Payne PF4MNA - User Manual

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PF4MNA

DIRECT EXPANSION

FAN COIL UNIT

Installation Instructions

FOR R410A REFRIGERANT

SIZES 018 TO 061

NOTE: Read the entire instruction manual before starting the

installation.

TABLE OF CONTENTS

PAGE

SAFETY CONSIDERATIONS 1........................

INTRODUCTION 1..................................

HEATER PACKAGES 1..............................

INSTALLATION 1...................................

Step 1 -- Check Equipment 1..........................

Step 2 -- Mount Unit 2...............................

Step 3 -- Air Ducts 4................................

Step 4 -- Electrical Connections 4......................

Step 5 -- Refrigerant Tubing Connection and Evacuation 7...

Step 6 -- Refrigerant Flow--Control Device 7..............

Step 7 -- Condensate Drains 7.........................

Step 8 -- Accessories 8...............................

Step 9 -- Sequence of Operation 9......................

START--UP PROCEDURES 9..........................

CARE AND MAINTENANCE 9........................

AIRFLOW PERFORMANCE TABLES 10................

R--410A QUICK REFERENCE GUIDE 12................

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service, maintenance,

or use can cause explosion, fire, electrical shock, or other

conditions which may cause death, personal injury or property

damage. Consult a qualified installer, service agency, or your

distributor or branch for information or assistance. The qualified

installer or agency must use factory--authorized kits or accessories

when modifying this product. Refer to the individual instructions

packaged with kits or accessories when installing.

Follow all safety codes. Wear safety glasses, protective clothing

and work gloves. Have a fire extinguisher available. Read these

instructions thoroughly and follow all warnings or cautions

included in literature and attached to the unit. Consult local

building codes and the current editions of the National Electrical

Code (NEC) NFPA 70.

In Canada, refer to the current editions of the Canadian Electrical

Code CSA C22.1.

Recognize safety information. This is the safety--alert symbol

When you see this symbol on the unit and in instruction manuals,

be alert to the potential for personal injury.

Understand the signal words DANGER, WARNING,and

CAUTION. These words are used with the safety--alert 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.

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury

or death.

Before installing or servicing unit, always turn off all power

to unit. There may be more than 1 disconnect switch. Turn

off accessory heater power, if applicable.

WARNING

INTRODUCTION

Model PF4MNA Fan Coils are designed for flexibility and can be

used for upflow, horizontal, or downflow (kit required) and

manufactured and mobile home applications. These units are

designed to meet the low air leak requirements currently in effect.

Because of this, the units need special attention in the condensate

pan and drain connection area and when brazing tubing. These

units are designed specifically for R--410A refrigerant and must be

used only with R--410A refrigerant air conditioners and heat

pumps as shipped. These units are available for systems of 18,000

through 60,000 Btuh nominal cooling capacity.

Factory--authorized, field--installed electric heater packages are

available in sizes 5 through 30kW. See Product Data literature for

available accessory kits.

HEATER PACKAGES

Factory--approved, field--installed, UL listed heater packages are

available from your equipment supplier. See unit rating plate for a

list of factory--approved heaters. Heaters that are not factory

approved could cause damage which would not be covered under

the equipment warranty.

INSTALLATION

Step 1 — Check Equipment

Unpack unit and move to final location. Remove carton taking care

not to damage unit. Inspect equipment for damage prior to

installation. File claim with shipping company if shipment is

damaged or incomplete.

Locate unit rating plate which contains proper installation

information. Check rating plate to be sure unit matches job

specifications.

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Summary

Safety Considerations

Understanding Safety Signal Words

Explains signal words DANGER, WARNING, and CAUTION, defining hazard levels and potential outcomes.

Product Introduction and Heater Packages

Installation Overview

Check Equipment

Inspect unit upon unpacking for damage and verify it matches job specifications via the rating plate.

Unit Mounting

Upflow Installation

Details for setting up the unit for upflow airflow, including duct and gasket requirements.

Downflow Installation

Instructions for converting unit to downflow, focusing on condensate drain modifications.

Horizontal Installation

Guidance for horizontal mounting, emphasizing leveling and potential use of water management kits.

Horizontal Conversion Procedures

A-Coil Horizontal Right Conversion

Step-by-step guide to convert A-coil units for horizontal right installation, involving panel removal and component adjustment.

Slope Coil Horizontal Right Conversion

Instructions for converting slope coil units to horizontal right orientation, requiring specific gasket kits.

Ductwork Acoustical Considerations

Electrical Connections

PCB Features for Certain Models

Details the printed-circuit board (PCB) in specific models, including fuse, speed tap, and TDR jumper.

Fuse and Speed Selection for Other Models

Explains the 5 amp fuse and speed selection methods for models 019, 025, 031, 037, 043, 049, and 061.

Electrical Wiring Details

Line Voltage Wiring

Guidance on connecting 208/230v power leads and ground wire, especially with accessory electric heaters.

24-V Control System Wiring

Instructions for low voltage wiring using 18 AWG wire, specifying wire gauge based on distance.

Transformer Operation

Details on transformer wiring for 230v operation and adjustments for 208v applications.

Electrical and System Configuration

Electric Heater Staging Configuration

Explains heater staging controls, use of emergency heat relay, and specific kits for 2-stage and 3-stage operation.

Manufactured Housing Considerations

Addresses CFR requirements for supplemental electric heat lockout at 40°F (4°C) in manufactured housing.

Ground Connections and Safety

Emphasizes the necessity of an uninterrupted ground connection for safety according to NEC and local codes.

Motor and Fan Speed Selection

Motor Speed Selection for Specific Models

Details motor speed selection for different model series, including low, medium, and high speed applications.

Refrigerant System Installation

Tubing Connection and Evacuation Process

Instructions for connecting refrigerant tubing, brazing, and evacuating the system to 500 microns.

Refrigerant Flow-Control Device

Information on the R-410A refrigerant TXV and requirements for compatible outdoor units and compressors.

Condensate Drain Connections and Traps

Accessory Installation

Electric Heater Installation

Guidance on installing factory-approved electric heater kits, referring to their specific instructions.

Electronic Air Cleaner Installation

Instructions for connecting an electronic air cleaner, noting the need for a field-supplied transformer.

Sequence of Operation

Continuous Fan Operation

Describes how the unit operates in continuous fan mode, including the 90-second delay after de-energization.

Cooling Mode Operation

Details thermostat connections and fan relay operation during the cooling cycle, with a 90-second fan delay.

Heat Pump with Auxiliary Electric Heat

Explains operation when the heat pump uses auxiliary electric heat, detailing relay and element engagement.

Electric;Emergency Heat Mode

Describes operation in electric heat or emergency heat mode, including blower engagement via normally closed contacts.

Airflow Performance Tables

Table 1: Airflow Performance (CFM)

Provides CFM airflow data for various models and blower speeds across different external static pressures.

Table 2: Air Delivery Pressure Drop

Details pressure drop corrections for airflow at different conditions and sizes, crucial for system balancing.

Electric Heater Static Pressure Drop

R-410 A Quick Reference Guide

R-410 A Refrigerant Pressure and Component Compatibility

Highlights R-410A pressure differences, component compatibility, cylinder color, and manifold requirements.

Brazing Precautions for R-410 A

Advises on protecting components with wet cloths during brazing and other critical service procedures.

Observe Warnings and Cautions

Emphasizes the importance of heeding all warnings, cautions, and bold text for safe and proper operation.

The PF4MNA Direct Expansion Fan Coil Unit is a versatile indoor air handling unit designed for use with R-410A refrigerant in air conditioning and heat pump systems. It is suitable for residential and mobile home applications, offering flexibility in installation configurations (upflow, horizontal, or downflow with a kit). The unit is manufactured to meet low air leak requirements, emphasizing careful attention to condensate pan and drain connections, as well as brazing procedures.

Function Description:

The primary function of the PF4MNA fan coil is to circulate air and facilitate heat exchange within a building. In cooling mode, it works with an outdoor R-410A air conditioner to remove heat and humidity from the indoor air. In heating mode, when paired with an R-410A heat pump, it distributes warm air. The unit can also be equipped with factory-approved electric heater packages for supplemental or emergency heating. Its design ensures efficient airflow and condensate management, crucial for maintaining indoor comfort and preventing water damage.

Important Technical Specifications:

Refrigerant: Specifically designed for R-410A refrigerant.
Cooling Capacity: Available in nominal cooling capacities ranging from 18,000 to 60,000 Btuh.
Electric Heater Packages: Factory-authorized, field-installed electric heater packages are available in sizes from 5 through 30kW.
Low Air Leak Requirements: Manufactured to meet current low air leak standards.
Condensate Drains: Equipped with primary and secondary 3/4-in. FPT drain connections.
Transformer: Factory-wired for 230v operation, with a selectable 208v terminal.
Low Voltage Circuit Protection: Model sizes 018, 024, 030, 036, 042, 048, and 060 utilize a printed-circuit board (PCB) with a 5 amp protective fuse. Model sizes 019, 025, 031, 037, 043, 049, and 061 use a 5 amp automotive type fuse inline on the wire harness.
Motor Speed Taps:
- Sizes 018 through 036 have 2 motor speed taps (Low/Red for mismatched outdoor units, Medium/Blue for straight matched operations).
- Sizes 042, 048, and 060 have 3 motor speed taps (Low/Red, Medium/Blue, High/Black for high external static duct systems).
- Models 019, 025, 031, 037, 043, 049, and 061 have fan speed selection at the motor (one/low, two/medium, three/high).
Ductwork Clearance for Electric Heaters: Units with 20-30kW electric heaters require a 1-in (25 mm) clearance to combustible materials for the first 36-in (914 mm) of supply duct.
Ductwork Acoustical Treatment: Metal duct systems without a 90° elbow and 10-ft (3m) of main duct to first branch takeoff may require internal acoustical insulation lining or fibrous ductwork compliant with SMACNA standards and UL Standard 181 for Class 1 air ducts.
R-410A Refrigerant Properties: Operates at 50-70 percent higher pressures than R-22. Cylinders are rose colored. Recovery cylinder service pressure rating must be 400 psig (DOT 4BA400 or DOT BW400). Systems should be charged with liquid refrigerant using a commercial type metering device. Manifold sets should be 700 psig high side and 180 psig low side with 550 psig low-side retard. Hoses must be rated for 700 psig service pressure. Leak detectors should be designed for HFC refrigerant. R-410A is compatible only with POE oils. Vacuum pumps will not remove moisture from oil. Liquid-line filter driers must have rated working pressures less than 600 psig. Suction-line filter driers should not be left in line longer than 72 hours and should not be installed in the liquid line. POE oils absorb moisture rapidly and may damage certain plastics and roofing materials. A factory-approved liquid-line filter drier is required on every unit.
Flow-Control Device: Equipped with an R-410A refrigerant TXV. If an R-22 TXV or piston metering device is present, it must be changed to a hard-shutoff R-410A refrigerant TXV.
Capillary Tube Coils: Not to be used.

Usage Features:

Installation Flexibility: Can be installed in upflow, horizontal (left or right with conversion), or downflow (with a kit) configurations.
Modular Design: Units can be disassembled for easier transport and reassembly in tight installation spaces.
Condensate Management: Requires proper installation of primary and secondary condensate traps, with recommendations for trap depth and pitching of drain lines to prevent overflow. External condensate pans or separate secondary drain lines are recommended for installations in or above living spaces.
Motor Speed Selection: Fan motor speeds can be adjusted via terminals on the PCB (for certain models) or directly at the motor (for other models) to optimize airflow for different static pressure applications and to prevent water blow-off from the coil in low static conditions.
Time Delay Relay (TDR): Some models include a TDR jumper on the PCB, which can be severed to disable the feature.
Control System: Low voltage control wiring (18 AWG or 16 AWG for longer runs) connects the thermostat, unit, and outdoor equipment.
Heater Staging: Supports single-stage, 2-stage (with outdoor thermostat kit KHAOT0301FST), and 3-stage (with kits KHAOT0201SEC and KHAOT0301FST) electric heat operation. Emergency heat relay is required for 3-stage or when the E terminal is not tied to W2.
Manufactured Housing Compliance: For manufactured housing, supplemental electric heat must be locked out at outdoor temperatures above 40°F (4°C), except during a heat pump defrost cycle.
Accessory Connections: Provisions for connecting an electronic air cleaner (requires field-supplied transformer) and a humidifier/humidistat.

Maintenance Features:

Filter Replacement/Cleaning: The only consumer service recommended or required is filter replacement or cleaning on a monthly basis. Filters are essential for unit operation and must always be in place to prevent damage to the blower motor or coil. Factory-authorized filter kits are used for internal filter placement; for impractical internal access, a field-supplied filter must be installed in the return duct system.
Periodic Maintenance: To ensure high performance and minimize equipment failure, periodic maintenance by a qualified dealer is essential.
Service Access: Requires adequate clearance (e.g., 21" or 24" front service clearance, 1.75" filter access clearance) for wiring, piping, and servicing.
Brazing Precautions: A brazing shield must be used to prevent damage to the unit surface and condensate pan fitting caps during tubing connections. Wet cloths should be wrapped around fittings to protect TXVs and factory-made joints.
Evacuation: ALWAYS evacuate the coil and field-supplied tubing to 500 microns before opening outdoor unit service valves. The system should never be opened to atmosphere while under a vacuum. If opened for service, refrigerant must be recovered, the system evacuated, filter driers replaced, and then evacuated to 500 microns prior to recharging. R-410A refrigerant should not be vented into the atmosphere.
Grounding: The cabinet must have an uninterrupted ground to minimize personal injury in case of an electrical fault, in accordance with NEC, ANSI/NFPA 70, and local codes.
Disconnect Switch: The unit must have a separate branch electric circuit with a field-supplied disconnect switch located within sight and readily accessible. For units with a factory-installed disconnect, service on incoming wiring requires turning off the main disconnect switch (remote to the unit).