ICP Package Units(both Units Combined) Manual L0604329

User Manual: ICP ICP Package Units(both units combined) Manual ICP Package Units(both units combined) Owner's Manual, ICP Package Units(both units combined) installation guides

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Installation Instructions
PGX3 Series
PACKAGED

GAS / ELECTRIC

UNITS

TABLEOF CONTENTS
UNITDIMENSIONS ......................................

2-3

ELECTRICALWIRtNG..................................

SAFEINSTALLATIONREQUIREMENTS .........................

DUCTWORK.........................................

LOCATINGTHE UNIT .......................................

FILTERS ............................................

CLEARANCES ............................................

AIRFLOWADJUSTMENT ...............................

INSTALLATION............................................

START-UPPROCEDURES ..............................

GROUNDLEVELINSTALLATION ..............................

GAS PRESSURES ....................................

HOISTING................................................

HEATINGSTART-UPPROCEDURES ......................

DOWNFLOWCONVERSION ..................................

OPERATION.........................................

HEATINGVENTASSEMBLY ..................................

MAINTENANCE ......................................

CONDENSATEDRAIN.......................................

INSPECTIONAND CLEANING............................

PRE-EXISTINGCOMMONVENTCHECK .........................

COMPONENTLOCATION ...............................

GAS SUPPLYAND PIPING ...................................

RIGGING ...........................................

ORIFICES ...............................................

WIRING DIAGRAMS ................................

20 - 21

CQUS
LISTED

InternationalComfortProducts,LLC
Lewisburg,TN. 37091

462 01 1201 00
Printed in U.S.A.
Code: PGX3

1-10-06

"B" CHASSIS UNIT DIMENSIONS

1. Unit Dimensions
Units

COMBINATION
GAS/
ELECTRIC
UNITS
"B" Chassis
DIM=

A
B
C
D
E
F
G
H
I
J
K
L
M
N
P
Q
R
S

in "B"

PGX324

Chassis

Configuration

- 36

(473/8 x 473/8)
INCHES

"0" _

"B"

MILLOMETERS

47-3/8
47-3/8
3-1/8
32-1/2
11-1/8
12

1203
1203
79
826
283
306

14-1/4

363

14-1/4

383

308

314 I19 28
4

102

4-1/4

lO8

12-1/4

311

12-1/8
14-1/4

308
363

12-1/4

318

'w'

"1''/

[ o \
//_
/

_..J

_
_/

;'E'_

j'G_._

'U'_'" _
_
_

"H"
'

i_--_

'_
-">,/

._--'/_
/

2-1/2"

1/2" (12.7) CONDUIT

_i,,

(53975)

.-li8

(282.575)

'_L"_

_._

A
B
C
D
E
F
G
H
K*

_'__

(101.6)

//_¢

..X._/_--

ROOF CURB

Unit Base shown separately to

for units in
"B" Chassis

illustrate

(473/8 x 473/8)
DIM.

"d"

1--1/2"

,.c,Es
42-3/4
39-3/4
18

18
3-3/4
42-3/4

Units

M.........
1086
1010
457

in "B"

PGX324

Chassis

95
1086

_x
_

_
//

_._.

/
_

_/._..._
/_

_._

"F'_

* Roof curbs are also available in 8" (203) and 24" (610) heights (K Dimensions),

•

openings,

of duct

Configuration_

- 36

457

bottom

8o:_o:12

"C" CHASSIS UNIT DIMENSIONS
CAL
CONDUIT

('K"

1/2"
GAS
1/2"

POWER
DIM.)

VOLTAGE
(12.7)

CONDUIT

CONNECTION
(12,7)

PIPE

1/2"

COMBINATION
GAS/
ELECTRIC
UNITS
"C" Chassis
(473/8 x 73)
DIM

A
B
C
D
E
F
G
H
I
J
K
L
M
N
P
Q
R
S
T

INCHES

36
47-3/8
73
4-5/8
15
12
18-3/4
18-3/4
12
4
1 &1-1/4
4-1/4
5-1/4
12-1/4
19
15
19
12-1/4
16-7/8

MILLOMETERS

914
1203
1354
117
361
307
476
476
306
102
25&31
108
133
311
483
381
483
318
429

,,p,,

Unit Base shown separately to
illustrate bottom of duct openings,

ROOF

CURB
for
"C" Chassis
(473/8 x 73)

_IM

A
B
C
D
E
F
G
H
I
J
K*

INCHES

67-3/4
64-3/4
23
23
2-1/2
42-3/4
39-3/4
23
12
12
14

Units in "C" Chassis Configuration
PGX342-60

MgLLIM_T_RS

1721
1645
584
584
64
1086
1010
584
305
305
356

* Roof curbs are also available in 8" (203) and 24" (610) heights (K Dimensions),

2. SAFE INSTALLATION

REQUIREMENTS

Installation and servicing of air-conditioning equipment can
be hazardous due to system pressure and electrical
components. Only trained and qualified personnel should
install, repair, or service air-conditioning equipment.
Untrained personnel can perform basic maintenance
functions of cleaning coils and filters. All other operations
should be performed by trained service personnel. When
working
on
air-conditioning
equipment,
observe
precautions in the literature, tags, and labels attached to the
unit, and other safety precautions that may apply.
Follow all safety codes. Wear safety glasses and work
gloves. Use quenching cloth for unbrazing operations.
Have fire extinguisher available for all brazing operations.

FIRE,
EXPLOSION,
ELECTRICAL
SHOCK,
CARBON MONOXIDE POISON HAZARD

AND

Improper installation, adjustment, alteration, service,
maintenance,
or use can cause carbon monoxide
poisoning, fire, or an explosion which could result in
personal injury or unit damage.
Consult a qualified
installer, service agency, or gas supplier for information
or assistance. The qualified installer or agency must use
only factory-authorized
kits or accessories
when
modifying this product.

FIRE,
EXPLOSION,
ELECTRICAL
SHOCK,
CARBON MONOXIDE POISON HAZARD

AND

Failure to follow this warning could result in personal
injury, death and/or property damage.
Before performing service or maintenance operations
on unit, turn off gas supply to unit. Then turn off unit main
power switch and install lockout tag.

Recogniz_ safety information. This is the safety-alert
symbol/.rX. When you see this symbol in instructions or
manuals, be alert to the potential for personal injury.
Understand the signal words DANGER, WARNING,
CAUTION, and NOTE. These words are used with the
safety-alert symbol. DANGER identifies the most serious
hazards which will result in serious injury or death.
WARNING signifies a hazard which could result in serious
injury or death. CAUTION is used to identify unsafe
practices which may result in minor personal injury or
product and property damage. NOTE is used to highlight
suggestions which will result in enhanced installation,
reliability, or operation.
These instructions cover minimum requirements and
conform to existing national standards and safety codes. In
some instances, these instructions exceed certain local
codes and ordinances, especially those that may not have
kept up with changing residential construction practices.
We require these instructions as a minimum for a safe
installation.

141

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON
MONOXIDE POISON HAZARD
Failure to carefully read and follow all instructions in this
manual could result in furnace malfunction, property
damage, personal injury and/or death.
Installation or repairs made by unqualified persons can
result in hazards to you and others. Installation MUST
conform with local building codes or, in the absence of
local codes, with the National Fuel Gas Code NFPA
54-2005/ANSI Z223.1-2005 and the National Electrical
Code NFPA70-2005 or in Canada the National Standard
CAN/CGA B149-1 and CSA C.22.1 - Canadian Electrical
Code Part 1.
The information contained in this manual is intended for
use by a qualified service technician familiar with safety
procedures and equipped with the proper tools and test
instruments.
SAFETY CONSIDERATIONS
• Use only with type of gas approved for this unit. Refer to
unit rating plate.
• Install this unit only in a location and position as specified
in section 3 of this manual.
• Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the
detection of leaks to check all connections, as specified in
section 5.
• Always install unit to operate within the unit's intended
temperature-rise range with a duct system, which has an
external static pressure within the allowable range, as
specified in section 9. Refer to unit rating plate for the allowable external static pressures.
• All connecting ductwork to the unit (supply and return)
must be sealed to the unit casing as specified in section 7.
• Do NOT use this furnace as a construction heater.
• Check to see that filters are installed correctly and are the
proper type an size.
NOTE: It is the personal responsibility and obligation of the
customer to contact a qualified installer to ensure that the
installation is adequate and conforms to governing codes
and ordinances.

UNIT SAFETY
Failure to follow this caution may reduce unit reliability.
It is recommended that a qualified service technician
check the heat exchanger integrity every two (2) years,
after the first four (4) years of operation.
INTRODUCTION
The PGX3 unit is a fully self-contained,
combination
Category I gas heating/electric cooling unit designed for
outdoor installation (See pages 2 and 3 for unit
dimensions).
All unit sizes have return and discharge
openings for both horizontal and downflow configurations,
and are factory-shipped with all downflow duct openings
covered.
Units may be installed either on a rooftop, cement slab, or
directly on the ground if local codes permit.
Models with a'l" in the twelfth position ofthe model number
are dedicated Low NOx units designed for California
installations. The emissions ofthese models do not exceed
40 nanograms of nitrogen oxide emissions per joule of heat
output as shipped from the factory, and must be installed in
California Air Quality Management Districts or any other
regions in North America where a Low NOx rule exists.

3. LOCATING

THE UNIT
FiGuRE i

Minimum Clearances
Panels(B
Chassis and
Shown)
Access

ACCESS PANELS
I

See Figure 1 for a general view of unit and location of
access panels.

Blower Compartment

Panel

B Chassis - 2"
C Chassis - 6"

CLEARANCES
The location MUST allow for minimum clearances

and

should not be adjacent to a patio or other area where the
unit's operating sound level might be objectionable. The
combustion air inlet openings MUST not be obstructed (see
Figure 1). In addition, local codes MUST be observed.
NOTE: Units with available filter racks (3-1/2 to 5ton), need
a 26" minimum clearance at side of unit for removal of
filters. See chart below if unit is going to be placed near
combustible construction or materials.
While minimum clearances are acceptable for safety
reasons, they may not allow adequate air circulation around
the unit for proper operation in the cooling mode. Whenever
possible, it is desirable to allow additional clearance,
especially around the condenser inlet and discharge
openings.
Do NOT install the unit in a location that will permit
discharged air from the condenser to recirculate to the
condenser inlet.

Internal Filter Access
from Burner Compartment
26" (C Chassis Units)

Side

Burner Compartment
Panel

INSTALLATION
NOTICE

Unit will NOT operate properly unless it is installed
level front to rear and side to side. The slope MUST NOT
be greater than 1/8" per foot (10mm per meter). For side
to side leveling, the drain side MUST always be lower.
Ground Level Installation
Ground level platform requirements:
- The unit MUST be situated to provide safe access for
servicing.
- Platform may be made of either concrete or pressure
treated wood and MUST be level and strong enough to
support unit weight.

UNIT DAMAGE HAZARD

- Position platform separate from building foundation.

Failure to follow this caution may result in shorten life
of unit components.

- Install in well-drained area, with top surface of platform
above grade level.
- Platform must be high enough to allow for proper
condensate
trap installation and drainage. See
FIGURE 4 and associated text for more information
about condensate drainage.

Do NOT operate unit in a corrosive atmosphere
containing chlorine, fluorine, or any other corrosive
chemicals.
Minimum

Clearances

to Combustible

Construction

Furnace Plenum .....................................
Duct Side ...........................................
Condenser Inlet ....................................
Blower Service (Side) ...............................
Control Service Side

2"
2"
30"
30"

(Front Combustion Air Inlet) ..............
Clearance between 3 Ft. Overhang
and Top of Unit .........................
Combustible Base
(Wood or Class A, B or C
roof covering material) .....................

30"
30"

151

Rooftop Installation
Rooftop platform requirements:

FIGURE2

Heating Vent Assembly

Screws for
"B" Chassis
(473/8 x 473/8)

- The unit MUST be situated to provide safe access for
servicing.

Screw for
"C" Chassis
(473/8 x 73)

- The existing roof structure MUST be adequate to
support the weight of the unit or the roof MUST be
reinforced.
Check the weight of the unit in relation to the roof
structure and local building codes or ordinances and
reinforce roof structure if necessary. See the last page
of this manual for unit weights.
- Support for the unit MUST be level and strong enough
to carry unit weight. The support may consist of a
platform or a combination of platform and roof beams or
curb.
- See Hoisting section for hoisting instructions,
HOISTING
NOTE: All access panels MUST be secured in place before
hoisting.
The unit should be hoisted with two lifting slings. Attach the
slings to rigging shackles that have been hooked through
holes in the base rail,
Two spreader bars MUST be placed on top of the unit to
protect the unit from damage from the pressure exerted by
the slings. Make sure that all equipment is adequate to
handle the weight ofthe unit and that the slings will not allow
the unit to shift.
Refer to FIGURE 18 on the back cover of this manual for
illustrated rigging instructions and weight chart,
DOWNFLOW CONVERSION
NOTE: In downflow applications with roof curbs or jack
stands, the center rail under the unit must be removed. The
center rail is attached to the base rail with screws.

2. Install the removed plates on the horizontal return and
supply air openings.
3, Install roof curb on the building. Be sure to follow all
directions included with curb and all applicable building
codes in your installation. See page 2 or 3 for
appropriate roof curb to use.
Heating Vent Assembly
The flue cover is packed with installation screws in the
return air compartment, Refer to FIGURE 3 and assemble
as shown,
FIGURE

Heating Vent Assembly

Flue Support
(Shipped mounted to unit
Flue Cover

These units are adaptable to downflow use, To convert to
downflow use, follow these steps:
1. Remove the blockoff plates found in the return air
compartment and the supply air compartment.
NOTE: Blockoff plate in the supply air compartment only
contains one screw. If reinstalling plate, back part of plate
MUST fit into mating dimples on flange. To reinstall, slant
plate into dimples, then put plate into position and fasten
with screw.

UNIT DAMAGE
Failure to follow this caution may result in unit
damage.
Do not operate the unit without the vent assembly
installed.

161

Condensate Drain

5. GAS SUPPLY AND PIPING

The condensate drain outlet is a 3/4" (19.1 mm) female PVC
connection located atthe bottom ofthe unit to the right ofthe
filter access panel (see FIGURE 4).

NOTE: Because there are many types of liquified petroleum
(LP) gases, the term LP as used in this manual refers to
propane gas. If you intend to use any type of LP gas, proper
precautions MUST be used in the handling, piping, and use
of such gas. NOTE: In Canada, installations MUST be
performed by licensed LP installers.

The circulating blower creates a negative pressure on the
condensate drain line that can prevent the condensate from
draining properly. To combat this negative pressure, a field
supplied condensate trap that will allow a standing column
of water of at least 2" (50.8mm) MUST be installed. Top of
outlet from trap MUST be at least 1" (25.4mm) below top of
outlet from unit. Install the trap as near to the unit as
possible for proper drainage.
A 3/4" (19.1 mm) drain line MUST be installed if required by
local codes or if location of unit requires it. Run the drain line
to an open drain or other suitable disposal point.
FIGURE 4

Condensate

Drain Information*

25-1/2 ("B" Chassis)
32-1/4 ("C" Chassis)

The UL rating plate located on the side panel on the unit
contains the model number, type of gas, gas input rating,
and other important information.

FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage.
Make certainthe unit isequipped to operate on the type of
gas available. Models designated as natural gas are to be
used with natural gas only. Models designated for use
with liquefied petroleum (LP) gas are shipped with
orifices sized for commercially pure propane gas. They
MUST not be used with butane or a mixture of butane and
propane unless properly sized orifices are installed by a
licensed LP installer.

3/4" (19,1mm)
Threaded Female

GAS PIPING

PVC Fitting
1 "

(25.4mm)

/
2" (5O.8mm)

The gas supply line MUST be of adequate size to handle the
Btu/hr requirements and length of the run for the unit being
installed. Determine the minimum pipe size for natural gas
from the table in FIGURE 5 or FIGURE 6. Base the length
of the run from the gas meter or source to the unit.
Gas Pipe Size
Btu ratings of all other gas appliances MUST be considered
for sizing of main gas line. Check gas line to installation for
compliance with local codes or, in the absence of local
codes, with the National Fuel Gas Code NFPA
54-2005/ANSI Z223.1-2005 or in Canada the National
Standard CAN/CGA B149-1 or current editions.

80-30-27

* Condensate

4. PRE-EXISTING

trap MUST be installed,

COMMON

VENT CHECK

If the installation of this new combination gas heat/electric
cool unit involves removing an existing gas-fired furnace
from a common vent system with other gas-fired
appliances (gas-fired hot water heater, etc.), the existing
vent system must be checked and inspected by a qualified
technician. The qualified technician can determine if the
existing vent system will properly vent the flue products of
the remaining gas-fired appliances. In many cases, the
existing vent system may be oversized for the remaining
appliances.

FIGURE 5

Pipe Length
(includes
Fittings)

Gas Pipe Size, Length and Btu/hr Capacity
for Schedule 40 Iron Pipe/English/
NATURAL GAS
Btu/hr

(in thousands)

3/4"

11/4"

20'

190

350

730

11/2"
1,100

2,100

40'

130

245

500

760

1,450

60'

105

195

400

610

1,150

LP GAS
Pipe Length
(includes
Fittings)

Btu/hr (in thousands)
3/4"

11/4"

11/2"

20'

189

1/2"

393

732

1,496

2,299

40'

129

267

504

1,039

1,559

60'

103

217

409

834

1,275

LZJ

FIGURE 6

Gas Pipe Size, Length and Btu/hr Capacity
for Schedule 40 Iron Pipe (English)

UNIT OPERATION AND COMPONENT

NATURAL GAS
Pipe Length
(includes
Fittings)

Failure to follow this caution may result in misaligned
burners, flame rollout and or unit damage.
Overtightening assembly may cause damage to the gas
valve and/or wirin_land may misali_lnthe burners.

kW**
3/4"

6.1m

103

12.2m

18.3m

11/4 "

11/2"

214

322

615

147

223

425

117

179

337

6. Use a wrench on gas valve when making connections
to prevent gas valve from turning. Do NOT use a pipe
wrench on the gas valve body.

LP GAS
Pipe Length
(includes
Fittings)

7. Provide a t/8 inch (3mm) National Pipe Thread (NPT)
plug for test gauge connection immediately upstream of
the gas supply connection to the furnace if none is
supplied with the gas valve of unit.

kW**
1/2"

3/4"

11/4 "

11/2 "

6.1m

115

1"
215

438

674

12.2m

148

305

457

18.3m

120

244

374

**kW (Ki!owatts) is the metric equivalent

DAMAGE HAZARD

8. Install a manual shutoff valve and tighten all joints
securely.

of Btu/hr.

LEAK CHECK/PRESSURE
PIPING

PIPING AT UNIT

TESTING OF GAS SUPPLY

Connections
NOTE: The rules listed apply to natural and LP gas pipe
installations.
1. If installation is for LP gas, have LP gas installer use
TWO-STAGE
REGULATION
and
make
all
connections from storage tank to unit.
2. Use black iron or steel pipe and fittings or other pipe
approved by local code.
3. If copper tubing is used, it MUST comply with limitation
set in Fuel Gas Code.
NOTE: If a flexible gas connector is used, it MUST be
acceptable to local authority. Connector MUST NOT be
used inside the furnace or be secured or supported by the
furnace or ductwork. Do not use a connector which has
previously serviced another gas appliance. Always use a
new listed connector.

FIRE OR EXPLOSION

HAZARD

Failure to follow the safety warnings could result in personal injury, death or property damage.
Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for
the detection of leaks to check all connections. A fire or
explosion may result causing property damage, personal injury or loss of life.

The unit and its equipment shutoff valve must be
disconnected from the gas supply piping system during any
pressure testing of that system at test pressures in excess
of .5 psi (3.5kPa).
The unit must be isolated from the gas supply piping system
by closing the equipment shut off valve during any pressure
testing of the gas supply piping system at test pressures
equal to or less than .5 psi (3.5 kPa).
ORIFICES

Failure to do so could result in personal injury, death
and/or property damage.
Gas connector MUST be properly installed and can NOT
be used inside the furnace.
4. Use pipe joint compound on external (male) threads
ONLY. Joint compound MUST be resistant to any
chemical action of LP gases.
Do NOT put pipe
compound on last 2 threads of pipe.
5. Use ground joint unions and install a drip leg no less
than 3 inches (76 mm) long to trap dirt and moisture
before it can enter gas valve.

TABLE 1 & 2: Equivalent

FIRE OR EXPLOSION

Orifice Sizes
Orifice sizes MUST be matched to the heating value of the
gas (see TABLE 1 & 2). Check with your gas supplier and
the National Fuel Gas Code ANSI Z223.1.
NOTE: An LP Conversion Kit MUST be used for conversion
to LP gas.
NOTE: For elevations above 2000 feet (610 meters), the
Btu input rating MUST be reduced by 4% for each 1000 feet
(305 meters) above sea level, unless the gas supplier's
Btu!ft 3 content has already been adjusted for altitude.
Check Table 1 & 2 for the proper orifice sizes.

Orifice Sizes at High Altitudes

Table1

NATURALGASORIFICESIZING
MEANELEVATIONFEETABOVESEALEVEL
0 to 2000

NominalHeatingSize
All Sizes

Orifice
Drill #
44

Kit
Number
1173863

2001to
4000

4001to
5000

5001 to
6000

6001to
7000

7001to
8000

8001to
9000

9001 to
10000

Orifice
Drill #
45

Orifice
Drill #
46

Orifice
Drill #
47

Orifice
Drill #
48

Orifice
Drill #
49

NOTE:

The orifice

sizes

above

sea level.

If converting

330732-401,
Btu/Cu.Ft.,

in the chart
from

above derate

the input rate at 4% per 1000 feet above

LP gas to Natural

Gas

at altitudes

exceeding

sea level for altitudes

2000

feet

above

exceeding

sea level,

use

2000 feet

part number

plus the required orifice size # shown in Table 1. Natural Gas data is based on 0.60 specific gravity, a heating value of 1030
and 3.5" W.C. manifold
pressure.
For fuels with different
specific
gravity, consult the National
Fuel Gas Code NFPA

54-2005/ANSI

Z223.1-2005

or National

Standard

of Canada,

Table2

Natural

Gas and Propane

Installation

Code

CSA B149.1-05.

LPGASORIFICESIZING
MEANELEVATIONFEETABOVESEA LEVEL
0 to2000

Nominal Heating
Size

Orifice
Drill #

All Sizes

NOTE:

The orifice

sizes

2001 to4000

Kit
Number

Orifice
Drill #

1173857
in the chart

Kit
Number

40011o7000
Orifice
Drill #

1173857

above derate

7001to9000

Kit
Number

Orifice
Drill #

1173859

the input rate at 4% per 1000 feet above

90011o10,000

Kit
Number

Orifice
Drill #

1173859

sea level for altitudes

exceeding

Kit
Number
1173861
2000 feet

above sea level. LP Gas data is based on 1.52 specific gravity, a heating value of 2500 Btu/Cu. Ft., and 10.0" W.C. manifold pressure. For
fuels with different specific gravity, consult the National Fuel Gas Code NFPA 54-2005/ANSI
Z223.1-2005
or National Standard
of
Canada,

Natural

Changing

Gas and Propane

Installation

Code

CSA B149.1-05.

Orifices

ELECTRICAL
HAZARD

FIGURE 7

SHOCK,

FIRE AND/OR

Removing

NOx Baffles

EXPLOSION
or

Failure to follow this warning could result in personal
injury, death and/or property damage.
Shut off electric power at unit disconnect or service
panel and shut off gas at manual shut off valve before
beginning the following procedure.
Changing
technician.

orifices

requires

qualified

service

1. Shut OFF gas at manual shut off valve.
2, Shut OFF electric power at unit disconnect or service
panel. If unit is still running, allow 3 minutes after gas
shut off before turning off power.
3, Disconnect the wires from the gas valve, sparker, and
flame sensor.
4. Remove the four screws holding the manifold to the
manifold brackets.
5. Carefully remove the manifold with the gas valve
attached.

25-22-46a
7, Remove the orifices from the manifold
end or socket wrench.

with

a 7/t6"

box

8, Check to be sure that the size of each orifice is correct
for the Btu input desired,
FIGURE8

Manifold/Orifice Measurement

Measure 13/16 " from face of orifice
back edge of manifold pipe.

6, If unit has v-shaped NOx baffles installed in the firing
tubes, they must be removed when coverting to LR
Some baffles may be attached by screws, Replace
screws after removing NOx baffles (figure 7).

CARBON MONOXIDE HAZARD.
Failure to follow this warning could result in personal injury death and/or property damage.

Install the correct orifices. Gauge the size of the orifices
with a new twist drill bit of the correct size.

NOx baffles for use with Natural Gas units ONLY. If
LP Gas is required, NOx inserts must be removed.

Make sure that the orifices go in straight so that they
form a right angle (90 °) to the manifold pipe.
Tighten the orifices so that there is a 13/t6"
distance
between the faces of the orifices to the back of the
manifold pipe.
Measure the distance with a set of calipers, If you do not

191

have a calipers, you can use an adjustable wrench and
measure between the face of the jaws.
10. Reassemble in reverse order.

6. ELECTRICAL

ELECTRICAL

WIRING

SHOCK

HAZARD.

Failure to follow this warning could result in personal
injury, death, and/or property damage,
The unit cabinet must have an uninterrupted,
unbroken electrical ground to minimize the possibility
of serious injury if an electrical fault should occur.
This ground may consist of an electrical
wire
connected to the unit ground lug in the control
compartment,
or conduit approved for electrical
ground when installed in accordance with National
Electric Code (NEC) NFPA 70, National Fuel Gas Code
NFPA 54-2005/ANSI Z223.1-2005 and local electrical
codes. In Canada, follow Canadian Electrical Code
CSA (Canadian Standards Association) C22.1 and
local electrical codes.

REDUCED EQUIPMENT

LIFE HAZARD

Failure to follow these cautions could result in damage
to the unit being installed.
1) Make all electrical connections in accordance with
National Electric code (NEC) NFPa 70, National Fuel Gas
Code NFPA 54-2005/ANSI
Z223.1-2005
and local
electrical codes governing such wiring. In Canada, all
electrical connections must be in accordance with CSA
standard C22.1, Canadian Electrical Code Part 1, and
applicable local codes. Refer to unit wiring diagram.
2) Use only copper conductor for connections between
field-supplied electrical disconnect switch and unit. DO
NOT USE ALUMINUM WIRE.
3) Be sure that high-voltage
power to unit is within
operating voltage range indicated on unit rating plate.
4) Do not damage internal components when drilling
through any panel to mount electrical
hardware,
conduit, etc.
Consult local power company for
correction of improper voltage and/or phase imbalance.

the electrical service panel or a properly driven and
electrically grounded ground rod. See warning above.
Line Voltage Wiring
Connections for line voltage are made in the unit control box
area. Refer to wiring diagram located on the Burner Access
panel. For access, remove the burner access panel.
1. Run the high voltage (L1, L2) and ground leads into the
control box.
2. Connect ground lead to chassis ground connection.
3. Connect L1 to pressure
compressor contactor.

lug connection

11 of the

4. Connect L2 to pressure lug connection
compressor contactor.

23 of the

Thermostat / Low Voltage Wiring
Location of the thermostat has an important effect on home
comfort. FOLLOW THE THERMOSTAT INSTRUCTION
MANUAL FOR CORRECT LOCATION, MOUNTING, AND
WIRING.
A two-stage thermostat is required for proper operation.
Thermostat should have the following terminals:
"R",
"W/W1 ", "Y1", "Y2", and "G'. Some electronicthermostats
use low voltage from the unit for power for temperature
display and programming. These electronic thermostats
will have a "C" terminal. The outdoor unit has color-coded
wires for easy connection. Using wire nuts, follow figure 10
for proper connections:
FIGURE 9

Connections

,,1_ Red
White

White
,,1_

Yellow
ed
Pink

Yellow
Pink

miD" Green
Typical
Mechanical
Thermostat
Subbase

THERMOSTAT
For access, remove the burner access panel. See Figure 1
for access panel location. Wiring MUST be protected from
possible mechanical damage.

Thermostat

Typical
Electronic
Thermostat
Subbase

HEAT ANTICIPATOR

The unit must have separate electrical service with a
field-supplied, waterproof, disconnect switch mounted at,
orwithin sight from, the unit. Refer tothe unit rating plate for
maximum fuse/circuit breaker size and minimum circuit
amps (ampacity) for wire sizing.

Some thermostats have an adjustable heat anticipator. The
heat anticipator prevents temperature overshoot in heating
mode. If the heat doesn't turn off until the set point
temperature on the thermostat is exceeded, then the
anticipator setting is too low. If the heat turns off before the
thermostat reaches the set point temperature on the
thermostat, then the anticipator setting is too high. Follow
the thermostat instruction manual for proper adjustment of
the heat anticipator.

Ground Connections

Final Electrical Check

Disconnect Switch

Do NOT complete line voltage connections until unit is
permanently grounded. All line voltage connections and the
ground connection MUST be made with copper wire.
A ground lug is installed in the control box area for the
ground connection. Use a copper conductor of the
appropriate size from the unit to a grounded connection in

1. Make a final wiring check to be sure system is correctly
wired. Inspect field installed wiring and the routing to
ensure that rubbing or chafing due to vibration will not
occur.
NOTE: Wiring MUST be installed so it is protected from
possible mechanical damage.

7. DUCTWORK
Ductwork

permitted. If flexible connectors are used, they should be
protected from potential mechanical damage such as
punctures and tears.

Sizing

The maximum recommended velocity in trunk ducts is 1000
feet per minute. The maximum recommended velocity in
branch ducts is 800 feet per minute.
Ductwork sizing affects the discharge temperature, airflow
velocity, and efficiency of the system. Be sure to properly
size ductwork to the capacity of the unit and to the airflow
requirements of the conditioned space. Failure to properly
size ductwork can result in inadequate airflow and poor
efficiency. Undersized ductwork may result in tripped limit
controls and premature failure of compressors, motors and
other components.
Ductwork

Insulation

Ductwork installed outdoors must have a minimum 2" thick
fiberglass "wrap" insulation and a weatherproof vapor
barrier installed around it. The insulation and vapor barrier
must be protected against potential damage. Caulking,
flashing, and other means of providing a permanent
weather seal must be used.
Ductwork

NOTE: When connecting the supply and return plenums to
the unit, make sure that the plenums are sealed against the
side casing of the unit and do not interfere with removal of
the top of the unit.
FILTERS
All return air MUST pass through a filter before entering the
unit. An electronic air cleaner, optional filter racks, or other
accessible filter arrangement must be installed in the return
air ductwork. Minimum recommended filter sizes are listed
in FIGU RE 10 and are based on maximum face velocities of
300 ft/min for disposable filters and 600 ft/min for washable
(high velocity) filters. See figure 10 for filter sizes.

REDUCED

EQUIPMENT

LIFE

HAZARD

Failure to follow this caution may result in improper
unit operation,

Connections

The use of flexible, non-combustible connectors between
main trunk ducts and supply and return air plenums is
FIGURE 10

Do not operate the unit without

a filter,

Filter Sizes

Disposable

Filters

Nominal Size

Minimum Area

Washable

Filters"

Nominal Size

Minimum Area

(qty x w x d)

(sq. inches)

(qty x w x d)

(sq. inches)

PGX324040K ....

1 x 20" x 20"

384

1 x 10" x 20"

192

PGX324060K ....

1 x 20" x 24"

428

1 x 12" x 20"

214

PGX324080K ....

2 x 15" x 20"

576

1 x 15" x 20"

288

PGX330040K ....

1 x 20" x 24"

480

1 x 12" x 20"

240

PGX330060K ....

1 x 20" x 24"

480

1 x 12" x 20"

240

PGX330080K ....
PGX336060K ....

2 x 15" x 20"
2 x 15" x 20"

576
576

1 x 15" x 20"
1 x 15" x 20"

288
288

PGX336080K ....

2 x 15" x 20"

576

1 x 15" x 20"

288

PGX336100K ....

2 x 18"x20"

720

1 x 18" x20"

36O

PGX342080K ....

2 x 18"x20"

672

1 x 18" x20"

336

PGX342100K ....

2 x 18"x20"

720

1 x 18" x20"

36O

PGX348080K ....

2 x20" x20"

768

1 x 20" x 20"

384

PGX348120K ....

2 x 20" x 24"

854

1 x 20" x 24"

427

PGX348140K ....

2 x 24" x 24"

1008

1 x 24" x 24"

5O4

PGX360080K ....
PGX360120K ....

2 x 20" x 24"
2 x 20" x 24"

960
960

1 x 20" x 24"
1 x 20" x 24"

48O
48O

PGX360140K ....

2 x 24" x 24"

1008

1 x 24" x 24"

504

1 Washable filter size based on an allowable face velocity of 600 ft/min.
filter manufacturer's

specifications

Refer to

for allowable face velocity and required filter area.

L//J

8. AIRFLOW

ADJUSTMENT
PGX3 SERIES HEATING CHART
External Static Pressure (in H20)
.1"

Cooling
Model

PGX324040K....

PGX32406OK
....

PGX32408OK
....

PGX33O04OK
....

PGX33O06OK
....

PGX33OOSOK
....

Tuns

Hea6n0 Input Heating Hise
(8tuih0

40000

60000

80000

40000

60000

80000

Range(_F)

80000

35 65

PGF342089K....

PGX3421OOK
....

PGX34808OK
....

PGX34812OK
....

PGX34814OK
....

PGX36O08OK
....

PGX36012OK
....

100000

80000

100000

80000

120000

140000

80000

120000

.T'

Heating

Rise (_F) CFM

Rise (°F)

OFM

Rise(_F)

Heating

OFM

Rise (°F)

OFM

Rise(_F)

CFM

Rise (°F)

CFM

1251

/218

1194

1170

1139

1100

1063

988

95/

914

883

858

811

775

733

697

869

842

809

768

736

684

650

599

2
/

71I
66/

42
45

655
4(8

45
62

623
334

48
NA

564
262

53
NA

529
219

56
NA

48I
/96

62
NA

43/
NA

NA
NA

392
NA

NA
NA

/251

/218

1/94

/170

1139

/I00

1063

988

4
3

951
869

47
51

9/4
842

49
58

883
809

50
55

858
768

52
58

81/
736

55
69

775
684

57
65

733
650

6/
NA

697
599

64
NA

711

655

623

564

529

48I

43I

892

66/

4(8

334

262

2/9

/96

/251

/218

1/94

1170

1/39

/I00

1083

988

95I

914

883

858

811

775

733

697

869

842

809

768

736

684

850

599

2
/

71I
66/

NA
NA

655
478

NA
NA

623
334

NA
NA

564
262

NA
NA

529
219

NA
NA

48I
/98

NA
NA

43/
NA

NA
NA

392
NA

NA
NA

/255

/227

/20I

1164

1138

11/2

1077

/027

1106

/080

1048

1017

992

954

924

881

958

923

894

857

828

788

750

712

2
1

789
/54

38
39

747
/08

40
42

714
6/1

4/
44

668
618

44
48

630
584

47
51

582
524

5I
5(

542
494

55
60

495
443

60
NA

1255

1227

120I

1164

1138

/I12

1077

/027

1106

1080

1048

1017

992

954

924

88I

958

923

894

857

828

786

750

712

789

747

714

668

630

582

542

495

/54

/08

6/I

6/8

584

524

494

443

1255

/227

120I

I164

1138

/I/2

1077

/027

1106

/080

1048

I017

992

954

924

88I

958

923

894

857

828

788

750

712

2
1

789
754

NA
NA

747
708

NA
NA

714
671

NA
NA

668
818

NA
NA

630
584

NA
NA

582
524

NA
NA

542
494

NA
NA

495
443

NA
NA

1630

1588

/528

1477

1415

1354

1287

/216

/276

/242

1209

/179

1150

/I/7

1086

/045

2
1

/026
876

43
5/

994
84I

45
53

949
794

47
56

913
756

49
59

87/
894

5/
64

84I
65I

53
NA

793
598

56
NA

735
543

60
NA

4
3

1630
/276

36
46

/588
/242

37
48

1526
1209

39
49

I477
1179

40
50

14/5
1/50

42
52

/354
/I/7

44
53

1287
1086

46
55

/216
/045

49
57

1026

994

949

913

87I

84I

793

735

8/6

84I

/94

(56

694

65I

598

543

/630

/588

1528

1477

14/5

/354

1287

/216

1276

1242

1209

1179

1150

/I17

1086

/045

2
/

1026
8/6

NA
NA

994
84I

NA
NA

949
/94

NA
NA

913
(56

NA
NA

871
694

NA
NA

84I
65I

NA
NA

793
598

NA
NA

735
543

NA
NA

/589

/537

1500

/463

1423

/389

1353

/317

/481

/448

1412

/374

1336

/298

1283

/226

1302

/269

1219

I179

1138

/I03

1060

/015

2
/

1170
/028

51
58

/I29
969

52
6I

1088
924

54
64

I050
881

58
NA

1007
838

59
NA

963
789

82
NA

912
73/

65
NA

888
680

NA
NA

5
4

/589
1481

47
50

/537
1448

48
5I

1500
1412

49
52

1463
1374

5I
54

1423
1336

52
55

/389
/298

53
57

1353
1283

55
59

/317
/226

58
60

3
2
1

1302
//70
1028

57
63
NA

1260
/I29
969

59
NA
NA

1219
/088
924

6/
NA
NA

1179
1050
881

83
NA
NA

1138
1007
836

65
NA
NA

/I03
963
/89

NA
NA
NA

1060
912
/31

NA
NA
NA

/015
886
689

NA
NA
NA

2103

205/

200I

1942

1878

1809

1723

/632

183I

/797

1783

1732

1696

166/

1621

/559

/680

/850

1614

1578

1544

/507

1470

/427

2
1

/304
//f3

45
51

/256
112/

47
53

1218
1085

49
55

1167
/g2(

5I
58

1/26
983

53
69

/077
92f

55
64

1026
88I

58
NA

979
82I

6I
NA

2103

2051

200I

1942

1878

/809

1723

/632

/83I

/797

1783

/732

1696

/66/

1621

/559

3
2

/680
1304

53
NA

/850
/256

54
NA

1614
1218

55
NA

/578
1167

58
NA

1544
1126

58
NA

/507
1077

59
NA

1470
1026

60
NA

/427
979

62
NA

1/73

1127

1085

1027

983

927

881

821

5
4

2103
/83I

49
57

205/
/797

5I
58

200I
1783

52
59

I942
1732

53
80

1878
1696

55
61

/809
/66/

57
62

1723
1621

60
64

/632
/559

64
NA

/680

/850

1614

1578

1544

/507

1470

/427

2
/

1304
///3

NA
NA

1256
/I2/

NA
NA

/218
/085

NA
NA

1167
I02(

NA
NA

1126
983

NA
NA

1077
92(

NA
NA

1026
881

NA
NA

979
821

NA
NA

2/88

2140

2098

2039

1974

1905

1827

/745

2091

2056

2023

1987

1935

1878

1811

/729

1839

/807

1772

1735

1702

1667

1629

/590

2
/

1393
/300

43
46

/356
/263

44
4(

1313
1214

45
49

I280
/I69

48
5I

1226
1/1/

48
53

/I84
10/3

50
55

1130
1026

52
56

/086
9f5

55
6I

2188

2140

2098

2039

1974

/905

1827

/745

2091

2056

2023

1987

1935

/878

1811

/729

1839

1807

1772

1735

1702

/667

1629

/590

2
/

1393
/300

64
NA

1356
/263

NA
NA

/313
/214

NA
NA

1280
1169

NA
NA

1226
1/I7

NA
NA

1184
1073

NA
NA

1/30
1026

NA
NA

/086
975

NA
NA

35 65

.6"

Heating

Rise(_F)

35 65

PGX33608OK
....

.5"

Heatln0

CFM

35 65

.4"

Heating

Rise (°F)

35 65

60000

Heatrng

CFM

35 65

Heating

.3"

Tap

35 65

PGX33606OK
....

PGX33610OK
....

Speed

35 65

NA = Not Allowed for Heating Speed.

CIRCULATING AIR BLOWER SPEEDS
FIGURE 11

Factory-Shipped

Blower Tap Connections

Factory-Shipped
BlowerTap Connections
Coofing

Heatinglnput

Tons

(Btu/hr)

Range(°F)

(Red)

High Stage Coofing
Speed Tap (Black)

PGX32404OK....

40000

35-65

PGX32406OK....
PGX32408OK....

2
2

60000
80000

35-65
35-65

5
5

3
3

PGX330040K....

2.5

40000

35 - 65

PGX33006OK....
PGX33008OK....

2.5
2.5

60000
80000

35 - 65
35 - 65

5
5

4
4

PGX33606OK....
PGX336080K....

3
3

60000
80000

35-65
35-65

2
4

3
3

PGX336100K....
PGX342080K....

3
3.5

100000
80000

35-65
35-65

4
5

3
4

PGX342100K....
PGX348080K....

3.5
4

100000
80000

35-65
35-65

5
4

4
3

PGX34812OK....
PGX34814OK....

4
4

120000
140000

35-65
35-65

4
4

3
3

PGX360080K....

80000

35-65

PGX36012OK....
H_X3bU_4UK....

5
b

120000
]4UUUU

35-65
3b-_b

3
3

4
4

Model

ELECTRICAL

SHOCK

Heating Rise Heating SpeedTap

Low Stage Cooling

SpeedTap(Violet)
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
Z

HAZARD.

Failure to follow this warning could result in personal injury, death and/or property damage.
Turn off electric power supply at disconnect switch or service panel before removing access or service panels from unit.

Verify that the proper blower speeds for heating and cooling
are selected on the blower motor by removing the blower
access panel and inspecting the blower motor. The motor
has up to 5 speeds numbered "1", "2", "3", "4", and "5". The
wires for the speed selection are as follows:
Red

=1_

Black _
Violet _

Heating
High Stage Cooling
Low Stage Cooling

Using the same speed for Heating and Cooling.
If the same speed is required for heating and high stage
cooling the following procedure must be used:
1. Set Red wire on proper speed selection on blower
motor.
2. Remove Black wire from "HI" on Blower Interface
Board. Tape end of Black lead using electrical tape.

3. Adjust thermostat setting to below room temperature.
4. Turn power ON, for approximately one minute, then
OFF. During power application check the following:
a. Contactor - Contacts Closing
b. Compressor - ON
c. Condenser fan motor - ON
d. Circulating Air Blower - ON 0 second delay
5. Turn power OFF, check the following:
a.
b.
c.
d.

Contactor contacts opening.
Compressor - OFF
Condenser fan motor - OFF
Circulating blower - OFFafter
all models.

9. START-UP

90 second delay on

PROCEDURES

3, Jumper the Red wire to both the "Heat" terminal and
"HI" terminal on the Blower Interface Board,
If the same speed is required for heating and low stage
cooling, the following procedure must be used:
1. Set Red wire on proper speed selection on blower
motor.
2. Remove Violet wire from "LO" on Blower Interface
Board. Tape end of Violet lead using electrical tape.
3. Jumper the Red wire to both the "Heat" terminal and the
"LO" terminal on the Blower Interface Board.
CONTINUOUS

FAN OPERATION

Continuous fan speed operates at the low stage cooling
speed for all models.
COOLING
1. Turn electric power OFF
2. Set thermostat Heat-Cool

FIRE OR EXPLOSION

HAZARD

Failure to follow this warning could result in personal
injury, death and/or property damage.
Do NOT attempt to light
flame of anv kind.

the burner with a match or

CHECK BEFORE STARTING
1. Check that the blower motor speed terminal block is
running the correct heating and cooling speeds.
2. Check to see that clean, properly sized air filters are
installed.
3, Replace

all service

access

panels,

select to COOL.

1131

NOTE: Adjustment screw cover MUST be placed on gas
valve before reading manifold pressure and operating
furnace.

FIREOR EXPLOSIONHAZARD.
Failureto follow this warning could resultin personalinjury
and/ordeath.

FIREAND/OREXPLOSIONHAZARD
TurnOFFgasat shutoffbeforeconnectingU-tubemanometer.
Failureto follow this warning couldresultin personalinjury,
deathand/or propertydamage.
FIGURE i2

[

RegulatorAdjustment
UnderCa

Honeywell

Gas Valve

DoNOTadjustmanifold
pressure
morethan+0.3incheswater
columntoobtainratedinput.

HONEYWELL

Pressure
Tap
1/8NPT

©o

Outlet
OUTLET
Inlet
Pressure
Tap 1/8NPT

25-24-98a

3. Set pressure to value shown in FIGURE 14, +_0.07kPa
(0.3 inches) water column. Pressure is also listed on
furnace rating plate. In NO case should final manifold
pressure vary more than _+0.07kPa (0.3 inches) water
column.
Check the unit's operation as outlined in the following
instructions. If any unusual sparking, odors or unusual
noises are encountered,
shut off electric power
immediately. Recheck for wiring errors, or obstructions in or
near blower motors.
1. Set thermostat Heat-Cool selector to OFF.
2. Set thermostat fan switch to AUTO.

GASPRESSURES

3. Turn electric power ON. Nothing should start running.

1. Do NOT allow gas supply pressure to fall below the
listed minimums. Doing so will decrease input to
furnace. Refer to FIGURE 13 for gas supply pressures.
2. Gas input MUST NOT exceed rated input shown on
rating plate.
3. Do NOT allow pressures to exceed the maximum limits
as listed in FIGURE 13.
Gas Pressures

Natural Gas

LP Gas

Minimum
Inlet

4.5"W.C. (1120 Pa)

11" W.C. (2740 Pa)

Recommended
Inlet

7" W.C. (1740 Pa)

11" W.C. (2740 Pa)

Maximum
Inlet

13" W.C. (3230 Pa)

Manifold
Pressure

3.5" W.C. (870 Pa)

10" W.C. (2490 Pa)

Manifold Pressure Adjustment
Manifold pressures are listed in Figure 14. Check manifold
pressure using the following procedure.
1. With gas OFE Connect U-Tube manometer to tapped
opening on gas valve. Use manometer with a 0 to 12
inches water column range.
FIGURE

Gas Type

Manifold Pressure Settings
Manifold Pressure

Natural

3.5 Inches Water Column

(870 Pa)

Propane

10 Inches Water Column (2490 Pa)

2. Turn gas ON and remove adjustment screw cover on
gas valve. Turn counterclockwise to decrease pressure
and clockwise to increase.

1141

4. Turn manual gas valve ON.
5. Turn gas control valve ON.
6. Set thermostat fan switch to ON.
7. Reset thermostat fan switch to AUTO.
HEATING START-UP

PROCEDURE

1. Adjust thermostat setting above room temperature and
set thermostat selector to HEAT. The combustion air
blower should come ON.
2. The combustion air blower will run for 15 seconds to
purge the combustion chamber.
3, After the 15 second purge, the combustion air blower
will remain on. The sparker will turn on to ignite the gas.
Make sure the gas valve is in the "ON" position. (Refer
to Figure 14 and the instructions label located on
Burner Access Panel of unit.
NOTE: On a call for heat the sparker will remain energized
for 7 seconds or until a flame is detected by the flame
sensor. It may take several ignition attempts to purge the air
out of the gas lines at initial start-up of the unit.
4, 30 seconds after the burners
blower will begin to run,

light, the circulating

will normally be obtained when the unit is operating
input with the recommended
blower speed.
FIRE

AND/OR

EXPLOSION

HAZARD

Failure to follow this warning could result in personal
injury, death, and/or property damage.

Do NOT attempt to light the burner with a match or
flame of any kind.
HEATING INPUT RATE CHECK
The gas input to the unit is determined by measuring
the gas flow at the meter. Measuring gas flow at the
meter is recommended for natural gas units.
To
measure the heating input, perform the following
steps:
1.

Turn off all other gas appliances that use the same
meter.

Turn off gas supply to unit and attach manifold
pressure gauge as instructed in the "Manifold
Pressure Adjustment" section.

With gas ON to the unit and the unit operating, record
the number of seconds for the gas meter dial to make
one revolution.

Divide number of seconds in Step 3 into 3600
(number of seconds in 1 hour).

Multiply result of Step 4 by the number of cubic feet
shown for one revolution of the meter dial to obtain the
cubic feet of gas flow per hour.
Multiply result of Step 5 by Btu heating value of gas to
obtain total measured input in Btu/hr. Compare this
with the heating value shown in figure 11. Consult
with local gas supplier ifthe heating value of gas is not
known.

The temperature rise must be within the specifications
marked on the unit rating plate.
To check the temperature rise through the unit, place thermometers in the supply and return air ducts as close to the
unit as possible.
Open ALL registers
and duct dampers.
Operate
LEAST 15 minutes before taking readings.

NOTE: The blower speed MUST be set to give the correct
air temperature rise through the furnace as marked on the
rating plate. See Figure 12 for more information.
2. After 15 minutes of operation check the limit control
function by blocking the
return air grille(s).
After several minutes the main burners and pilot should
go OFE The circulating air blower should continue to
run.
Remove air restrictions. Pilot and main burners should
relight after a cool down period of a few minutes.
Adjust the thermostat setting below room temperature.
Main burners and combustion air blower should go
OFF,
The circulating air blower should continue to run for 60,
100, 140 or 180 seconds. This time is adjustable. See
FIGURE 15 for more information.
4. Set thermostat Heat-Cool selector to OFF.
FAN CONTROL CHECK
Fan Delay DIP Switch

IG#_ _IOR C0_TROL BOARD fIAT

t8¢ _

0FF

Settings

DEI_.Y DEL CT;0N

1_8

. 18¢
18/}

1.38 sec. To complete 1 revolution
2. 3600/38 = 94.7
3.94.7 x 1 = 94.7
4.94.7 x 1020 = 96,632 Btu!hr
For this example, the nameplate input is 100,000 Btu/hr, so
only a minor change in manifold pressure is required. In no
case should the final manifold pressure vary more than
+- .3 "water column from the values in figure 14.
TEMPERATURE

RISE CHECK

NOTE: Air temperature rise is the temperature difference
between supply and return air. With a properly designed
distribution system, the proper amount of temperature rise

unit AT

If the correct amount of temperature rise is not obtained
when operating on the recommended blower speed, it may
be necessary to change the blower speed. A faster blower
speed will decrease the temperature rise. A slower blower
speed will increase the temperature rise.

FIGURE i5

Example: Assume that the size of the meter dial is 1 cu. ft.,
one revolution takes 44 seconds, and the heating value of
the gas is 1020 Btu/ft3. Proceed as follows:

at rated

148__

100

The Fan Control has adjustable settings for the circulating
air blower to delay it "ON" and "OFF".
1. The Fan Control has a fixed "ON" delay of 30 seconds,
and a field adjustable "OFF" delay of 60, 100, 140 and
180 seconds. The "OFF" delay is factory set at 140
seconds.
Refer to FIGURE 15 for proper DIP switch settings.
2. Operate the furnace and ensure that the blower turns
ON and OFF at the appropriate time to provide the
desired comfort level.

1151

10. OPERATION

directly into the heat exchanger tubes and the turbulators
should glow orange (after about five minutes of operation).
Main burner flame should be inspected monthly.
FIGURE i6

ELECTRICAL

Normal

Flame

SHOCK HAZARD.

Failure to follow this warning could result in personal
injury, death and/or property damage.
Turn off electric power supply at disconnect switch or
service panel before removing any access or service
panel from unit.

COMBUSTION/INDOOR

Turbulator will glow
orange when hot.

stable and solid
blue.
Flame should be

FAN CONTROL

All functions of the combustion and indoor blower are
controlled bythe ignition control board and interface board.
On a call for heat:
The ignition control energizes the combustion blower.
Once the combustion air proving switch closes, the ignition
sequence begins. The ignition control will sense when the
main operator of gas valve has been energized thereby
firing the burners and starting the "delay on" timing
sequence of the indoor blower.
NOTE: Ifthe control senses that one of the safety limits has
opened, the combustion and indoor fans will operate until
the limit resets.
On a call for cooling:
The fan control board starts the indoor blower immediately.
Once the thermostat is satisfied, the fan control will operate
the blower for 90 additional seconds.

Using a light and mirror (as required) inspect the inside of
the vent hood and the inlet air opening in the burner
compartment. Look for soot and severe rust or corrosion
and any obstructions due to leaves, spiderwebs, etc. Clean
as required.
COOLING SEASON CHECKS (MONTHLY)
Condenser

11. MAINTENANCE
MONTHLY MAINTENANCE
CHECKS

AND INSPECTION

Keep the condenser inlet and outlet area clean and free of
leaves, grass clippings or other debris. Grass should be
kept short in front of the condenser inlet. Shrubbery MUST
be trimmed back so it is no closer than 30 inches to unit,
Condensate

Air Filters

Drain

Check for condensate drainage.
ANNUAL

REDUCED EQUIPMENT

Coil

MAINTENANCE

Clean as required.

AND INSPECTION

LIFE HAZARD

Failure to follow this cautions may result in damage to
the unit being installed.

ELECTRICAL

Do not operate the unit without

Failure to follow this warning could result in personal
injury, and/or death.

a filter,

Inspect filters at least monthly and replace or clean as
required. Washable filters may be cleaned by soaking in
mild detergent and rinsing with cold water. Replace filters
with the arrows on the side pointing in the direction of air
flow. Dirty filters are the most common cause of inadequate
heating or cooling performance,
and of compressor
failures.
HEATING SEASON CHECKS

(MONTHLY)

Main Burner Flame
Flames should be stable and solid blue, (dust may cause
orange tips or they may have wisps of yellow, but they
MUST not have solid yellow tips). They should extend

b2J

SHOCK HAZARD.

Turn off electric power supply at disconnect switch or
service panel before removing any access or service
panel from unit.

The annual inspection should include cleaning as required
to ensure efficient operation of the unit. To simplify access,
remove all access panels and the top from the unit if
possible.
Condenser

Fan Motor

Note: The condenser fan motor is permanently lubricated.
No further lubrication is required.
Do not attempt to
lubricate the condenser fan motor,

VENT ASSEMBLY

1. Disconnect electrical power to unit.
2. Turn OFF gas at manual shut off valve.
3. Remove burner access panel.

BURN HAZARD.

4. Remove the vent assembly flue pipe.

Failure to follow this caution
injury or property damage.

may result in personal

Flue cover may be hot! Allow adequate time for flue
cover to cool.

5. Disconnect gas pipe at union.
6. Disconnect wires from gas valve, note connections.
7. Remove screws that secure the flame shield and
remove gas control valve, manifold and burners as an
assembly.

Clean the surrounding area and the condenser and
evaporator coils. Use caution to avoid damage to coil fins.

8. Remove collector box, injector plate, and restrictor
plate, including gaskets.

BLOWER MOTOR ACCESS
motor and

9. Hold the burner assembly vertically and lightly tap it
against a wood block. Clean also with a stiff brush.
Severe cases of lint clogging may require washing the
burners in hot water.

2. Remove the three screws securing the blower motor
housing. If unit has a support bracket, remove the two
screws securing the bracket.
3. Remove the two red wires attached to the limit switch.

10. Clean flue gas passages by using small brushes and a
vacuum cleaner. It may be necessary to fabricate
handle extensions for the brushes to reach the areas
that require cleaning. Reinspect after cleaning and
replace the heat exchanger if defective.

Refer to Figure 17 for a view of blower
compartment.
1. Remove the blower access panel

Motor removal and replacement
This method is required to replace or repair blower wheel,
blower housing, or any unreachable components behind
blower assembly.
1. Remove all screws around rim of unit top, (except
screws which are inaccessible because of proximity to
structure).
2. Raise unit top at corner of unit closest to blower at least
2" and place a sturdy brace at least 2" thick between top
and unit corner. A 2X4 piece of wood is ideal for this.
3. Disconnect all wires from housing and slide housing out
of unit. Reverse this process to reinstall.
Circulating

11. Reinstall parts and gaskets in reverse order. On direct
spark models check the spark gap. 1/8 inch is required
between the sparker electrodes.
12. Turn gas on and check for leaks.
13. Install all access panels, turn power on and check for
normal operation.
REFRIGERANT CIRCUIT
For Qualified Service Technician Only
Annually inspect all refrigerant tubing connections and the
unit base for oil accumulations.
Detecting oil generally
indicates a refrigerant leak.

Air Blower

Visually inspect the blower wheel for accumulations of dirt
or lint. Clean the compartment and the blower wheel. If
accumulation is excessive on blower wheel, or does not
easily remove, it will be necessary to remove the blower
assembly.
Note: The blower motor is permanently lubricated.
No
further lubrication is required. Do not attempt to lubricate
the blower motor.
Burners / Heat Exchangers

/ Flue Gas Passages

To inspect the burners, heat exchanger and interior flue gas
passages, use a light and small mirror on an extension
handle.
Check the exterior of the heat exchanger and the interior
flue gas passages for any evidence of deterioration due to
corrosion, cracking or other causes. If signs of scaling or
sooting exist, remove the burners and clean the heat
exchanger, as required.
INSPECTION AND CLEANING OF BURNER
ASSEMBLY/HEAT EXCHANGERS/FLUE GAS
PASSAGES
For Qualified Service Technician

Only

See FIGURE 17 for identification of parts.

FIRE AND EXPLOSION

HAZARD.

Failure to follow this warning could result in personal
injury, death and/or property damage.
System under pressure. Relieve pressure and recover
all refrigerant before system repair or final unit
disposal to avoid serious injury or death. Use all
service ports and open all flow control devices,
including solenoid valves.

If oil is detected or if low cooling performance is suspected,
leak-test all refrigerant tubing using an electronic leak
detector, halide torch, or liquid-soap solution.

FIGURE 17

Component

Locations

I Remote

Sparker

Unit I

0
Y

I GasValve
I

I Flame
I Rollout

/
_,1

/
J

©©

/
i
f

i
i

[ Selector
'FM and Leads
Speed

Switch
Primary Limit I

Switch

Sensor I
I

RIGGING INSTRUCTIONS

10962_,,_-A

FAILURE TO FOLLOW THESE INSTRUCTIONS
CAN RESULT IN PROPERTY DAMAGE,
BODILY INJURY OR DEATH.

/K WARNING
- ALL PANELS

MUST BE IN PLACE WHEN

RIGGING

AND LIFTING.

- HOOK RIGGING SHACKLES THROUGH
HOLES IN BASE RAIL, AS SHOWN IN DETAIL-A.
- USE SPREADER BARS, WHEN RIGGING,
TO PREVENT UNIT DAMAGE.
- BE SURE RIGGING AND SHACKLES ARE SUFFICIENT TO HANDLE WEIGHT LISTED BELOW.

DETAIL-A

fo
m,

BARS

o
:3

____

H'_EIGHT

-OR-

r.. ilillimiili .
LENGTH _,_

WIDTH
MAX, HEIGHT

MAX. WEIGHT

IN
,,, ,,,,,,

MAX. WIDTH'

MAX. LENGTH

CABINET

.,_,,,

SMALL

52.00

1219

48.00

1219

38.00

965

50O

LARGE

73.00.

1854

48.00

1219

38.00

965

900

409

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ICP Package Units(both Units Combined) Manual L0604329

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