Amana IO-646 Installation Instructions Manual

Amana
Brand
Amana
Model
IO-646
Category
Split-system air conditioners
Type
Installation Instructions Manual
Condensate Disposal Pump Kit
The internal condensate pump serves as an effective means for disposing of condensate
generated during heat pump operation by transferring it to the indoor coil. The warm coil
surface and the warm room air help in evaporation of the condensate while adding humid-
ity to the room. As with any equipment of this type, the addition of this kit will decrease the
sensible heating capacity of the unit. This kit is not intended for use in seacoast or corro-
sive 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.
Preparation
1. Remove front by rotating bottom outward and then lifting
up and out from chassis.
2. Unplug and remove the PTAC chassis from the wall
sleeve. Move the chassis where the front and back of the
chassis can be easily accessed.
3. Remove the discharge screen by unscrewing two screws
holding the screen to the blower panel. Set screen aside
(Figure 1).
Figure 1
PTAC
CONDENSATE DISPOSAL PUMP KIT
INSTALLATION INSTRUCTIONS
Part No. IO-646
Printed in USA
October 2005
WARNING
Disconnect electrical power source before installing these kits.
Failure to do so may result in injury or death from electrical shock.
The unit “OFF” switch does not disconnect all power to the unit.
2
4. Lift the blower panel approximately 10 inches by unscrew-
ing two screws holding the blower panel to the chassis and
lift upward being careful not to pinch heater wires (Figure 2).
Condensate
Tube
Mounting Screw
Holes
Figure 2
5. Using the short leg of the condensate tube push out the 1/2
inch diameter knockout on the back wall of the styrofoam
scroll. The condensate tube should protrude through the
partition panel by 1-3/4 inches. Rotate the condensate tube
so the tube lays flat on the coil (Figures 2 & 3).
Condensate
Tube
Figure 3
6. Orient the condensate tube on the coil so when the blower
panel is lowered the condensate tube fits snugly into the
raised embossment of the blower panel.
7. Make sure the holes in the condensate tube are facing
inward toward the blower wheel.
8. Lower the blower panel over the condensate tube and
screw the blower panel to the chassis with the existing
screws. Replace the discharge screen and screw the
screen to the blower panel with the existing screws.
9. Using the overflow tube holder and the overflow tube, hold
the tube with the metal holder and screw the holder to the
partition panel with the provided 1/2 inch #8 screw (Figures
4 & 5).
Holder
Tube
Figure 4
Figure 5
10. Place the pump bracket onto the end of the pump by
feeding the pump cord through the hole in the bracket and
pushing the bracket onto the threads of the pump. Slide the
supplied washer onto the threads of the pump. Screw the
pump nut onto the threads of the pump and tighten the nut
so that the bracket is secure against the pump (Figure 6).
Figure 6
11. Orient the pump in the back left corner of the basepan and
screw the pump bracket to the basepan with the provided
two 1/2 inch #8 screws (Figure 7).
Screws
Figure 7
12. Remove the protective adhesive backing from the plastic U
clip and mount the U clip to the plastic condenser shroud in
approximately the position shown (Figure 8).
13. Attach the p-clamp to the brace with the screw provided.
(Figure 8).
14. Place one of the hose clamps over one end of the 16 inch
vinyl hose. Place the same end over the barbed discharge
tube of the pump assembly. Place a hose clamp on the
other end of the 16 inch hose. Place this same end over the
shorter leg of the overflow tube and secure the hose with
the hose clamp (Figure 8).
3
U Clip
P-Clamp
Overflow
Tube
Figure 8
15. Place a hose clamp over one end of the 11 inch long hose.
Push this same end over the longer leg of the overflow tube
and secure with the hose clamp. Place another hose clamp
over the other end of the 11 inch hose. Push this same end
over the condensate tube protruding out from the back of
the partition panel and secure with the hose clamp (Figure
8).
16. Route the condensate pump cord through the U clip on the
condenser shroud, through the p-clamp attached to the
brace, and then through the hole in the panel where the
compressor wires are routed through the panel. NOTE: The
permagum may have to be removed to feed the wires
through the panel, make sure wires have no slack and
replace the permagum back into place to prevent air leaks
(Figures 8 and 9).
Permagum
P-Clamp
Condensate
Pump Cord
Tie Brace
Figure 9
17. To gain access inside the control panel, remove the knobs
and escutcheon. Remove the three screws holding the
panel in position. Tilt the control panel forward, being
careful not to pinch any wires (Figure 10).
18. Lift the control panel up so the control panel is free of its
hinges. Orient the control panel so there is easy access for
mounting components to the control panel (Figures 10 and
11).
1
2
3
O
N
SCREW
SCREW
SCREW
Figure 10
Transformer
Mounting Holes
Relay Mounting
Holes
Back Of Escutcheon
Figure 11
19. Using two #8 screws that are provided, screw the trans-
former to the control panel in the transformer mounting
holes provided in the panel (Figure 11).
20. Mount the relay in one of the three relay mounting holes in
the control panel making sure that the threaded stud is in
the smaller hole and the metal tab is in the adjacent larger
hole. Screw the provided nut onto the threaded stud from
the opposite side of the control panel (Figure 11).
21. Disconnect the RD33, VT12, and BK19 wires from the
control board and connect the YL5 (where RD33 was
connected), YL3 (where VT12 was connected), and YL1
(where BK19 was connected). Connect RD33 to the
piggyback terminal of YL5, VT12 to the piggyback terminal of
YL3, and BK19 to the piggyback terminal of YL1. Make sure
the OR8 wire is connected from the #6 terminal of the relay
to 24 volt terminal of the transformer (Figure 12).
22. For 208 volt applications move the WH6 wire terminal from
the 240 volt terminal of the transformer to the 208 terminal of
the transformer.
23. Units that have a Power Vent or Power Door Kit already
installed in the chassis should refer to Figure 13 for proper
wiring of the condensate pump kit. Use the second set of
transformer holes to mount the transformer.
24. Units that have a 2 stage heater already installed in the
chassis should refer to Figure 14 for proper wiring of the
condensate pump kit.
25. Units that have a Power Vent or Power Door Kit and a two
stage heater already installed in the chassis should refer to
Figure 15 for proper wiring of the condensate pump kit.
26. Install the basepan drain plug into the basepan drain hole
by pushing it up into the drain hole from the bottom of the
basepan. This will defeat the thermostatic controlled drain
valve. The basepan drain is located left of the outside coil
(as viewed from the back of the unit).,
4
Figure 12
Standard Unit with Single Stage Heat
R
C
S
FH
RIBBED
WIRE
2
2
NOTES:
1
TO UNIT MUST BE PROP ER LY POLAR IZED (FOR 265V) AND GROUNDED.
REV
VALVE
SOLENOID
WIRING DIAGRAM
20319601 R EV 1
CONTROL
PANEL
CHASSIS
WIRE LEGEND
HIG H VOLT AGE
(FACTORY)
HIG H VOLT AGE
(FACTORY OR FIELD)
3
BR14
WH15
LOW VOLTAGE
(FACTORY OR FIELD)
3
4
COMP
OD
FAN/COMP
CAP
1ST STAGE
ANTICIPATOR
CURRENT: .1
2ND STAGE
ANTICIPATOR
CURRENT: .1
ELECTRIC
HEATER
1
3
5
A
CONDENSATE
RELAY
2
4
6
B
CONDENSATE
PUMP
1
LINE 1 HEATER HEATER LINE 2 COMP FAN HIGH FAN LOW R-VALVE
5
5
POWER CORD TO LINE 2.
6
7
265V TRANSFORMER NOT SHOWN.
TRANSFORMER
LINE
OR8
(CP )
8
7
BK16 RD17
HEAT PUMP W/AUXILIARY
ELECTRIC H EAT
CONNECT
R TO:
-----
G, Y/W1
G,B,Y/W1
G, W2
FUNCTION
OFF
COOL
1ST STAGE
HEAT
2ND STAGE
HEAT
COOLING UNIT
W/ELECTRIC H EAT
CONNECT
R TO:
G, Y/W1
G, W2
OR
G,B,Y/W 1
FUN CTION
COOL
OFF
-----
REMOTE THERMOSTAT OPERATION
HEAT
G
FAN
G
FAN
*
* FOR A HEAT PUMP
THERMOSTAT USED
ON A STRAIGHT
COOL UN IT
USE COPPER
CONDUCTORS ONLY
230V265V
6
FRONT
DESK
SWITCH
4
RMT/STD
THERMOSTAT
CONTROL
ON / OFF
MA ST ER
SWITCH
EH
IN LS TF1 TF2 C R GL W2 B GH
AUXILIARY REMOTE THERMOSTAT
FUSE
ON / AUTO
FAN
CYCLE
ALL OFF
C
B
A
D
P6
BLUE
P5
RED
P3
BLACK
OUTDOOR
COIL
IND O O R
COIL
IND O O R
AIR
8
Y/W1
FD2FD1
WARNING: DISCONNECT POWER BEFORE SERVICING. WIRING
RIBBED WIRE MUST BE CONNECTED AS SHOWN.
ON HEAT PUMP MODELS ONLY.
ON UNITS WITH FRONT DESK CONTROL SWITCH.
BK18 ON LINE 2 WIT H FUSE SHO W N CONN ECT ED FO R 265V . FOR 230 V, CON NEC T
CONNECTED TO APPROPRIATE TERMINAL AT FACTORY.
IF SUPPLY VOLTAGE IS 208V MOVE 240V LEAD TO 208V TAP ON TRANSFORMER.
FOR REM OTE OPERATION, SET SW ITCH TO RMT POSITION.
BK20
BK19
FAN
MOTOR
VT12
GN
YL10
RD13
C
RD33
WH6
(CP )
YL1
(CP )
YL3
(CP )
YL5
(CP)
BK18BR34BR34
GN1
240240
208208
COM
5
Figure 13
Single Stage Heat with Power Vent or Power Door
R
C
S
RD13
YL10
FH
BR34BR34
RD33
RIBBED
WIRE
GN
2
RIBBED WIRE MUST BE CONNECTED AS SHOWN.
NOTES:
1
TO UNIT MUST BE PROPERLY POLARIZED (FOR 265V) AND GROUNDED.
REV
VALVE
SOLENOID
BK19
WIRING DIAGRAM
20319501 REV 1
GN1
CONTROL
PANEL
CHASSIS
WIRE LEGEND
HIGH VOLTAGE
(FACTORY)
HIGH VOLTAGE
(FACTORY OR FIELD)
3
BR14
WH15
LOW VOLTAGE
(FACTORY OR FIELD)
3
4
COMP
OD
FAN/COMP
CAP
FRONT
DESK
SWITCH
ELECTRIC
HEATER
BK20
4
1
3
5
A
CONDENSATE
RELAY
2
4
6
B
CONDENSATE
PUMP
MUFFIN
FAN
POWER
VENT
2
4
0
2
0
8
C
O
M
L
O
A
D
LINE
1
POWER
VENT
MOTOR
LINE 1
RMT/STD
THERMOSTAT
CONTROL
ON / OFF
MASTER
SWITCH
HEATER HEATER LINE 2 COMP FAN HIGH FAN LOW R-VAL VE
BK18
5
VT12
5
POWER CORD TO LINE 2.
6
7
ON/OFF
SWITCH
3
2
1
240
2
08
C
OM
L
OAD
LINE
TRANSFORMER
TRANSFORMER
WH8
(PV)
BK12
(PV)
OR8
(CP)
WH6
(CP)
BU10
(PV)
BU9
(PV)
BK11
(PV)
WH7
(PV)
BU4
(PV)
8
265V TRANSFORMER NOT SHOWN.
9
9
9
BK17
(PV)
1
4
7
A
POWER
VENT
RELAY
2
5
89
6
3
B
TERMINAL
BLOCK
RD14
(PV)
YL1
(CP)
YL5
(CP)
YL3
(CP)
BU15
(PV)
BK16 RD17
BU2
(PV)
1ST STAGE
ANTICIPATOR
CURRENT: .1
2ND STAGE
ANTICIPATOR
CURRENT: .1
HEAT PUMP W/AUXILIARY
ELECTRIC HEAT
CONNECT
R TO:
-----
G, Y/W1
G,B,Y/W1
G, W2
FUNCTION
OFF
COOL
1ST STAGE
HEAT
2ND STAGE
HEAT
COOLING UNIT
W/ELECTRIC HEAT
CONNECT
R TO:
G, Y/W1
G, W2
OR
G,B,Y/W1
FUNCTION
COOL
OFF
-----
REMOTE THERMOSTAT OPERATION
HEAT
G
FAN
G
FAN
*
* FOR A HEAT PUMP
THERMOSTAT USED
ON A STRAIGHT
COOL UNIT
7
USE COPPER
CONDUCTORS ONLY
230V265V
6
FUSE
ON / AUTO
FAN
CYCLE
ALL OFF
C
B
A
D
P6
BLUE
P5
RED
P3
BLACK
OUTDOOR
COIL
INDOOR
COIL
INDOOR
AIR
8
EH IN LS TF1TF2
CRGL
W2Y/W1 B GH
AUXILIARY REMOTE THERMOSTAT
FD2FD1
WARNING: DISCONNECT POWER BEFORE SERVICING. WIRING
ON HEAT PUMP MODELS ONLY.
ON UNITS WITH FRONT DESK CONTROL SWITCH.
BK18 ON LINE 2 WITH FUSE SHOWN CONNECTED FOR 265V. FOR 230V, CONNECT
CONNECTED TO APPROPRIATE TERMINAL AT FACTORY.
ON UNITS WITH POWER VENT ONLY.
FOR REMOTE OPERATION, SET SWITCH TO RMT POSITION.
IF SUPPLY VOLTAGE IS 208V MOVE 240V LEAD TO 208V TAP ON TRANSFORMER.
2
C
FAN
MOTOR
6
Figure 14
Standard Unit with Two Stage Heat
4
ALL OFF
6
(CP)
7
RELAY
R
C
S
RD13
YL10
FH
RIBBED
WIRE
GN
2
2
NOTES:
1
TO UNIT MUST BE PROPERLY POLARIZED (FOR 265V) AND GROUNDED.
REV
VALVE
SOLENOID
BK19
WIRING DIAGRAM
20320401 REV 1
3
BR14
WH15
4
COMP
OD
FAN/COMP
CAP
1ST STAGE
ANTICIPATOR
CURRENT: .1
2ND STAGE
ANTICIPATOR
CURRENT: .1
BK20
1
3
5
A
CONDENSATE
2
4
6
B
CONDENSATE
PUMP
1
BK18
VT12
5
POWER CORD TO LINE 2.
L
O
A
D
LINE
TRANSFORMER
OR8
6
265V TRANSFORMER NOT SHOWN.
7
YL1
(CP)
YL5
(CP)
YL3
(CP)
RD17
WH6
(CP)
RD33
VT20
2
STGE
HT
VT19
2 STGE
HT
VT18
2 STGE
HT
1
3
5
A
2 STGE HT
2
4
6
B
VT17
2 STGE
HT
BK16
ELECTRIC
HEATER
YL36
2 STGE HT
BR34BR34
HEAT PUMP W/AUXILIARY
ELECTRIC HEAT
CONNECT
R TO:
-----
G, Y/W1
G,B,Y/W1
G, W2
FUNCTION
OFF
COOL
1ST STAGE
HEAT
2ND STAGE
HEAT
COOLING UNIT
W/ELECTRIC HEAT
CONNECT
R TO:
G, Y/W1
G, W2
OR
G,B,Y/W1
FUNCTION
COOL
OFF
-----
REMOTE THERMOSTAT OPERATION
HEAT
G
FAN
G
FAN
*
* FOR A HEAT PUMP
THERMOSTAT USED
ON A STRAIGHT
COOL UNIT
GN1
CONTROL
PANEL
CHASSIS
WIRE LEGEND
HIGH VOLTAGE
(FACTORY)
HIGH VOLTAGE
(FACTORY OR FIELD)
LOW VOLTAGE
(FACTORY OR FIELD)
USE COPPER
CONDUCTORS ONLY
8
8
FRONT
DESK
SWITCH
FUSE
C
B
A
D
P6
BLUE
P5
RED
P3
BLACK
WARNING: DISCONNECT POWER BEFORE SERVICING. WIRING
RIBBED WIRE MUST BE CONNECTED AS SHOWN.
3
ON HEAT PUMP MODELS ONLY.
ON UNITS WITH FRONT DESK CONTROL SWITCH.
BK18 ON LINE 2 WITH FUSE SHOWN CONNECTED FOR 265V. FOR 230V, CONNECT
FOR REMOTE OPERATION, SET SWITCH TO RMT POSITION.
IF SUPPLY VOLTAGE IS 208V MOVE 240V LEAD TO 208V TAP ON TRANSFORMER.
CONNECTED TO APPROPRIATE TERMINAL AT FACTORY.
5
C
FAN
MOTOR
240
208
COM
EH
IN LS TF1 TF2
CRGL
W2Y/W1 B GH
AUXILIARY
REMOTE THERMOSTAT
FD2FD1
ON / OFF
MASTER
SWITCH
RMT/STD
THERMOSTAT
CONTROL
ON / AUTO
FAN
CYCLE
OUTDOOR
COIL
INDOOR
COIL
INDOOR
AIR
LINE 1 HEATER HEATER LINE 2 COMP FAN HIGH FAN LOW R-VALVE230V265V
7
Figure 15
Two Stage Heat with Power Vent or Power Door
GN
FUSE
RD13
YL10
FCH
RD33
RIBBED
WIRE
2
BK19
WIRING DIAGRAM
20320601 REV 1
3
BR14
WH15
OD
FAN/COMP
CAP
BK20
CONDENSATE
PUMP
MUF FIN
FAN
POWER
VENT
2
4
0
2
0
8
C
O
M
L
O
A
D
LINE
POWER
VENT
MOTOR
LINE 1 HEATER H EATER LINE 2 COMP FAN HIGH FAN LOW R-VALVE
BK18
5
VT12
ON/OFF
SWITCH
3
2
1
TRANSFORMER
WH8
(PV)
BK12
(PV)
OR8
(CP)
WH6
(CP)
BU10
(PV)
BU9
(PV)
BK11
(PV)
WH7
(PV)
BU4
(PV)
7
7
BK17
(PV)
1
4
7
A
POWER
VENT
RELAY
2
5
89
6
3
B
TERMINAL
BLOCK
RD14
(PV)
YL1
(CP)
YL5
(CP)
YL3
(CP)
BU15
(PV)
BK16 RD17
BU2
(PV)
VT20
2
STGE
HT
VT19
2 STGE
HT
VT18
2 STGE
HT
VT17
2 STGE
HT
BR34
ELECTRIC
HEATER
YL36
2 STGE HT
BR34
1ST STAGE
ANTICIPATOR
CURRENT: .1
2ND STAGE
ANTICIPATOR
CURRENT: .1
HEAT PUMP W/AUXILIARY
ELECTRIC HEAT
CONNECT
R TO:
-----
G, Y/W1
G,B,Y/W1
G, W2
FUNCTION
OFF
COOL
1ST STAGE
HEAT
2ND STAGE
HEAT
COOLING UNIT
W/ELECTRIC HEAT
CONNECT
R TO:
G, Y/W1
G, W2
OR
G,B,Y/W1
FUNCTION
COOL
OFF -----
REMOTE THERMOSTAT OPERATION
HEAT
GFANGFAN
*
* FOR A HEAT PUMP
THERMOSTAT USED
ON A STRAIGHT
COOL UNIT
8
8
230V265V
9
9
4
RMT/STD
THERMOST AT
CONTROL
ON / OFF
MASTER
SWITCH
EH IN LS TF1 TF2 C R GL W2 B GH
AUXILIARY REMOTE THERMOSTAT
ON / AUTO
FAN
CYCLE
ALL OFF
C
B
A
D
P6
BLUE
P5
RED
P3
BLACK
OUTDOOR
COIL
INDOOR
COIL
INDOOR
AIR
8
Y/W1FD2FD1
R
C
S
COMP
1
3
5
A
2 STGE HT
2
4
6
B
1
3
5
A
CONDENSATE
RELAY
2
4
6
B
2
4
0
2
0
8
C
O
M
L
O
A
D
LINE
TRANSFORMER
REV
VALVE
SOLENOID
FRONT
DESK
SWITCH
2
NOTES:
1
TO UNIT MUST BE PROPERLY POLARIZED (FOR 265V) AND GROUNDED.
WARNING: DISCONNECT POWER BEFORE SERVICING. WIRING
RIBBED WIRE MUST BE CONNECTED AS SHOWN.
3 ON HEAT PUMP MODELS ONLY.
4 ON UNITS WITH FRONT DESK CONTROL SWITCH.
5
POWER CORD TO LINE 2.
6
265V TRANSFORMER NOT SHOWN.
7
BK18 ON LINE 2 WITH FUSE SHOWN CONNECTED FOR 265V. FOR 230V, CONNECT
FOR REMOTE OPERATION, SET SWITCH TO RMT POSITION.
IF SUPPLY VOLTAGE IS 208V MOVE 240V LEAD TO 208V TAP ON TRANSFORMER.
CONNECTED TO APPROPRIATE TERMINAL AT FACTORY.
ON UNITS WITH POWER VENT ONLY.
GN1
CONTROL
PANEL
CHASSIS
WIRE LEGEND
HIGH VOLTAGE
(FACTORY)
HIGH VOLTAGE
(FACTORY OR FIELD)
LOW VOLTAGE
(FACTORY OR FIELD)
USE COPPER
CONDUCTORS ONLY
FAN
MOTOR
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Amana IO-646 Installation Instructions Manual

Amana
Brand
Amana
Model
IO-646
Category
Split-system air conditioners
Type
Installation Instructions Manual
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