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Payne PY4G B Series Installation Instructions Manual

14 seer single-packaged air conditioner and gas furnace system with r-410a refrigerant
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PY4G- -- -B
IMPORTANT: Effective January 1, 2015, all split system and
packaged air conditioners must be installed pursuant to applicable
regional efficiency standards issued by the Department of Energy.
NOTE:
Read the entire instruction manual before starting the
installation.
NOTE:
Installer: Make sure the Owner's Manual and Service
Instructions are left with the unit after installation.

TABLE OF CONTENTS

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14 SEER SINGLE ---PACKAGED AIR CONDITIONER AND
GAS FURNACE SYSTEM WITH R ---410A REFRIGERANT
SINGLE PHASE 2---5 NOMINAL TONS (SIZES 24---60)
THREE PHASE 3---5 NOMINAL TONS (SIZES 36---60)
Installation Instructions
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SAFETY CONSIDERATIONS
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Improper installation, adjustment, alteration, service maintenance,
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or use can cause explosion, fire, electrical shock, or other
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conditions which may cause death, personal injury, or property
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damage. Consult a qualified installer, service agency, or your
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distributor or branch for information or assistance. The qualified
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installer or agency must use factory- -authorized kits or accessories
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when modifying this product. Refer to the individual instructions
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packaged with the kits or accessories when installing.
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Follow all safety codes. Wear safety glasses, protective clothing,
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and work gloves. Have a fire extinguisher available. Read these
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instructions thoroughly and follow all warnings or cautions
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included in literature and attached to the unit. consult local
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Fig. 1 - - Unit PY4G- -- -B
(Low NOx Model Available)
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Summary of Contents for Payne PY4G B Series

  • Page 1: Table Of Contents

    PY4G- -- -B 14 SEER SINGLE ---PACKAGED AIR CONDITIONER AND GAS FURNACE SYSTEM WITH R ---410A REFRIGERANT SINGLE PHASE 2---5 NOMINAL TONS (SIZES 24---60) THREE PHASE 3---5 NOMINAL TONS (SIZES 36---60) Installation Instructions IMPORTANT: Effective January 1, 2015, all split system and packaged air conditioners must be installed pursuant to applicable regional efficiency standards issued by the Department of Energy.

  • Page 2: Introduction

    RECEIVING AND INSTALLATION building codes, the current editions of the National Fuel Gas Code (NFGC) NFPA 54/ANSI Z223.1, and the National Electrical Code Step 1 — Check Equipment (NEC) NFPA 70. Identify Unit In Canada refer to the current editions of the National Standards of The unit model number and serial number are stamped on the unit Canada CAN/CSA- -B149.1 and .2 Natural Gas and Propane information plate.

  • Page 3: Field Fabricate Ductwork

    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 OPTIONAL OPTIONAL RETURN SUPPLY lifts to adapt to various sizes or kinds of loads. OPENING OPENING 2.
  • Page 4 A150563 Fig. 3 - - 24- -36 Unit Dimensions...
  • Page 5 A150564 Fig. 4 - - 42- -60 Unit Dimensions...
  • Page 6 Dashed lines show cross support location for large basepan units. HVAC unit HVAC unit basepan base rails Sealing Gasket Roofcurb Anchor screw Wood nailer* Flashing field Roofcurb* supplied Insulation (field supplied) Roofing material field supplied Cant strip field supplied SMALL/COMMON CURB A09413 *Provided with roofcurb A09090...
  • Page 7 CAUTION - NOTICE TO RIGGERS PRUDENCE - AVIS AUX MANIPULATEUR ACCESS PANELS MUST BE IN PLACE WHEN RIGGING. PANNEAUX D'ACCES DOIT ÊTRE EN PLACE POUR MANIPULATION. Use top skid as spreader bar. / Utiliser la palette du haut comme barre de répartition DUCTS MINIMUM HEIGHT: 36"...

  • Page 8: Connect Condensate Drain

    Table 1—Physical Data Con’t UNIT SIZE 48090 48115 48130 60090 60115 60130 NOMINAL CAPACITY (ton) SHIPPING WEIGHT lb SHIPPING WEIGHT kg COMPRESSOR / QUANTITY Scroll / 1 REFRIGERANT (R --- 410A) Quantity lb Quantity (kg.) REFRIGERANT METERING DEVICE Orifice ORIFICE ID in./mm .080 / 2.03 .084 / 2.14 OUTDOOR COIL...

  • Page 9: Install Gas Piping

    NOTE: Dedicated low NOx models MUST be installed in 2. When flexible connectors are used, the maximum length shall not exceed 36 inches (915 mm). California Air Quality Management Districts where a Low NOx rule exists. 3. When lever handle type manual equipment shutoff valves are used, they shall be T- -handle valves.

  • Page 10: Install Duct Connections

    tion, and only the piece over the downshot knockout needs WARNING to be removed. Discard insulation. 4. To remove the downshot (plastic) knockouts for both sup- FIRE OR EXPLOSION HAZARD ply and returns, break front and right side connecting tabs with a screwdriver and hammer.

  • Page 11: Install Electrical Connections

    5. Size all ductwork for maximum required airflow (either codes for maximum fuse/circuit breaker size and minimum circuit heating or cooling) for unit being installed. Avoid abrupt amps (ampacity) for wire sizing. duct size increases or decreases or performance may be The field- -supplied disconnect switch box may be mounted on the affected.

  • Page 12: Standard Connection

    Standard Connection PRE- - START- - UP Run the low- -voltage leads from the thermostat, through the inlet WARNING hole, and into unit low- -voltage splice box. Locate six (seven for 3- -phase) 18- -gage wires leaving control box. These low- -voltage connection leads can be identified by the colors ENVIRONMENTAL, FIRE, EXPLOSION,...

  • Page 13: Check For Refrigerant Leaks

    Step 2 — Start- -up Heating and Make Adjust- 4. Verify the following conditions: a. Make sure gas line is free of air. Before lighting the unit ments for the first time, perform the following with the gas Complete the required procedures given in the Pre- -Start- -Up valve in the OFF position: section before starting the unit.

  • Page 14: Check Gas Input

    5. For 3- -phase models the evaporator fan will turn on 45 sec. CAUTION after the flame has been established. The evaporator fan will turn off 45 sec. after the thermostat has been satisfied. For single phase models the evaporator fan will turn on 30 sec. UNIT DAMAGE HAZARD after the flame has been established.

  • Page 15: Check Burner Flame

    4. 112.5 x 1050 = 118,125 Btuh input. 3. Replace regulator cover screw on gas valve (See Fig. 13). If the desired gas input is 115,000 Btuh, only a minor change in the 4. Turn off gas supply to unit. Remove manometer from manifold pressure is required.
  • Page 16 Table 4 – High Altitude Compensation, Natural Gas - - Single Phase Models Rated Heating Input (Btu/hr), Natural Gas at Installation Altitude Above Sea Level, U.S.A.* Nameplate 0 to 2000 ft 2001 to 3000 ft* 3001 to 4000 ft 4001 to 5000 ft 5001 to 6000 ft Input (Btu/hr) (0--- 610 m)
  • Page 17 A150502 Fig. 14 - - 208/230- -1- -60 Connection Wiring Diagram...
  • Page 18 A150510 Fig. 14 Cont. - - 208/230- -1- -60 Ladder Wiring Diagram...
  • Page 19 A150508 Fig. 15 - - 208/230- -3- -60 Connection Wiring Diagram...
  • Page 20 A150511 Fig. 15 Cont. - - 208/230- -3- -60 Ladder Wiring Diagram...
  • Page 21 A150509 Fig. 16 - - 460- -3- -60 Connection Wiring Diagram...
  • Page 22 A150512 Fig. 16 Cont. - - 460- -3- -60 Ladder Wiring Diagram...

  • Page 23: Normal Operation

    Normal Operation Table 7 – LED Indications STATUS CODE LED INDICATION An LED (light- -emitting diode) indicator is provided on the Normal Operation integrated gas unit controller (IGC) to monitor operation. The IGC No Power or Hardware Failure is located by removing the control access panel (see Fig. 20). Check fuse, low voltage circuit 1 Flash During normal operation, the LED is continuously on (See Table 7...

  • Page 24: Checking & Adjusting Refrigerant Charge

    Checking and Adjusting Refrigerant Charge (psig) to determine desired system operating liquid line temperature (See Table 9). The refrigerant system is fully charged with R- -410A refrigerant 6. Compare actual liquid line temperature with desired liquid and is tested and factory sealed. Allow system to operate a line temperature.

  • Page 25: Cooling Sequence Of Operation

    the temperature rise associated with each fan speed for a speed in Table 11 or 12 that will deliver the nominal cooling given static pressure. Make sure that the speed chosen airflow as listed in Table 1 for each size. delivers a temperature rise within the rise range listed on the 3.
  • Page 26 HEAT HIGH OILL AB A15 R3 R5 R6 C 24VAC SSTZ-8 W2 Y2/ DH G A09058 Fig. 18 - - Interface Fan Board (IFB) Shunt in no Shunt in dehumidification dehumidification position position A14399 Fig. 17 - - Single Phase IGC Board...
  • Page 27 Table 9 – Cooling Charging Chart Superheat charging table is derived from optimum performance point. (95_F [35_C] outdoor ambient and (80_F [27_C] dry bulb; 67_F [19_C] wet bulb indoor condition.) Where a dash( --- ---) appears do not attempt to check charge or charge unit under these conditions using the superheat method. (Weigh in method should be used.) A150625 To properly check or adjust charge, conditions must be favorable for subcooling charging.

  • Page 52: Maintenance

    MAINTENANCE 3. Inspect blower motor and wheel for cleanliness at the beginning of each heating and cooling season. Clean when To ensure continuing high performance and to minimize the necessary. For first heating and cooling season, inspect possibility of premature equipment failure, periodic maintenance blower wheel bi- -monthly to determine proper cleaning must be performed on this equipment.

  • Page 53: Induced Draft (Combustion Air) Blower

    f. Connect 5 pin plug and 4 pin plug to indoor blower 7. Remove the mounting screw that attaches the burner rack to motor. the unit base (See Fig. 19). g. Reinstall blower access panel (see Fig. 20). 8. Partially slide the burner rack out of the unit (see Fig. 19 3.

  • Page 54: Outdoor Fan

    A07680 Fig. 22 - - Burner Rack Removed Outdoor Fan Control CAUTION Access Panel Blower Access Panel UNIT OPERATION HAZARD Compressor Access Failure to follow this caution may result in damage to unit Panel components. A09215 Keep the condenser fan free from all obstructions to ensure Fig.

  • Page 55: Refrigerant Circuit

    FAN GRILLE MOTOR MOTOR SHAFT A08505 MAX DISTANCE BETWEEN TOP OF FAN GRILLE AND BOTTOM OF FAN BLADE “A” SIZE Fig. 23 - - Fan Blade Position Refrigerant Circuit Pressure Switches Annually inspect all refrigerant tubing connections. Pressure switches are protective devices wired into control circuit (low voltage).

  • Page 56: Troubleshooting

    Servicing Systems on Roofs with Synthetic Materials The compressor is an electrical (as well as mechanical) device. Exercise extreme caution when working near compressors. Power POE (polyolester) compressor lubricants are known to cause long should be shut off, if possible, for most troubleshooting techniques. term damage to some synthetic roofing materials.
  • Page 57 R- -410A QUICK REFERENCE GUIDE S 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 S R- -410A refrigerant cylinders are rose colored. S Recovery cylinder service pressure rating must be 400 psig, DOT 4BA400 or DOT BW400.
  • Page 58 Table 17 – Troubleshooting Chart SYMPTOM CAUSE REMEDY Power failure Call power company Fuse blown or circuit breaker tripped Replace fuse or reset circuit breaker Defective contactor, transformer, or high--pressure, Replace component loss--of--charge or low--pressure switch Compressor and condenser fan will not start. Insufficient line voltage Determine cause and correct Incorrect or faulty wiring...
  • Page 59 Table 18 – Troubleshooting Guide–Heating SYMPTOM CAUSE REMEDY Water in gas line Drain. Install drip leg. No power to furnace Check power supply fuses, wiring or circuit breaker. Check transformer. No 24--v power supply to control circuit NOTE: Some transformers have internal over--current protection that requires a cool--down period to reset.
  • Page 60 MEASURED TEMPERATURE RISE * Measured at suction inlet to compressor { Measured at liquid line leaving condenser. Catalog No: IM---PY4G ---03 E2015 Payne Heating & Cooling Systems D 7310 W. Morris St. D Indianapolis, IN 46231 Edition Date: 12/15 Replaces: NEW...

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