Trane Pthd0902dca Service Manual

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Packaged Terminal

Air Conditioner/Heat Pump

SERVICE MANUAL

CAUTION

http://www.lgservice.com

• BEFORE SERVICING THE UNIT, READ THE SAFETY PRECAUTIONS IN THIS MANUAL.

• FOR AUTHORIZED SERVICE ONLY.

CONTENTS

1. PREFACE

1.1 SPECIFICATIONS...............................................3

1.2 FEATURES AND BENEFITS..............................5

1.3 CONTROL LOCATIONS .....................................7

1.4 ADDITIONAL CONTROLS..................................9

DISASSEMBLY INSTRUCTIONS

2.1 MECHANICAL PARTS......................................13

2.1.1 FRONT GRILLE.......................................13

2.1.2 CONTROL BOX.......................................14

2.2 AIR HANDLING PARTS....................................15

2.2.1 ELECTRIC HEATER

(Electric heater model only) .....................15

2.2.2 CROSS FLOW FAN.................................16

2.2.3 AXIAL FAN...............................................16

2.2.4 SHROUD..................................................17

2.3 ELECTRICAL PARTS .......................................17

2.3.1 OUTDOOR MOTOR ................................17

2.3.2 INDOOR MOTOR ....................................17

2.3.3 COMPRESSOR .......................................17

2.3.4 CAPACITOR ............................................17

2.3.5 POWER CORD........................................18

2.3.6 P.C.B........................................................18

2.4.2 EVAPORATOR ........................................19

2.4.3 CAPILLARY TUBE...................................19

INSTALLATION

3.1 HOW TO INSTALL THE UNIT...........................22

3.2 WALLSLEEVE INSTALLATION ........................23

3.2.1 WALL SLEEVE INSTALLATION DATA ...23

3.2.2 PREPARATION OF FRONT GRILLE ......24

3.2.3 UNIT INSTALLATION ..............................25

3.3 ELECTRICAL REQUIREMENTS ......................28

3.3.1

ELECTRICAL DATA (FOR 230V/208 MODEL)...............

3.3.2 ELECTRICAL SAFETY

FIELD INSTALLED ACCESSORIES

FERFORMANCE DATA

TROUBLESHOOTING GUIDE

6.1 OUTSIDE DIMENSIONS...................................50

6.2 PIPING SYSTEM...............................................50

6.3 TROUBLESHOOTING GUIDE..........................51

.................................

.......................................

.........

28 28

7. SCHEMATIC DIAGRAM..........................56

8. EXPLODED VIEW ......................................57

2.4 REFRIGERATION CYCLE................................19

2.4.1 CONDENSER ..........................................19

1. PREFACE

This SERVICE MANUAL provides various service information, including the mechanical and electrical parts, etc. This room air conditioner was manufactured and assembled under a strict quality control system. The refrigerant is charged at the factory. Be sure to read the safety precautions prior to servicing the unit.

1.1 SPECIFICATIONS

LP 12 0 C E M 1

12 34 5 6 7 8 9

Digits 1,2 - LG Packaged Terminal Air Conditioner Digit 6 - Product Type Digits 3,4 - Unit Cooling Capacity C = Air Conditoner 07 = 7,000 Btu/h H = Heat Pump 09 = 9,000 Btu/h Digit 7- Electric Heat 12 = 12,000 Btu/h E = Electric Heater 15 = 15,000 Btu/h Digit 8 - D = Digital M = Mechanical Digit 9 - Electric Voltage 1 = 265V, 60Hz None = 230V, 60Hz

—2—

1.1.1 COOLING

Models

Cooling Capacity

Heating Capacity

Electric Heater Capacity kW

Power Input Cooling/Heating W Running Current Cooling/Heating A Starting Current Cooling/Heating A

EER

COP W/W Power Supply Ø / V / Hz Power Factor %

Air Flow Rate

Moisture Removal l/h Sound Level Indoor,H/M/L dB(A)+3

Refrigerant & Charge g(oz)

Compressor

Fan Motor Type

Power Supply Cable No.*mm

Dimension W*H*D

Net Weight Indoor kg(lbs) Tool Code(Chassis)

Functions Range Heating

Indoor,Max m3/min(cfm) Outdoor,Max m3/min(cfm)

Outdoor,Max dB(A)+3

Type Model Motor Type Oil Type Oil Charge cc O.L.P Name Type(In/Out)

Motor Output W

Temperature Control Energy Saver Switch Prefilter(washable/anti-fungus) Plasma Filter Steps, Fan/Cool/Heat Airflow Direction Control(up&down) Airflow Direction Control(left&right) Remocon Type Setting Temperature Cooling

Auto Operation (Micom Control) Panel Touch Type Timer Air Discharge Air Ventilation Deice Control(Defrost) Hot Start Look Cabinet Type(Chassis Type) Special Function

Btu/h

W/W

Btu/h.W

mm inch

LYC073ATA02 LYH093ATA32 LYC123ATA32

2.17 2.23 2.58 2.64 3.37 3.46

7400 7600 8800 9000 11500 11800

--- ---

2.5 3.5 3.5

8530 11940 11940

590 610 750 770 1025 1055

3.0 2.8 3.8 3.5 5.2 4.8

-/- -/- -/- -/- -/- -/-

3.68 3.66 3.44 3.43 3.29 3.28

12.5 12.5 11.7 11.7 11.2 11.2

--- ---

1/208/60 1/230/60 1/208/60 1/230/60 1/208/60 1/230/60

94.6 94.7 94.9 95.7 94.8 95.6

9.5(335) 9.5(335) 11(390)

---

0.9 1.2 1.5

45/-/43 45/-/43 49/-/47

60/58 60/58 63/61

R22, 650(22.75) R22, 790(27.9) R22, 630(22.2)

Rotary(Non Tropical) Rotary(Non Tropical) Rotary(Non Tropical)

2R10S236A6G QK125KBD QK145KBA

PSC PSC PSC

Atmos M60 or SUNISO 4GDID

300 280 350

Internal Internal Internal

Cross Flow Fan / Axial Fan Cross Flow Fan / Axial Fan Cross Flow Fan / Axial Fan

4 POLES 4 POLES 4 POLES

50 50 50

3*2.1 3*2.1 3*2.1

1066*406*505 1066*406*505 1066*406*505

42*16*19-7/8 42*16*19-7/8 42*16*19-7/8

44.0(97) 44.1(97) 46.8(103) YA YA YA

Thermistor Thermistor Thermistor

OOO OOO

---

2/2/2 2/2/2 2/2/2

Manual Manual Manual

---

--54°F~86°F(12.2°C~30°C) 54°F~86°F(12.2°C~30°C) 54°F~86°F(12.2°C~30°C) 54°F~86°F(12.2°C~30°C) 54°F~86°F(12.2°C~30°C) 54°F~86°F(12.2°C~30°C)

---

Mechanical Mechanical Mechanical 12h, On/Off 12h, On/Off 12h, On/Off

Rear Rear Rear

OOO OOO

---

L-Look L-Look L-Look

---

Electric Heater Electric Heater Electric Heater

SUNISO 4GSI SUNISO 4GSI

Note:

: Applied, - : No relation

For circuit breaker rating, please conform to local standards wherever necessary.

❈

Some of functions are slightly different depending upon models.

❈

The specification may be subject to change without notice for purpose of improvement.

—3—

1.1.2 HEATING

Models

Cooling Capacity

Heating Capacity

Electric Heater Capacity kW

Power Input Cooling/Heating W Running Current Cooling/Heating A Starting Current Cooling/Heating A

EER

COP W/W Power Supply Ø / V / Hz Power Factor %

Air Flow Rate

Moisture Removal l/h Sound Level Indoor,H/M/L dB(A)+3

Refrigerant & Charge g(oz)

Compressor

Fan Motor Type

Power Supply Cable No.*mm

Dimension W*H*D

Net Weight Indoor kg(lbs) Tool Code(Chassis)

Functions Range Heating

Indoor,Max m3/min(cfm) Outdoor,Max m3/min(cfm)

Outdoor,Max dB(A)+3

Type Model Motor Type Oil Type Oil Charge cc O.L.P Name Type(In/Out)

Motor Output W

Auto Operation (Micom Control) Panel Touch Type Timer Air Discharge Air Ventilation Deice Control(Defrost) Hot Start Look Cabinet Type(Chassis Type) Special Function

Btu/h

W/W

Btu/h.W

mm inch

LYH07EATA32 LYH09EATA22 LYC12EATA32

2.14 2.73 3.46

7300 9300 11800

1.82 2.35 -

6200 8000 -

2.0 3.7 3.7

6823 12623 12623

630 550 830 690 1,105 -

2.5 2.2 3.3 2.7 4.4 -

-/- -/- -/-

3.39 3 3

11.6 11 11

3.3 3 -

1/265/60 1/265/60 1/265/60

94.6 94.7 94.9 95.7 94.8 95.6

8.5(300) 8.5(300) 12.0(420)

---

0.9 1.2 1.5

45/-/43 45/-/43 49/-/47

60/58 60/58 63/61

R22, 650(22.75) R22, 790(27.9) R22, 630(22.2)

Rotary(Non Tropical) Rotary(Non Tropical) Rotary(Non Tropical)

2R10S276A6C 2R13S276A6C 2P16S276A1A

PSC PSC PSC

ATMOS M60 or SUNISO 4GDID ATMOS M60 or SUNISO 4GDID ATMOS M60 or SUNISO 4GDID

300 260 270

Internal Internal Internal

Cross Flow Fan / Axial Fan Cross Flow Fan / Axial Fan Cross Flow Fan / Axial Fan

4 POLES 4 POLES 4 POLES

50 50 50

3*2.1 3*2.1 3*2.1

1066*406*505 1066*406*505 1066*406*505

42*16*19-7/8 42*16*19-7/8 42*16*19-7/8

44.0(97) 44.1(97) 46.8(103) YA YA YA

Thermistor Thermistor Thermistor

OOO OOO

---

2/2/2 2/2/2 2/2/2

Manual Manual Manual

---

--54°F~86°F(12.2°C~30°C) 54°F~86°F(12.2°C~30°C) 54°F~86°F(12.2°C~30°C) 54°F~86°F(12.2°C~30°C) 54°F~86°F(12.2°C~30°C) 54°F~86°F(12.2°C~30°C)

---

Mechanical Mechanical Mechanical 12h, On/Off 12h, On/Off 12h, On/Off

Rear Rear Rear

Åõ Åõ Åõ Åõ Åõ Åõ

---

L-Look L-Look L-Look

---

Electric Heater Electric Heater Electric Heater

Note:

: Applied, - : No relation

For circuit breaker rating, please conform to local standards wherever necessary.

❈

Some of functions are slightly different depending upon models.

❈

The specification may be subject to change without notice for purpose of improvement.

—4—

1.2 FEATURES AND BENEFITS

The PTAC has many features, some of which are different than those found on conventional PTAC units. The servicer must be familiar with these features in order to properly service the unit.

THE SLEEVE AND THE REAR GRILLE

(Available as an option)

REAR GRILLE (Aluminum Rear Grille)

AIR FILTER

VERTICAL AIR DEFLECTOR

(Horizontal Louver)

SLEEVE ASSEMBLY (Including Aluminum Rear Grille)

INDOOR

INLET GRILLE

(Air Intake)

EXPANDED METAL GRILLE

(Superior for a performance)

• IIR (Infinite Impulse Response) The IIR function senses the temperature several times per second and makes micro-adjustments several times per

• Compressor Restart Delay

This feature extends the overall life of compressor by preventing the short-cycling of the air-conditioner. When the compressor restarts, LG PTAC is designed to give a minimum of three minutes to have a time of equalizing the refrigerant pressures for optimizing cycling.

• Fan-Only Setting - High/Low

The fan can run at HIGH or LOW speed without COOLING or HEATING to provide air circulation and ventilation.

• Indoor Fan Speed Selections - High/Low

The fan can run at HIGH or LOW speed for either COOLING or HEATING.

• Two Fan motors

The unit has two fan motors to provide quiet operation and maximum efficiency.

• LED Diagnostics

All units have this feature indicating the problem when the unit is not operating properly with easy-to-read diagnostics. For example, 1 blink every 2 seconds indicates compressor failure.

—5—

• Indoor Filters

The unit uses two indoor filters which slide in and cut easily. The filters may be cleaned by washing and brushing without removing the front grille.

• Rotary Compressor

The unit uses a rotary compressor for quiet, reliable operation and long life.

• 2 Position Discharge Grille

The discharge grille can provide air flows upward at an angle of 40 off vertical or 15 degree off vertical. The angle is changed by removing the front grille and 4 screws that fasten the discharge grille to the front grille and rotating the louvers to an alternate position.

• Indoor Room Freeze Protection

When the unit senses the room temperature falls to less than 40° F the unit activates the fan motor and either the electric resistance heater or the hydronic heater to prevent pipes or fixtures from freezing. This also overrides front desk control of the unit mounted or wall mounted controls.

• Door Switch/Occupancy Sensor

The unit is capable of accommodating a field installed door switch and occupancy sensor to operate the energy management feature. For additional information, refer to the unit operation section.

• Compressor Overload Protection

This feature prevents the damage of the compressor by sensing the indoor tube temperature in heating. If the indoor temperature is over 130˚ F, the outdoor fan will be switched off and back on when the temperature drops below 120˚ F.

• Outdoor Air Temperature Switchover

This will effectively change the unit from heat pump mode to total electric resistance heat.

• Temperature limits

The unit is programmed to provide both heating and cooling temperature limits by dip switches on control panel from 50˚ F to 90˚ F. Temperature limits help to prevent overheating and overcooling and reduce energy costs.

• Condensate Drain Valve

The unit has a condensate drain valve to prevent water from collecting or freezing in the basepan.

• Quick Heater Recovery

The unit is designed to operate the electric heater to warm the room to the temperature set point as soon as heat pump cycle is on in heating. This feature has an advantage of reducing the time to reach the set point and improving the temperature increase for better comfort.

• Reverse Cycle Defrosting - (PTHDs only)

The unit will activate the reverse cycle defrost when the outdoor coil temperature has remained at a cold temperature to form the ice on the coil.This ice will reduce airflow though the coil and will also reduce the efficiency of unit. The LG PTHP will employ an active reverse cycle defrost function to melt the ice off the outdoor coil for insuring room comfort conditions and savings from extended operation.

• High Temperature Heat Pump Operation Protection

The compressor will be switched off to prevent damage when the heat pump is operated in high outdoor temperatures.

• Remote Thermostat Control

Each unit is built to be operated from any standard 4 or 5 wire remote-mounted thermostat, if desired. The unit has a built-in low voltage power source which can accommodate a large variety of thermostat choices-manual, auto changeover, or programmable. A remote thermostat can also be added to any installed unit.

• Zone Sensor

Occupants enjoy ultimate comfort with consistent climate control. Attach an optional, inexpensive remote Zone Sensor to exactly match the functions of the PTAC without disabling any features.

—6—

1.3 CONTROL LOCATIONS

VENT OPEN

VENT

• OPERATION

ELECTRIC HEATING MODEL COOLING ONLY MODEL

TEMPERATURE CONTROL

Set the Thermostat control to the desired temperature mark 5 (the mid-point is a good starting position). If the room temperature is not satisfactory after a reasonable time, adjust the control to a cooler or warmer setting, as appropriate.

• VENTILATION

The ventilation lever is located to the lower left side of the unit. The ventilation lever must be in the CLOSE position in order to maintain the best cooling conditions. When fresh air is necessary in the room, set the ventilation lever to the OPEN position. The damper is opened and outdoor air is drawn into the room. This will reduce the cooling or heating efficiency.

CAUTION

When the air conditioner has performed a cooling or heating operation and is turned off or set to the fan position, wait at least 3 minutes before resetting to the cooling operation.

OPERATION MODE SELECTOR

OFF Turns air conditioner off. LOW FAN Low speed fan operation without cooling. HIGH FAN High speed fan operation without cooling. LOW COOL Cooling with the low speed fan operation. HIGH COOL Cooling with the high speed fan operation. LOW HEAT Heating with the low speed fan operation. HIGH HEAT Heating with the high speed fan operation.

NOTE

A slight heat odor may come from the unit when first switching to HEAT after the cooling season is over. This odor, caused by fine dust particles on the heater, will disappear quickly. This is harmless.

—7—

• ELECTRONIC CONTROLS

TEMP

MODE

HEAT

E/SAVE

FANFAN

COOLCOOL

HIGHHIGH

LOWLOW TIMERTIMER

FAN TIMER

OFFONOFF

POWER

MODE

Push this button to cycle through the modes from COOL → FAN

→ HEAT→ COOL.

- COOL

• Fan runs continually for normal cooling operation.

- ENERGY SAVER

• The fan stops when the compressor stops cooling. Approximately every 3 minutes the fan will turn on and the unit will check the room air temperature to determine if cooling is needed.

- FAN

• Fan operation without heating or cooling.

- HEAT

• Fan runs continually for normal heating operation.

TIMER

- SHUT-OFF TIME

• You will usually use shut-off time while you sleep.

• If unit is running, use Timer to set number of hours until shut-off.

• For your sleeping comfort, once Time is set, the Temperature setting will raise 2° F after 30 minutes, and once again after another 30 minutes.

• Push Timer to cycle through the settings from 1 Hour → 2 Hours → ... → 12 Hours maximum.

TEMPERATURE SETTING

• Use this button to automatically control the temperature of the room. The temperature can be set within a range of 54° F to 86° F by increments of 2° F.

• The setting appears in the display.

FAN SPEED

• Every time you push this button, it cycles through the settings as follows: {High(F2) → Low(F1) → High(F2) → Low(F1)}

• To turn the air conditioner ON, push this button. To turn the air conditioner OFF, push the button again.

• This button takes priority over any other button.

The controls will look like one of the following.

—8—

ONREMOTE

OFF

ON ON ON

Remote/Local Energy Saver Temperature Limit 1 Temperature Limit 2 Temperature Limit 3 PTAC/PTHP UNIT TYPE

LOCALLOCAL

OFF

LOCAL

OFF2OFF3OFF4OFF

LOCAL

OFF

LOCAL

OFF2OFF3OFF4OFF5OFF6OFF

LOCALLOCAL

OFF

LOCAL

OFF2OFF3OFF

OFF

1.4 ADDITIONAL CONTROLS

• REMOVING THE FRONT GRILLE

Additional controls are available after removing the front grille and option cover of control box. To remove the front grille, pull out the bottom of front grille and then lift up. To replace the front grille, place the tabs over the top of the unit and push the bottom of front grille until the clips snap into place.

• ADDITIONAL CONTROLS

The additional controls are located behind the option cover of control box. The standard settings will be in the OFF position. The authorized servicer has to check switches and ensure the switches are in the desired position.

• TEMPERATURE LIMITING

Temperature Limiting can save money by limiting the lowest temperature for cooling and the highest temperature for heating. The temperature limiting is controlled by switches #1 - #3. This temperature limiting is not available with the Remote Wall Thermostat.

Temperature Temperature Temperature

Cooling Operation

Limit #1 Limit #2 Limit #3

OFF OFF OFF 54° F (12.2° C) 86° F (30.0° C)

ON OFF OFF 56° F (13.3° C)

OFF ON OFF 58° F (14.4° C)

ON ON OFF 60° F (15.5° C)

OFF

ON OFF ON 64° F (17.7° C)

OFF ON ON 66° F (18.9° C) 74° F (23.3° C)

ON ON ON 68° F (20.0° C) 72° F (22.2° C)

OFF ON 62° F (16.6° C)

ON ON

Lowest Temp. Highest Temp. Lowest Temp. Highest Temp.

54° F (12.2° C)

86° F (30.0° C)

OFF

54° F (12.2° C)

Cooling+Electric Heater+Heat PumpOFFOFF Cooling+Electric HeaterONOFF

Heat Pump Only Cooling Only

Heating Operation

86° F (30.0° C)

84° F (28.9° C)

82° F (27.8° C)

80° F (26.7° C)

78° F (25.5° C)

76° F (24.4° C)

Unit Type

—9—

• REMOVING THE FRONT GRILLE

ONREMOTE

OFF

ON ON ON

Remote/Local Energy Saver Temperature Limit 1 Temperature Limit 2 Temperature Limit 3

LOCAL

OFF

OFF3OFF4OFF

LOCAL

OFF2OFF3OFF4OFF

LOCAL

OFF

OFF3OFF4OFF

LOCAL

OFF2OFF3OFF4OFF

Additional controls are available after removing the front grille and option cover of control box. To remove the front grille, pull out the bottom of front grille and then lift up.

To replace the front grille, place the tabs over the top of the unit and push the bottom of front grille until the clips snap into place.

• ADDITIONAL CONTROLS

The additional controls are located behind the option cover of control box. The standard settings will be in the OFF position. The authorized service man has to check switches and ensure the switches are in the desired position.

• TEMPERATURE LIMITING

Temperature Limiting can save money by limiting the lowest temperature for cooling and the highest temperature for heating. The temperature limiting is controlled by dip switch #1 - #3. This temperature limiting is not available with the Remote Wall Thermostat.

Temperature Temperature Temperature

Limit #1 Limit #2 Limit #3

OFF OFF OFF 54°F (12.2°C) 86°F (30.0°C) 54°F (12.2°C) 86°F (30.0°C)

ON OFF OFF 56°F (13.3°C) 86°F (30.0°C) 54°F (12.2°C) 84°F (28.9°C)

OFF ON OFF 58°F (14.4°C) 86°F (30.0°C) 54°F (12.2°C) 82°F (27.8°C)

ON ON OFF 60°F (15.5°C) 86°F (30.0°C) 54°F (12.2°C) 80°F (26.7°C)

OFF OFF ON 62°F (16.6°C) 86°F (30.0°C) 54°F (12.2°C) 78°F (25.5°C)

ON OFF ON 64°F (17.7°C) 86°F (30.0°C) 54°F (12.2°C) 76°F (24.4°C)

OFF ON ON 66°F (18.9°C) 86°F (30.0°C) 54°F (12.2°C) 74°F (23.3°C)

ON ON ON 68°F (20.0°C) 86°F (30.0°C) 54°F (12.2°C) 72°F (22.2°C)

Cooling Operation Heating Operation

Lowest Temp. Highest Temp. Lowest Temp. Highest Temp.

—10—

Wiring Schematic for Remote Heat Pump

Wiring Schematic for Straight Cool Unit.

• REMOTE/LOCAL CONTROL

GL GH O W Y R C

Low Fan

High Fan

Reversing Valve

Heater

Compressor

24 Volt-L

24 Volt-N

FD2 FD1 DR2 DR1 MS2 MS1

Front Desk Control

Door Switch

Motion Sensor

When remote/local switch #1 is on, it allow the unit to operate by the Remote Wall Thermostat. The unit control by knobs are not available.

• ENERGY SAVER

The energy saver switch #2 is on. This switch is set at cycle fan to provide continuous fan operation in cool or heat modes. When the switch is off the continuous fan allows continuous circulation of room air and make the more balanced temperature of the room. When the switch is on, the fan is on or off with the compressor or with the heater.

• FRONT DESK CONTROL

When the pair wire is connected to the connector FD2 and FD1, the unit can be turned ON or OFF with a switch located at the Front Desk Control panel. When the front desk switch is ON, the fan operates according to the setting without working compressor and heater. When the front desk switch is OFF, the unit can operate according to the setting of controls.

Wire # AWG Maximum Length

#22 #20 900 ft (270 m) #18 1500 ft (450 m) #16 2000 ft (610 m)

600 ft (180 m)

Note: The following figures show wiring schematics for heat pump and straight cool units with electric heat, respectively.

(Molex Housing Spec 396-06V)

• REMOTE WALL THERMOSTAT

When the wires are connected, the unit will be controlled by a remote wall thermostat. The thermostat connections supply the 24 Volt AC. When you install the digital/electronic thermostat, you must set it to 24 Volt AC. See the installation Instruction in this manual for the Remote Wall Thermostat.

(Molex Housing Spec 396-07V)

—11—

• REMOTE/LOCAL CONTROL

GL GH O W Y R CLO LI

Front Desk Switch

LO LI GL GH O W Y R C

Low Fan

High Fan

Reversing Valve

Heater

Compressor

24 Volt-L

24 Volt-N

Wiring Schematic for Remote Heat Pump

Wiring Schematic for Straight Cool Unit.

When remote/local switch #1 is on, it allow the unit to operate by the control of Remote Wall Thermostat. The unit control by knobs are not available.

• ENERGY SAVER

The energy saver switch #2 is on. This switch is set at continuous fan to provide continuous fan operation in cool or heat modes. When the switch is off the continuous fan allows continuous circulation of room air and make the more balanced temperature of the room. When the switch is on the fan is on or off with the compressor or with the heater.

• FRONT DESK CONTROL

When the pair wire is connected to the connector LOand LI, the unit can be turned ON or OFF with a switch located at the Front Desk Control panel. When the front desk switch is ON, the fan operate according to the condition of setting without working compressor and heater. When the front desk switch is OFF, the unit can operate according to the setting of controls.

Wire # AWG Maximum Length

#22 600ft(180m) #20 900ft(270m) #18 1500ft(450m) #16 2000ft(610m)

Note:The following figures show wiring schematics for heat pump and straight cool units with electric heat, respectively.

• REMOTE WALL THERMOSTAT

When the wires are connected, the unit will be controlled by a remote wall thermostat.

The thermostat connections supply the 24 Volt AC. When you install the digital / electronic thermostat, you must set it to the 24 Volt AC. See the installation Instruction in this manual for the Remote Wall Thermostat.

(Molex Housing Spec 396-09V)

—12—

40˚

15˚

Screws

2. DISASSEMBLY INSTRUCTIONS

— Before the following disassembly, POWER SWITCH is set to OFF and disconnected the power cord.

2.1 MECHANICAL PARTS

2.1.1 FRONT GRILLE

1. Remove the front grille. (See Figure 1)

2. To remove the front grille, pull out the bottom of the front grille and then lift up. Re-install the component by referring to the removal procedure.

3. To replace the front grille, place the tabs over the top of the unit and push the bottom of front grille until the clips snap into place.

Figure 1

• This Room Air Conditioner (PTAC) discharges air from the top of the unit through reversible, 2-position discharge grille louvers. The unit is shipped from the factory with the discharge grille louvers at an angle of 40˚ off vertical. In the alternate position, the louvers will be at an angle of 15˚ off vertical.

To adjust air direction, remove the front grille. Remove the 4 screws that fasten the discharge grille to the front grille.

Flip the discharge grille 180°, then reattach the discharge grille to the front grille with 4 screws.

—13—

2.1.2 CONTROL BOX

1. Remove the front grille. (Refer to section 2.1.1)

2. Remove the two screws which fasten the control

box. (See Figure 2)

3. Pull the control box from the Air guide.

4. Remove the control box cover. (See Figure 3)

5. Disconnect wire housings on the control box.

Figure 2

6. Pull the control box assembly out from the unit.

(See Figure 4)

7. Re-install the components by referring to the

removal procedure.

Figure 3

Figure 4

—14—

2.2 AIR HANDLING PARTS

2.2.1 ELECTRIC HEATER (ELECTRIC HEATER MODEL ONLY)

1. Remove the front grille.(Refer to section 2.1.1)

2. Remove the control box assembly.

(Refer to section 2.1.2)

3. Remove the 4 screws which fasten the Evaporator.

(See Figure 5)

4. Remove the top cover assembly, net steel, brace.

(See Figure 6)

Figure 5

5. Remove the 6 screws which fasten the Air-guide.

6. Pull the Air-guide assembly out from the unit.

(See Figure 7)

7. Remove the 2 screws which fasten the electric

heater in the left hand side.

8. Pull the electric heater towards left for a while and

then lift up vertically to disassemble it completely from Air guide.

Figure 6

Figure 7

—15—

Figure 8

2.2.2 CROSS FLOW FAN

1. Remove the front grille. (Refer to section 2.1.1)

2. Remove the control box assembly.

(Refer to section 2.1.2)

3. Remove the Air-Guide Assembly from the unit.

(Refer to section 2.2.1)

4. Loosen the screw on the cross flow fan.

(See Figure 9)

5. Remove the 4 screws which fasten the indoor

motor and the earth wire. (See Figure 10)

6. Remove the supports on both sides.

7. Pull the cross flow fan out from the air-guide.

8. Re-install the components by referring to the

removal procedure.

Figure 9

2.2.3 AXIAL FAN

1. Remove the brace.

2. Remove the 4 screws which fasten the condenser

with the shroud and the basepan. (See Figure 11)

3. Remove the condenser sideways carefully.

4. Remove the clamp which secures the fan with

pliers.(See Figure 12)

5. Remove the axial fan.

6. Re-install the components by referring to the

removal procedure.

Figure 10

Figure 11

—16—

Figure 12

2.2.4 SHROUD

1. Remove the axial fan. (Refer to section 2.2.3)

2. Remove the 4 screws which fasten the condenser

with the shroud and the basepan. (See Figure 11)

3. Remove the shroud.

4. Re-install the component by referring to the

removal procedure.

2.3. ELECTRICAL PARTS

2.3.1 OUTDOOR MOTOR

1. Remove the clamp cord and disconnect a wire

housing in control box. (Refer to section 2.1.2)

2. Remove the axial fan. (Refer to section 2.2.3)

3. Remove the 2 screws which fasten the motor.

(See Figure 12)

4. Remove the motor

5. Re-install the component by referring to the

removal procedure, above.

2.3.2 INDOOR MOTOR (Refer to section 2.2.2)

2.3.3 COMPRESSOR

1. Discharge the refrigerant system using a refrigerant recovery system. If there is no valve to attach the recovery system, install one (such as a WATCO A-1) before venting the refrigerant. Leave the valve in place after servicing the system.

2. Disconnect the 3 leads from the compressor.

3. After purging the unit completely, unbraze the suction and discharge tubes at the compressor connections.

4. Remove the 3 nuts and the 3 washers which fasten the compressor. (See Figure 15)

5. Remove the compressor.

6. Re-instill the components by referring to the removal procedure, above.

Figure 13

Figure 14

Figure 15

2.3.4 CAPACITOR

1. Remove the control box. (Refer to section 2.1.2)

2. Remove 1 screw and disconnect the leads which connected to the box type capacitor. (See Figure 16)

3. Remove 1 screw and the clamp which fastens the can-type capacitor.

4. Disconnect all the leads of capacitor terminals.

5. Re-install the components by referring to the removal procedure, above.

Figure 16

—17—

2.3.5 POWER CORD

1. Remove the control box. (Refer to section 2.1.2)

2. Disconnect the grounding screw from the control box.

3. Disconnect 2 receptacles.

4. Remove a screw which fastens the clip cord.

5. Separate the power cord from the control box. (See Figure 17)

6. Re-install the component by referring to the removal procedure, above. (Use only one ground-marked hole for ground connection.)

7. If the supply cord of this appliance is damaged, it must be replaced by an exact replacement part. (The special cord means the cord which has the same specification marked on the supply cord fitted to the unit.)

2.3.6 P.C.B.

1. Remove the escutcheon.

2. Remove the two knobs.

3. Remove the 2 screws which fasten P.C.B. cover.

4. Disconnect all the leads which connected to the P.C.B.

5. Remove the two screws which fasten the P.C.B. board.

6. Re-install the components by referring to the removal procedure, above.

Figure 17

WARNING

After servicing control box ,make sure that AC and DC wires are separated and tied up properly.

The wires should also be pressed a little downwards to prevent touching it to the display pcb.

—18—

Figure 18

2.4 REFRIGERATION CYCLE

CAUTION

Discharge the refrigerant system using a refrigerant recovery system. If there is no valve to attach the recovery system, install one (such as a WATCO A-1) before venting the refrigerant. Leave the valve in place after servicing the system.

2.4.1 CONDENSER

1. Remove the brace and the shroud. (Refer to section 2.2.2)

2. Remove the 4 screws which fasten the shroud. (Refer to section 2.2.2)

3. Push forward the shroud and remove the 2 screws which fasten the condenser with the basepan.

4. After discharging the refrigerant completely, unbraze the interconnecting tube at the condenser connections.

5. Remove the condenser.

6. Re-install the components by referring to notes. (See Figure 19)

Figure 19

2.4.2 EVAPORATOR

1. Remove the front grille. (Refer to section 2.1.1)

2. Discharge the refrigerant completely.

3. Remove the control box assembly. (Refer to section 2.1.2)

4. Remove the 4 screws which fasten the evaporator at the left side and the right side.

5. Move the evaporator sideward carefully and then unbraze the interconnecting tube at the evaporator connectors.

6. Remove the evaporator.

7. Re-install the components by referring to notes. (See Figure 20)

2.4.3 CAPILLARY TUBE

1. After discharging the refrigerant completely, unbraze the interconnecting tube at the capillary tube.

2. Remove the capillary tube.

3. Re-install the components by referring to notes.

Figure 15

Figure 20

—19—

NOTES

— Replacement of the refrigeration cycle.

1. When replacing the refrigeration cycle, be sure to discharge the refrigerant system using a refrigerant recovery system. If there is no valve to attach the recovery system, install one (such as a WATCO A-1) before venting the refrigerant. Leave the valve in place after servicing the system.

2. After discharging the unit completely, remove the desired component, and unbraze the pinch-off tubes.

3. Solder service valves into the pinch-off tube ports, leaving the valves open.

4. Solder the pinch-off tubes with service valves.

5. Evacuate as follows.

1) Connect the vacuum pump, as illustrated

Figure 16 A.

2) Start the vacuum pump, slowly open manifold

valves A and B with two full turns counterclockwise and leave the valves closed. The vacuum pump is now pulling through valves A and B up to valve C by means of the manifold

and entire system.

CAUTION

If high vacuum equipment is used, just crack valves A and B for a few minutes, then open slowly with the two full turns counterclockwise. This will keep oil from foaming and being drawn into the vacuum pump.

3) Operate the vacuum pump for 20 to 30 minutes,

until 600 microns of vacuum are obtained. Close valves A and B, and observe the vacuum gauge for a few minutes. A rise in pressure would indicate a possible leak or moisture remaining in the system. With valves A and B closed, stop

the vacuum pump.

Remove the hose from the vacuum pump and place it on the charging cylinder. See Figure 16 B. Open valve C. Discharge the line at the manifold connection.

5) The system is now ready for final charging.

6. Recharge as follows :

1) Refrigeration cycle systems are charged from the high-side. If the total charge cannot be put in the high-side, the balance will be put in the suction line through the access valve which you installed as the system was opened.

Connect the charging cylinder as shown in Figure 16B. With valve C open, discharge the hose at the manifold connection.

3) Open valve A and allow the proper charge to enter the system. Valve B is still closed.

4) If more charge is required, the high-side will not take it. Close valve A.

5) With the unit running, open valve B and add the balance of the charge.

a. Do not add the liquid refrigerant to the low-

side.

b. Watch the low-side gauge; allow pressure to

rise to 30 lbs. c. Turn off valve B and allow pressure to drop. d. Repeat steps B and C until the balance of the

charge is in the system.

6) When satisfied the unit is operating correctly, use the pinch-off tool with the unit still running and clamp on to the pinch-off tube. Using a tube cutter, cut the pinch-off tube about 2 inches from the pinch-off tool. Use sil-fos solder and solder pinch-off tube closed. Turn off the unit, allow it to set for a while, and then test the leakage of the pinch-off connection.

—20—

Equipment needed: Vacuum pump, charging cylinder, manifold gauge, brazing equipment. pinch-off tool capable

COMPOUND GAUGE

EVAPORATOR (LOW PRESSURE SIDE)

COMPRESSOR

CAPILLARY TUBE

CONDENSER (HIGH PRESSURE SIDE)

SEE INSETS

BELOW

MANIFOLD

GAUGE

EXTERNAL VACUUM PUMP

of making a vapor-proof seal, leak detector, tubing cutter, hand tools to remove components, service valve.

LOW

CHARGING CYLINDER

Figure 16 A-Pulling Vacuum

Figure 16 B-Charging

—21—

3. INSTALLATION

406 mm

(16")

1,066 mm

(42")

349 mm (13 3/4")

505 mm

(20")

42"

13-3/4"

16"

1-1/2" TYP

1/2"

21"

36"

1/2" SQ. HOLE (2 REQ'D.)

1/2" DIA.

HOLE (3 REQ'D.)

2-3/4"

5-5/8"

Over 20"

HEAT

RADIATION

WALL

INSULATION SLEEVE

INTAKE

AIR

COOLED

AIR

1/4" Bubble

of the level

Front

Insulation Strip

Rear

Sleeve

280 mm

(11")

Recommended

3.1 HOW TO INSTALL THE UNIT

CAUTION

• There are sharp edges that can cause serious cuts.

• When lifting the air conditioner, it is HEAVY. Use 2 people to lift.

For existing sleeve, you should measure the wall sleeve dimensions. Install the new air conditioner according to these installation instructions to achieve the best performence. All wall sleeves used to mount the new air conditioner must be in good structural condition and have a rear grille that securely attaches to the sleeve or the flange of the sleeve to secure the new air conditioner.

• To avoid vibration and noise, make sure the unit is installed securely and firmly.

Dimension of air conditioner

Dimension of sleeve assembly (optional)

When installing the sleeve, make certain there is nothing within 20" of the back that would interfere with heat radiation and exhaust air flow.

1) Take out the insulation strip from the upper packing.

2) Attach the insulation strip onto the rear upper side of the

wall sleeve.

3) To improve unit energy efficiency, it is recommended the

change of outside grille for an unit protection and an addition of a plastic rear grille. (This is optional.)

4) Insulation strip prevents the exhaust air from re-entering

from either side of condenser space which may decrease the cooling efficiency of condenser.

Wall opening 16-1/4"x42-1/4"

Insulation strip must be attached to prevent the re-circulation of exhaust air to inward side from the either side of condenser space. The insulation strip is provided with the box. Refer to the diagram below.

13-3/4"

TOP VIEW

42"

GRILLE

ROOM

CABINET

—22—

3.2 WALL SLEEVE INSTALLATION

3.2.1 Wall Case Installation Data

General

Generally, units are installed 3" to 5" above the floor (flush to finished floor installation is possible) as near to the center of the room as possible; underneath a window or a glass panel is typical. Normal installation of the wall case allows installation flexibility; from flush with the finished interior wall to a minimum of 1/4" of the wall case extending beyond the finished exterior of the building. Special consideration must be given to installations where the wall case does not extend a minimum of 1/4" beyond the finished exterior wall.

Regardless of the installation, there are several things to consider when selecting a location for installing the unit. For instance, drapery location could interfere with air discharge, and placement of furniture may have an impact on the performance of the unit. The following information is intended to minimize installation problems and assure you of trouble-free installation.

Refer to page 20 for required wall opening dimensions. Minimum recommended interior and exterior case projection for standard wall thicknesses are shown in the drawings in this manual. The case may be installed flush with the finished indoor wall.

framing, moving electrical outlets, and other expensive modifications.

For existing construction it is important that carpentry, masonry and electrical work be performed by competent, qualified personnel. Since installations in

existing construction may involve removal of building material from the structure, locating the wall case must be done correctly.

Mounting an outdoor grille or louver section to the building face may cause a space between the outdoor coil and the louver section. Air splitters, aligned with the ends of the outdoor coil, must be installed between the outdoor coil inlet and outlet air streams. Gaps between the outdoor coil and the louver section may allow condenser air recirculation and affect the operation of the unit. See page 40 for requirements for custom louver sections.

The wall case should be level from side to side and from level to 1/4 bubble tilt to the outdoors. The condensate disposal system in the unit is designed to dissipate the condensate water generated during cooling operation in accordance with ARI standards and actually uses this water for maximum unit efficiency. A level unit will also insure proper performance of the Internal Condensate Removal (ICR) system optional on heat pump units.

For new construction, early planning with the architect is necessary. Unit location, electrical connection locations, and wall openings of the proper dimensions are essential to avoid the necessity of rework, fillers,

—23—

3.2.2

Shipping Tape

PREPARATION OF THE FRONT GRILLE

Carefully remove shipping tape from the front grille.

Brick, Frame, Stucco and Shingle Construction

For new construction, the opening for the wall case should be framed and the wall case inserted into the opening during construction. Lintels should be used when the building material is heavy and is not self supporting (such as brick). The wall case will fit an opening of six courses of standard brick or five courses of jumbo brick. Wall framing in this type construction is normally on 16" centers and the wall case will fit a framed opening spanning three 16" O.C. 2" x 4" stud spaces.

For existing construction the indoor and outdoor wall will need to be cut out, allowing for clearances of 1/8" on all sides of the wall case. Work should begin on the inside wall. Cut the correct dimensions and mark (using drill holes) the outside wall from each corner of the inside cutout. Studding that interferes with the opening must be removed and a suitable frame constructed to secure the wall case and provide adequate support for case and chassis.

Preparation of the Wall Case for All Types of Construction

As shipped, the LG wall sleeve is ready for installation. Do not remove the stiffener from inside the wall case or the weather closure panel from the outside face of the wall case until the outdoor grille and chassis are ready to be installed.

The outside edge of the wall case should extend at least 1/4" beyond the outside wall. This is necessary for proper caulking, to prevent sealing thedrain holes in the rear flange of the wall case, and to facilitate the installation of an accessory drain, if used.

2. The wall case should be secured to the wall at both sides. Use a minimum of two screws or other fastening device on each side. See Figure 2 page 24. Mark the wall case on each side 2" from the bottom and 2" from the top at a point where basic wall structure is located. Drill wall case and use fasteners appropriate for wall construction. All holes for fasteners in the side of the wall case must be at least 2" up from the bottom of the wall case. Never locate screws or

put other holes in the bottom of the wall case.

If the wall opening is greater than the case dimensions, spacers must be used on the sides between the wall case and the wall support structure to prevent distorting the wall case.

3. Caulk or gasket the entire opening on the outside between the wall case and exterior wall surface (4 sides) to provide total water and air seal.

4. Caulk or gasket room-side opening between wall case and interior wall surface (4 sides). Opening beneath or around the wall case can allow outdoor air to leak into the room resulting in increased operating costs and improper room temperature control.

Care should be taken in location of electrical supply entry in relationship to wall sleeve to assure access to receptacle or junction box once unit is installed.

Installation of Wall Case in Wall Opening

Position the wall case into the wall. The room side edge of the wall case should be at least flush with the finished wall for line cord installations and permanent connection installations when no sub-base is used, and should project into the room at least 2-3/8" when a sub-base is used. If the minimum exterior dimensions are not met, refer to page 23.

—24—

—25—

1/4"

CAULK*

GRILLE

OUTDOOR

*Caulk around

perimeter of wall

case all four

sides where it

joins the building

- Interior and

Exterior.

Sub-Base Connected

FRAME AND BRICK VENEER INSTALLATION

WALL SECTION – DETAILED SIDE VIEW

LINTEL

2-3/8"

CAULK*

STEEL LINTEL

CAULK*

BY INSTALLER

MOUNTING SCREWS

WALL CASE

ROOM

CABINET

GRILLE

OUTDOOR

2" MIN.

SIDE CHANNEL

1-5/16"

CAULK*

3-11/16"

3" MIN.

5" MAX.

1/4"

MIN.

CAULK*

CARPET

OR TOP OF

POWER SUPPLY CONDUIT

(RAK204)

SUB-BASE

FINISHED FLOOR

(ALTERNATE ENTRY)

Cord Set Connected

CAULK*

RAB71 13-3/4"

RAB77 13-7/8"

20-7/8" (RAB71)

21" (RAB77)

—26—

WALL CASE

BY INSTALLER

MOUNTING SCREWS

ROOM

CABINET

2" MIN.

CAULK*

CONDUIT

POWER SUPPLY

(BY OTHERS)

WALL RECEPTACLE

CARPET

*Caulk around perimeter of wall case all four sides

OR TOP OF

FINISHED FLOOR

where it joins the building - Interior and Exterior.

3.2.3 UNIT INSTALLATION

1. Remove the shipping screw from the ventilation door. (See Figure 17)

2. Remove the front gille by pulling it out at the bottom to release it, then lift it up along the unit top front. (See Figure 18)

Figure 17

Figure 18

3. Slide the unit into the wall sleeve and secure with 6 screws through the unit flange holes. (See Figure 19)

4. Reinstall the front grille by hooking the top over the unit top, then pushing it in at the bottom. (See Figure 20)

Figure 19

Figure 20

—27—

Perpendicular

20 A

Tandem

15 A

Large Tandem

30 A

230/208 volt receptacle configuration

3.3 ELECTRICAL REQUIREMENTS

3.3.1 ELECTRICAL DATA (FOR 230/208V MODEL)

CAUTION

1. Do not use an extension cord with this unit.

2. When the unit is in the OFF position, the power supply to the electrical controls is still energized.

3. Disconnect the power to the unit before servicing the unit.

4. Remove the power cord from the wall receptacle.

5. Remove or turn off the protective device (fuses or circuit breaker).

Wirings including installation of the receptacle must comply with the NEC and local codes, local regulations.

FUSE- Use a time-delay fuse or circuit breaker. Refer to the nameplate

for proper power supply requirements.

3.3.2 ELECTRICAL SAFETY

IMPORTANT GROUNDING INSTRUCTIONS

The air conditioner has a three-prong grounding plug on its power supply cord which must be plugged into properly grounded three-prong wall receptacle for your protection against possible shock hazard.

FUSE – Use a time-delay fuse or circuit breaker. Refer to the nameplate for proper power supply requirements. 208, 230, and 208/230 VOLT UNITS

These units are equipped with a three-prong grounding plug on the power supply cord which must be plugged into a matching properly grounded three-prong wall receptacle for your protection against possible shock hazard. If such an outlet is not present, one must be installed by a qualified electrician in accordance with the National Electrical Code and local codes and ordinances. NOTE: DO NOT USE AN EXTENSION CORD on 208, 230, and 208/230 Volt units.

—28—

4. FIELD INSTALLED ACCESSORIES

Door

Front

Hinge Pins (Each Side)

Brackets (Each Side)

Note: The installation and servicing of this equipment must be performed by qualifieed.

experienced technicians

NOTICE:

Warnings and Cautions appear at appropriate sections throughout this manual. Read these carefully.

WARNING - Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION - Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may

also be used to alert against unsafe practices.

CAUTION –Indicates a situation that may result in equipment or property-damage-only accidents.

Control Panel Key Lock

Part No: AYCP101

Description

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

Receiving

Upon receipt of the product, inspect the shipping carton for signs of visible damage. Report any damage or shortage to the carrier and note it on the delivery receipt. Unit must be stored in its original shipping carton in a dry, secure place prior to its installation and use.

Installation

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

1. Remove front from unit by pulling bottom out and then lifting upward. (Figure 21)

Figure 21 - Remove Front

2. Remove existing door assembly by lifting door halfway and using both hands, bow door just enough for door hinge pins to slide out of mating holes. (Figure 22)

Figure 22 - Door Removal

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 bracket in the front. (Figure 23)

Important Note:

Personal Risk Hazard Underwriter’s Laboratories Inc. listed. For institutional use only where supervisory monitoring is available. Any other use may increase the risk of personal injury or property damage.

Figure 23 - New Door Installation

—29—

Condensate Disposal Pump Kit

Figure 25

Installation

Part No: AYSB2101

Description

The internal condensate pump serves as a 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 effective 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.

Receiving

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

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

3. Remove the wire junction box cover by removing four screws and lifting up as shown in fig. 24

Figure 24

4. Remove and set aside the air discharge screen by unscrewing the 5 screws on the top.

5. Remove the one screws holding the control board cover as shown fig. 25. Remove the cover by lifting it up so its free from its hinges, and put aside.

Installation

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

WARNING

Hazardous Voltage!

Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury.

Important Note:

The unit OFF switch does not disconnect all electrical power to this unit.

—30—

6. Unplug the electric heater connecter located inside the wire junction box.

7. Remove the screw that attaches the electric heater wire to

Figure 26

Figure 29

Figure 30

Figure 27

Figure 28

the side of the indoor fan housing.

8. Remove the 3 screws which fasten the top cover assembly.

9. Position water spraying plastic tube into the electric heater cover. Make sure that the three pairs(total of six) of plastic tongues snap into the corresponding metal slots of the heater frame as shown in fig. 27. Then install one of the three rubber elbows(ref. fig. 31) at the inlet of the spraying tube and through the rubber grommet.

11. Install tube #1 and tube #2 (ref. fig. 31) on the pump

12. Position pump assembly to the basepan as shown in fig.

assembly using the rubber elbows as shown in fig. 28.

29 and fasten the pump bracket to the basepan using the three screws provided.

10. Place the top cover assembly back into the unit.

13. Insert tube #2 of the pump assembly through the plastic grommet of the sheet metal partition as shown in fig. 30. Then connect the end of tube #2 to the plastic elbow coming out of the inlet of the spraying tube.

—31—

15. Assembly the unit back following the

Figure 31

Pump assembly

Tube #1

Tube #2

Rubber elbows(3)

Spraying Tube

Figure 32

BL BL

Figure 33

reverse order of disassembly. NOTE: All tube should be inserted into rubber elbows by at least 1/2 inch

14. Connect the condensate pump to the ICR relay of the terminal of the board as shown in fig. fig 32 & 34 whichever is applicable Make sure to fasten the pump wire through the wire clip on the back side of the control barrier as shown in fig. 33

Figure 34

—32—

Architecture Grille Aluminum - Single Pack

Part No: AYAGALA01

Stamped Aluminum Grille

Note:

A baffle kit must not be used with a stamped aluminum grille on any PTAC installation.

Stamped Aluminum Grille

1. Prepare the wall sleeve for installation of the grille by removing the cardboard stiffener and rear enclosure panel from the sleeve. These items may be removed from inside of the building.

Architecture Grille

Note:

The sleeve stiffener must be taken out before the rear sleeve enclosure panel can be removed from the sleeve.

2. Prepare the stamped aluminum grille for installation on the

Description

Outdoor grilles are attached to the wall sleeve and exposed to the exterior wall. The grilles are an industry standard size of 42" x 16".

Receiving

Upon receipt of the product, inspect the shipping carton for signs of visible damage. Report any damage or shortage to the carrier and note it on the delivery receipt. The unit must be stored in its original shipping carton in a dry, secure place prior to its installation and use.

3. Turn the grille so it can be removed through the rear sleeve

4. Install the stamped aluminum grille by aligning the guide

5. Secure the grille by threading each of the screws into the

6. Remove the wire handle (not shown in the picture) from the

Installation

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

WARNING

Hazardous Voltage!

Important Note:

The unit OFF switch does not disconnect all electrical power to this unit.

Note:

Be sure to keep a firm grip on wire handle and grille to prevent it from dropping and/or causing possible injury or property damage.

Architectural Grille

1. Remove the cardboard sleeve stiffener and the rear

2. Turn the grille so it can be removed through the rear sleeve

3. Install the grille by aligning the four screws supplied to their

sleeve by inserting the six (6) plastic grommets into the square holes located near the outer edges of all four sides of the grille. With the grille positioned so the flanges of all four sides are in the up position, insert the grommets so the square end protrudes through the grille in the opposite direction from the flanges.

opening.

pins located in the lower right and left hand corners of the grille with the corresponding holes in the rear of the wall sleeve.

plastic grommets.

center of the grille prior to installing the chassis into the sleeve.

enclosure of the sleeve as described in Step 1 of the stamped aluminum grille instructions.

opening.

corresonding holes in the architectural grille.

—33—

4. Secure the grille to the sleeve by tightening the four screws

DRAIN FITTING

PLATE B

BLANK-OFF

PLATE C

BLANK-OFF

PLATE C

GASKETS A

1/2" DRAIN FITTING

MTG. SCREWS

BLANK-OFF

PLATE D

GASKET E FOR

PLATE D

to their corresponding holes in the grille.

5. Remove the wire handle after the installation is complete.

Receiving

Upon receipt of the product, inspect the shipping carton for signs of visible damage. Report any damage or shortage to the carrier and note it on the delivery receipt. The product

Note:

The stamped aluminum grille includes 6 screws, washers,

must be stored in its original shipping carton in a dry, secure place prior to its installation and use.

nuts, and plastic grommets. The architectural grille includes 4 screws.

Installation

The installation and servicing of the equipment referred to in

Condensate Drain kit

this booklet should be performed by qualified, experienced technicians.

Part No: AYDR101

Figure 35 – Components of Drain Kits

Description

Condensate water will drain from the chassis into the sleeve during normal heat pump operation. This can also occur during times of high humidity when in cooling operation. Install either the outdoor or indoor drain kit components to control the condensate water where normal drainage from the wall sleeve is not possible or undesirable. See Figure 35 for all components of the drain kit.

WARNING

Hazardous Voltage!

Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury.

Important Note:

The unit OFF switch does not disconnect all electrical power to this unit.

Drain Installation

Note:

The optional 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 and therefore should not be used. Contact your sales representative when considering the use of a commercial algaecide. See Figure 35 for components of the drain kit.

—34—

1/2" DRAIN

FITTING

DRAIN FITTING

PLATE B

GASKETS A

MTG. SCREWS

BLANK-OFF

PLATE C

Figure 36 – Outdoor Drain Kit Installation

PLATE "B"

DRAIN FITTING

BLANK-OFF PLATE

SHEET METAL SCREWS

See Detail A

Sleeve overflow port Do not close up this port

Gasket

MTG. Screws (2)

1/2" Outdoor Drain Fitting

Detail A

Cover

Plate

Wall Sleeve Bottom

(4) Mounting Screws

Gasket (2)

Blank-off Plate (2)

contact the front edge of sleeve. Secure the chassis to the wall sleeve on each side with screws provided.

Re-install the cabinet front.

See the following pages for installation instructions of indoor drain kit.

Outdoor Drain Kit Installation

Before installing the wall sleeve louvered condenser grille, it must be determined if the optional outdoor wall sleeve drain kit is to be installed. The drain kit will allow the condensate from the outdoor and indoor coils to be routed to a suitable area. The drain kit can be installed so the condensate can be drained from the right or left hand side of the wall sleeve. See Figure 36. See local codes for proper condensate disposal.

Figure 37 Figure 38

Figure 39

To install the outdoor drain components proceed as follows:

1. Remove the rear enclosure panel and the sleeve stiffener.

2. The drain fitting can be installed on the left or right hand

3. Locate the other gasket A on the back of blank off plate C

If the unit chassis is to be installed right away, install the condenser grille to wall sleeve with hardware provided. See condenser grille installation instructions.

If the unit chassis will not be installed right away, replace the rear enclosure panel in the wall sleeve. This will help protect the inside of the building from weather damage.

If a subbase is used, be sure the right hand subbase cover is removed before the chassis is installed in the sleeve. Slide the chassis into the wall sleeve until the chassis flanges

These items may be removed from the inside of the building.

side of the sleeve. (Illustration will be for a right hand installation.) Insert the drain fitting in the opening of gasket A and hole of plate B. Secure this assembly to the rear of the sleeve with two sheet metal screws into holes G provided in sleeve. See Figures 37 and 38.

and secure the assembly to the left rear of wall sleeve with sheet metal screws provided. See Figure 39 for finished left hand side installation.

—35—

Figure 40

Indoor Drain Kit Installation

The internal drain is installed on the bottom of the wall sleeve when it is required to drain the condensate into a drain system inside of the building. The components of the wall sleeve drain kit are shown in Detail A. Use components C (2), D, E, mounting screws (6) and the Outdoor drain fitting.

1. The components D, E, and drain fitting of the kit are mounted on the bottom of the wall sleeve prior to the installation of the sleeve. It may be located in a feasible area on the bottom of the sleeve which is inside of the room except when a subbase is used. When a subbase is installed, the drain may be a minimum of 3 1/2 " from the front flange of the wall sleeve. The minimum clearance should provide adequate clearance for the subbase, see Figures 40 and 41.

2. Cut out the template in the lower right hand corner of these instructions to locate the field drilled holes. (Two to mount the plate and one for the Outdoor drain fitting). See Detail A on how the components have to be installed after the holes are drilled in the bottom of the wall sleeve. If the drain fitting is not connected to an indoor drainage system immediately after the wall sleeve is installed, it must be plugged with a cork to prevent indoor water damage in case it rains.

An indoor tube or hose (furnished by others) must be installed on the drain fitting and interconnected to the drain system inside of the building.

Install the two blank-off plates C and gaskets A on the outdoor portion of the wall sleeve as shown in Figure 40. These components may be installed after the sleeve is secured in the wall opening just prior to the installation of the condenser grille and chassis.

Figure 41

Leveling Legs

Part No: AYLL101

Description

Leveling legs are designed to provide extra front support and leveling of the wall sleeve. Two leg assemblies are required per unit and are provided in each kit. Four screws are also provided with each kit for attachment to the wall sleeve. See Figure 42.

The leveling legs must be installed before the chassis is installed, but after the wall sleeve is in place. Holes must be drilled in each side of the wall sleeve, below the duct package holes, for attachment to the wall sleeve.

Receiving

• Compare kit identification number with sales order to ensure

• Inspect the leveling legs for shipping damage. File damage

Installation

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

Important Note:

The unit OFF switch does not disconnect all electrical power to this unit.

that the correct kit has been received.

claims with the delivering carrier immediately.

WARNING

Hazardous Voltage!

Checklist

The following is an abbreviated guide to leveling leg installation. Refer to appropriate areas for more detailed information.

—36—

Leveling Leg Assembly

Adjuster Screw

Speed Grip Nut

Leveler Bracket

1/8" Diameter holes

(four required per unit field-drilled)

1/4"

1/2"

NOTES:

1. Two leveling legs are supplied in each kit.

2. One kit is required per unit.

3. Fout mounting screws are provided in each kit.

To install the leveling leg assembly, complete the following:

1. Drill two 1/8-inch holes in each side of the wall sleeve, as shown in Figure 43, using the leveling leg assembly as a template. Locations near the front of the sleeve provide more support.

2. Adjust the leveling legs to the approximate height needed and install them on either side of the wall sleeve, using the screws provided. Bottom of wall sleeve can be anywhere from three to five inches above the screw base. Caulk around screws to prevent water leaks.

3. Level the sleeve horizontally from side-to-side. Provide a slight slope (one-quarter bubble in the sight glass) toward the outside. Check the level again after the unit has been installed. Adjust the legs as needed.

Figure 43 - Leveling Leg Assembly

Installation on Wall Sleeve

1. Drill four 1/8-inch diameter holes in the wall sleeve, two on each side, using the leveling legs as a template. Caulk around screws to prevent water leaks.

2. Attach the legs to the wall sleeve, using the screws provided.

3. Adjust the leveling legs to level the wall sleeve from side to side and provide a slight pitch to the outside (one-quarter bubble in sight glass).

Figure 44 - Leveling Leg Installation on Wall Sleeve

—37—

Hard Wire Kit

Part No: AYAGALA01

Description

Hard Wire Junction Box (Direct Wire Sub-Base) The hard wire junction box kit is used to hard 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 hard wire 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 hard wire 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.

Receiving

Installation

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

Junction Box Kit Installation and Wiring Procedure

EIectrical 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 door.

Hazardous Voltage!

Important Note:

The unit OFF switch does not disconnect all electrical power to this unit.

CAUTION

Use Copper Conductors Only!

Unit terminals are not designed to accept other types of conductors. Failure to use copper conductors may result in equipment damage.

Important Note:

All wiring must comply with applicable local and national codes. Types and location of disconnect switches must comply with all applicable codes.

1. Remove the cover plate from the junction box

2. Mount the junction box to the wall or floor within 28 inches (711

3. If a disconnect switch is to be used, make electrical

4. Remove control panel assembly by removing the two screws

5. Disconnect the power cord leads from all electrical connections

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

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

8. Remove the retaining ring from the threaded portion of the

9. Replace the retaining ring back on the conduit clamp inside the

10. Insert the three wires extending from the metal box into the

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

12. Insert the wire tie into the 1/4-inch diameter hole located just

WARNING

mm) of the lower right corner of the wall sleeve.

connections to it and mount the switch in the junction box. Refer to the Power Switch Installation Instructions.

holding control panel in place. Rotate the panel forward.

including the ground wire.

unit.

the wire assembly. For 265-volt units, remove and discard the red lead from the wire assembly.

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.

metal box and tighten the ring securely.

incoming power opening on the unit so that approximately 20 inches (508 mm) of the wires protrude through the opening.

provided. See Figure 45.

above the incoming power opening. Tie all wires together securely with the wire tie. See Figure 46.

—38—

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.

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 bare ground wire of the wire assembly at the junction box.

8. Install the junction box cover plate.

9. Reinstall the control panel assembly.

Figure 45 - Mounting Hard Wire Junction Box Kit

Wall Sleeve

Ground Wie

with Eyelet

Terminal

Cover plate

28 Inch es Max

Conduit

with Straight Clamp

Power Leads

with Push on

Connectors

Metal Box

Figure 46 - Metal Box Location

Control Panel

Base Pan

Bracket

Figure 47 - Electrical Wiring Routing

Right Side of Chassis

Wire Tie

3/16 Inch

Diamenter Hole

Electrical Supply Wires

Back of Control Panel

—39—

Fuse Holder Kit

Mode Switch

Thermostat

Remove two screws to gain access inside Control Panel

Fuse Holder Knockouts under panel

Part No: AYFH1101

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.

CAUTION

Use Copper Conductors Only!

Unit terminals are not designed to accept other types of conductors. Failure to use copper conductors may result in equipment damage.

Important Note:

All wiring must comply with applicable local and national codes. Type and location of fused disconnect switch(es) must comply with all applicable codes. Failure to follow these codes could result in overheating and equipment failure.

Receiving

Installation

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

Note:

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

WARNING

Hazardous Voltage!

Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury.

Important Note:

The unit OFF switch does not disconnect all electrical power to this unit.

Fuse Holder Kit Installation (Without Subbase)

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

Figure 48 - Control Panel

—40—

2. To gain access inside the control panel, after removing the knobs and escutcheon, remove the screws holding panel in position. Tilt control panel forward, being careful not to pinch any wires. (Figure 48)

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. (Figure 48)

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. (Figure 49)

7. Install the remaining power cord lead on the center terminal of the second fuse holder. (Figure 49)

5. Connect the stripped RD-9 wire to the center quick-connect

8. Connect BK-10 wire from the side terminal of one fuse holder to the Line terminal on the electronic board. (Figure 48)

9. Connect RD-10 wire from the side terminal of the other

6. Connect the other stripped RD-9 wire to the quick-connect

fuse holder to the common (C) terminal on the capacitor. (Figure 49)

10. Tilt control panel back to original location, being careful

not to pinch any wires. Align the control panel with the

7. Insert time delay fuses into the fuse holders. Size all fuses

cover and screw panels into place with original screws. Replace escutcheon and control knobs.

Fuse Holder Kit Installation (With Subbase)

See previous section for installation in the control panel.

1. Remove both knockouts at the fuse holder location. (Figure 50)

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 (TB1). (Figure 51)

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. (Figure 51)

Figure 49 - Fuse Holder Diagram

Control Panel Installation

FUSEHOLDERS

Terminal Blocks Behind

the Control Panel

Transformer

Status Light

Control Board

tab of the second fuse holder. Wire nut the other end to the red field connection wire (TB3). (Figure 51)

tab on the side of the second fuse holder. Wire nut other end to red subbase wire which leads to receptacle. (Figure 51)

by the Maximum Overcurrent Protection shown on the nameplate. Also refer to the serial plate on the unit.

Figure 50 - Subbase (Left Side)

Fuse Holder

Knockouts

Leveling

Leg

Power Switch

Knockouts

Figure 51 - Fuse Holder Diagram Subbase Installation

Electrical

Receptacle

Fuseholder

BK-9

RD-9

—41—

Field Connection

Wiring

Green

Black

Red

Remote Escutcheon Kit

TEMP/TIME

MODE

HEATHEAT

E/SAVEE/SAVE

FANFAN

COOLCOOL

HIGHHIGH

LOWLOW TIMERTIMER

FAN TI MER

OFFONOFF

F1 LOW

F2 HIGH

Part No: AYRE110

Description

This kit provides an attractive replacement escutcheon (see Figure 52). The kit allows the removal of control knobs and graphics, which are not required when a wall thermostat is used to control the unit.

Receiving

Installation

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

WARNING

Hazardous Voltage!

Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury.

Important Note:

The unit OFF switch does not disconnect all electrical power to this unit.

Figure 53

1. Grasp the cabinet front as shown in Figure 53.

2. Pull the bottom of the cabinet front away from the chassis until the retaining clips disengage as in Figure 54.

3. Lift the cabinet front off the chassis.

4. 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. See Figure 55.

Figure 54

Figure 51—Standard Escutcheon

—42—

5. Replace the escutcheon with the one from this kit by

Escutcheon

inserting the tabs at the top of the escutcheon into the retaining holes and laying the escutcheon flat on the control panel.

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

7. Store the control knobs and escutcheon just removed from the unit for possible reinstallation if the wall thermostat is no longer desired.

Figure 55

Installation

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

Hazardous Voltage!

Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury.

Important Note:

The unit OFF switch does not disconnect all electrical power to this unit.

CAUTION

Use Copper Conductors Only!

Unit terminals are not designed to accept other types of conductors. Failure to use copper conductors may result in equipment damage.

Subbase

WARNING

Part No: AYSB1101 (230/208V 20A)

AYSB2101 (230/208V 30A)

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.

Receiving

Note:

When using a subbase, the wall sleeve must be installed a minimum of 3-1/4 inches (83 mm) above a finished floor and a minimum of 2-3/

1. Remove parts B and C (Figure 57, next page) from the subbase and join together using two metal screws provided. This assembly now becomes the right front cover (Part F) of the subbase. (Figure 56, next page)

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

3. Align the back edge of the flange on cover A (Figure 57, next page) to front of the wall sleeve flange. (Figure 58, next page)

4. Drill four 1/8 inch holes in wall sleeve to line up with holes in subbase. (Figure 57, Location D, next page) Mount subbase to wall sleeve with four sheet metal screws provided with kit. (Figure 57, Location D, next page)

5. Remove the left front cover from the subbase. (Figure 57, Part A, next page)

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. (Figure 57, Location E, next page)

7. Wire subbase for appropriate voltage (Figure 59, next page).

4 inches (70 mm) from a finished wall.

—43—

Note:

The proper subbase must be ordered to obtain the correct electrical receptacle. (Figure 60)

8. After wiring is complete, mount covers A and F to the subbase with provided screws. (Figure 57)

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

Figure 55

Figure 58 - Dimensions

Wall Sleeve (Outdoor Side)

13 3/4"

16"

2 5/8"

Left End View

2 3/4"

Wall Sleeve Inside Edge

Back of Flange "A"

Figure 57 - Part/Location Identification

Part/Location Identification

Left Front Cover

Right Front Cover

Front Cord Panel

Wall Sleeve Hole Location

Skirting Hole Location

Right Cover Assembly

Wall Sleeve

Concentric

2" (50 mm)

Ground Screw Location

13-7/8" (352 mm)

1-3/8" (35 mm)

Knockouts In Bottom

Top View

Receptacle Provided Inside subbase

3-1/16"

(78 mm)

Accessory

Concentric Knockouts In Rear

Front View

Figure 59 - Wiring Diagram

Field Wiring Line Voltage

NEMA 6-20R Receptacle

NEMA 6-30R Receptacle

230/208 VAC Field Schematic 265 VAC Field Schematic

NEMA 7-20R Receptacle

NEMA 7-30R Receptacle

20-5/16" (515.5 mm)

2" (50 mm) Max. Adjustment

Field Wiring Line Voltage

4" (101 mm)

2-5/8" (67 mm)

Cover Wiring Access

Subbase Box Assy

Low Voltage Compartment

11-13/16"

2-13/16" (71 mm)

(300 mm)

Figure 60 - NEMA Plug Configurations

Voltage Subbase ReceptacleUnit Plug

—44—

5. PERFORMANCE DATA

Voltage (V)

Cooling Data

Cooling Capacity (Btu/h)

Cooling Amps (A) Cooling Power (W) EER (Btuh/Watt) Moisture Removal

(Pts/h)

Airflow

Indoor CFM (W et) @0.3ESP (Hi)

Indoor CFM (W

et)

@0.3ESP (Lo) Indoor CFM (Dry)

@0.3ESP (Hi) Indoor CFM (Dry)

@0.3ESP (Lo)

LP070CE*

208 230

7,400 7,600

2.8 2.6

595 610

12.5 12.5

2.0 2.0

185 215

145 175

210 240

170 200

LP090CE*

208 230

8,800 9,000

3.9 3.6

760 775

11.6 11.6

2.6 2.6

230 260

180 220

250 250

210 210

LP120CE*

208 230

11,500 11,800

4.8 5.2

1045 1075

11.0 11.0

3.6 3.6

300 330

290 290

320 350

280 310

LP150CE*

208 230

14,100 14,300

7.1 6.5

1470 1490

9.6 9.6

4.5 4.5

315 355

275 315

350 390

310 350

Voltage (V)

Cooling Data

Cooling Capacity (Btu/h) Cooling Amps (A) Cooling Power (W) EER (Btuh/Watt) Moisture Removal (Pts/h)

Heat Pump Heating Data

Heating Capacity (Btu/h) Heating Amps (A) Heating Power (W) COP (W/W)

Airflow

Indoor CFM (W

et)

@0.3ESP (Hi) Indoor CFM (W

et)

@0.3ESP (Lo) Indoor CFM (Dry)

@0.3ESP (Hi) Indoor CFM (Dry) @0.3ESP (Lo)

LP090HE*

208 230

9,000 9,300

4.1 3.8

820 845

11.0 11.0

2.6 2.6

8,000 8,200

3.4 3.1

690 705

3.4 3.4

240 270

190 230

260 290

220 250

LP120HE*

208 230

11,800 12,000

5.6 5.1

1145 1165

10.3 10.3

3.6 3.6

10,600 10,800

3.4 3.1

1000 1,020

3.1 3.1

310 340

270 300

330 360

290 330

LP150HE*

208 230

14,000 14,100

6.5 7.1

1445 1455

9.7 9.7

4.5 4.5

13,300 13,500

6.0 5.5

1210 1235

3.2 3.2

315 355

275 315

350 390

310 350

LP070HE*

208 230

7,300 7,600

3.0 2.8

600 625

10.9 10.9

2.0 2.0

6,200 6,400

2.6 2.4

520 535

3.5 3.5

195 225

155 185

220 250

180 210

Air Conditioner Performance Data

Heat Pump Performance Data

—45—

Model LP070CE* LP090CE* LP120CE* LP150CE* Temperature

Outdoor

Ai r Return Air Total W attage Total Wattage Total W attage Total Wattage

Dry Bulb Wet Bulb Input Input Input

Input

Min Max M in Max Min Max Min Max

Rating W attage 560 625 785 810 1045 1090 1045 1090

85 590 715 815 900 1050 1180 1080 1190 80 585 720 820 905 1055 1180 1090 1205 75 585 720 820 905 1060 1180 1100 1215

100 70 585 720 820 905 1055 1180 1100 1220

65 590 715 815 900 1050 1180 1095 1215 60 580 710 805 890 1045 1175 1090 1205 55 570 700 795 880 1030 1160 1070 1190 85 560 685 770 855 1000 1125 1025 1140 80 565 690 775 860 1005 1130 1035 1150 75 565 695 780 865 1005 1135 1035 1160

95 70 565 690 775 860 1005 1130 1045 1165

65 560 690 770 855 1000 1125 1040 1160 60 555 680 765 850 990 1120 1030 1150 55 540 670 765 835 980 1105 1020 1135 85 540 660 730 815 950 1070 965 1085 80 540 665 735 820 950 1075 980 1095 75 540 665 735 820 955 1080 990 1105

90 70 540 665 735 820 950 1075 990 1105

65 535 660 730 815 950 1070 990 1100 60 525 660 720 805 940 1060 980 1095 55 520 640 710 795 930 1055 965 1075 85 510 635 690 770 895 1020 915 1025 80 515 640 690 775 900 1020 930 1040 75 520 640 695 780 905 1030 936 1046

85 70 515 640 690 775 900 1020 935 1050

65 510 635 690 770 895 1020 930 1045 60 505 625 680 765 890 1010 925 1035 55 490 615 670 755 880 1000 907 1020 85 485 605 645 730 850 970 860 970 80 490 610 650 735 850 970 870 985 75 490 610 650 735 850 975 880 990

80 70 490 610 650 735 850 970 885 990

65 485 605 645 730 850 970 880 990 60 475 600 635 720 940 960 870 980 55 465 585 625 710 830 950 855 9

Cooling Wattage - Air Conditioners

—46—

Model LP070HE* LP090HE* LP120HE* LP150HE* Temperature

Outdoor

Air Return Air Total W attage Total Wattage Total W attage Total Wattage

Dry Bulb Wet Bulb Input Input Input

Input

Min Max Min Max Min Max Min Max

Rating W attage 600 625 810 850 1120 1145 1430

1460

85 625 705 830 935 1120 1230 1445 1570 80 620 710 835 940 1125 1235 1465 1590 75 620 710 835 940 1130 1240 1475 1600

100 70 620 710 835 940 1125 1240 1475 1600

65 615 705 830 935 1120 1230 1470 1600 60 605 695 820 925 1115 1230 1460 1580 55 595 685 810 915 1100 1210 1440 1562 85 580 670 785 890 1070 1180 1375 1500 80 585 675 790 890 1075 1190 1390 1520 75 590 680 795 890 1075 1190 1410 1530

95 70 585 675 790 890 1075 1190 1410 1530

65 580 670 785 890 1070 1180 1400 1520 60 575 675 780 880 1060 1170 1390 1515 55 560 655 770 865 1050 1160 1370 1495 85 550 640 745 845 1020 1130 1305 1430 80 555 645 750 850 1025 1135 1325 1445 75 555 645 750 850 1025 1135 1335 1460

90 70 555 645 750 850 1025 1125 1340 1460

65 550 640 745 845 1020 1130 1335 1455 60 540 630 735 835 1010 1120 1320 1440 55 530 620 720 825 1000 1110 1260 1420 85 515 610 700 800 970 1080 1240 1360 80 520 610 705 800 975 1085 1260 1380 75 525 615 705 810 975 1085 1265 1390

85 70 520 610 705 800 975 1085 1265 1395

65 515 610 700 800 970 1080 1260 1390 60 510 600 690 790 960 1070 1250 1375 55 500 590 680 775 950 1060 1230 1355 85 485 575 655 755 920 1030 1170 1290 80 490 580 660 760 925 1030 1185 1310 75 490 480 660 760 925 1035 1195 1320

80 70 490 580 660 760 920 1030 1200 1320

65 485 575 655 755 920 1030 1195 1315 60 475 565 650 745 910 1020 1180 1305 55 465 555 635 735 900 1010 1160

1280

Cooling Wattage - Heat Pumps

—47—

Cooling change of temperature - Air Conditioners

Room Air Room Air LP070CE* LP090CE* LP120CE* LP150CE*

Dr y Wet Temperature Across Temperature Across Temperature Across T

emperature Across

Bulb Bulb Indoor Coil (∆ T) Indoor Coil (∆ T) Indoor Coil (∆ T)

Indoor Coil (∆ T)

Min Max Min Max Min Max Min Max

Rating Btu/h 7000 7600 9000 9300 11700 12000 14300

14600

Rating CFM 185 225 230 260 300 330 315 355

85 1 3 2 6 1 5 1 4 80 8 13 11 14 9 13 8 12

90 75 19 22 19 22 18 22 16 20

70 30 33 28 30 26 30 25 27 80 4 9 7 11 5 10 5 8 75 14 19 15 18 13 18 12 16

85 70 23 27 23 25 21 25 20 23

65 34 36 31 33 29 33 28 30 75 9 14 11 14 9 13 8 12 70 18 21 18 20 15 20 15 18

80 65 26 29 24 27 23 26 21 24

60 35 36 32 33 29 33 29 30 70 12 16 13 16 10 15 10 14 65 18 22 18 21 15 20 15 19

75 60 25 28 23 26 21 25 20 24

55 31 34 28 31 26 30 26 28 65 12 15 12 14 9 13 9 13

70 60 17 20 16 18 13 17 13

55 22 24 20 22 18 21 17

Model

Room Air Room Air LP070HE* LP090HE* LP120HE* LP150HE*

Dr y Wet Temperature Across Temperature Across Temperature Across T

emperature Across

Bulb Bulb Indoor Coil ( ∆ T) Indoor Coil ( ∆ T) Indoor Coil ( ∆ T) Indoor Coil ( ∆

Min Max Min Max Min Max Min Max

Rating Btu/h 7300 7600 9300 9600 12300 12600 14300

14600

Rating CFM 195 225 240 270 310 340 315 355

85 13 26 151 4 80 8 13 11 15 10 13 8 12

90 75 19 22 19 22 18 22 17 20

70 30 33 29 30 26 30 25 28 80 4 9 7 11 5 10 5 9 75 14 19 15 18 14 18 12 16

85 70 23 27 23 25 21 25 21 23

65 33 36 31 33 30 33 28 31 75 9 14 11 15 10 13 8 12 70 18 21 18 20 16 20 16 18

80 65 26 29 24 27 23 26 22 25

60 35 36 32 33 30 33 29 31 70 12 16 13 16 11 15 10 14 65 18 22 18 21 16 20 16 19

75 60 24 28 23 26 21 25 21 24

55 31 34 29 31 26 30 26 29 65 12 15 12 15 10 13 9 13

70 60 17 20 16 18 14 17 13

55 22 24 20 22 18 21 18

Cooling Change of Temperature - Heat Pumps

—48—

Cooling Ampere Chart - Air Conditioners

Cond Inlet Air Te

mperature

Rating Ampere

100

95 90 85 80

Model

Amperage Min Max

6.5 7.1

6.6 8.0

6.2 7.6

5.9 7.2

5.6 6.8

5.3 6.4

Model

Amperage

Min Max

3.6 3.9

3.4 4.0

3.2 3.8

3.1 3.6

2.9 3.4

2.8 3.3

Model LP070CE* LP090CE* LP120CE* LP150CE* Amperage Min Max

2.6 2.9

2.4 2.8

2.3 2.7

2.2 2.6

2.1 2.4

Model

Amperage

Min Max

4.8 5.2

5.6 5.6

5.4 5.3

5.2 5.1

4.9 4.8

4.7 4.6

Model

Room Air Room Air LP070HE* LP090HE* LP120HE* LP150HE*

Dry Wet Temperature Across Temperature Across Temperature Across Temperature Across

Bulb Bulb Indoor Coil (∆ T) Indoor Coil (∆ T) Indoor Coil (∆ T)

Indoor Coil (∆ T)

Min Max Min Max Min Max Min Max

Rating Btu/h 6200 6400 8200 8400 10900 11200 13300 13500 Rating CFM 220 250 260 290 330 360 350 390

85 22 24 24 27 27 30 28 30 80 23 24 25 28 28 31 29 31

50 75 24 25 26 29 29 32 30 31

70 26 27 28 30 31 34 32 33 65 26 27 28 30 31 34 32 33 85 19 22 22 24 24 29 27 30 80 20 23 23 25 25 29 28 31

45 75 21 24 24 26 26 30 29 31

70 22 24 24 27 27 31 30 32 65 23 25 25 28 28 32 31 33 85 17 20 20 22 23 27 27 30 80 18 21 21 23 23 28 28 31

40 75 19 22 22 24 24 29 29 31

70 20 23 23 24 25 29 30 32 65 21 24 24 25 26 30 31 33 85 15 17 17 20 21 24 27 29 80 16 18 18 21 22 25 28 30

35 75 17 19 19 22 23 26 29 31

70 18 20 20 23 23 27 30 31 65 19 21 21 24 24 28 31

Heating Change of Temperature - Heat Pumps

Cond Inlet Air Te

mperature

Rating Ampere

0 95 90 85 80

Model LP070HE* LP090HE* LP120HE* LP150HE* Amperage Min Max

.6 2.9

2.6 2.9

2.4 2.8

2.3 2.6

2.1 2.5

2.1 2.3

Model

Amperage Min Max

3.6 3.9

3.4 4.0

3.2 3.8

3.1 3.6

3.1 3.4

2.9 3.3

Model

Amperage

Min Max

4.8 5.2

5.6 5.5

5.3 5.2

5.0 5.0

4.8 4.7

4.6 4.5

Model

Amperage Min Max

6.5 7.1

6.6 8.0

6.2 7.6

5.9 7.2

5.6 6.8

5.3 6.4

Cooling Ampere Chart - Heat Pumps

—49—

6. TROUBLESHOOTING GUIDE

1,066mm (42")

505mm (20")

406mm (16")

MOTOR

COMPRESSOR

OIL

(LIQUID REFRIGERANT)

CAPILLARY TUBE

OUTSIDE COOLING AIR FOR REFRIGERANT PASS THROUGH

SUCTION LIME COOL LOW PRESSURE VAPOR

COOLED AIR

COMPLETE LIQUID BOIL OFF POINT

LIQUID PRESSURE DROP

ROOM AIR HEAT LOAD

VAPOR INLET

HOT DISCHARGED AIR

LIQUID OUTLET

HIGH PRESSURE VAPOR

LIQUID PEFRIGERANT

LOW PRESSURE VAPOR

ROOM AIR CONDITIONER

EVAPORATOR COILS CONDENSER COILS

CYCLE OF REFRIGERATION

6.1 OUTSIDE DIMENSIONS

6.2 PIPING SYSTEM

Following is a brief description of the important components and their functions in the refrigeration system. Refer to Figure 61 to follow the refrigeration cycle and the flow of the refrigerant in the cooling cycle.

Figure 60

—50—

6.3 TROUBLESHOOTING GUIDE

Ineffective Cooling

Check of outdoor coil (heat exchanger) & the fan operation.

Check gas leakage.

Repair gas leak.

Replacement of unit if the unit is beyond repair.

Satisfactory operation with temperature difference of inlet & outlet air 44.6~50˚ F (7~10˚ C)

Check heat load increase.

Unexpected residue

Overloaded Circuit

Check of inside gas pressure.

Adjusting of refrigerant charge

Malfunction of compressor

Replacement of compressor

Check of cold air circulation for smooth flow.

Dirty indoor coil (Heat exchanger)

Malfunction of fan

Clogged of air filter

Obstruction at air outlet

Correct above trouble

Check clogging in refrigeration circuit.

Repair clogging in refrigeration circuit.

In general, possible trouble is classified in two causes. The one is Starting Failure which is caused from an electrical defect, and the other is Ineffective Air Conditioning caused by a defect in the refrigeration circuit and improper application.

Unit is running but cooling is ineffective

—51—

Fails to Start

Check circuit breaker and fuse.

Gas leakage of feeler bulb of thermostat

Check control switch.

Only fan fails to start.

Improper wiring.

Defect of fan motor capacitor.

Irregular motor resistance ( ). Irregular motor insulation ( ).

Replacement of fan motor

Regular but fails to start

Replacement of compressor (locking of rotor, metal)

Improper thermostat setting

Loose terminal connection.

Improper wiring

Irregular motor resistance ( )

Irregular motor insulation ( )

Replacement of compressor (Motor damaged)

Drop of power voltage.

Check capacitor.

Replacement.

Only compressor fails to start.

Defect of compressor capacitor.

Check power source.

Check control switch setting.

—52—

COMPLAINT CAUSE REMEDY

Fan motor will not run.

No power

Power supply cord

Rotary switch

Wire disconnected or connection loose

Capacitor (Discharge capacitor before testing.)

Will not rotate

Check voltage at outlet. Correct if none.

Check voltage to rotary switch. If none, check power supply cord. Replace cord if circuit is open.

Check switch continuity. Refer to wiring diagram for terminal identification. Replace switch if defective.

Connect wire. Refer to wiring diagram for terminal identification. Repair or replace loose terminal.

Test capacitor. Replace if not within ±10% of manufacturer's rating. Replace if shorted, open, or damaged.

Fan blade hitting shroud or cross flow fan hitting scroll. Realign assembly.

Units using slinger ring condenser fans must have 1/4to 5/16inch clearance to the base. If it is hitting the base, shim up the bottom of the fan motor with mounting screw(s).

Fan motor runs intermittently

Fan motor noise.

Revolves on overload.

Grommets

Fan

Turbo fan

Loose set screw

Check fan motor bearings; if motor shaft will not rotate, replace the motor.

Check voltage. See limits on this page. If not within limits, call an electrician.

Test capacitor. Check bearings. Does the fan blade rotate freely? If not, replace fan motor.

Pay attention to any change from high speed to low speed. If the speed does not change, replace the motor.

Check grommets; if worn or missing, replace them.

If cracked, out of balance, or partially missing, replace it.

Tighten it.

Worn bearings

If knocking sounds continue when running or loose, replace the motor. If the motor hums or noise appears to be internal while running, replace motor.

—53——53—

COMPLAINT CAUSE REMEDY

Compressor will not run, but fan motor runs.

Voltage

Wiring

Rotary

Thermostat

Capacitor (Discharge capacitor before servicing.)

Compressor

Check voltage. See the limits on the preceding. page. If not within limits, call an electrician.

Check the wire connections, if loose, repair or replace the terminal. If wires are off, refer to wiring diagram for identification, and replace. Check wire locations. If not per wiring diagram, correct.

Check for continuity, refer to the wiring diagram for terminal identification. Replace the switch if circuit is open.

Check the position of knob If not at the coldest setting, advance the knob to this setting and restart unit. Check continuity of the thermostat. Replace thermostat if circuit is open.

Check the capacitor. Replace if not within ±10% of manufacturers rating. Replace if shorted, open, or damaged.

Check the compressor for open circuit or ground. If open or grounded, replace the compressor.

Overload

Check the compressor overload, if externally mounted. Replace if open. (If the compressor temperature is high, remove the overload, cool it, and retest.)

ROOM AIR CONDITIONER VOLTAGE LIMITS

NAME PLATE RATING MINIMUM MAXIMUM

208/230V 187V 253V

—54—

COMPLAINT CAUSE

REMEDY

Compressor cycles on overload.

Insufficient cooling or heating

Excessive noise.

Voltage

Overload

Fan motor

Condenser air flow restriction

Condenser fins (damaged)

Capacitor Wiring Refrigerating system Air filter Exhaust damper door Unit undersized

Cross flow fan

Copper tubing

Check the voltage. See the limits on the preceding page. If not within limits, call an electrician.

Check overload, if externally mounted. Replace if open. (If the compressor temperature is high, remove the overload, cool, and retest.)

If not running, determine the cause. Replace if required.

Remove the cabinet. inspect the interior surface of the condenser; if restricted, clean carefully with a vacuum cleaner (do not damage fins) or brush. Clean the interior base before reassembling.

If condenser fins are closed over a large area on the coil surface, head pressures will increase, causing the compressor to cycle. Straighten the fins or replace the coil. Test capacitor. Check the terminals. If loose, repair or replace. Check the system for restriction. If restricted, clean of replace. Close if open. Determine if the unit is properly sized for the area to be cooled. Check the set screw or clamp. If loose or missing, correct. If the blower or fan is hitting air guide, rearrange the air handling parts. Carefully rearrange tubing not to contact, compressor, shroud, and barrier.

—55—

7. SCHEMATIC DIAGRAM

MECHANICAL

CN-N

CN-L

CN-EXTN(N)

CN-IDF

CN-COMP

CN-ODF

CN-TRANS

CN-EXT

RY-OFD

P/NO:3850A20594J

CN-IDAT

CN-IDPT

RY-HEST1

—56—

753010

W50400

152302

135312

330870

354210

349600

546810

559011

549990

130411

554170

554030

148000

135515

135800

135500

567502

550140

552206

346810

152302-1

359011

352390

149400

337000

349600-1

435300

567480-4

263230-1

435300-1

552114 35211A 552113

352116

352115

249951

A-1

237200

W0CZZ-2

W0CZZ

W6640

268711-2

135511

147910

264110

149410

238310

249941-1

8. EXPLODED VIEW

8.1 MECHANICAL COOLING

—57—

753000

W50400

152302

135312

330870

354210

349600

546810

559011

549990

130411

554170

554030

148000

135515

135800

135500

567502

550140

249951

552206

346810

152302-1

359011

352390

149400

337000

349600-1

435300

567480-4

263230-1

C-1

552113

552116

552112

352116

352115

A-1

237200

W0CZZ-2

W0CZZ

W6640

268711-2

135511

147910

264110

149410

238310

249941-1

8.2 MECHANICAL HEATLING

—58—

P/No.: 3828A20308L

Setember, 2007 Printed in Korea

Trane Pthd0902dca Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual