Amana R-22 Service Instructions Manual

Download

Page 1

Service Instructions

ACCESSORIES MANUAL

R-22 Package Terminal

Air Conditioners & Heat Pumps

All Models and Manufacturing Numbers For R-22 Amana® Brand Units

This manual is to be used by qualified, professionally trained HVAC technicians only. Goodman does not assume any responsibility for property damage or personal injury due to improper service procedures or services performed by an unqualified person.

is a registered trademark of Maytag Corporation or its related companies and is used under

RS4900003r2

December 2010

Page 2

Table of Contents

When Ordering Parts .................................................................................................................................................... 3

Circuit Breaker Kit......................................................................................................................................................... 4

Condensate Drain Kit .................................................................................................................................................... 6

Condensate Removal Pump .........................................................................................................................................10

Condenser Baffles ........................................................................................................................................................13

Curtain Guard...............................................................................................................................................................14

Duct Kit........................................................................................................................................................................16

Electric Heat ................................................................................................................................................................22

Escutcheon - Hydronic Remote....................................................................................................................................27

Escutcheon - Remote ..................................................................................................................................................28

Fuse Kit .......................................................................................................................................................................29

Hard Wire.....................................................................................................................................................................31

Hydronic Heat ..............................................................................................................................................................33

Hydronic Transformer ...................................................................................................................................................42

Keylock........................................................................................................................................................................43

Power Disconnect Switch ............................................................................................................................................44

Remote T emperature Sensor ........................................................................................................................................46

Subbase ......................................................................................................................................................................48

Remote Thermostat High Fan Kit .................................................................................................................................51

Right Hand Subbase Conversion ..................................................................................................................................53

IMPORTANT INFORMATION

Pride and workmanship go into every product to provide our customers with quality products. It is possible, however, that during its lifetime a product may require service. Products should be serviced only by a qualified service technician who is familiar with the safety procedures required in the repair and who is equipped with the proper tools, parts, testing instruments and the appropriate service manual. REVIEW ALL SERVICE INFORMATION IN THE

APPROPRIATE SERVICE MANUAL BEFORE BEGINNING REPAIRS. FOLLOW CAREFULLY ALL CAUTIONS AND WARNINGS IN THE SERVICE MANUAL.

IMPORTANT NOTICES FOR CONSUMERS AND SERVICERS

RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS

HIGH VOLTAGE D

ISCONNECT ALL POWER BEFORE

SERVICING

ULTIPLE POWER SOURCES MAY BE PRESENT

AILURE TO DO SO MAY CAUSE PROPERTY

DAMAGE

INSTALLING THIS UNIT

PERSONAL INJURY OR DEATH

Page 3

WARNING

THIS AIR CONDITIONE R IS NOT ME ANT TO PROV IDE UNATTENDED COOLI NG OR LIFE S UPPORT FO R PERSONS OR AN IMALS WHO ARE UNABL E TO REACT TO THE FAILURE OF THIS PRODUCT.

THE FAILURE OF AN UNATTENDED AIR CONDITIONER MAY RESUL T IN EX TREM E HEAT IN THE CON DITIONED SPACE CAUSING OVERHEATING OR DEATH OF PERSONS OR ANIMALS.

PRECAUT IONS MUST BE TAKE N TO WARN OF OR GUARD AGAINST SUCH AN OCCURENCE.

CAUTION

OODMAN WILL NOT BE RESPONSIBLE FOR ANY

INJURY IMPROPER

F YOU PERFORM SERVICE ON YOUR OWN

PRODUCT

PERSONAL INJURY OR PROPERTY DAMAGE

ANY WHICH

PROPERTY DAMAGE ARISING FROM

SERVICE OR SERVICE PROCEDURES

YOU ASSUME RESPONSIBILITY FOR

MAY RESULT

WARNING

When Ordering Parts

All product model and serial nameplates carry an additional number called the manufacturing number. It is possible to have one or more like products with the same model number, but that a portion of the parts would not be interchangeable.

The manufacturing number has been added to the product to assist the service department in identifying any given product.

It is extremely important when looking up service repair parts in the parts list, or when requesting service information, that the manufacturing, model and serial numbers be used to properly identify the product.

To locate an authorized servicer, please consult your telephone book or the dealer from whom you purchased this product. For further assistance, please contact:

CONSUMER INFORMATION LINE -

AMANA® BRAND PRODUCTS TOLL FREE

1-877-254-4729 (U.S. only)

email us at: customerservice@goodmanmfg.com

fax us at: (713) 856-1821

(Not a technical assistance line for dealers.)

Outside the U.S., call 1-713-861-2500.

(Not a technical assistance line for dealers.)

Your telephone company will bill you for the call.

Page 4

ACCESSORY INST ALLA TIONS

Circuit Breaker Kit

HIGH VOLTAGE

ISCONNECT ALL POWER BEFORE

WIRING SOURCES SO INJURY

HE UNIT

CONNECT ALL POWER TO THIS UNIT

ALL

LOCAL LOCATION MUST COMPLY WITH ALL APPLICABLE CODES

THE SUBBASE

MAY BE PRESENT

MAY CAUSE PROPERTY DAMAGE, PERSONAL

DEATH

“OFF”

WIRING MUST COMPLY WITH APPLICABLE

AND NATIONAL CODES

FUSED DISCONNECT SWITCH(ES

CAUTION

USE

COPPER CONDUCTORS ELECTRICAL TYPES VANIC CORROSION, OVERHEATING AND RESUL TANT EQUIPMENT FAILURE

CONNECTIONS

CONDUCTORS MAY RESULT IN GAL

. M

ULTIPLE POWER

. F

AILURE TO DO

SWITCH DOES NOT DIS

. T

YPE AND

ONLY

. THE

FOR

USE OF OTHER

Description

The circuit breaker kit provides POWER ON/OFF and current overprotection function at the unit. The circuit breaker kit contains the appropriate circuit breaker, replacement access cover for the high voltage section of the subbase, mounting bracket and clips, and required hardware. Select circuit breaker kits according to unit amperage.

Installation

1. Check circuit breaker for manufacturers name. Select mounting holes in mounting bracket to match part as indicated in the following figure (GE and Westinghouse use outer holes). Secure one of the two small mounting clips to the mounting bracket. Do not fully tighten the mounting screw at this time.

2. Position the circuit breaker on the mounting bracket so that the locking tabs on the small clip (installed in Step

1) hold the circuit breaker on the mounting bracket.

3. Install the second small clip on the mounting bracket, locking the circuit breaker on the mounting bracket. Tighten both mounting screws securely.

)

4. Disconnect electrical power to the unit (if already wired).

5. Remove access cover from subbase.

6. Position the entire circuit breaker assembly in the subbase as shown in Figure 2. Using the two screws provided, secure the assembly to the subbase back wall in the subbase high voltage section. The large compression connections should be on the left (“ON” to the left, “OFF” to the right).

7. Connect the line voltage to the large compression terminals (left of breaker). Connect subbase wiring to the smaller compression connections (right of breaker). If a ground lug is provided, ground the lug to the unit.

8. Install the circuit breaker guard and the replacement access cover for the high voltage section. Install the assembly over the circuit breaker handle using the two screws removed from the original access cover.

Page 5

ACCESSORY INST ALLA TIONS

Page 6

ACCESSORY INST ALLA TIONS

Condensate Drain Kit - DK900-*

1/2" DRAIN FITTING

BLANK-OFF

PLATE C

QTY: 2

DRAIN FITTING

PLATE B

DRAIN FITTING

Figure 1

PLATE D

GASKET A

GASKET E FOR

PLATE D

QTY: 2

Installation for Outdoor Use

The drain components for outdoor use must be installed before the wall sleeve condenser grille.

1. Remove the rear enclosure panel and the sleeve stiffener. These items can be removed from the inside of the building.

2. Insert the 1/2” drain fitting in the opening of gasket A and plate B. Secure this assembly into the holes located on the rear of the wall sleeve using two of the Phillips mounting screws provided.

Figure 2

3. Place the remaining gasket A on the back of blank-off plate C and secure the assembly to the left rear of wall sleeve with the remaining Phillips mounting screws provided.

Description

This kit is used to control condensate from the unit. Condensate water drains from the chassis into the sleeve during normal heat pump operation and during times of high humidity when the unit is in cooling operation. The drain kit allows the condensate from the outdoor and indoor coils to be routed to a suitable area. It can be installed for either outdoor or indoor use. For outdoor use, the condensate can be drained from either the right- or left-hand side of the wall sleeve. Local codes will determine the proper condensate disposal. For indoor use, the drain components must be installed on the bottom of the wall sleeve and connected to a drain system inside the building.

NOTE: This drain kit serves only as a link between the unit and field-supplied condensate drain system. Installing the kit without connecting it to a drainage system will result in inadequate condensate removal, possible leakage and corrosion.

ALGAECIDE: Some algaecide products may cause damage to the unit basepan or coils and should not be used. Contact your sales representative when considering the use of a commercial algaecide.

Figure 3

If unit chassis installed right away

Install the grille to wall sleeve with hardware provided. See

grille installation instructions.

If unit chassis is not installed right away

Replace the rear enclosure panel in the wall sleeve to pro-

tect the inside of the building from weather damage.

Page 7

ACCESSORY INST ALLA TIONS

SLEEVE OVERFLOW PORT DO NOT CLOSE UP THIS PO RT

GASKET (2)

SEE DETAIL A

BLANK-OFF PLATE (2)

Figure 4

The components of the wall sleeve drain kit for indoor use are shown in the detail of the figure above. These compo-

nents must be installed prior to the installation of the wall sleeve.

1. Locate an area on the wall sleeve that will be inside the room when the sleeve is installed. If a subbase is installed, locate the kit a minimum of 3 1/2” from the front flange of the wall sleeve. This clearance will provide adequate clearance for the subbase.

2. Cutout the template in Figure 5. Using this template, locate and drill the drain kit holes as close to the outside wall as possible.

3. Using detail A in Figure 4 as a guide, assemble the gasket (E), drain fitting plate (D), and 1/2” drain fitting together. Install the assembly into the drilled holes and secure using the two slotted mounting screws included in the kit. Be sure drain tube is not restricted.

NOTE: If the drain fitting is not connected to an indoor drainage system immediately after the wall sleeve is installed; plug the hole with cork (not included) to prevent indoor water damage in case it rains

4. Install a 1/2” ID tube or hose (not included) on the drain fitting and interconnect it to the drain system inside of the building. Ensure that there are no kinks or traps in tube or hose. Kinks or traps can cause improper drainage.

5. Install the two blank-off plates C and gaskets A on the outdoor portion of the wall sleeve as shown in Figure 4. These components can be installed after the sleeve is secured in the wall opening just prior to the installation of the condenser grille and chassis.

.500" DIA.

.156” DIA. MTG. HOLES (2)

.687"

INSID E ED GE OF FRONT SLEEVE FLANGE

.687"

Figure 5

Page 8

ACCESSORY INST ALLA TIONS

Condensate Drain Kit - DK900*

(Combination Drain Kit...for outdoor or indoor sleeve drainage.)

The installation and servicing of the equipment should be done by qualified experienced technicians.

Description

This kit is used to control condensate from the unit. Condensate water drains from the chassis into the sleeve during normal heat pump operation and during times of high humidity when the unit is in cooling operation. The drain kit allows the condensate from the outdoor and indoor coils to be routed to a suitable area. It can be installed for either outdoor or indoor use. For outdoor use, the condensate can be drained from either the right- or lefthand side of the wall sleeve. Local codes will determine the proper condensate disposal. For indoor use, the drain components must be installed on the bottom of the wall sleeve and connected to a drain system inside the building.

Outdoor

Drain

Fitting

Indoor

Mtg. Screws

Qty: 2

Indoor

Drain Fitting

Gasket

Outdoor

Mtg. Screws

Qty: 4

Indoor

Drain

Fitting

Indoor

Drain Fitting

Plate

NOTE: This drain kit serves only as a link between the unit

and field-supplied condensate drain system. Installing the kit without connecting it to a drainage system will result in inadequate condensate removal, possible leakage and corrosion.

ALGAECIDE: Most algaecide products will cause damage to the unit basepan or coils and should not be used. Contact your sales representative for the recommended algaecide pan treatment for your unit.

Installation for Outdoor Use

The drain components for outdoor use must be installed before the wall sleeve condenser grille.

1. Remove the rear enclosure panel and the sleeve

stiffener. NOTE: These items can be removed from the inside of the building.

2. Install the outdoor drain fitting and one of the outdoor drain fitting gaskets over one of the drain holes on the rear of the wall sleeve using two of the provided outdoor mounting screws.

3. Cover and seal the remaining drain hole using the remaining outdoor drain gasket, blank-off plate and outdoor screws.

If unit chassis installed right away

Install the condenser grille to wall sleeve with hardware provided. See condenser grille installation instructions.

If unit chassis is not installed right away

Replace the rear enclosure panel in the wall sleeve to protect the inside of the building from weather damage.

Blank-Off

Plate Qty: 2

Outdoor

Drain Fitting

Gasket Qty: 2

Drain Kit Components

Outdoor Drain Fitting Installation

Blank-Off Installation

Page 9

ACCESSORY INST ALLA TIONS

Installation for Indoor Use

The components of the wall sleeve drain kit for indoor use are shown in figure below. These components must be installed prior to the installation of the wall sleeve.

MTG.

SCREWS (2)

WALL

DRAIN

GASKET

DRAIN

FITTING

PLATE

SLEEVE

BOTTOM

Detail A

2. Cutout the template shown to the right. Using this template, locate and drill the drain kit holes as close to the outside wall as possible.

3. Using detail A (above) as a guide, assemble the drain gasket, drain fitting plate, and indoor drain fitting together. Install the assembly into the drilled holes and secure using the two indoor mounting screws provided. The screws must be inserted INSIDE the wall sleeve.and TOP driven down into the drain fitting plate. Ensure drain tube is not restricted. Cover the two screw heads with a good quality outdoor caulking (not supplied) for additional corrosion protection.

5. Install the two drain blank-off plates and outdoor drain gaskets on the outdoor portion of the wall sleeve as shown in the figure above. These components can be installed after the sleeve is secured in the wall opening just prior to the installation of the condenser grille and chassis.

.500" DIA.

.187" DIA. MTG. HOLES (2)

.687"

INSIDE EDGE OF FRONT SLEEVE F LANGE

.687"

Template

Due to policy of continual product

improvement, the right is reserved to

change specifications and design

without notice.

3.5" Min.

for PTSB

clearanc e

(not to

scale)

C of

MTG. HOLES MIN. DIM.

Page 10

ACCESSORY INST ALLA TIONS

Condensate Removal Pump

HIGH VOLTAGE

ISCONNECT ALL POWER BEFORE

SERVICING

ULTIPLE POWER SOURCES MAY BE PRESENT

AILURE TO DO SO MAY CAUSE PROPERTY

DAMAGE

Description

The internal condensate pump serves as an effective means for disposing of condensate generated during heat pump operation by transferring it to the indoor coil. The warm coil surface and the warm room air help in evaporation of the condensate while adding humidity to the room. As with any equipment of this type, the addition of this kit will decrease the sensible heating capacity of the unit. This kit is not intended for use in seacoast or corrosive environments.

NOTE: Under extreme high humidity conditions, the internal condensate pump may not be able to dispose of all the condensate produced, and condensate would then drip from the outside of the wall sleeve. If this condensation is unacceptable, then a drain system (including factory approved drain kit for the wall sleeve) should be installed.

1. Remove front by rotating bottom outward and then lifting up and out from chassis.

2. Unplug and remove the PTAC chassis from the wallsleeve. Move the chassis where the front and back of the chassis can be easily accessed.

3. Remove the discharge screen by unscrewing two screws holding the screen to the blower panel. Set screen aside.

INSTALLING THIS UNIT

PERSONAL INJURY OR DEATH

4. Lift the blower panel approximately 10 inches by unscrewing two screws holding the blower panel to the chassis and lift upward being careful not to pinch heater wires.

Mounting Screw

Holes

Condensate

Tube

5. Using the short leg of the condensate tube push out the 1/2 inch diameter knockout on the back wall of the styrofoam scroll. The condensate tube should protrude through the partition panel by 1-3/4 inches. Rotate the condensate tube so the tube lays flat on the coil.

Condensate

Tube

6. Orient the condensate tube on the coil so when the blower panel is lowered the condensate tube fits snugly into the raised embossment of the blower panel.

7. Make sure the holes in the condensate tube are facing downward toward the evaporator coil.

8. Lower the blower panel over the condensate tube and screw the blower panel to the chassis with the existing screws. Replace the discharge screen and screw the screen to the blower panel with the existing screws.

9. Using the overflow tube holder and the overflow tube, hold the tube with the metal holder and screw the holder to the partition panel with the provided 1/2 inch #8 screw.

Tube

Holder

Page 11

ACCESSORY INST ALLA TIONS

10. Place the pump bracket onto the top of the pump and screw the pump bracket to the pump with the provided two (2) 1/2 inch #8 screws so that the bracket is secure against the pump.

PUMP

12. Remove the protective adhesive backing from the plastic U clip and mount the U clip to the plastic condenser shroud in approximately the position shown.

13. Attach the p-clamp to the brace with the screw provided (see figure below.

14. Place one of the hose clamps over one end of the 16 inch vinyl hose. Place the same end over the barbed discharge tube of the pump assembly. Place a hose clamp on the other end of the 16 inch hose. Place this same end over the shorter leg of the overflow tube and secure the hose with the hose clamp.

BRACKET

11. Orient the pump in the back left corner of the basepan and screw the pump bracket to the basepan with the provided two 1/2 inch #8 screws.

Page 12

ACCESSORY INST ALLA TIONS

15. Place a hose clamp over one end of the 11 inch long hose. Push this same end over the longer leg of the overflow tube and secure with the hose clamp. Place another hose clamp over the other end of the 11 inch hose. Push this same end over the condensate tube protruding out from the back of the partition panel and secure with the hose clamp.

16. Route the condensate pump cord through the U clip on the condenser shroud, through the p-clamp attached to the brace, and then through the hole in the panel where the compressor wires are routed through the panel. NOTE: The permagum may have to be removed to feed the wires through the panel, make sure wires have no slack and replace the permagum back into place to prevent air leaks.

SCREW

N O

3 2 1

SCREW

Back Of Escutcheon

Transformer

Mounting Holes

Relay Mounting

Holes

holes provided in the panel. (See figure above.)

20. Mount the relay in one of the three relay mounting holes in the control panel making sure that the threaded stud is in the smaller hole and the metal tab is in the adjacent larger hole. Screw the provided nut onto the threaded stud from the opposite side of the control panel.

21. Disconnect the RD33, VT12, and BK19 wires from the control board and connect the YL5 (where RD33 was connected), YL3 (where VT12 was connected), and YL1 (where BK19 was connected). Connect RD33 to the piggyback terminal of YL5, VT12 to the piggyback terminal of YL3, and BK19 to the piggyback terminal of YL1. Make sure the OR8 wire is connected from the #6 terminal of the relay to 24 volt terminal of the transformer.

22. For 208 volt applications move the WH6 wire terminal from the 240 volt terminal of the transformer to the 208 terminal of the transformer.

23. Units that have a Power Vent or Power Door Kit already installed in the chassis should refer to the proper wiring schematic for proper wiring of the condensate pump kit. Use the second set of transformer holes to mount the transformer.

24. Units that have a 2 stage heater already installed in the chassis should refer to the proper wiring schematic for proper wiring of the condensate pump kit.

25. Units that have a Power Vent or Power Door Kit and a two stage heater already installed in the chassis should refer to the proper wiring schematic for proper wiring of the condensate pump kit.

26. Install the basepan drain plug into the basepan drain hole by pushing it up into the drain hole from the bottom of the basepan. This will defeat the thermostatic controlled drain valve. The basepan drain is located left of the outside coil (as viewed from the back of the unit).

NOTE: When using a condensate removal pump, extra care must be taken to keep the basepan clean and free of algae or fungus. Failure to do so may result in the failure of the condensate removal system.

19. Using two #8 screws that are provided, screw the transformer to the control panel in the transformer mounting

Page 13

ACCESSORY INST ALLA TIONS

Condenser Baffles

Description

The condenser baffle kit is required when replacing an existing package terminal unit and the original outdoor grille is not made by the same manufacturer. These baffles are required to deflect discharge air away from the inlet, preventing recirculation of hot condenser air.

This kit is intended to be used with outdoor grilles having horizontal louvers. If the outdoor grille has vertical louvers, contact the manufacturer of the package terminal unit.

NOTE: This kit is not to be used when the outdoor grille is provided by the original manufacturer of the package terminal unit.

CAUTION

PREVENT DAMAGE TO THE UNIT DUE TO RESTRICTED OR

DEFLECTORS OF ANY KIND FROM THE OUTDOOR

AIR FLOW, REMOVE ANY BAFFLES

GRILLE

Installation

1. Locate the baffles on the condenser coil flange as shown. Position the louvers to direct the air toward the center as the air leaves the coil.

Condenser Baffles

2. Using the screws and shoulder washers provided, secure the grille to the condenser flange. NOTE: Be sure to install the gasket between the grille and the flange as shown.

HIGH VOLTAGE

ISCONNECT ALL POWER BEFORE

SERVICING

ULTIPLE POWER SOURCES MAY BE PRESENT

AILURE TO DO SO MAY CAUSE PROPERTY

DAMAGE

INSTALLING THIS UNIT

PERSONAL INJURY OR DEATH

CONDENSER

FLANGE

SHOULDER

WASHER

SCREW

BAFFLE

GASKET

Page 14

ACCESSORY INST ALLA TIONS

PTCB10B Curtain Guard Description

The PTAC PTCB10B Kit is a curtain guard kit that redirects the airflow of the PTAC unit to provide added comfort. Each kit contains 10 guards. Before installing this kit, ensure that the correct kit has been ordered and received for your unit.

This curtain guard has been designed to work in most curtain applications, but may NOT work in some applications. If you are unsure if the curtain guard will work in YOUR application, please contact your Amana® brand PTAC sales person for assistance before you order guards for the entire property.

IMPORTANT NOTE: This kit is designed for models with R-22 refrigerant and should NEVER be used on models using R410A refrigerant.

Below are two ways to determine if your unit requires PTCB10B kit:

1. Check the underside of the guard next to the side tab for specific guard/unit compatibility statement. See Figure 1 for location of this statement:

“Install on units with serial numbers starting with 0304****** and less than 1001******”

IMPORT ANT NOTE: Do NOT remove curtain guard until front is removed from unit. Trying to uninstall the curtain guard before removing the cabinet front may cause the curtain guard to break.

1. Position the curtain guard over the cabinet front (tab side down) so the left and right side tabs on the guard line up with the 2nd horizontal louver on each side of the cabinet front. Make sure the 2 middle tabs on the curtain guard are positioned over the 2nd and 4th vertical louvers on the cabinet front. Gently snap the left side of the curtain guard onto the 2nd horizontal louver of the cabinet front and then gently snap the tab on the right side of the cabinet front into place. See Figure 1. DO NOT FORCE

CURT AIN GUARD INTO PLACE.

Check here to verify

curtain guard and unit’s compatibility.

2. If your unit’s model number contains LETTERS B, C or D for the 7th digit (i.e. PTH123

D35AR), PTCB10B is the correct kit

to use (see note below for “A” series information).

If your unit’s model number contains the letter “E” for the 7th digit, DO NOT USE THIS KIT. The correct curtain guard kit for these units is PTCB10E.

NOTE: Use of the incorrect part may cause the guard to break and it will not be replaced by Goodman. If you are in doubt about which kit is needed, please contact your sales representative.

Attach s ide tabs

to 2nd Horizontal Louver

on the left & ri ght sides

of the cabinet front

“

Figure 1

”

Page 15

ACCESSORY INST ALLA TIONS

2. After tabs are secure on the left and right side horizontal louvers, gently slide the two middle tabs along the bottom of the 2nd & 4th vertical louvers and snap in place.

DO NOT FORCE CURTAIN GUARD INTO PLACE.

When installed, the tabs should point towards the outside of the unit. See Figure 2.

Figure 2

See Figures 3 and 4 for views of correctly installed curtain guard.

Side Tabs attached on 2nd Horizontal Louver

2nd Louver

View of R-22 Model with Curtain Guard Installed Correctly.

3. T o remove the curt ain guard, remove cabinet front from the chassis. Rotate the cabinet front so the back of the cabinet is facing you. Depress the tabs of the curtain guard while gently pulling the guard away from the front.

4th Louver

Figure 4

2nd Vertical Louver 4th Vertical Louver

Tabs

snapped

into p lace

Figure 3

Page 16

ACCESSORY INST ALLA TIONS

Duct Kit

Description

Extends air distribution to an adjoining room.

Kit Contents

The kit consists of a main duct for the room of origin and an extension duct to reach the adjoining room, and terminal duct. NOTE: All required hardware is provided within kit.

TRANSITION

Terminal Duct Kit - TDK02B

BAFFLES

Main Duct Kit - MDK02*

Extension Duct Kit -EDK02B

5/8"

TOP

Ø 1/8"

2 3/8"

11/16"

Ø 1/8"

Hole Placement Template

Page 17

ACCESSORY INST ALLA TIONS

10"

1/2"

18-3/8"

3-1/4" MIN

TRANSITION

UNIT FRONT

7-1/2"

BOTTOM OF

WALL SLEEVE

END OF DUCT

EXTENSION

INNER WALL CUT-OUT

1-3/8" MIN

(FOR DUCT KIT)

WALL SLEEVE

2-3/4" MIN

(FOR SUBBASE KIT)

SUBBASE KIT

OUTSIDE WALL

FLOO R LINE

MDK INSTALLATION INSTRUCTIONS

Disconnect power source before removing the chassis.

PRE-ASSEMBLY (Transition/Front)

1. If the cabinet front is screwed to the chassis, remove the screw located behind the inlet grille. Pull the inlet grille forward from the top of the grille to access two screws. Figure 1.

2. Remove cabinet front from chassis by tilting the bottom of the front forward, lifting slightly up and forward.

20-1/2" MAX

1/4" MIN

FRONT MOUNTING

HOLE

Figure 1 - Cabinet Front Removal

3. Disengage discharge grille from cabinet front by removing four pal nuts from under the front.

Page 18

ACCESSORY INST ALLA TIONS

4. Place transition in air discharge opening of cabinet front and secure with the provided U-clip. See Figures 2 & 3.

TRANSITION

AIR DISCHARGE OPENIN G

CABINET FRONT

Figure 2

PRE-ASSEMBLY (Wall Sleeve) Hole Dimension and Placement

1. Unplug and remove chassis from wall sleeve. Drill two 1/8” holes on left and right sides of wall sleeve in proper locations (see template on page 2).

2. Install chassis back into wall sleeve.

3. Install transition/front assembly on to chassis. Make sure top of cabinet front catches metal flange on chassis.

WALL

2-3/8"

11/16"

5/8"

1/8" HOLES

SLEEVE

INDOOR

U-CLIP

Figure 3

5. Using 1/8” drill bit, pre-drill holes in front using the actual transition as a template. Fasten with three screws. Do not overtighten. Figure 4.

Figure 4

WALL

SLEEVE

1/8" HOLES

5/8"

2-3/8"

11/16"

INDOOR

Figure 5 - Wall Sleeve Hole Placement

NOTE: If there is not enough clearance between sleeve and partition wall to drill the holes, layout and drill the holes from inside the sleeve.

MDK ASSEMBLY

Determine if the duct is to be extended to the right of the unit (where controls are located) or to the left of the unit (opposite the controls). Figure 6.

For left side extensions remove the main duct end cap and reinstall on the right end of the duct. Using the four painted sheet metal screws, secure the two mounting brackets to the main duct.

Page 19

ACCESSORY INST ALLA TIONS

Two mounting slots are provided in each bracket. To mount extension on right side, adjust bracket so the screws are in left side of bracket slots; for mounting extension on the left, adjust brackets so the screws are in right side of slots.

On right side extensions shift the brackets to the right. For left side extensions shift the brackets to the left.

DISCHARGE AIR GRILLE

AIR BAFFLE

SUPPORT BRACKETS

RIGHT SHIFT

Figure 6 - Mounting Brackets installation

AIR BAFFLE INSTALLATION INSTRUCTIONS

1. Determine amount of air desired at main duct and at extension duct. Using the table provided, select the appropriate baffle.

BAFFLE DIMENSIONS

Small 3 11/16" x 31 3/4" 80% 20% Large 4 5/16" x 31 3/4" 65% 35%

Table 1

2. Place baffle on grille support brackets on main duct. Ensure the two extruded holes of the baffle are on top of the front bracket holes.

3. Install discharge air grille on top of the air baffle. Secure the grille to the duct with pal nuts (provided) by reaching through the opening in the bottom of the duct. See figure

LEFT SHIFT

AIRFLOW

MAIN DUCT EXT. DUCT

Figure 7 - Air Grille Inst allation

4. Place main duct assembly on the transition. Secure the brackets to the wall sleeve with four #10 hex head screws. Figure 8. Do not apply pressure on top of duct dur-

ing this installation!

Figure 8

MDK Installation Onto T ransition Assembly

5. Install two Phillips head screws into the top flange of the main supply duct at extension duct connection. Do not tighten screws. Leave space for one thickness of the duct sheet metal between screw head and main duct flange. Figure 9.

Page 20

ACCESSORY INST ALLA TIONS

Figure 9 - Main Supply Duct Top Flange

IMPORTANT NOTE: Total length of duct extension assembly, including field supplied duct between main and extension duct, should not exceed 15 effective feet (according to ASHRAE standards). For additional dimensions, refer to Main Duct and Duct Extension Dimensions illustration.

7. Measure from the end of the main duct where the extension duct will be connected to the hole in the wall. If necessary cut the extension duct to a length where the cut end protrudes into the wall’s inner space and one inch from the adjoining room’s wall surface.

8. Insert the extension duct into the opening in the wall. Install the extension duct by placing the slotted flange over the two screws in the main duct. Using two #8 round Phillips head screws, mount bottom of extension duct to mounting bracket through the bracket slot (see Main Supply Duct T op Flange illustration).

NOTE: The EDK02B can be cut into two sections and used with two MDK02s if the needed length does not exceed 21-1/4”.

6. In the room where the main duct kit is attached to the chassis, cut a hole in the wall at the same height from the floor that the main duct is located. Cut the hole 1/8” larger than the width and height (10” x 5”) dimensions of the extension duct.

42-27/32" 6" TO 42-1/2"

AIR FLOW

BRACKET

TRANSITION DUCT

MAIN DUCT

DUCT EXTENSION

BRACKET

MINIMUM

BOTH SIDES

PARTITION WALL

DUCT

TERMINATION

KIT

AIR FLOW

1" to adjoining wall surface

Figure 10 - Main Duct and Duct Extension Dimensions

Page 21

ACCESSORY INST ALLA TIONS

TDK INSTALLATION INSTRUCTIONS

IMPORTANT NOTE: ANY FIELD-SUPPLIED GRILLE, MUST HAVE FIXED LOUVERS THAT CANNOT BE CLOSED.

The sheet metal collar of the terminal duct kit must be mounted in the wall of the adjoining room opposite the room where the main duct kit is attached to the PTAC chassis.

1. Cut a hole in the wall of the adjoining room such that the hole is centered on the extension duct that is currently in the wall of the opposite room. Figure 1 1. See wall hole dimensions illustration for sheet metal collar. Figure 12.

11-1/2”

GASKET

Figure 12 - Sheet Metal Collar

3. Center the metal grille over the sheet metal collar and use two #8 screws (provided) to attach the grille to the metal collar . Figure 13.

6-1/4"

Figure 1 1 - Wall Hole Dimension

2. Insert the sheet metal collar into the wall so that the flanges will mount flush to the wall after the collar is pushed all the way into the wall. While pushing the collar into the wall make sure the extension duct is inside the collar. Use four #8 screws to att ach metal collar to wall.

USE

TWO

#8 SCREWS

Figure 13 - Metal Grille

Page 22

ACCESSORY INST ALLA TIONS

Electric Heat

Description

The supplemental electric heater kits described in this manual are available for field installation on heaterless models of packaged air conditioners and heat pumps.

Unit power cords are factory installed for heater kits up to 15 amps on 230/208 volt units and 20 amps on 265 volt units. When a 20 (230/208 volt units), 25, or 30 amp heater kit is installed, the corresponding power cord is supplied with the heater kit.

NOTE: The incoming electrical power on 230/208 volt units is not fuse protected unless a fuseholder kit has been either factory or field installed.

Power Cord Installation (HK335E, HK350E, HK450E)

HIGH VOLTAGE D

ISCONNECT ALL POWER BEFORE

SERVICING

ULTIPLE POWER SOURCES MAY BE PRESENT

AILURE TO DO SO MAY CAUSE PROPERTY

DAMAGE

INSTALLING THIS UNIT

PERSONAL INJURY OR DEATH

Unit Preparation

NOTE: The unit power cord is shown in Figure 1. The power cord plug configurations are shown in Figure 3.

1. Remove the unit front by tilting the bottom of the front outward and then lift the front straight up.

2. Remove the control knobs on the control panel cover by pulling upward on the knobs. Remove the escutcheon.

3. Remove the control panel cover by removing the two screws holding the control panel cover. Tilt the control panel forward to gain access to the wires.

Power Cord

4. The incoming electrical power on all 265 volt units is fuse protected. On all kits, except the 5 kW kit, replace the fuse with the fuse supplied with the kit. On 5 kW heater kits replace the existing fuseholder with the fuseholder (with fuse) supplied with the kit.

1. If the unit has a power cord, remove the power cord clamp located near the bottom right of the chassis.

Right Side

Power

Cord

Of Unit

Incoming

Power

Opening

Control

Panel

Power Co rd Clamp

Incoming Power Opening

2. On 230/208 volt units disconnect the ribbed lead from the C terminal on the capacitor and the smooth lead from LINE 2 terminal on the control board and the green ground wire from the partition panel. Discard both the cord and the cord clamp.

Page 23

ACCESSORY INST ALLA TIONS

On 265 volt units disconnect the ribbed lead from the C terminal on the capacitor and the smooth lead from the fuseholder and the green ground wire from the partition panel. Discard both the cord and the cord clamp.

3. Push about 20 inches of the power cord shipped in the kit through the incoming power opening.

4. Secure the cord to the partition panel using the power cord clamp and #8 screw shipped in the kit.

LINE1 LINE 2 COMP FAN

Ribbed Wire

BK18 on LINE 2 with fuse shown connected is for 265 volt units. For

BK18

230/208 volt units, connect power cord to LINE 2.

Control Panel

Capacitor

HIGH

FAN

LOW

R-VAL VE

Power Cord Connections

5. Connect the ribbed lead to the C terminal on the capacitor.

6. On 230/208 volt units connect the smooth lead to LINE 2 terminal on the control board.

On 265 volt units connect the smooth lead to the fuseholder.

7. Connect the power cord’s green ground wire to the partition panel using the ground screw provided in the kit.

8. If the unit is mounted on a subbase with a power receptacle, remove the right front cover plate of the subbase, connect the plug end of the power cord into the subbase power receptacle, and route the cord up out of the subbase through the cord slot in the right side of the subbase. Replace the subbase right front cover panel.

Subbase Power Cord

Electric Heater Installation.

CAUTION

AVOID CUTS FROM SHARP EDGES OF SHEET

METAL, USE GLOVES

IMPORTANT NOTE: To prevent component failure, do not install HK350E or HK450E (5 Kw) heater kits into 7,000 or 9,000 BTU air conditioners (PTC07, PTC09) or heat pumps (PTH07, or PTH09).

1. Remove the two mounting screws holding the screen above the indoor coil in place. Remove the screen.

2. Remove the two screws holding the blower inlet panel in place. Lift the blower inlet panel out of the unit and set aside.

3. Attach heater to the blower inlet panel with two #8 screws provided with the kit

Page 24

ACCESSORY INST ALLA TIONS

#8 Screw

4. While placing the blower inlet panel back into the chassis, insert the heater wires through the clip and into the hole located on the mid partition panel.

Clip

Outdoor Section

Heater Wires

Control Panel

For single Stage Heaters Follow Step 6 then skip to Step 16.

6. Connect brown 34 and brown 35 heater wires to the 1/4 inch terminals on the control board marked HEATER.

5. Lower the blower inlet panel down into the chassis. Secure the blower inlet panel to the chassis with the screws removed in Step 1 and replace the screen removed in Step 2.

Single Stage Heater Schematic

For two stage heaters Follow Steps 7 through 15

7. Mount the heater relay supplied with the heater kit to the middle section of the control panel. Place the studs on the heater relay through the respective holes on the control panel and tighten the nut onto the threaded stud.

NOTE: All wiring required for this kit is preconnected to the heater relay or the heater assembly.

Page 25

ACCESSORY INST ALLA TIONS

Relay Mounted Inside of Control Panel

Control Panel

8. After disconnecting the BK16 wire from the FAN HIGH terminal on the control board, connect it to the heater relay 3 terminal.

9. On the LINE 1 terminal of the control board: A. Disconnect the RD33 wire. B. Connect VT19 from the heater relay A terminal. C. Reconnect the RD33 wire to the piggyback terminal

of VT19.

10. Connect BR34 from the heater 34 terminal to the HEATER terminal next to the LINE 1 terminal on the control board.

11. Connect VT17 from the heater relay 6 terminal to the HEATER terminal next to the LINE 2 terminal on the control board.

12. Connect BR35 from the heater 35 terminal to the HEATER terminal next to the piggyback terminal of VT17 on the L2 terminal on the control board.

13. Connect VT18 from the heater relay B terminal (as shipped from the factory) to the FAN HIGH terminal on the control board.

14. On the LINE 2 terminal of the control board: A. Disconnect the power wire (BK18 on 265 volt units,

power cord on the 230/208 volt units).

B. Connect VT20 from the heater relay 5 terminal. C. Reconnect the power wire to the piggyback terminal

of VT20.

BR34

BR35

BR36

Two Stage Heater Wire Connections

15. Connect wire BR36 from the heater 36 terminal to the heater relay 4 terminal.

3 5

6 B

36 35

HEATERHEATER

2 Stage Heater Schematic

6. Find the auxiliary “electric heater” data plate label on the PTAC unit near the serial plate. Check mark the appropriate box on the data plate to indicate data for the heater installed in the unit.

17. Replace the control panel, control panel cover, escutcheon plate and the unit front.

Page 26

ACCESSORY INST ALLA TIONS

Electric Electrical Heater kW Heater Total Total Mini mum Overcurrent

Heater 230/208 V BTU/HR Watts Amps Circuit Protection**

Size (kW) Ord. No. Stage 1 Stage 2 230V 208V 230V 208V 230V 208V Ampacity

1.5 HK315E 1.5/1.2 - 5100 4100 1580 1280 7.1 5.8 8.8 15A

2.5 HK325E 2.5/2.0 - 8500 6800 2580 2080 11.5 11.5 14.2 15A

3.5 HK335E 3.5/2.9 - 12000 9900 3580 2980 15.8 15.8 19.6 20A

5.0* HK350E 3.5/2.9 1.5/1.2 17100 14000 5080 4180 22.3 22.3 27.8 30A

*On two stage heater kit “High Heat” = both stages ON; “Low Heat” = stage 1 on only. **Recommended field supplied time delay fuses or HACR type circuit breaker.

230/208 Volt Electric Heater and Power Cord Data

Electric Electrical Heater kW Heater Total Total Minimum Overcurrent

Heater 230/208 V BTU/HR Watts Amps Circuit Protection**

Size (kW) Ord. No. Stage 1 Stage 2 265V 265V 265V Ampacity

1.5 HK415E 1.5 - 5100 1580 6.3 7.7 15A

2.5 HK425E 2.5 - 8500 2580 9.9 12.3 15A

3.7 HK435E 3.7 - 12600 3780 14.5 18 20A

5.0* HK450E 3.5 1.5 17100 5080 19.4 24.1 25A

*On two stage heater kit “High Heat” = both stages ON; “Low Heat” = stage 1 on only. **Recommended field supplied time delay fuses or HACR type circuit breaker.

265 Volt Electric Heater and Power Cord Data

LISTED ACCESSORIES - PACKAGE TERMINAL AIR CONDITIONER

AUXILIARY HEATERS - 230/208 VOLT INSTALLER TO MARK HEATERS INSTAL LED: NONE HEATER HEATER MAX MIN. CIR. MAX. FUSE KW P/N AMPS AMPACITY SIZE

1.5/1.2 20252001 7.1 8.8 15

2.5/2.0 20252002 11.5 14.2 15

3.5/2.9 20252003 15.8 19.6 20

5.0/4.1 20257501 22.3 27.8 30

(SA5810)

230/208 Volt Electric Heat Auxiliary Data Label

LISTED ACCESSORIES - PACKAGE TERMINAL AIR CONDITIONER

AUXILIARY HEATERS - 265 VOLT INSTALLER TO MARK HEATERS INSTAL LED: NONE HEATER HEATER MIN. CIR. CIRCUIT MAX. FUSE KW P/N AMPACITY BRKR. SIZE

1.5 20252006 7.7 15 15

2.5 20252007 12.4 15 15

3.7 20252008 18.1 N/A 20

5.0 20257502 24.2 N/A 25

(SA5810)

265 Volt Electric Heat Auxiliary Data Label

Page 27

ACCESSORY INST ALLA TIONS

Escutcheon - Hydronic Remote

Description

This kit provides an attractive replacement escutcheon, allowing the removal of control knobs and graphics no longer required when a wall thermostat is used to control the unit.

Standard Escutcheon

THIS UNIT IS CONTROLLED BY

WALL MOUNTED THERMOSTAT

Low Heat

High Heat

Fan

Only

High Cool

Off

Low Cool

B-Nut

4. Reaching below the hydronic top, remove the extensions from the chassis by pulling the extensions off the control shafts. Pull the extensions out of the hydronic top.

Hydronic Escutcheon

Extension Shafts

Hydronic Top

Control Board

Cover

Remote Escu tch eon

HIGH VOLTAGE

ISCONNECT ALL POWER BEFORE

SERVICING

ULTIPLE POWER SOURCES MAY BE PRESENT

AILURE TO DO SO MAY CAUSE PROPERTY

DAMAGE

Installation Instructions

1. Lift the cabinet front off the chassis.

2. Remove the unit control knobs by pulling the knobs off the extension shafts.

3. Remove the b-nut mounting the extensions to the hydronic escutcheon.

INSTALLING THIS UNIT

PERSONAL INJURY OR DEATH

5. After removing the backing, carefully place the remote escutcheon over the hydronic escutcheon. Ensure the escutcheon is firmly in place, without any air bubbles.

6. In the event the extension shafts may be needed, after reassembling the B-nut and the extension shafts, tape the extension shafts to the control board cover.

7. Replace the cabinet front.

Page 28

ACCESSORY INST ALLA TIONS

Escutcheon - Remote

Description

This kit provides an attractive replacement escutcheon, allowing the removal of control knobs and graphics no longer required when a wall thermostat is used to control the unit.

Standard Escutcheon

THIS UNIT IS CONTROLLED BY

WALL MOUNTED THERMOSTAT

Low Heat

High

Heat

Fan

Only

High Cool

Off

Low Cool

2. Grasp the cabinet front as shown.

3. Pull the bottom of the cabinet front away from the chassis until the retaining clips disengage.

Remote Escu tch eon

HIGH VOLTAGE D

ISCONNECT ALL POWER BEFORE

SERVICING

ULTIPLE POWER SOURCES MAY BE PRESENT

AILURE TO DO SO MAY CAUSE PROPERTY

DAMAGE

Installation Instructions

1. Remove the two screws securing the front to the chassis. NOTE: Not all installations will use these screws.

INSTALLING THIS UNIT

PERSONAL INJURY OR DEATH

Mounting Screws

Location

4. Lift the cabinet front off the chassis.

5. Remove the unit control knobs by pulling the knobs off the control shafts.

Pull To Remove

Mode Switch Knob

Pull To Remove

Thermostat Knob

Escutcheon

6. Lifting the front edge of the escutcheon, slide the tabs at the top of the escutcheon out of the retaining holes and remove the escutcheon.

7. Replace the escutcheon with the one from this kit by inserting the tabs at the top of the escutcheon into the retaining holes and laying the escutcheon flat on the control panel.

8. Replace the front by reversing steps 1 through 4.

9. Store the control knobs and escutcheon just removed from the unit for reinstallation if the wall thermostat is no longer used.

Page 29

ACCESSORY INST ALLA TIONS

Fuse Kit

ALL

WIRING MUST COMPLY WITH APPLICABLE LOCAL AND NATIONAL CODES LOCATION OF FUSED DISCONNECT SWITCH(ES MUST COMPLY WITH ALL APPLICABLE CODES

AILURE TO FOLLOW THESE CODES COULD RESULT IN OVERHEATING AND EQUIPMENT FAILURE

. T

YPE AND

Fuse Holder Kit Installation (Without Subbase)

See page 27 for installation in a subbase.

BK-10

)

Fuse Holder Kit

Description

This optional fuse holder kit can be installed directly in the chassis or in the optional subbase.

Fuse holder kits are available in 230/208 volt ratings. The installer should supply time delay fuses at 15, 20, 25 or 30 amps in accordance with the “Maximum Overcurrent Protection” as listed on the unit nameplate. Fuses may be purchased from the parts department.

Installation

The installation and servicing of the equipment referred to in this booklet should be performed by qualified, experienced technicians.

CAUTION

Fuseholder

X X

Line 1 Heater Heater Line 2 Comp Fan

Electronic Board

RD-10

Capacitor

High

Fan

Rev.

Low

Valve

Unit Electrical

Connector

Fuse Holder Diagram

Control Panel Installation

1. Remove front by rotating bottom outward and then lifting up and out from chassis.

2. To gain access inside the control panel, after removing the knobs and escutcheon, remove the two screws holding panel in position. Tilt control panel forward, being careful not to pinch any wires.

3. As viewed from the front, remove both knockouts on the control panel.

4. Insert two fuse holders from the front. The fuse holders should be oriented so the quick-connect tabs are toward the center of the unit. Attach fuse holders using the screws and nuts provided.

USE

COPPER CONDUCTORS ELECTRICAL TYPES VANIC CORROSION, OVERHEATING AND RESUL TANT EQUIPMENT FAILURE

CONNECTIONS

CONDUCTORS MAY RESULT IN GAL

. THE

ONLY

FOR

USE OF OTHER

Page 30

ACCESSORY INST ALLA TIONS

Remove Two Screws To Gain Access Inside Control Panel (One On Side Of Panel)

Fuse

Holder

Knockouts

2. Install the fuse holders using screws provided. The side connector tab on the fuse holders should be towards the left.

3. Connect a stripped BK-9 wire to the center of the quickconnect tab of the fuse holders. Wire nut the other end of this wire to the black field connection wire (L2).

4. Connect the other stripped BK-9 wire to the quick-connect tab on the side of the same fuse holder. Wire nut the other end to black subbase wire leading to receptacle.

Electrical

Receptacle

Fuseholder

BK-9

Control Panel

5. Remove both power cord leads, one lead from the capacitor and one from the electronic board.

6. Install one power cord lead on the center terminal of one fuse holder.

7. Install the remaining power cord lead on the center terminal of the second fuse holder.

8. Connect BK-10 wire from the side terminal of one fuse holder to the L2 terminal on the electronic board.

9. Connect RD-10 wire from the side terminal of the other fuse holder to the common (C) terminal on the capacitor.

10. Tilt control panel back to original location, being careful not to pinch any wires. Align the control panel with the cover and screw panels into place with original screws. Replace escutcheon and control knobs.

Fuse Holder Kit Installation (With Subbase)

See page 26 for installation in the control panel.

1. Remove both knockouts at the fuse holder location.

Fuseholder

Field Connection

Wiring

RD-9

Black

Red

Green

Fuse Holder Diagram

Subbase Installation

5. Connect the “stripped” RD-9 wire to the center quickconnect tab of the second fuse holder. Wire nut the other end to the red field connection wire (L1).

6. Connect the other stripped RD-9 wire to the quick-connect tab on the side of the second fuse holder. Wire nut other end to red subbase wire which leads to receptacle.

7. Insert time delay fuses into the fuse holders. Size all fuses by the “Maximum Overcurrent Protection” shown on the nameplate. Also refer to the serial plate on the unit.

Fuse Holder

Knockouts

Leveling

Leg

Power Switch

Knockout

Subbase (Left Side)

Page 31

ACCESSORY INST ALLA TIONS

Hard Wire

Description

Hardwire Junction Box (Direct Wire Sub-Base)

The hardwire junction box kit is used to direct wire the unit when it is not desirable to use the standard unit subbase or the unit power cord. The junction box provides a protected enclosure for electrical connections as required by some electrical codes.

The hardwire junction box is intended to be mounted on the floor or the adjacent wall.

The junction box is furnished with approximately 2-1/2 feet of 1/2 inch flexible steel conduit and a metal box for securing the conduit to the unit cabinet at the incoming power opening.

An optional 230/208V or 265V power switch assembly is available for use with the hardwire junction box or subbase. The switch provides a POWER ON/OFF function at the unit as required by some electrical codes. A replacement junction box cover plate is provided with each switch kit. For additional information, refer to the Power Switch Installation Instructions.

Junction Box Kit Installation and Wiring Procedure

The installation and servicing of this equipment should be performed by qualified, experienced technicians.

Electrical connections at the unit must be made after the unit chassis is installed in the wall sleeve.

The installer must determine and supply the mounting components for attaching the junction box to the wall or floor.

CAUTION

USE

COPPER CONDUCTORS ELECTRICAL TYPES VANIC CORROSION, OVERHEATING AND RESUL TANT EQUIPMENT FAILURE

CONNECTIONS

CONDUCTORS MAY RESULT IN GAL

ONLY

. THE

FOR

USE OF OTHER

ALL

WIRING MUST COMPLY WITH APPLICABLE LOCAL LOCATION MUST COMPLY WITH ALL APPLICABLE CODES

RESULT FAILURE

AND NATIONAL CODES

FUSED DISCONNECT SWITCH(ES

AILURE TO FOLLOW THESE CODES COULD

OVERHEATING AND EQUIPMENT

. T

YPE AND

)

1. Remove the cover plate from the junction box.

2. Mount the junction box to the wall or floor within 28 inches of the lower right corner of the wall sleeve.

Wall Sleeve

Ground Wire

With Eyelet

Terminal

Cover

Plate

28 Inches Max

Conduit

Power Leads

with Push

on Connectors

Metal Box

With Straight

Clamp

Mounting Hardwire Junction Box Kit

3. If a disconnect switch is to be used, make electrical connections to it and mount the switch in the junction box. Refer to the “Power Switch” Installation Instructions.

4. Remove control panel assembly by removing the two screws holding control panel in place. Rotate panel forward.

5. Disconnect the power cord leads from all electrical connections including the ground wire.

6. Remove the power cord clamp and the power cord from the unit.

7. For 230/208-volt units, remove and discard the white lead from the wire assembly. For 265-volt units, remove and discard the red lead from the wire assembly.

8. Remove the retaining ring from the threaded portion of the straight conduit clamp. Insert the three wires into the metal box through one of the two openings in the box. Replace the hole cover grommet into the unused hole to prevent objects from entering the box.

Page 32

ACCESSORY INST ALLA TIONS

9. Replace the retaining ring back on the conduit clamp inside the metal box and tighten the ring securely.

10. Insert the three wires extending from the metal box into the incoming power opening on the unit so that approximately 20 inches of the wires protrude through the opening.

11. Attach the metal box to the chassis with the two screws provided.

12. Insert the wire tie into the 3/16 inch diameter hole located just above the incoming power opening. Tie all wires together securely with the wire ties.

Control Panel

Base Pan

Junction Box

Metal Box Location

Right Side of

Chassis

Wire Tie

3/16 Inch

Diamenter

Hole

Electrical Supply

Wires

3. Connect the red lead to the common ( C ) terminal on the capacitor.

4. Connect the ground wire to the partition panel where the ground wire on the power cord was located. Use the supplied green ground screw.

5. Connect the red lead in the wire assembly at the junction box to the red lead of the field power source.

6. Connect the black lead in the wire assembly at the junction box to the black lead of the field power source.

7. Connect the ground wire of the field power source to the ground wire of the wire assembly at the junction box.

8. Install the junction box cover plate.

9. Reinstall the control panel assembly.

265 Volt Units

1. Remove and discard the red lead from the wire assembly.

2. Connect the black lead to the center terminal of the fuse holder.

3. Connect the white lead to the common ( C ) terminal on the capacitor.

4. Connect the ground wire to the partition panel where the ground wire on the power cord was located. Use the supplied green ground screw.

5. Connect the white lead of the wire assembly at the junction box to the white lead of the field power source.

6. Connect the black lead of the wire assembly at the junction box to the black lead of the field power source.

7. Connect the ground wire of the field power supply to the ground wire of the wire assembly at the junction box.

8. Install the junction box cover plate.

9. Reinstall the control panel assembly.

Back of

Control Panel

Electrical Wiring Routing

208/230 Volt Units

1. Remove and discard the white lead from the wire assembly.

2. Connect the black lead to the line 2 terminal on the control board.

Page 33

ACCESSORY INST ALLA TIONS

Hydronic Heat

Description

Where a central boiler is available, the Hydronic Kit can be installed on the PTAC unit. This kit completely encloses all plumbing and coils, but still allows easy access to controls. In addition, the chassis can slide out for service without removing hydronic plumbing. Heating and cooling operations are controlled by unit’s thermostat. Cooling operation is not affected by the addition of the hydronic kit. Heat Pump models will operate on heat pump function down to the switchover temperature before operating on hydronic heat. The electrical connections are plug-in type to assist in kit installation.

Freeze Protection

The hydronic kit has a factory installed freeze protection thermostat which will allow a normally closed or normally open water/steam valve to open when the thermostat senses near freezing temperatures at the hot water or steam coil. Once the temperature of the freeze thermostat rises above 58° F the water valve will return to normal mode operation.

Tools Required

1/4 Inch Electric Drill 1/8 Inch Diameter Drill Bit Center Punch and Hammer 6 Foot Rule Combination Square 1/4 Inch Nut Driver or Socket 5/16 Inch Nut Driver or Socket Torch, Solder, Flux, etc.

Job Preparation

Before installing the hydronic kit, the following steps should be complete:

1. Wall sleeve installed and completely sealed. NOTE: The wall sleeve must be extending at least 3”

and no more than 3-1/8” past the finished interior wall in order to properly install the hydronic kit.

2. Plumbing stub-outs complete.

3. Unit chassis uncrated but not installed and not yet con-

nected to electrical source.

4. A standard model chassis with an HTK3A or HTK4A kit installed or a hydronic model chassis.

Installation

HIGH VOLTAGE

ISCONNECT ALL POWER BEFORE

SERVICING

ULTIPLE POWER SOURCES MAY BE PRESENT

AILURE TO DO SO MAY CAUSE PROPERTY

DAMAGE

Be sure to engage the services of a qualified water treatment specialist to determine what water treatment, if any, is needed. The manufacturer will not assume responsibility for equipment failures resulting from untreated or improperly treated water.

1. If the chassis is not a hydronic model chassis, remove polymer front from chassis and discard. Install a HTK3A or HTK4A kit as required.

2. Drill two 1/8” diameter holes on both sides of wall sleeve as shown.

NOTE: If there is not enough room to drill holes from the side then drill holes from inside the wall sleeve.

INSTALLING THIS UNIT

PERSONAL INJURY OR DEATH

Page 34

ACCESSORY INST ALLA TIONS

Hydronic Heat Kit Application Data

Gal. Drop

per (psig) 200° F. EWT 180° F. EWT 200° F. EWT 180° F. EWT 200° F. EWT 180° F. EWT

Min. 2-Way Fan Speed Fan Speed Fan Speed Fan S peed Fan Speed Fan Speed

1.00 0.93 0.19 14910 13388 12639 11186 16945 14387 14257 12152 17858 15534 15049 13312

1.13 1.03 0.24 15216 13706 12898 11452 17360 14689 14607 12407 18276 15955 15401 13672

1.25 1.14 0.30 15500 13997 13139 11696 17745 14968 14930 12642 18666 16338 15729 14001

1.38 1.26 0.36 15762 14262 13361 11917 18099 15222 15228 12858 19025 16684 16032 14297

1.50 1.40 0.43 16003 14501 13565 12117 18423 15454 15501 13053 19356 16991 16311 14561

1.63 1.55 0.50 **16222 14714 13751 12295 18717 15661 15748 13228 19658 17261 16565 14792

1.75 1.71 0.58 16420 14900 13919 12450 18980 15845 15969 13384 19930 17494 16794 14991

1.88 1.89 0.66 16596 15061 14068 12584 19212 16006 16165 13519 20173 17689 16999 15158

2.00 2.10 0.76 16751 15195 14199 12696 **19268 16142 16212 13635 20387 17846 17179 15293

2.13 2.32 0.85 16884 15302 14312 12786 19586 16255 16479 13730 **20445 17965 17229 15395

2.25 2.57 0.96 16995 15384 14407 12854 19727 16345 16598 13806 20727 18047 17466 15465

2.38 2.84 1.07 17085 15439 14483 12900 19838 16410 16691 13861 20853 18091 17572 15503

2.50 3.14 1.18 17154 15467 14541 12924 19919 16452 16759 13897 20950 18110 17654 15508

2.63 3.48 1.30 17201 15470 14581 12926 19968 16471 16801 13912 21018 18125 17711 15520

2.75 3.85 1.43 17226 15505 14603 12956 19988 16580 16817 14004 21056 18140 17744 15545

** Based on ARI Rating Conditions of 70°F Entering Air Temp., 200°F Entering Water Temp and 180°F Leaving Water Temp. Max. Water Temperature

Pressure 7000 & 9000 BTUH Units 12000 BTUH Units 15000 BTUH Units

Coil

200°F. Max. Water Pressure - 200 Psig.

alve Hi Lo Hi Lo Hi Lo Hi Lo Hi Lo Hi Lo

Heating Capacity (Btu h )- Hot Water

Hydronic Heat Kit Application Data

Heating Capacity (Btuh) - Steam

Steam 7000 & 9000 BTUH Units 12000 BTUH Units 15000 BTUH Units (psig) Fan Speed Fan Speed Fan Speed

Hi Low Hi Low Hi Low

2**

3 4

Maximum steam pressure 5 psig **Based on ARI rating conditions of 70° F entering air temp. and 2 psig steam pressure

20,236 17,816 21,694 18,306 23,709 20,962 20,686 18,253 22,100 19,003 25,676 21,899 20,821 18,544 22,822 19,313 26,325 23,678

Water Valve Inlet/ Outlet Dimensions

Model Inlet Outlet VW2WNOA 5/16" 5/16" VW3WNOA 5/16" 5/16" VW2WNCA 5/16" 5/16" VW3WNCA 5/16" 5/16"

Steam Valve Inlet/ Outlet Dimensions

Model Inlet ( Inches) Outlet (Inches) VS2WNOA 5/16" 5/16" VS2WNCA 5/16" 5/16"

Page 35

ACCESSORY INST ALLA TIONS

Water Valve Pressure Drop

2-Way Valve 3-Way Valve Bypass 3-Way Valve

Wate

GPM (psig) GPM (psig) GPM (psig)

1.00 0.19 1.00 0.13 1.00 0.04

1.13 0.24 1.13 0.16 1.13 0.05

1.25 0.30 1.25 0.20 1.25 0.06

1.38 0.36 1.38 0.24 1.38 0.08

1.50 0.43 1.50 0.29 1.50 0.09

1.63 0.50 1.63 0.34 1.63 0.11

1.75 0.58 1.75 0.39 1.75 0.12

1.88 0.66 1.88 0.45 1.88 0.14

2.00 0.76 2.00 0.51 2.00 0.16

2.13 0.85 2.13 0.58 2.13 0.18

2.25 0.96 2.25 0.65 2.25 0.20

2.38 1.07 2.38 0.72 2.38 0.23

2.50 1.18 2.50 0.80 2.50 0.25

2.63 1.30 2.63 0.88 2.63 0.28

2.75 1.43 2.75 0.96 2.75 0.30

CV=2.3 CV=2.8 CV=5.0

Pressure Drop Wate

Pressure Drop

Q = CV

Q = Flow in Gallons/Min CV = Flow Coefficient of Valve Pd = Pressure Drop (psig)

Dimensions of Complete Installation

Top of Wal l Sleeve

10-13/16"

Bottom of Wall Sleeve

4-1/8"

l S

Hydron ic Front

Toe Plate 0" - 3.0" Lo ng

PT AC Unit Wall Sleeve

5-1/2"

9-7/8"

Side View

Hydronic Air

Discharge

Unit Controls

Compartment

Top View

Page 36

ACCESSORY INST ALLA TIONS

Steam Plumbing Dimensions

(2 places)

3-1/2"

5-3/4"

1" x 1-1/2" opening for piping

5-1/2"

1/2" I.D. 5/8" O.D.

5/8"

Steam Outlet Connection

3-1/4"

1-7/8"

PTAC UNIT WALL SLEEVE

COIL

TOP VIEW OF C OIL LOCATION

(with t op grille and s heet metal r emoved)

1-1/2"

COIL

13-3/8"

1-1/2"

1-7/8"

3-1/4"

2-1/4 "

(2 places)

1" diameter opening for piping

1/2" I.D. 5/8" O.D.

5/8"

Steam Inlet Connection

Steam Outlet Connection

16-7/8"

16-3/4"

20-3/16"

COIL

1-1/2"

8-1/4"

Hydronic Air Inlet

Steam Coil Position

2-1/8"

53"

FRONT VI EW

(unit with Hydronic Kit installed)

Steam Inlet Connection

COIL

1-1/2"

17-3/8"

Steam Trap (optional)

(

: Steam Trap may be

NOTE

installed on one or both sides of Hyrdronic Unit)

SIDE VIEW SIDE VIEW

Page 37

ACCESSORY INST ALLA TIONS

Hot Water Plumbing Dimensions

5-1/2"

3-1/4"

3-3/8"

1-13/16"

1' 1-5/8"

1-13/16"

3-1/4"

5-11/18"

1/2" I.D. 5/8" O .D.

4-3/4"

2-3/4"

COIL

4' 5"

1-1/16"

1/2" I.D.

5/8" O.D.

2-1/8"

3-3/8"

1' 8-3/16"

1' 4-1/8"

0" TO 3"

Finished Floor

Page 38

ACCESSORY INST ALLA TIONS

Wall

3-1/4"

1/8" Hole s

2-1/4"

Indoor

Right

Side

Wall

Sleeve

1/8" Hole s

3-1/4"

2-1/4"

Indoor

Left

Side

5. Remove the control knobs and metal escutcheon from the control panel area of the chassis.

6. Remove the discharge screen from the chassis by removing the two screws holding the screen to the chassis.

7. Mount the transition to the chassis with supplied two 1/ 2-inch #8 screws.

3. Unbox the hydronic kit and discard the packaging material. The cardboard packaging material should be recycled.

4. Mount the two support brackets to the bottom of the hydronic top as shown with supplied four, 3/8-inch #8 screws.

Slide Brackets Before Tightening Screws

Rubber Splash

Shield

Move the brackets to the left so that screws are located in right side of slot and tighten screws.

Transistion

8. Position the hydronic top with support brackets to the wall sleeve and fasten the support brackets to the drilled holes in the wall sleeve with supplied four 1/2-inch #10 screws.

Page 39

ACCESSORY INST ALLA TIONS

9. Place the chassis back into the wall sleeve and secure chassis to wall sleeve. Be careful not to bind or pinch the flexible shafts protruding from the bottom of the hydronic top assembly.

10. Place the ends of the flexible shafts protruding from the hydronic top over the corresponding D shafts on the chassis control board. Make sure the plastic inside the flexible shaft fitting is mating with the flat surface of the control board’s D shaft.

NOTE: The splash guard must be pushed against the control panel.

Plastic

Insert

Skirt

Exterior Wall

Hydronic Front

Wall Sleeve

11. Measure the distance from the bottom of the chassis basepan to the finished floor to determine how far to extend the skirt below the metal front. If the distance is less than two inches the skirt must be trimmed so the skirt will not interfere with gasket or block inlet air on the front.

L L

Basepan

Between 0" to 3"

12. Mount the skirt to the metal front with four 3/8” #8 screws. NOTE: Skirt is attached to front of top piece during shipping.

Hydronic Front (Inside Surface)

3/8" #8 Screws

(2 On Each Side)

13. Remove the six screws from the top of the hydronic top. Lift the hydronic top straight up and set aside along with the six screws.

1/2" to 3-3/4"

Floor

Page 40

ACCESSORY INST ALLA TIONS

14. Position the wires from the freeze thermostat found on the left side of the hydronic top so the wires slide through the slot opening in the hydronic top.

Place all wires into the supplied round plastic grommet through the slit in the grommet.

Information relating to U.L. approved valves and current loads is shown on the label on the kit. In addition, water and steam valve model numbers are listed in the following table.

Water Valve

Model Description Position End Switch VW2WNOA 2-Way Normally Open Yes VW3WNOA 3-Way Normally Open Yes VW2WNCA 2-Way Normally Closed Yes VW3WNCA 3-Way Normally Closed Yes

Steam Valve

Model Description Position End Switch

VS2WNOA 2-Way Normally Open Yes VS2WNCA 2-Way Normally Closed Yes

NOTE: WHEN HYDRONIC HEAT IS USED, DISREGARD THE MINIMUM CIRCUIT AMPACITY AND MAXIMUM FUSE SIZE SHOWN ON THE AUXILIARY NAMEPLATE FOR FIELD INSTALLED HEATERS. USE VALVES SHOWN ON THE MASTER UNIT NAMEPLATE.

ERIE MANUFACTURING CO. 654C0507EA01 654C0407EA01 UNIT VOLTAGE RATING 230/208 265

BARBER-COLMAN VA-1403-201 VA-9224-201 MAX. WATER TEMPERATURE 200° F

HONEYWELL V8043A

CAUTION: VOLTAGE RATING OF VALVE IS 24VAC AND DOES NOT CORRESPOND TO

THIS KIT MAY BE USED WITH ONE OF THE FOLLOWING ELECTRIC CONTROL VALVES:

VOLTAGE RATING ON THE UNIT NAMEPLATE.

HOT WATER

654C0527EA01 654C0427EA01 FAN MOTOR AMPS .6 .6 654C0509EA01 MOTORIZED VALVE, WATTS 6.5 6.5 654C0529EA01

VA-1403-301 VA-9214-201 MAX. WATER PRESSURE 200 PSIG VA-3403-201 MAX. STEAM PRESSURE 5.0 PSIG

V8043B V8043J V8044A

STEAM

NOTE: WHEN HYDRONIC HEAT KIT IS

EMPLOYED, THE FOLLOWING LOADS

OPERATE CONCURRENTLY:

15. Snap the grommet into the hydronic top and pull the wires forward to take out the slack in the wires.

16. Route the freeze thermostat wires through the u-clip on the hydronic top assembly and down in front of the control panel. Snap the plastic male pin connector into the plastic female pin connector located on the outside front surface of the control panel.

17. Determine whether a 2-way or 3-way normally open or normally closed valve is required. Also determine if an end switch is required to control the circulating pump.

18. Remove the valve cover and connect the supplied valve wire harness leads to the two leads for the valve motor (not the end switch leads) with the supplied wire nuts. The fiber washer and strain relief supplied with the valve harness must be located in the valve motor enclosure after assembly.

19. Replace the valve cover. Use the two remaining wire nuts to connect the wires from the chassis wire harness to the flow valve harness. The BK24 wire from the chassis harness connects to the BK49 wire of the valve harness. For normally open valves, connect the YL13 wire from the chassis harness to the BK48 wire of the valve harness. For normally closed valves connect the BU21 wire from the chassis harness to the BK48 wire of the valve harness. Cut either the YL13 or BU21 wire that is not being used at the plastic male connector on the control panel.

Two-Way Valve Installation

When installing two-way valves, the flow direction is from end “B” as shown below.

Page 41

ACCESSORY INST ALLA TIONS

Control Cord/Plug

N.O. YL13

N.C. BU21

From

Heat

Coil

Motor

Return To

Water System

Wire Nuts

* Connect YL13 for Normally Open Valves.

Connect BU21 for Normally Closed Valves

20. Before soldering pipes to normally closed valves, manually open valve by slowly moving lever to retaining notch and allow spring to secure lever in notch. The lever will reset to the automatic position the first time the valve is energized.

Three-Way Valve Installation

When installing three-way diverting valves, end “B” is the supply to coil and end “A” is the by-pass end. The inlet port is unmarked. Port markings “A” and “B” are located on the bottom of the valve body.

22. The plumbing may enter from the left and/or right side of the unit through the slots and holes that are supplied in the hydronic top assembly. (See Plumbing Dimensions)

23. Hydronic water kits (HWK03) may have water entering either the left or right side of the coil. Hydronic steam kits (HVK03) can only have entering steam on the right side of the coil. (See Plumbing Dimensions)

24. Make sure all piping is plumbed to the coil and system has been bled of air. Using the existing six screws and hydronic top from Step 13, place the top cover over the coil deck assembly. Make sure the back flange of the top cover fits inside the small vertical flange in the back of the coil assembly.

Motor

End "B"

To Coil

(Normally

Closed)

* Connect YL13 for Normally Open Valves. Connect BU21 for Normally Closed Valves.

Coil Assembly

Wire Nuts

Control Cord/Plug

N.O. YL13

N.C. BU21

Return

Prior to soldering the normally closed 3-way valve, open both ports by slowly moving manual operating lever to retaining notch until lever is secured by valve spring.

Flow valve and tubing is to be installed so that it does not restrict removal of the chassis from the sleeve for service.

21. Solder the flow valve and other necessary components in line with the plumbing rising from the floor or wall. The components should not be placed inside the hydronic top assembly.

Flange

Water

Piping

NOTE: A manual bleed valve is supplied with both the

Hydronic Water Kit and the Hydronic Steam Kit (HWK03 and HVK03). It is recommended that the installer install an automatic bleed valve for Hydronic Steam Kits (HVK03) to eliminate frequent access to the manual bleed valve for purging air from the steam system.

25. Place the hydronic front on the top assembly so the flanges of the front fit tightly into the flanges of the top assembly.

26. Check to ensure the inlet air filter is located inside of the inlet grille between the inlet grille and the coil. The inlet grille can be hinged open by unlatching the two top levers on the grille.

27. Attach the supplied ball knob to the control door using the #10 machine screw supplied with the kit.

Page 42

ACCESSORY INST ALLA TIONS

Hydronic Transformer

Description

The hydronic transformer kit must be installed into a standard PTAC chassis to make the chassis operate electrically with the HWK03 and HVK03 hydronic kits. This kit is not required on hydronic chassis (model number ending with "HA"). Do not use this kit with heat pump chassis - consult your Amana® brand sales representative for information.

HIGH VOLTAGE

ISCONNECT ALL POWER BEFORE

SERVICING

ULTIPLE POWER SOURCES MAY BE PRESENT

AILURE TO DO SO MAY CAUSE PROPERTY

DAMAGE

1. Remove front by rotating bottom outward and then lifting up and out from chassis.

2. To gain access inside the control panel, after removing the knobs and escutcheon, remove the two screws holding panel in position. Tilt control panel forward, being careful not to pinch any wires.

3. Lift the control panel up so the control panel is free of its hinges. Orient the control panel so there is easy access for mounting components to the control panel.

INSTALLING THIS KIT

PERSONAL INJURY OR DEATH

Remove Two Screws To Gain Access Inside Control Panel (One On Each Side Of Panel)

4. Using the two #8 screws that are provided, screw the transformer to the control panel in the transformer mounting holes provided in the panel.

5. Mount the relay in one of the three pairs of relay mounting holes in the control panel making sure that the threaded stud is in the smaller hole and the metal tab is in the larger hole. Screw the provided nut onto the threaded stud from the opposite side of the control panel.

Cross

Knockout

Transformer

Mounting Holes

Relay Mounting

Holes

Transformer

Mounting Holes

6. Remove the cross shaped knockout from the control panel. Insert the female wire connector into the cross shaped hole from the side of the control panel where the transformer and relay are mounted.

NOTE: If the cross knockout is not located in the control

panel, disconnect the terminals of the wire harness from the relay and transformer. Route the wires through the power cord opening in the basepan until about 6 to 8 inches of the harness protrudes from the opening. Reconnect the harness wire terminals to the relay and transformer as follows:

Wire YL12 to Relay 1 terminal Wires BU20, BU22 to Relay 3 terminal Wire RD20 to Relay 5 terminal Wire BK25 to one Transformer 24V terminal Wire BK23 to other Transformer 24V terminal

7. (1) If the unit has an electric heater, remove the BR34 and BR35 heater wires from the control board and push these wires through the mid partition panel so that the wires will not be loose in the control panel area.

(2) If the unit has a 2 stage electric heater, disconnect the BR34, BR35, VT20, VT19, VT17, and VT18 heater wires from the control board. Remove the heater relay and wires from chassis and discard . Push the heater wires (BR34, BR35, and BR36) through the mid partition panel so the wires will not be loose in the control panel area.

Page 43

ACCESSORY INST ALLA TIONS

8. Connect the PK30 and PK31 wires from the relay to the heater terminal next to the Line 1 terminal and to the heater terminal next to the Line 2 terminal respectively, on the control board.

9. (1) Remove the RD33 and Line 2 power cord (BK18 for 265 volt units) wires from the control board. Connect the GY21 and GY22 wires from the transformer to the Line 1 and Line 2 terminals, respectively. On the control board, reconnect the RD 33 and Line 2 power cord (BK18 for 265 volt units) wires to the piggy back terminals of the GY21 and GY22 wires on the control board, respectively.

(2) If the unit already has a power vent or power door kit installed in the chassis, remove the WH7 wire from the Line 1 terminal on the control board and connect the WH7 wire to the GY21 wire at the transformer.

10. Install the control panel back onto its hinges. Close the control panel being careful not to pinch any wires. Reinstall the control panel cover and screw control panel back into place.

11. See hydronic installation instructions to finish installing hydronic heat kit.

and, using both hands, bow door just enough for door hinge pins to slide out of mating holes.

3. Install the new door assembly with the key lock by bowing the door with both hands and aligning the door hinge pins with their mating holes in the front.

4. For further security, secure the front cover to the chassis with two 1/2 inch #8 sheet metal screws (see chassis installation).

Key Lock Kit

Keylock

Description

The Key Lock kit prevents tampering of the controls used to set temperatures and heating or cooling functions.

CAUTION

PERSONAL RISK HAZARD

NDERWRITER’S LABORATORIES

U F

OR INSTITUTIONAL USE ONLY WHERE SUPER

VISORY MONITORING IS AVAILABLE

MAY INCREASE THE RISK OF PERSONAL

USE INJURY

Installation

The installation and servicing of the equipment referred to in this booklet must be performed by a qualified, experienced technician.

1. Remove front from unit by pulling bottom out and then

2. Remove existing door assembly by lifting door halfway

PROPERTY DAMAGE

lifting upward.

, INC. L

. ANY

ISTED

OTHER

Door

Hinge Pins (Each Side)

Mati ng H oles (Each Side)

Front

Page 44

ACCESSORY INST ALLA TIONS

Power Disconnect Switch

Power Switch Kit Components

(Cover Plate Not Shown)

Description 230/208 and 265 Volt Power Switch Assemblies

An optional 230/208V or 265V power switch assembly kit can be installed in a full-length subbase or in the junction box of the Hard Wire Junction Box kit. The switch provides a POWER ON/OFF function as required by some electrical codes. A replacement junction box cover plate is provided with each switch.

CAUTION

USE

COPPER CONDUCTORS ELECTRICAL TYPES

CONNECTIONS

CONDUCTORS MAY RESULT IN GAL VANIC CORROSION, OVERHEATING AND RESUL TANT EQUIPMENT FAILURE

ALL

WIRING MUST COMPLY WITH APPLICABLE LOCAL AND NATIONAL CODES LOCATION OF FUSED DISCONNECT SWITCH(ES MUST COMPLY WITH ALL APPLICABLE CODES

AILURE TO FOLLOW THESE CODES COULD RESULT IN OVERHEATING AND EQUIPMENT FAILURE

Power Switch Installation for Junction Box

NOTE: Refer to Hard Wire Assembly Kit Instructions for mounting junction box. If the junction box is mounted vertically, the switch must be installed so that the ON position is up.

ONLY

. THE

. T

FOR

USE OF OTHER

YPE AND

)

HIGH VOLTAGE D

ISCONNECT ALL POWER BEFORE SERVICING BASE PRESENT PROPERTY DEATH

HE UNIT’S

DISCONNECT ALL POWER TO THE UNIT

INSTALLING THE SUB

. M

ULTIPLE POWER SOURCES MAY BE

. F

AILURE TO DO SO MAY CAUSE

DAMAGE, PERSONAL INJURY OR

OFF

SWITCH DOES

NOT

230/208V Installation

1. Remove and discard the white lead of the hard wire assembly.

2. Connect the black lead of the hardwire assembly to one terminal of the disconnect.

Ground Wire

(Connect to Power

Supply Ground Wire)

Switch

Mounting

Tab

Red Wire

Switch Terminal

(Connect to L2 of

Power Supply)

White Wire

(Remove & Discard)

Switch

Mounting

Tab

Black Wire

230/208V Disconnect

Switch

Switch Terminal

(Connect to L1 of

Power Supply)

Page 45

ACCESSORY INST ALLA TIONS

3. Connect the red lead of the hardwire assembly to the switch terminal opposite the terminal where the black lead was assembled in step 2.

4. Remove the knockout from the desired power entry point on the junction box and route field supplied power wires into the junction box.

5. Connect the red and black leads of the field power supply to the two unused terminals on the power switch.

6. Connect the ground wire of the field power supply to the bare ground wire assembly.

7. Mount the switch on the tabs in the junction box and install the switch cover plate provided with the power switch kit.

265V Installation

1. Remove and discard the red lead of the wire assembly

2. Connect the black lead of the hard wire assembly to one terminal of the disconnect.

3. Remove the knockout from the desired power entry point on the junction box and run field supplied power wires into the junction box.

4. Connect the black lead of the power supply to the remaining disconnect switch terminal.

5. Connect the ground wire of the field power supply to the bare ground wire assembly.

6. Connect the white lead of the wire assembly to the Neutral lead of the power supply.

7. Mount the switch on the tabs in the junction box and install the switch cover plate provided with the power switch.

Power Switch Installation for Subbase

1. Remove the left and right subbase cover panels by removing screws holding them in place. Retain the screws.

2. Remove the rectangular knockout located in the center of the recessed area on left cover panel.

3. Install the switch using the two bolts and nuts provided so that the “ON” position of the switch is on the right. Install ground lead (provided) between switch mounting tab and mounting plate.

7. Insert the BLACK wire from the receptacle into the lower right hole in the rear of the switch and tighten the screw. Insert the BLACK power wire (field wiring) into the lower left hole in the switch and tighten the screw.

8. Attach the ground field wire by connecting the green wire on the disconnect to the ground terminal (screw) on the back wall of the subbase high voltage section.

9. Replace the cover panels (with the switch installed) to the subbase using the screws removed in step 1.

265V Wiring Procedure

4. Insert the BLACK wire from the receptacle into the lower right hole in the rear of the switch and tighten the screw. Insert the BLACK power wire (field wiring) into the lower left hole in the switch and tighten the screw.

5. Connect the WHITE wire from the receptacle to the WHITE power wire (field wiring) with the wire nut provided.

6. Attach the ground field wire by connecting the green wire on the disconnect to the ground terminal screw on the back wall of the subbase high voltage section.

7. Replace the cover panels (with the switch installed) on the subbase using the screws removed in step 1.

Ground Wire

(Connect to Power

Supply Ground Wire)

265V

Disconnect S witch

Red Wire

(Remove and

Discard)

White Wire

(Connect to Neutral

of Power Sup p l y)

Switch

Mounting

Tab

Black Wire

Switch Terminal

(Connect to L1 of

Power Supply)

230/208V Wiring Procedure

4. Route the RED wire from the receptacle through the barrier in the subbase using the hole provided.

5. Insert the RED wire from the receptacle into the upper right hole in the rear of the switch and tighten the screw.

6. Route the BLACK wire from the receptacle through the barrier in the subbase using the hole provided.

Left Subbase

Cover Panel

Screws

Right Subbase

Cover Panel

Page 46

ACCESSORY INST ALLA TIONS

Remote Temperature Sensor

The installation and servicing of the equipment referred to in these instructions must be performed by qualified, experienced technicians.

Description

With control functions remaining at the unit, the remote temperature sensing feature is a unique accessory capable of providing accurate sensing of room temperature from a central location, separate from the unit.

Remote Temperature Sensor

HIGH VOLTAGE D

ISCONNECT ALL POWER BEFORE

SERVICING

ULTIPLE POWER SOURCES MAY BE PRESENT

AILURE TO DO SO MAY CAUSE PROPERTY

DAMAGE

INSTALLING THIS UNIT

PERSONAL INJURY OR DEATH

Mounting Sensor

Loosen the screw in the lower right corner of the cover and pull the decorative cover off the sensor base. Position the sensor base on the wall, in the desired location, and mark two mounting holes as shown. Pull the two sensor wires (shielded, twisted pair wiring not required) through the opening in the sensor base and secure the sensor base to the wall using wall anchors, if required. Obtain the wall anchors locally. Be careful not to let the wires fall into the wall opening.

Wall

Sensor Wires Through Wall

Opening

Wall

Anchor

Mounting

Hole

Wall

Anchor

Subbase

Terminal 3 Terminal 2

Mounting

Hole

Mounting

Screws (2)

Sensor Base Mounting

Installation

Locating the Temperature Sensor

For best performance results, the remote temperature sensor should be located approximately 5 feet above the floor on an inside wall in an area with good air circulation. The sensor should be mounted so that it is sensing the temperature of the room where the occupants will be spending most of their time.

Do not install the sensor where it may be affected by the following:

• Dead spots behind doors, in corners or under cabinets

• Hot or cold drafts from air ducts

• Radiant heat from the sun, appliances, or fireplaces

• Concealed pipes and chimneys

• Surfaces affected by a cold or heat source on side op-

posite the sensor.

Page 47

ACCESSORY INST ALLA TIONS

1. Remove the PTAC cabinet front to expose the control panel area.

IMPORTANT NOTE: Disconnect power to the unit and/or turn the Master Switch on the control board to OFF when connecting or altering wiring to any terminal - failure to do so may result in shorting the fuse or damaging the control board.

2. Remove the terminal strip cover by removing the screw securing it to the control panel cover.

3. Set the Remote/Standard switch to the STANDARD position.

4. Connect the two sensor wires running from the RC and RS terminals on the PTAC Remote Thermostat terminal strip to terminals 2 and 3 on the remote temperature sensor base as shown.

5. Wire the sensor using standard 20 gage thermostat wire (shielded, twisted pair wiring not required) with a maximum wire length of 50 ft.

NOTE: Shorting the thermostat wires to ground will cause control board failure.

6. Replace the terminal strip cover and reinstall the cabinet front.

7. When power is reestablished to the unit, the remote temperature sensor will automatically be activated. The mode switch must be in the OFF position before electrical power is applied to the unit. If the mode switch is not in the OFF position when electrical power is applied to the unit, the random restart feature will activate causing a two to four minute start-up delay.

Thermostat

LINE 1 HEATER HEATER LINE 2 COMP F AN H IGH FAN LOW R-VALVE230V265V

ON / OFF

MASTER SWITCH

FUSE

Mode Switch

Terminal Strip

Cover

Control Panel

REMOTE THERMOSTAT

AUXILIARY

CRGL

Y/W1FD2FD1

W2 B GH

EH IN L S TF1 T F2

CRGW2Y\W1BRSFD

OUTDOOR

COIL

INDOO R

COIL

INDOO R

ON / AUT O

FAN

CYCLE

Thermostat

AIR

ALL OFF

RMT/STD

THERMOSTAT

CONTROL

Remote/Standard

Control Switch

(Remote ←, Standard →)

Remote

Sensor

BLUE

RED

BLACK

C B A

Wiring Schematic for Remote Temperature

Sensor

Page 48

ACCESSORY INST ALLA TIONS

Subbase

Description

The subbase may be installed on the wall sleeve before or after installing the wall sleeve. The subbase is prewired. Electrical connections can be made on the left side after the access cover is removed. A grounding screw is provided.

NOTE: The wall sleeve must be installed a minimum of 3¼ inches or maximum of 5 inches above a finished floor and a minimum of 2¾ inches from a finished wall.

HIGH VOLTAGE D

ISCONNECT ALL POWER BEFORE

SERVICING

SUBBASSE OR ANY EQUIPMENT OR

THE CHANGING POWER

DO SO

TO PERSONAL INJURY OR DEATH

HE UNIT’S

DISCONNECT

IMPORTANT NOTE: To avoid equipment damage, use cop-

per conductors only. NOTE: The installation and servicing of this equipment must

be performed by qualified, experienced technicians only.

1. Remove parts B and C from the subbase and join together using two metal screws provided. This assembly now becomes the right front cover (Part Z) of the subbase.

INSTALLING OR CONNECTING

ANY EXISTING WIRING

SOURCES MAY BE PRESENT

MAY CAUSE PROPERTY DAMAGE

. M

OFF

SWITCH DOES

ALL POWER TO THE UNIT

NOT

ULTIPLE

. F

AILURE

ALWAYS

2. Position subbase under the front of the wall sleeve.

3. Align the back edge of the flange on cover A to front of the wall sleeve flange.

NOTE: A properly installed subbase will extend 1-1/2 inches to the front of the wall sleeve. Do not mount flush to the front of the wall sleeve.

4. Drill four in subbase. Mount subbase to wall sleeve with four sheet metal screws provided with kit.

5. Remove the left front cover from the subbase.

6. Position skirting on each side of wall sleeve to prevent the entry of foreign materials. Trim skirting to desired length. Attach skirting with four sheet metal screws provided with kit.

7. Wire subbase for appropriate voltage. NOTE: The proper subbase must be ordered to obtain the correct electrical receptacle.

8. After wiring is complete, mount covers A and Z to the subbase with provided screws.

9. When installing optional accessories to the subbase, refer to each installation instruction for that accessory.

/8 inch holes in wall sleeve to line up with holes

Page 49

ACCESSORY INST ALLA TIONS

Part/Location Identification

A Left Front Cover B Right Front Panel C Front Cord Panel D Wall Sleeve Hole Location E Skirting Hole Location Z Right Front Cover Assembly

-- Leveling Legs (Not Shown)

Wall Sleeve

Cover

Wiring

Access

Low Voltage Compartment

Page 50

ACCESSORY INST ALLA TIONS

13-3/4"

Wall Sle eve

(Outdoor Side)

16-1/16"

3-1/4"

2-3/4"

Wall Sleeve Inside Edge

Back of Flange "A"

19-9/16"

1-3/8"

Ground Screw Location

3-1/2"

Concentric

Knockouts In Rear

Front View

Receptacle

Provided

Inside Subbase

Accessory

13-1/2"

2-5/8"

2" Ma x. Adjustment

Left End View

NEMA 6-20R

Receptacle

NEMA 6-30R

Receptacle

Field Wiring

Line Voltage

L1 L2

BLK

RED

L1 L2

NEMA 7-20R

Receptacle

NEMA 7-30R

Receptacle

Concentric

Knockouts In Bottom

Top View

GRN

WHT

BLK

L1 L2

Field Wiring

Line Voltage

230/208 VAC Field Schematic

265 VAC Field Schematic

Wiring Diagram

Page 51

ACCESSORY INST ALLA TIONS

Remote Thermostat High Fan Kit

Description

When a wall mounted thermostat is used, the PTAC unit will operate in low speed only. Following these instructions will allow the PTAC unit to operate on high speed only. This kit contains twenty labels, enough for ten units.

HIGH VOLTAGE

ISCONNECT ALL POWER BEFORE

SERVICING

ULTIPLE POWER SOURCES MAY BE PRESENT

AILURE TO DO SO MAY CAUSE PROPERTY

DAMAGE

1. Remove the two screws securing the front to the chassis. NOTE: Not all installations will use these screws.

secure front

2. Grasp the cabinet front as shown.

3. Pull the bottom of the cabinet front away from the chassis until the retaining clips disengage.

INSTALLING THIS UNIT

PERSONAL INJURY OR DEATH

Holes to

4. Lift the cabinet front off the chassis.

5. Remove the unit control knobs by pulling the knobs off the control shafts.

Control Panel

Pull To Remove

Mode Switch Knob

Pull To Remove

Thermostat Knob

6. Lifting the front edge of the escutcheon, slide the tabs at the top of the escutcheon out of the retaining holes and remove the escutcheon.

7. Remove the control panel cover by removing the two screws holding the control panel cover in place. Tilt the control panel forward to gain access to the wiring.

8. On the control board switch BK16 along with all other wires on the “FAN HIGH” and RD17 and all other wires on the “FAN LOW” 1/4 inch terminals.

Cove r Screws

Located on Both Sides of Control Panel

Page 52

ACCESSORY INST ALLA TIONS

ELECTRIC HEATER

RD33

BR35BR34

LINE 1 HEATER HEATER LINE 2 COMP R-VALVE

BK18

FUSE

VT12

Unit Wiring As Shipped From The Factory

NOTE: If additional accessories have been added, the wiring may differ from what is shown.

BK16

FAN

HIGH

FAN

MOTOR

RD17

FAN

LOW

BK19

REV VALVE SOLENOID

9. Replace control panel cover, escutcheon, and control knobs.

10. Place one label supplied with this kit on the wiring diagram supplied with the unit.

11. Place a second label on the sheet metal control cover near the top left edge.

Label Replacement

ELECTRIC HEATER

RD33

BR35BR34

LINE 1 HEATER HEATER LINE 2 COMP R-VALVE

BK18

FUSE

VT12

BK16

FAN

HIGH

FAN

MOTOR

RD17

FAN LOW

BK19

Unit Wiring

To Allow For

High Fan Speed

REV VALVE SOLENOID

12. Replace the wiring diagram and the front cover.

Page 53

ACCESSORY INST ALLA TIONS

Right Hand Subbase Conversion

Description

The right hand subbase cover is used when existing subbases are already installed on the wallsleeve and the subbase needs to be converted to a upgraded subbase. The Right Hand Subbase Cover kit must be installed in order to maintain proper clearances from the subbase to all PTAC chassis manufactured after January 1, 1996.

NOTE: The right-hand subbase cover can only be used on subbases manufactured prior to January 1, 1996 model subbases.

Installation

1. Remove the right hand subbase cover from the existing subbase by removing the two screws holding the cover in place. Save these screws for later use.

2. Unplug and remove the old PTAC chassis from the wall sleeve.

3. Install the new PTAC chassis into the wallsleeve and plug the PTAC power cord into the subbase power receptacle.

4. Place the right hand subbase cover supplied with this kit on the subbase in the same location that the old right hand cover was removed. Secure the right hand subbase cover to the subbase using the screws removed in Step 1.

Install