, evacuate system, andrecharge
Indoor or outdoor air restricted or air short--cycling Determine cause and correct
Head pressure too lowLow refrigerant charge Check for leaks, repair and rechargeRestriction in liquid tube Remove restriction
Excessive suction pressureHigh heat load Check for source and eliminateReversing valve hung up or leaking internally Replace valveRefrigerant overcharged Recover excess refrigerant
Suction pressure too low
Dirty air filter Replace filterLow refrigerant charge Check for leaks, repair and rechargeMetering device or low side restricted Remove source of restrictionInsufficient coil airflow Check filter–replace if necessaryTemperature too low in conditioned area Reset thermostat settingOutdoor ambient below 55°F Install low--ambient kitFilter drier restricted Replace
19
START-UP CHECKLIST(Remove and Store in Job File)
I. Preliminary InformationMODEL NO.:_________________________________SERIAL NO.:__________________________________DATE:_______________________________________TECHNICIAN:_________________________________
II. PRE-START-UP (Insert checkmark 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. START-UPELECTRICALSUPPLY VOLTAGE __________________________________COMPRESSOR AMPS_________________________________INDOOR (EVAPORATOR) FAN AMPS___________TEMPERATURESOUTDOOR (CONDENSER) AIR TEMPERATURE ___________DBRETURN-AIR TEMPERATURE ___________DB ___________WBCOOLING SUPPLY AIR ___________DB ___________WB
PRESSURESREFRIGERANT SUCTION ___________PSIG SUCTION LINE TEMP*___________REFRIGERANT DISCHARGE ___________PSIG DISCHARGE TEMP†___________( ) VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS
*Measured at suction inlet to compressor†Measured at liquid line leaving condenser.
