McQuay PNSE2 Installation Manual

ENR & ENH Type 45 Replacement Chassis

Installation & Maintenance Data

IM 435-3

Group: PTAC Part No.: 106018611 Date: May 1999

EXISTING LOUVER

CHASSIS SIDE SEAL (LEFT-HAND)

CHASSIS TOP SEAL

CONDENSER COIL BAFFLE SEAL

➤

CHASSIS

➤

WALL SLEEVE BOTTOM SEAL

CHASSIS SIDE SEAL (RIGHT-HAND)

➤

EXISTING WALL SLEEVE

WALL SLEEVE CHASSIS SUPPORT CHANNEL

IM 435-3 / Page 1 (Rev. 5/99)

Table of Contents

Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wall Sleeve Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chassis Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing The Condenser Coil Baffle Seal . . . . . . . . . . . . . . . . . .

Additional Alteration With Heat Pump . . . . . . . . . . . . . . . . . . . .

Chassis Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Equipment Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Approximate Ship Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 4 4 5 5

ENR (Electric Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENH (Heat Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENH (Heat Pump with Supplemental Hydronic Heat) . . . . .

ENR/ENH (Hydronic Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Catalog Number Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6,7

8-11

Installation

The installation of this equipment shall be in accordance with the regulations of authorities having jurisdiction and all applicable codes. It is the responsibility of the installer to determine and follo w the applicable codes. Sheet metal parts, selftapping screws, clips and such items inherently have sharp edges, and it is necessary that the installer exercise caution. This equipment is to be installed only by an experienced installation company which employs trained personnel.

Inspection

When the equipment is delivered all items should be checked carefully against the bill of lading to be sure all crates and cartons have been received. All units should be carefully inspected when received. If any damage is noticed, the carrier should make proper notification on the delivery receipt acknowledging the damage. The carrier should also complete a carrier inspection report and forward it to AAF–McQuay Incorporated.

The unit nameplate should be checked to be sure the voltage agrees with the power supply available. The ENR/ENH-45 is a replacement chassis for Singer and American Standard T ype 45 units. It is designed to be installed into the existing Type 45 wall sleeve using the retrofit kit provided with the new chassis. Installation of this retrofit kit is described herein. Do not install the chassis until the retrofit kit has been properly installed on the chassis and in the wall sleeve.

The ENR/ENH-45 retrofit kit is packaged in a separate carton and shipped in addition to the chassis. Careful inspection should

be made of the retrofit kit package to insure all components have been included. The retrofit kit should include the following pieces:

No. of

Parts

Pieces

1. Wall sleeve bottom seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Wall sleeve chassis support channel . . . . . . . . . . . . . . . . . . .

3. Chassis side seal (RH & LH 1 each) . . . . . . . . . . . . . . . . . . .

4. Chassis top seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Condenser coil baffle seal . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Sheet metal screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. Tinnerman clips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

If any of these pieces are missing from the retrofit kit package notify AAF–McQuay Incorporated, Service Parts Dept., 13600 Industrial Park Blvd., Plymouth, MN 55440.

9 10 11 12 12

3 10

Figure 1. Exploded View of Retrofit Kit

WALL SLEEVE CHASSIS

SUPPORT CHANNELS

CONDENSER COIL

BAFFLE SEAL

CHASSIS SIDE SEAL

(LEFT-HAND)

CHASSIS TOP SEAL

REQUIRED FASTENERS

WALL SLEEVE BOTTOM SEAL

CONDENSER COIL BAFFLE SEAL

CHASSIS SIDE SEAL (RIGHT-HAND)

CHASSIS TOP SEAL

IM 435-3 / Page 2 (Rev 5/99)

Wall Sleeve Preparation

CAUTION: Disconnect all power to the unit before continuing.

1. Remove existing chassis from wall sleeve and discard.

2. Clean existing wall sleeve to remove any residual dirt and debris. If any rust exists, remove it with a wire brush or steel wool then coat the spot(s) with rust inhibiting paint.

3. Inspect the condition of the wall sleeve and repair as required. Be sure all wall sleeve gaskets are intact and repair as needed.

4. Locate the retrofit kit package and take out the wall sleeve bottom seal and two chassis support channels.

5. Place the square edge of the chassis support channels into the weephole slots of the existing wall sleeve. The slotted ends of the chassis supports will extend toward the roomside of the wall sleeve.

6. Place a heavy bead of RTV silicone sealant (or equivalent) to the leading edge of the wall sleeve bottom seal. The leading edge, is that edge that will be closest to the outdoor side of the wall sleeve.

7. Place the wall sleeve bottom seal into the wall sleeve so that the leading edge engages the slots of the chassis support channels. Position the leading edge of the bottom seal approximately 10

/8 inches from the rear of the wall sleeve. Be

sure the black rubber gasket of the wall sleeve bottom seal is facing upward. Press down firmly on the chassis

bottom seal to insure a positive seal.

Chassis Preparation

1. Remove the chassis from the carton and place it on the floor near the wall sleeve.

2. Remove the remaining retrofit kit parts from the package and place them near their final installation position, as shown on the front cover.

3. Locate the two side seals and mount them on the sides of the chassis so that the gasket faces the outdoor side. This requires that the existing screws be removed and reinstalled through the side seals. Note also that the gasket of these side seals extends beyond one end of each seal. This gasket extension must be positioned towards the top.

4. Locate the three chassis top seal pieces and assemble them for installation using the screws provided. If the unit has electric

8. Drill a

/8" diameter hole in each end of the wall sleeve using

the holes of the wall sleeve bottom seal as a template.

CAUTION: Drilling holes elsewhere in the wall slee ve will destroy the weather integrity and could interfere with chassis installation.

9. Fasten the wall sleeve bottom seal to the wall sleeve using the (2) #8 x

/8 sheet metal screws supplied.

10. Caulk the ends of the wall sleeve bottom seal with RTV silicone sealant (or equivalent) to insure weather integrety. The bottom seal must be completely water tight to prevent condensate from entering the indoor space.

Figure 2. Installation of Wall Sleeve Bottom Seal

CHASSIS

SUPPORT

CHANNELS

MOUNTING

SCREW

SEAL ALONG

THIS EDGE

EXISTING WALL SLEEVE

RAISED RUBBER GASKET

WALL SLEEVE BOTTOM SEAL

heat, all (3) parts will be used. If the unit has hydronic heat, only the front and right side pieces will be used.

5. Align the top seal with the perimeter of the chassis discharge plenum and drill

/8" diameter holes in the discharge plenum

flange using the top seal as a template.

6. Fasten the top seal to the discharge plenum flange. NOTE:

Pop rivets must be used to secure the sides of this top seal to the plenum flange to prevent interference with the existing seals of the wall sleeve. Screws may be used to

attach the front portion of the top seal as no interference will occur. NOTE: For hydronic units, the left-hand piece of the top seal is discarded.

Installing the Condenser Coil Baffle Seal

1. Assemble the three pieces so as to form a "U" shape as shown in Figure 1. Fasten these pieces together using the screws provided.

2. Position the assembled seal against the condenser coil so that the tangs of the assembly engage between the coil and the chassis drain pan. The gasket of the condenser coil baffle seal should rest tightly against the end plates of the condenser coil. The installed condenser coil baffle seal is shown in Figure 3.

3. Using the two Tinnerman clips supplied, attach the condenser coil baffle seal to the condenser coil end plates 3" to 4" from the top of the coil.

Additional Alteration with Heat Pump Models

Heat pumps generate condensate during the heating season that must be disposed of using a drain kit. The drain kit is furnished from the factory with all heat pump chassis, for field installation. The following modifications must be made to the retrofit kit and existing wall sleeve when using heat pumps.

Figure 3. Condenser Coil Baffle Seal

RIGHT-HAND

SIDE SEAL

TINNERMAN

CLIP

CONDENSER COIL BAFFLE

SEAL

TANG

1. Using a hacksaw, Sawsall, or tin snips, cut a 5/8" x 5/8" slot in the left-hand side seal of the retrofit kit. This slot should be located 1/2" from the bottom of the wall sleeve. Align this slot with the flange of the wall sleeve and cut an identical second slot in flange of the wall sleeve.

IM 435-3 / Page 3 (Rev. 5/99)

CHASSIS TOP SEAL

CONDENSER COIL

2. Insert the copper tube into the wall sleeve. Be certain that the drain tube extends well into the wall sleeve and maintains a downward pitch to assure proper drainage.

3. The drain kit is designed to allow condensate to run into the wall sleeve where it can be carried away through a condensate drain system. To drain the condensate directly to the outside, extend the drain tube using a second

/8" flexible polymer

connection and a piece of copper tube cut to the proper length.

4. Caulk around the tube that protrudes through the wall sleeve side seal.

5. When the chassis is slid into place, be sure the drain tubes engage properly, as shown in Figure 4.

Chassis Installation

Before installing the chassis, make the following visual and mechanical inspection:

1. Rotate the condenser fan and evaporator fans to be sure they spin freely . If they do not, make the necessary adjustments or remove any obstruction.

2. Check the evaporator coil fins and the condenser coil fins for damage. If any damage is minor, straighten fins with the proper fin comb. If the damage is extensive, notify the carrier immediately .

3. Check all fasteners and tighten as required.

4. Do not remove or loosen hold-down bolts on compressor as they are properly adjusted at the factory.

5. Remove the cardboard base from the chassis and discard.

6. When installing the size 15 chassis, be sure to remove the shipping angles. Instructions for removal of these angles can be found attached to the top of the chassis.

Once the chassis inspection has been completed, proceed as follows:

1. Align the chassis with the existing wall sleeve making sure nothing is obstructing the opening to the wall sleeve.

2. Slide the chassis into the sleeve until it seats against the side seals of the wall sleeve. CAUTION: Do not push on the coil surface, control box or scroll housings when inserting the chassis into place.

3. For units with 115V, 208V and 230V power cords, insert the cord set through the opening in the base of the wall sleeve at the right hand side.

Equipment Startup

Initial startup of the lncremental® conditioners by experienced personnel is usually the responsibility of the installing contractor. This startup consists of inspecting and operating the equipment for all functions at the time of initial installation, and making necessary adjustments. It also includes demonstrating its proper operation to the owner or his agent. Note that unless otherwise specifically agreed to in writing, McQuay includes no field labor, startup service or the like in the price of its equipment. After the equipment leaves the factory, it may become damaged or maladjusted during transportation or on the job. Sometimes wires are disconnected accidentally, or fan motors move on their bases due to rough handling, causing fans to strike. The correction of such conditions is part of the startup.

Before starting equipment, make certain that:

1. Correct voltage has been supplied to the equipment.

2. The electric plug from the control box has been inserted into

the receptacle. (If applicable).

IM 435-3 / Page 4 (Rev 5/99)

Figure 4. Optional Condensate Drain Kit

/8" DRAIN TUBE

WALL SLEEVE

CHASSIS

/8" FLEXIBLE POLYMER CONNECTION

4. Set the manual damper to the "open" or "closed" position as desired. For units equipped witn the automatic damper, place the switch to the "auto" or "closed" position as desired. In the "auto" position, the damper is open whenever the indoor fan motor is running. The "auto/closed" switch is located at the bottom left-hand corner of the chassis.

5. For hydronic units, plug in the valve wires. A cord and plug is supplied to match its existing receptacle.

6. For heat pump chassis, connect the drain tube of the chassis with the drain pipe installed in the wall sleeve as shown in Figure 4.

7. Install the evaporator drain pan cover on the indoor side of the drain pan. This is done by setting the cover in place and firmly pressing in and down on the cover until it drops into place covering the exposed portion of the indoor drain pan.

8. For units equipped with 115V, 208V or 230V power cords, insert the plug into the receptacle. Excess cord should be coiled neatly beneath the unit or in the subbase.

9. For 265V units, make electrical connections to the pigtails located inside the control box. A conduit connection is provided at the bottom of the control box.

10.Insert the existing filter or replace with a new filter.

11.Replace the front panel making sure the tangs at the bottom of the front panel engage properly in the wall sleeve. Swing the front panel upward and lift slightly to engage the front panel tangs with the slots in the existing wall sleeve.

During startup (applies only to standard equipment):

1. Set manual ventilation damper to OPEN or CLOSED position as required by owner. Set "auto-off" switch as required if unit is equipped with electric fresh air damper.

2. Push HIGH button to preselect fan speed; push HEAT button. Move thermostat to the extreme heating position (counterclockwise). Push LOW button; fan should change to low speed. If it's a heat pump, the compressor and outdoor fan should start. If it has hydronic heat, the valve should open.

3. Push HIGH button to preselect fan speed; push COOL button. Move thermostat to the extreme cooling position (clockwise). Compressor and outdoor fan should cycle on and off as the thermostat requires. Push LOW button; fan should change to lower speed. Outdoor fan should be on whenever compressor operates.

4. Push OFF button. Fan should stop, and neither heater nor compressor should continue to operate.

/8" diameter knockout for

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