Perfect Comfort PCKK Series User manual

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PCKK SERIES
PACKAGED TERMINAL
AIR CONDITIONER/HEAT PUMP
WITH UNIVERSAL HEATER
Installation, Operation and
Maintenance Manual
MODELS: PCKK09K235HTM3, PCKK12K235HTM3

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Table of Contents
1. Read This First ……………………………………………………………………..……………………………………….…….3
To the installer………………………………………………………………………………..……………………………..…….3
General precautions …………………………………………………………………..…………...…………………….…… 3-4
2. Check List …………………………………………………….………………………………………….…………………….…… 4-6
3. General Product Information ………………………………………..……………………………………………...…… 7
Product description …………………………………………………..…………………………………………………..…….7
Standard controls and components ………………………………………………..…………..……………………… 7
Operation Instructions ..……………………….………………………………………………………..…………………… 8
Manual Control to Thermostat Instructions………………………………….……………..……………..………. 9
Model coding ………………………………………………………………………………...………..………………………… 10
4. Preparing for the installation …………………………………………………………………..……………………….. 11
Electrical supply ……………………………………………………………………………………………….…………..……. 11
Electrical short hazard ………………………………………………………………………………………….……….…… 11
Removing old chassis ………………………………………………………………………………………….……………… 12
Check existing sleeve …………………………………………………………………………………….…………………… 12
Check existing outdoor louver ……………………………………………………………………………………….…… 12
5. Installation instructions …………………………………………………………………………………………..………… 12
Chassis installation ……………………………………………………………………………………..……………………… 12
Wall thermostat installation ……….……………………………………………………………………………………… 13
Power Cord Installation…….. ………………………………………………………………………………………………. 13
Filter installation …………………………………………………………………………………………….…….……………. 14
Cover installation ………….………………………………………………………………………………..………………….. 14
6. Final inspection and start up …………………………………………………………………….…….…………….….. 15
Final check list ……………………………………………………………………………………………..…….................. 15
Start-up ………………………………………………………………………………………………………..……………………. 15
Wall Thermostat …………………………………………………………………………………………..……………………. 15
7. Maintenance and Troubleshooting ……………………………………………………..……………………………. 15
Monthly Inspection and Maintenance …………………………………………………………………..…………… 16
Seasonal Start-up and Maintenance ………………………………………………………………….………………. 17
Troubleshooting ………………………………………………………………………………………………………………… 18-23
Error Code …………………………………………………………………………………………………..…………...……….. 24
8. Performance Data ……………………………………………………………………………………………………………… 24
9. Warranty ……………………………………………………………………………………………………………………….….. 25

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TO THE INSTALLER
Retain this manual for future reference. For further assistance please call 1-866-233-4022.
Before leaving the premises, review this manual to be sure the unit has been installed correctly and
run the unit for one complete cycle to make sure it functions properly. To obtain technical service or
warranty assistance during or after the installation of this unit, contact your local representative.
When calling for assistance, please have the following information ready:
1. Model number
2. Serial number
3. Date of installation
NOTICE
Due to ongoing product development, product designs and specifications may change without
notice. Please contact Perfect Comfort for more information.
Electric shock hazard
Turn off electric power before service or installation.
Don’t use this unit if it has damaged wiring, is not working properly, or has been damaged or
dropped.
Read these instructions carefully and completely before attempting installation. Unit should be
installed by qualified service technician ONLY.
Failure to do so can result in property damage, personal injury and/or death.
WIRE SIZE: Use ONLY wiring size recommended for single outlet branch circuit.
FUSE/CIRCUIT BREAKER: Use ONLY type and size fuse or HACR circuit breaker indicated on
receptacles and fuse type (see Table 01). Proper current protection to the unit is the responsibility
of the owner.
GROUNDING: Unit MUST be grounded from branch circuit through service cord to unit, or through
separate ground wire provided on permanently connected units. Be sure that branch circuit or general
purpose outlet is grounded.
Do not modify the PERFECT COMFORT PTAC POWER CORD
WARNING
DANGER

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The power cord should be checked before every use. Do not use the product if the cord has failed
the test. A damaged power cord must be replaced with a new cord from the manufacturer and not
repaired.The use of extension cords is prohibited.
RECEPTACLE: The field supplied outlet must match plug on service cord and be within reach of
service cord. Refer to TABLE 1 for proper receptacle and fuse type
Failure to follow these instructions can result in a fire, explosion or electrical shock, causing property
damage, personal injury ordeath.
Table 01: Receptacles and FuseType
Table 1
250V
265/277V
AMPS
15
20
30
20
RECEPTACLE
TIME - DELAY
TYPE FUSE
(or HACR
circuit breaker)
15
20
30
20
HACR —Heating, Air Conditioning, Refrigeration
May be used for 15 Amp applications if fused for 15 Amp
Note: 265/277 –volt units require use of accessory subbase to meet NEC
and local codes.
NOTE: 265/277- volt units require use of accessory Remove
DAX99SB to meet NEC and local codes.
Sheet metal parts, self-tapping screws, clips and such items inherently have sharp edges, and it is
necessary that the installer exercise caution.
This equipment is to be installed only by experienced installation company which employs trained
technicians.
PTAC chassis are heavy. To avoid injury, use assistance when lifting.
Check List
When the equipment is received, all items should be carefully checked - refer to typical configuration
(see Fig.01). All units should be carefully inspected for damage when received. If any damage is noticed,
the carrier should make the proper notation on the delivery receipt acknowledging the damage. Please
call 1-866-233-4022 for customer service.
CAUTION

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1. Front Cabinet
-The tabs on the cover and inserts on the
sleeve should be checked for correct
placement and fitting.
2. Cooing Chassis and Fan Section
-The unit nameplate should be checked to make sure the voltage agrees with the power
supply available.
-Verify that the indoor blower wheels and outdoor fan are rotating freely.
-Verify the compressor and tubing in proper position and perfect status.
-Verify the compressor and tubing in proper position and perfect status.
3. Power Cord
-The power cord should be checked to comply with the receptacle available. (Sold
separately)
4. Sleeve
-The sleeve should be checked that the inside dimensions will fit the PTAC. (Sold separately)
5. Louver
-The dimensions for the louver should be checked and compared with the sleeve. It must
match and fit inside the sleeve. (Sold separately)
6. Filter
-Filter is placed within front of Fan Section
6
Fig.02 Filter
Fig.01: Typical Configuration

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For this replacement PTAC only 2 (Cooling Chassis and Fan Section) & 6 (Filter) are provided.
Installation,
Operation and
Maintenance
Manual
Thermostat Wiring Harness and
Manual located in plastic bag.

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General Product Information
Product Description
Perfect Comfort replacement package terminal air conditioners have a cooling chassis with electric heat.
The PERFECT COMFORT PTAC unit
1. Use R410A refrigerant. This refrigerant is not affected by a phase out schedule. R410 is
environment friendly.
2. Include high-efficiency rotary compressors protected by a 6-year warranty
3. Offer three speed for evaporator fan motor, and one speed for condenser fan motor
4. Condensate removal system with dual drain hose, re- evaporation to improve efficiency
5. Heat Pump efficient operation
6. Digital control with optional thermostat hookup
7. Universal electric heat
2.0 KW heat can be obtained when 15A power cord is used. Part Number PC15UP.
3.0 KW heat can be obtained when 20A power cord is used. Part Number PC20UP.
5.0 KW heat can be obtained when 30A power cord is used. Part Number PC30UP.
PTAC units are available in nominal sizes of 9,000BTU, or 12,000BTU
Standard control and components
Construction
1. 18 gauge galvanized steel and powder-coated for base pan and bulkhead, 20gauge
galvanized steel and powder-coat for construction.
2. Centrifugal evaporator fan with galvanized steel
3. Plastic fan blade for condenser
4. 20 gauge galvanized steel and powder coated for drain pan
5. Easily removable electric heater and easy access electrical box
6. Motors are thermally-protected.
7. Intelligent Control Board with digital control and optional thermostat control
(thermostat sold separately).
8. Washable filter
9. Metal protective discharge grille
Condensate removal system
1. Drain hose leads condensate to the outside base pan.
2. Slinger wheel, which is apart of the outdoor fan blade, throws condensate onto the
condenser coil during operation, where it evaporates, improving system performance.

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Operation instructions
ON/OFF button: When unit is off; press this key to turn the machine on. When the
machine is on, press this key to turn off the unit. Use the mode button to select
heat/cooling or fan options.
MODE button: Mode selecting key, press the key, mode change as follows.
cooling fan mode heating
Fan button: Fan selecting key, fan speed as followed.
low fan med fan high fan auto fan
Timer button; Pressing further will forward 1hr increase, each press adds 1hr, up to
24hr.
UP & Down button: used to adjust the temperature. Press once to increase the set
temperature by 1oF, Press once to DOWN, the set temperature by 1oF
Cancel button: Canceling timing setting
Press + hold “Down” button for 15 seconds to display Room Temperature.
Press and hold “Up” and “Down” together for 15 seconds to switch from C to F.
ON/OFF
MODE
FAN
TIMER
UP/DOWN
N
CANCEL
Controls
ROOM TEMPERATURE
Degree’s C to F

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How to Change from Manual control to Thermostat for PCKK
Please follow the instructions and pictures
Step 1. Take the unit out of its sleeve
Step 2. Remove the front grill to access the display panel (DO NOT drop anything in fan unit )
Step 3. Remove the control panel to reach to the main board.
Step 4. Turn Dip Switch No. 1 from OFF to ON. (This pair of “1,2”.
Image of Dip Switch Off (Switch #1) Image of Dip Switch On (Switch #1)

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PREPARING FOR THE INSTALLATION
Safety Precautions
1. This unit should be installed by a factory certified technician or a licensed mechanical contractor
to ensure proper operation and avoid any safety hazards.
2. Power supply wires must be located in areas where they will not be damaged or cut.
3. Never insert any type of object into the machine inside. Because the fan rotates at a high speed,
this may cause injury.
4. Disconnect the power supply from socket-outlet when the machine units are not in use.
5. Disconnect all electric power supplies before servicing.
6. Any type of repairs or maintenance done to the units must be done by a professionally licensed
contractor. Any unqualified person should not attempt to repair the units themselves.
7. WARNING: RISK OF ELECTRIC SHOCK: CAN CAUSE INJURY OR DEATH.
8. Be sure that the unit is free and clear of any debris around the outside of the unit. Do not place
or lean any items on the unit.
Moving parts can cause personal injury. Avoid contact with moving parts when testing or
servicing the unit.
Electrical supply
Each unit must have a separate branch circuit protected by a fuse or breaker. Refer to the unit
rating plate for the proper wire and breaker or fuse size
Use of extension cords is prohibited
DO NOT connect the PERFECT COMFORT unit to a circuit with an incorrectly-sized overcurrent-
protection device
Electrical short hazard
Before opening the existing unit:
Open the power supply disconnect switch. Secure it in an open position during installation.
Attach a sign stating,"DO NOT TURN ON"
On a plug and receptacle connection, unplug the existing unit at the wall outlet.
DO NOT plug in the new unit until installation is complete and the start-up check list has been
completed. Failure to comply with the above could result in severe personal injury, death or
substantial property damage.
WARNING

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Remove the old chassis
1. Disconnect power or unplug cord beforeproceeding
2. Remove the front panel to expose the old chassis
3. Loosen any tie-down bolts or screws and remove the old chassis
Check existing wall sleeve
PERFECT COMFORT replacement PTAC’s are to be used with a metal wall sleeve:
a) Clean the wall sleeve of any dirt
b) Repair any damage or rust
c) Ensure proper drainage of condensate or rainwater to exterior of building
d) Check the back of sleeve is pitched to the outside ¼ bubble on level
e) Check the sleeve is leveled left to right
f) Make sure the wall sleeve is secured in the wall
Check existing outdoor louver
Check whether the type of the outdoor louver match the baffle and insulation on the chassis,
adjust if it doesn’t match.
Remove any obstructions
INSTALLATION INSTRUCTIONS
CHASSIS INSTALLATION
1. Check the seal foam on the rear of chassis, make sure to avoid ventilation recirculation
2. Slide the chassis into the sleeve tight to the end of the sleeve.
3. Secure the chassis —tighten any tie down bolts or screws if necessary.
Fig. 03

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WALL THERMOSTAT INSTALLATION
Connect the wall thermostat cable with the chassis. See Fig.03 for wire colour coding.
Install the wall thermostat as per instructions from thermostat manufacturer. Connect cable from
chassis to the existing wires in the wall as Fig.04
Ensure to wrap and make protection at the joint points.
POWER CORD INSTALLATION
Connect Unverisal Power Cord to female connection on unit. See Fig 04. The connection will
clip in place and can be removed in future be compressing the sides and pulling the cord free.
Once the cord is connected securely to the unit plug cord into wall outlet. Once cord is
plugged in, confirm the LED light on the head of the plug is on.
Fig.04 Cable Connection for Wall Thermostat
and Connection for Universal Power Cord

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FILTER INSTALLTION
Filter is installed inside cover near the bottom. It rests on the metal that protrudes around
the bottom of the over. See Fig. 06.
Make note to have the angled corner near the power cord. This small section is for the power
cord to exit the unit.
Once the filter is in place, the cover can now be installed.
Fig. 06

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FINAL INSPECTION AND START-UP
Check list
1. Ensure the chassis is secured with the sleeve
2. Unit is installed in compliance with all codes
3. Circuit breakers and wire sizes are correct
4. Ensure the electrical supply matches the electrical requirements of the unit, and that
the unit is properly grounded
5. Check whether the electric heat match the power cord
6. Filter clean and in place
7. All panels in place
8. Make sure the chassis is leveled 1/4 bubble towards exterior
9. Verify that nothing will interfere with the room discharge air or the return air of
the units
Examples:
-Check for curtains or drapes that obstruct the air flow
-Check for plush carpeting that can obstruct the return air
-Items like these can cause serious damage to the chassis
-Ensure work area clean and free of debris
Start-up
-Plug the power cord to the receptacle
-Turn on the chassis, and operate all functions
Wall Thermostat
See wall thermostat instructions to operate thermostat. Test all functions to confirm PTAC unit is
working properly.

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Maintenance and Troubleshooting
Monthly inspection and maintenance
Electrical shock hazard. Disconnect power to the PERFECT COMFORT replacement PTAC before servicing
or accessing the control compartment. Failure to do so could result in severe personal injury or death.
It is illegal to discharge refrigerant into the atmosphere. Use proper reclaiming methods and equipment
when servicing a perfect comfort replacement PTAC.
For optimum performance and reliability of your PERFECT COMFORT replacement PTAC, PERFECT
COMFORT recommends performing the following sections and maintenance on a monthly basis.
Units that are installed in harsh or dirty environments will require more frequent inspections and
maintenance.
-Clean or replace the indoor air filter
-Vacuum return air grille surface
-Inspect & clean the chassis interior for rodent or insect infestation
-Clean & flush condensate drain pan and chassis base pan
-If applicable, ensure the condensation drain is functioning properly
-Inspect refrigeration tubing; especially braze joints, for signs of refrigerant leaks. (oil
residue) repair if necessary
-Inspect indoor and outdoor coils. Ensure dirt or debris has not collected on the fins. Clean if
necessary. Be careful not to damage coil fins when cleaning. Use a fin comb to straighten
any bents fins.
-Examine control box. Ensure all wire connections are secure
-Ensure indoor blower wheel and outdoor fan blades are secured to their motor shafts
-Ensure dirt or debris has not collected on the indoor blower wheels and outdoor fan blades.
Use a vacuum and soft brush
-Clean the exterior of the cabinet as desired with a mild soap or household cleaner
Clean or replace the return air filter as needed. Allowing dust to collect on the filter will cause the unit
to lose efficiency and eventually malfunction. Check the filter at least once a month. Some environments
may require more frequent replacement, depending on particulate in the air stream.
DANGER
WARNING
WARNING

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NOTICE
If a new air filter is needed for your PERFECT COMFORT replacement PTAC, consult supplier for
availability and/or proper sizing.
SEASONAL START-UP AND MAINTENANCE
At the beginning of the cooling and heating seasons, a complete mechanical check should be performed
and maintenance/inspections performed as described below.
Disconnect power to unit and remove necessary access panels
1. Performing the inspections and maintenance defined in “Monthly start-up and Maintenance”
2. Do a visual check of the equipment. Look for obvious changes in the unit such as damaged coils or
evidence of extended wear on any moving parts.
3. Check for unusual odors, oil leaks, or stains on or around the coils and refrigerant lines. The presence of
oil here may indicate a potentially serious problem such as a refrigerant leak.
4. Make sure the base pan is clean
5. Inspect all electrical connections. Look for frayed wires and poor connections. Terminal ends that are
loose will eventually fail, causing a loss of performance or worse.
6. Check fan motors and blower assemblies. Some units may require a drop of light oil to motors and/or
bearing assemblies (look for oil cups) ensure setscrews and motor mounting hardware are tight.
7. Brush and/or Vacuum the centrifugal fan blades ad blower cage assemblies as they must be clean to
operate efficiently.
WARNING: Do not use a solvent-based cleaner to clean coils, as some solvents will produce a noxious
odor when the unit is in operation.
8. Inspect both indoor and outdoor coils. Use a fin comb to straighten out any damaged fins. These coils
must be straight and free of any debris.
9. Inspect and clean the drain pan and drain line(s). The use of anti-fungicide tablet to keep the condensate
system free from bacterial contaminants is recommended.
10. Check the pitch of the unit. Over time the building and equipment may settle, causing a shift in the
direction of the condensate flows. Ideally the unit should pitch a minimum of ¼ bubble on level to the
outside to allow for proper drainage.
11. Check drainage holes along rear flange of the base pan to ensure they are free of debris.
12. Check to ensure the seal around the unit is not broken or damaged.
Notice: Air leaks may make the conditioned area uncomfortably drafty or produce noises. Visually inspect
the foam gasket between the wall and the unit, especially taking note of the separation between the air
inlet for the condenser and the condenser coil discharge. These two areas must be sealed off from each
other. If you experience poor cooling operation or erratic operation, check for air recirculation at the
condenser coil.
13. Replace the access panels and reconnect the electrical power.
14. Test the unit operation.

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TROUBLE SHOOTING GUIDE
SYMPTOM
CAUSE
CHECK/CORRECTION
Thermostat does
not properly
control room
temperature, runs
continuously or
causes abnormal
cycles in heating
or cooling mode
Sleeve seals are worn or missing
allowing outdoor air to be passed
over the thermostat sensing bulb
Inspect and replace if necessary
Defective thermostat
Test and replace if necessary
Thermostat bulb/sensor not
properly located
Ensure bulb is clipped to evaporator
coil at original factory specified
location
Thermostat/sensor temperature
limiting option not set up properly
Set up the temperature limiting option
according to the unit installation
instructions
Compressor Short
Cycles
Low Voltage
Check voltage with unit running and
ensure it is within nameplate limits
Restricted condenser air
Check for dirt or other condenser coil
restriction. Clean as necessary
Recycling of condenser air
Check for inadequate discharge air
installation clearances. Coil not sealed
against grille, unit may not be
completely pushed into sleeve
Condenser fan motor operating
intermittently, rotating slowly, or
not at all
Check to see if fan or shaft is being
rubbed or experiencing external
friction. Check free rotation of the
motor shaft. Check voltage to the
motor. Check motor capacitator. Check
for mis-wiring. Motor may have open
windings, or internal overload is
defective. If so, replace motor
Thermostat bulb/sensor not
properly located
Ensure bulb is clipped to evaporator
coil at original factory specified
location
Faulty or incorrect compressor
overload
Check for correct overload model
number and replace if incorrect.
Otherwise, if running amps seem
normal, replace overload.

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SYMPTOM
CAUSE
CHECK/CORRECTION
Compressor Short
Cycles (Cont.)
Indoor coil frozen
See “Evaporator Coil Frosts”
Recycling of indoor air
Ensure that curtains or other
obstructions are not short circuiting air
between the outlet grille and return air
intake
Compressor running too slow and
drawing high amps
Compressor may be mis-wired. Check
capacitator. Compressor may be
seizing –if so, replace compressor
Compressor will
not run
Fuse or circuit breaker tripped
Replace or reset as necessary
Defective switch
Test and replace if necessary
Defective thermostat/sensor
Test and replace if necessary
Indoor room temperature below
thermostat set point
Lower thermostat setting if comfort is
not yet achieved
Indoor room temperature below
65’F
Cooling will not operate if the room
temperature is below 65’F
Outdoor temperature too cold
Compressor is not intended to operate
at cold outdoor temperatures
Broken, shorted, loose or mis-wired
wiring
Inspect and correct
Defective compressor capacitor
Test and replace if necessary
Defective compressor overload
Test and replace if necessary
Low voltage or no voltage to
compressor
Check voltage and ensure it is within
nameplate limits

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SYMPTOM
CAUSE
CHECK/CORRECTION
Compressor will
not run (Cont.)
Compressor windings open
Disconnect overload from compressor
terminals. Check for winding resistance
across all winding pairs. C-S, C-R, S-R
and check each terminal to the
compressor shell for ground faults.
Replace compressor if any windings are
open-circuited or short circuited to the
shell
Seized compressor
If all of the above check out OK and if
pressures are equalized, and
compressor draws high amps and will
not start, the compressor is seized and
needs to be replaced
Unit Trips Fuse/
Circuit Breaker
Shorted or incorrect wiring
Check all connections. Also check for
shorts within devices such as motors,
switches, heater, etc.
Shorted capacitor
Test and replace if necessary
Compressor short cycling
See “Compressor Short Cycles”
Power was interrupted to the unit
Wait three minutes before starting
Fuse or breaker setting too low
Check nameplate fuse size
Broken, shorted, loose or mis-wired
wiring
Inspect and correct
Low voltage or no voltage
Check voltage with unit running and
ensure it is within nameplate limits
Seized or slow running compressor
See above