Amana R-22 Service Instructions Manual
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Amana R-22 Service Instructions Manual

Air conditioners & heat pumps
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Service Instructions
ACCESSORIES MANUAL
R-22 Package Terminal
Air Conditioners & Heat Pumps
All Models and Manufacturing Numbers For R-22 Amana
®
Brand Units
This manual is to be used by qualified, professionally trained HVAC technicians only.
Goodman does not assume any responsibility for property damage or personal injury
due to improper service procedures or services performed by an unqualified person.
RS4900003r2
is a registered trademark of Maytag Corporation or its related companies and is used under
December 2010
license to Goodman Company, L.P., Houston, TX. All rights reserved.
© 2001, 2010 Goodman Company, L.P.

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  • Page 1 Service Instructions ACCESSORIES MANUAL R-22 Package Terminal Air Conditioners & Heat Pumps All Models and Manufacturing Numbers For R-22 Amana ® Brand Units This manual is to be used by qualified, professionally trained HVAC technicians only. Goodman does not assume any responsibility for property damage or personal injury due to improper service procedures or services performed by an unqualified person.

  • Page 2: Table Of Contents

    Table of Contents When Ordering Parts ..............................3 Circuit Breaker Kit ................................. 4 Condensate Drain Kit ..............................6 Condensate Removal Pump ............................10 Condenser Baffles ................................ 13 Curtain Guard ................................14 Duct Kit ..................................16 Electric Heat ................................22 Escutcheon - Hydronic Remote ............................ 27 Escutcheon - Remote ..............................

  • Page 3: When Ordering Parts

    To locate an authorized servicer, please consult your telephone book or the dealer from whom you purchased this product. For further assistance, please contact: CONSUMER INFORMATION LINE - ® AMANA BRAND PRODUCTS TOLL FREE 1-877-254-4729 (U.S. only) email us at: customerservice@goodmanmfg.com fax us at: (713) 856-1821 (Not a technical assistance line for dealers.)

  • Page 4: Circuit Breaker Kit

    ACCESSORY INSTALLATIONS Description Circuit Breaker Kit The circuit breaker kit provides POWER ON/OFF and cur- rent overprotection function at the unit. The circuit breaker kit contains the appropriate circuit breaker, replacement access cover for the high voltage section of the subbase, mounting bracket and clips, and required hardware.
  • Page 5 ACCESSORY INSTALLATIONS...

  • Page 6: Condensate Drain Kit

    ACCESSORY INSTALLATIONS Installation for Outdoor Use Condensate Drain Kit - DK900-* The drain components for outdoor use must be installed be- fore the wall sleeve condenser grille. 1. Remove the rear enclosure panel and the sleeve stiff- ener. These items can be removed from the inside of the building.
  • Page 7 ACCESSORY INSTALLATIONS SEE DETAIL A SLEEVE OVERFLOW PORT DO NOT CLOSE UP THIS PORT GASKET (2) BLANK-OFF PLATE (2) Figure 4 5. Install the two blank-off plates C and gaskets A on the The components of the wall sleeve drain kit for indoor use outdoor portion of the wall sleeve as shown in Figure 4.
  • Page 8 ACCESSORY INSTALLATIONS Condensate Drain Kit - DK900* (Combination Drain Kit...for outdoor or indoor sleeve drainage.) The installation and servicing of the equipment should be done by qualified experienced technicians. Description This kit is used to control condensate from the unit. Con- Indoor densate water drains from the chassis into the sleeve Indoor...
  • Page 9 ACCESSORY INSTALLATIONS Installation for Indoor Use The components of the wall sleeve drain kit for indoor use are shown in figure below. These components must be installed prior to the installation of the wall sleeve. MTG. SCREWS (2) WALL SLEEVE D RA IN BOTTOM GA S KE T...

  • Page 10: Condensate Removal Pump

    ACCESSORY INSTALLATIONS 4. Lift the blower panel approximately 10 inches by un- Condensate Removal Pump screwing two screws holding the blower panel to the chassis and lift upward being careful not to pinch heater wires. Mounting Screw HIGH VOLTAGE Holes ISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT ULTIPLE POWER SOURCES MAY BE PRESENT...
  • Page 11 ACCESSORY INSTALLATIONS 10. Place the pump bracket onto the top of the pump and screw the pump bracket to the pump with the provided two (2) 1/2 inch #8 screws so that the bracket is secure 12. Remove the protective adhesive backing from the plas- against the pump.
  • Page 12 ACCESSORY INSTALLATIONS 15. Place a hose clamp over one end of the 11 inch long holes provided in the panel. (See figure above.) hose. Push this same end over the longer leg of the 20. Mount the relay in one of the three relay mounting holes overflow tube and secure with the hose clamp.

  • Page 13: Condenser Baffles

    ACCESSORY INSTALLATIONS Condenser Baffles Installation 1. Locate the baffles on the condenser coil flange as shown. Description Position the louvers to direct the air toward the center The condenser baffle kit is required when replacing an exist- as the air leaves the coil. ing package terminal unit and the original outdoor grille is not made by the same manufacturer.

  • Page 14: Curtain Guard

    2nd horizontal louver of the cabinet front and then gently snap the tab on the right side of the IMPORTANT NOTE: This kit is designed for models with R-22 cabinet front into place. See Figure 1. DO NOT FORCE refrigerant and should NEVER be used on models using R- CURTAIN GUARD INTO PLACE.
  • Page 15 See Figure 2. 2nd Louver 4th Louver Figure 4 View of R-22 Model with Curtain Guard Installed Correctly. Figure 2 See Figures 3 and 4 for views of correctly installed curtain guard. Side Tabs attached on 2nd Horizontal Louver 3.

  • Page 16: Duct Kit

    ACCESSORY INSTALLATIONS Duct Kit Description Extends air distribution to an adjoining room. Kit Contents The kit consists of a main duct for the room of origin and an extension duct to reach the adjoining room, and terminal duct. NOTE: All required hardware is provided within kit. TRANSITION Terminal Duct Kit - TDK02B 5/8"...
  • Page 17 ACCESSORY INSTALLATIONS 10" INNER WALL END OF DUCT 5" CUT-OUT EXTENSION 1/2" TRANSITION 1-3/8" MIN (FOR DUCT KIT) UNIT FRONT 18-3/8" WALL SLEEVE 7-1/2" OUTSIDE WALL 2-3/4" MIN (FOR SUBBASE KIT) BOTTOM OF WALL SLEEVE 3-1/4" MIN SUBBASE KIT 20-1/2" MAX 1/4"...
  • Page 18 ACCESSORY INSTALLATIONS 4. Place transition in air discharge opening of cabinet front PRE-ASSEMBLY and secure with the provided U-clip. See Figures 2 & 3. (Wall Sleeve) Hole Dimension and Placement 1. Unplug and remove chassis from wall sleeve. Drill two 1/8”...
  • Page 19 ACCESSORY INSTALLATIONS Two mounting slots are provided in each bracket. To mount extension on right side, adjust bracket so the screws are in left side of bracket slots; for mounting extension on the left, DISCHARGE adjust brackets so the screws are in right side of slots. AIR GRILLE On right side extensions shift the brackets to the right.
  • Page 20 ACCESSORY INSTALLATIONS 7. Measure from the end of the main duct where the exten- sion duct will be connected to the hole in the wall. If necessary cut the extension duct to a length where the cut end protrudes into the wall’s inner space and one inch from the adjoining room’s wall surface.
  • Page 21 ACCESSORY INSTALLATIONS TDK INSTALLATION INSTRUCTIONS IMPORTANT NOTE: ANY FIELD-SUPPLIED GRILLE, MUST HAVE FIXED LOUVERS THAT CANNOT BE CLOSED. GASKET The sheet metal collar of the terminal duct kit must be mounted in the wall of the adjoining room opposite the room where the main duct kit is attached to the PTAC chassis.

  • Page 22: Electric Heat

    ACCESSORY INSTALLATIONS NOTE: The incoming electrical power on 230/208 volt units Electric Heat is not fuse protected unless a fuseholder kit has been either factory or field installed. Description The supplemental electric heater kits described in this Power Cord Installation (HK335E, HK350E, HK450E) manual are available for field installation on heaterless mod- els of packaged air conditioners and heat pumps.
  • Page 23 ACCESSORY INSTALLATIONS On 265 volt units disconnect the ribbed lead from the C terminal on the capacitor and the smooth lead from the fuseholder and the green ground wire from the partition panel. Discard both the cord and the cord clamp. 3.
  • Page 24 ACCESSORY INSTALLATIONS Outdoor Section #8 Screw Heater Wires #8 Screw Control Panel 4. While placing the blower inlet panel back into the chas- sis, insert the heater wires through the clip and into the hole located on the mid partition panel. For single Stage Heaters Follow Step 6 then skip to Step 16.
  • Page 25 ACCESSORY INSTALLATIONS B. Connect VT20 from the heater relay 5 terminal. C. Reconnect the power wire to the piggyback terminal of VT20. Relay Mounted Inside of Control Panel Control Panel 8. After disconnecting the BK16 wire from the FAN HIGH terminal on the control board, connect it to the heater relay 3 terminal.
  • Page 26 ACCESSORY INSTALLATIONS Electric Electrical Heater kW Heater Total Total Minimum Overcurrent Heater 230/208 V BTU/HR Watts Amps Circuit Protection** Size (kW) Ord. No. Stage 1 Stage 2 230V 208V 230V 208V 230V 208V Ampacity HK315E 1.5/1.2 5100 4100 1580 1280 HK325E 2.5/2.0 8500...

  • Page 27: Escutcheon - Hydronic Remote

    ACCESSORY INSTALLATIONS Escutcheon - Hydronic Remote Description This kit provides an attractive replacement escutcheon, al- lowing the removal of control knobs and graphics no longer required when a wall thermostat is used to control the unit. B-Nut 4. Reaching below the hydronic top, remove the extensions from the chassis by pulling the extensions off the con- trol shafts.

  • Page 28: Escutcheon - Remote

    ACCESSORY INSTALLATIONS 2. Grasp the cabinet front as shown. Escutcheon - Remote Description This kit provides an attractive replacement escutcheon, al- lowing the removal of control knobs and graphics no longer required when a wall thermostat is used to control the unit. High High Heat...

  • Page 29: Fuse Kit

    ACCESSORY INSTALLATIONS Fuse Kit LL WIRING MUST COMPLY WITH APPLICABLE LOCAL AND NATIONAL CODES YPE AND LOCATION OF FUSED DISCONNECT SWITCH MUST COMPLY WITH ALL APPLICABLE CODES AILURE TO FOLLOW THESE CODES COULD RESULT IN OVERHEATING AND EQUIPMENT FAILURE Fuse Holder Kit Installation (Without Subbase) See page 27 for installation in a subbase.

  • Page 30: Control Panel

    ACCESSORY INSTALLATIONS 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 quick- connect tab of the fuse holders. Wire nut the other end of this wire to the black field connection wire (L2).

  • Page 31: Hard Wire

    ACCESSORY INSTALLATIONS Hard Wire LL WIRING MUST COMPLY WITH APPLICABLE LOCAL AND NATIONAL CODES YPE AND LOCATION OF FUSED DISCONNECT SWITCH MUST COMPLY WITH ALL APPLICABLE CODES Description AILURE TO FOLLOW THESE CODES COULD Hardwire Junction Box (Direct Wire Sub-Base) RESULT IN OVERHEATING AND EQUIPMENT The hardwire junction box kit is used to direct wire the unit FAILURE...
  • Page 32 ACCESSORY INSTALLATIONS 9. Replace the retaining ring back on the conduit clamp 3. Connect the red lead to the common ( C ) terminal on inside the metal box and tighten the ring securely. the capacitor. 10. Insert the three wires extending from the metal box into 4.

  • Page 33: Hydronic Heat

    ACCESSORY INSTALLATIONS Hydronic Heat Installation Description Where a central boiler is available, the Hydronic Kit can be installed on the PTAC unit. This kit completely encloses all plumbing and coils, but still allows easy access to controls. In addition, the chassis can slide out for service without re- moving hydronic plumbing.
  • Page 34 ACCESSORY INSTALLATIONS Hydronic Heat Kit Application Data Heating Capacity (Btuh)- Hot Water Pressure 7000 & 9000 BTUH Units 12000 BTUH Units 15000 BTUH Units Gal. Drop (psig) 200° F. EWT 180° F. EWT 200° F. EWT 180° F. EWT 200° F. EWT 180°...
  • Page 35 ACCESSORY INSTALLATIONS Water Valve Pressure Drop 2-Way Valve 3-Way Valve Bypass 3-Way Valve Water Pressure Drop Water Pressure Drop Water Pressure Drop (psig) (psig) (psig) 1.00 0.19 1.00 0.13 1.00 0.04 1.13 0.24 1.13 0.16 1.13 0.05 1.25 0.30 1.25 0.20 1.25 0.06...
  • Page 36 ACCESSORY INSTALLATIONS Steam Plumbing Dimensions 5-1/2" PTAC UNIT WALL SLEEVE 1-7/8" 3-1/4" 3-1/4" (2 places) 1-7/8" 3-1/2" 13-3/8" 5-3/4" COIL 2-1/4" (2 places) 1" x 1-1/2" TOP VIEW OF COIL LOCATION opening for piping (with top grille and sheet metal removed) 1"...
  • Page 37 ACCESSORY INSTALLATIONS Hot Water Plumbing Dimensions 5-1/2" 3-1/4" 3-1/4" 3-3/8" 1-13/16" 1-13/16" 1' 1-5/8" 3-3/8" 1-1/16" 1" 1/2" I.D. 5/8" O.D. COIL COIL 2-3/4" 4-3/4" 1/2" I.D. 5/8" O.D. 2-1/8" 1" 4' 5" 0" TO 3" Finished Floor...
  • Page 38 ACCESSORY INSTALLATIONS Wall Sleeve 3-1/4" 1/8" Holes 2-1/4" Indoor Right Side Wall Sleeve 3-1/4" 5. Remove the control knobs and metal escutcheon from the control panel area of the chassis. 5" 1/8" Holes 6. Remove the discharge screen from the chassis by re- moving the two screws holding the screen to the chas- 2-1/4"...
  • Page 39 ACCESSORY INSTALLATIONS 9. Place the chassis back into the wall sleeve and secure chassis to wall sleeve. Be careful not to bind or pinch the flexible shafts protruding from the bottom of the hy- dronic top assembly. 10. Place the ends of the flexible shafts protruding from the hydronic top over the corresponding D shafts on the chassis control board.
  • Page 40 ACCESSORY INSTALLATIONS Information relating to U.L. approved valves and current loads is shown on the label on the kit. In addition, water and steam valve model numbers are listed in the following table. Water Valve Model Description Position End Switch VW2WNOA 2-Way Normally Open...
  • Page 41 ACCESSORY INSTALLATIONS Control Cord/Plug Motor N.O. YL13 N.C. BU21 Wire Nuts From Heat Coil Return To Water System 22. The plumbing may enter from the left and/or right side of the unit through the slots and holes that are supplied in Connect YL13 for Normally Open Valves.

  • Page 42: Hydronic Transformer

    Screw the provided nut onto the "HA"). Do not use this kit with heat pump chassis - consult threaded stud from the opposite side of the control panel. ® your Amana brand sales representative for information. Cross Knockout...

  • Page 43: Keylock

    ACCESSORY INSTALLATIONS 8. Connect the PK30 and PK31 wires from the relay to and, using both hands, bow door just enough for door the heater terminal next to the Line 1 terminal and to hinge pins to slide out of mating holes. the heater terminal next to the Line 2 terminal respec- 3.

  • Page 44: Power Disconnect Switch

    ACCESSORY INSTALLATIONS Power Disconnect Switch CAUTION ONLY SE COPPER CONDUCTORS ELECTRICAL CONNECTIONS HE USE OF OTHER TYPES OF CONDUCTORS MAY RESULT IN GAL VANIC CORROSION OVERHEATING AND RESUL TANT EQUIPMENT FAILURE LL WIRING MUST COMPLY WITH APPLICABLE LOCAL AND NATIONAL CODES YPE AND LOCATION OF FUSED DISCONNECT SWITCH Power Switch Kit Components...
  • Page 45 ACCESSORY INSTALLATIONS 7. Insert the BLACK wire from the receptacle into the lower 3. Connect the red lead of the hardwire assembly to the right hole in the rear of the switch and tighten the screw. switch terminal opposite the terminal where the black Insert the BLACK power wire (field wiring) into the lower lead was assembled in step 2.

  • Page 46: Remote Temperature Sensor

    ACCESSORY INSTALLATIONS Remote Temperature Sensor Mounting Sensor Loosen the screw in the lower right corner of the cover and The installation and servicing of the equipment referred to in pull the decorative cover off the sensor base. Position the these instructions must be performed by qualified, experi- sensor base on the wall, in the desired location, and mark enced technicians.

  • Page 47: Mode Switch

    ACCESSORY INSTALLATIONS 1. Remove the PTAC cabinet front to expose the control panel area. Mode Switch IMPORTANT NOTE: Disconnect power to the unit and/or turn the Master Switch on the control board to OFF when Thermostat connecting or altering wiring to any terminal - failure to do so may result in shorting the fuse or damaging the control board.

  • Page 48: Subbase

    ACCESSORY INSTALLATIONS Subbase Description The subbase may be installed on the wall sleeve before or after installing the wall sleeve. The subbase is prewired. Electrical connections can be made on the left side after the access cover is removed. A grounding screw is provided. NOTE: The wall sleeve must be installed a minimum of 3¼...
  • Page 49 ACCESSORY INSTALLATIONS Part/Location Identification A Left Front Cover B Right Front Panel C Front Cord Panel D Wall Sleeve Hole Location E Skirting Hole Location Z Right Front Cover Assembly -- Leveling Legs (Not Shown) Wall Sleeve 3" Cover Wiring Access Low Voltage Compartment...

  • Page 50: Wiring Diagram

    ACCESSORY INSTALLATIONS Receptacle Provided Inside Subbase 19-9/16" Accessory 13-3/4" 3-1/2" 1-3/8" 13-1/2" Wall Sleeve (Outdoor Side) 16-1/16" 2-5/8" Wall Sleeve 2-3/4" Concentric Inside Edge Ground Knockouts In Rear 2" Max. Adjustment Back of Screw Location Front View Flange "A" 3-1/4" 4"...

  • Page 51: Remote Thermostat High Fan Kit

    ACCESSORY INSTALLATIONS Remote Thermostat High Fan Kit Description When a wall mounted thermostat is used, the PTAC unit will operate in low speed only. Following these instructions will allow the PTAC unit to operate on high speed only. This kit contains twenty labels, enough for ten units.
  • Page 52 ACCESSORY INSTALLATIONS 9. Replace control panel cover, escutcheon, and control knobs. 10. Place one label supplied with this kit on the wiring ELECTRIC diagram supplied with the unit. HEATER FUSE MOTOR VT12 11. Place a second label on the sheet metal control cover VALVE SOLENOID RD33...

  • Page 53: Right Hand Subbase Conversion

    ACCESSORY INSTALLATIONS 2. Unplug and remove the old PTAC chassis from the wall Right Hand Subbase Conversion sleeve. Description 3. Install the new PTAC chassis into the wallsleeve and The right hand subbase cover is used when existing sub- plug the PTAC power cord into the subbase power re- bases are already installed on the wallsleeve and the sub- ceptacle.

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