ICP Package Units(both Units Combined) Manual L0611150

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
PGF3 Series
3 Phase ( 208/230 Volt)
PACKAGED

GAS / ELECTRIC

UNITS

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

ELECTRICALWIRING ...................................

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

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

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

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

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

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

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

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

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

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

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

5
HEATINGSTART-UPPROCEDURES ......................

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

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

SEQUENCEOF OPERATION- COOLING ...................

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

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

COMBUSTIONBLOWERPIPEINSTALLATION ....................

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

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

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

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

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

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

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

19 - 22

CLIS_IEDUS

international
Comfort Products,LLC

Lewisburg,
TN.37091
Printed in U.S.A.
Key: PGF3

509 01 2501 00

8-1 0-06

P [IJ _11iI w]I_V_l
= __"'][o] __

3 TO 5 TON

I
'C"

[

BASE PAN - CHASSIS
ALL DIMENSIONSIN INCHES
L_-k

Connections

___

/
/

Detail

-1/4"
AS
CONNECTION

/
/
/
/
/
/
/
/
/

1/2" PIPE
LOW

-b_
4_

1-3/4, VOLTAGE

4-1/2" -_

1/2" CONDUI[
N

/
/
/
/

ELECTRICAL
POWER

46-1 8**

CONDUIT

/
/
/

i
--" 12-1/4

.,,/
/
/
/
/
/
/
/
/

SUPPLY

-1/4

Condensate

Drain

1-3/4

,, /

19
I

/
/

--r----

M
\

2-3/16

3-3/4
UNITSIZE

3 TO 3-1/2 Ton

37-1/2

47-1/2

3-1/2

6-1/2

4-1/2

21-1/2

42-3/4

1-9/16

46-1/2

4TO5Ton*

37-1/2

47-1/2

7-1/2

6-1/2

4-1/2

21-1/2

46-1/4

5-3/16

49-3/4

** Measuredfrominsideto insideon base rails.

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 can 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. Electrical shock or
explosion could cause serious injury or death.

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.

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.

[o] lJiiKe] #I
UNIT SAFETY
Failure to followthis caution may reduce unit tel!ability.
It is recommenaed that a quatifiea service tecnnician
check the heat exchanger integrity every two (2) years,
after the first four (4) years of operation.
INTRODUCTION
The PGF3 unit is a fully self-contained,
combination
Category I gas heating/electric cooling unit designed for
outdoor installation (See page 2 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.

131

3. LOCATING

THE UNIT

ACCESS PANELS
See FIGURE 1 for a general view of unit and location of
access panels.

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 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.

UNIT DAMAGE HAZARD

to Combustible

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.
- Install in well-drained
above grade level.

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

BurnerCompartment
Panel

- Position platform separate from building foundation.

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

Minimum

InternalFilter
AccessPanel

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"

area, with top surface of platform

- 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.
Rooftop Installation
Rooftop platform requirements:
- The unit MUST be situated to provide safe access for
servicing.
- 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:AllaccesspanelsMUSTbesecuredinplacebefore
hoisting.
Theunitshouldbehoistedwithtwoliftingslings.Attachthe
slingsto riggingshacklesthathavebeenhookedthrough
holesinthebaserail.
TwospreaderbarsMUSTbeplacedontopof the unitto
protecttheunitfromdamagefromthepressureexerted 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 19 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.
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: BIockoff 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.
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.
Combustion

Blower Pipe Installation

Remove the combustion blower pipe from the right corner of
the burner compartment and position the end of the pipe
with the screw hole over the opening of the combustion
blower. The other end of the pipe should now be aligned
through the opening in the side panel of the unit. The pipe
should slightly protrude through the opening in the side
panel. See Figure 2.
Remove (1) chisel pointed #10 screw (self-drilling) taped to
the vent cap. Position the screw to the hole in the pipe and
drill through the combustion blower outlet securing the pipe
to the combustion blower.
FIGURE 2

Combustion

FIGURE

Heating Vent Assembly

Attact_

Heating
Vent

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

Condensate

Drain

The condensate drain outlet is a 3/4" (19.1 mm) female PVC
connection located at the bottom on the left hand side (see
FIGURE 4).
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.

I F,GURE Cond°nsot°
O,ain
,n,ormotion*
3/4" (19.1mm)
Female PVC

Fitting

Pipe Installation

Combustion
Pipe
MUST be installed.

4. PRE-EXISTING

Heating Vent Assembly
Refer to FIGURE 3 and assemble as shown.

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

151

existing vent system may be oversized for the remaining
appliances.

FIGURE 6

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

5. GAS SUPPLY AND PIPING
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 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 is equipped 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.
GAS PIPING
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.
FIGURE

Pipe Length
(Includes
Fittings)

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

Capacity

3/4"

11/4"

20'

190

350

730

1,100

2,100

40'

130

245

500

760

1,450

60'

105

195

400

610

1,150

LP GAS
Pipe Length
(Includes
Fittings)

3/4"

11/4"

11/2"

103

214

322

615

12.2m

147

223

425

18.3m

117

179

337

LP GAS
Pipe Length
(Includes

kW**

Fittings)

1/2"

3/4"

11/4"

11/2"

6.1m

115

215

438

674

12.2m

148

305

457

18.3m

120

244

374

**kW (Kilowatts) is the metric equivalent of Btu/hr.

PIPING AT UNIT
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 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.

(in thousands)
11/2"

kW**

Pipe Length
(Includes
Fittings)
6.1m

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,

Btu/hr (in thousands)
1/2"

3/4"

11/4 "

11/2"

20'

189

393

732

1,496

2,299

40'

129

267

504

1,039

1,559

60'

103

217

409

834

1,275

UNIT OPERATION AND COMPONENT

DAMAGE HAZARD

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 wiring and may misalign the burners.

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,

7,Providea t/8inch(3mm)NationalPipeThread(NPT)
plugfortestgaugeconnection
immediately
upstream
of
the gas supplyconnectionto the furnaceif noneis
suppliedwiththegasvalveofunit.
8. Installa manualshutoffvalveand tightenall joints
securely,
LEAKCHECK/PRESSURE
TESTING OF GAS SUPPLY
PIPING

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
Orifice

FIRE OR EXPLOSION

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,

HAZARD

Failureto follow the safetywarningsexactlycouldresultin serious
injury,deathor propertydamage.

NOTE: An LP Conversion Kit MUST be used for conversion
to LP gas.

Never testfor gas leaks with an open flame. Use a commercially
availablesoapsolutionmadespecificallyfor the detectionof leaks
to check all connections. A fire or explosionmay result causing
propertydamage,personalinjuryor loss of life.
The unit and its equipment
shutoff
valve
must be
disconnected
from the gas supply piping system during any
TABLE 1 & 2: Equivalent
Orifice Sizes at High Altitudes
Table 1

Sizes

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.

NATURAL GAS ORIFICE SIZING
MEAN ELEVATION FEET ABOVE SEA LEVEL
0 to 2000

Orifice

2001 to
4000

4001 to
5000

5001 to
6000

6001 to
7000

7001 to
8000

8001 to
9000

9001 to
10000

Kit

Orifice

Number

Drill #

Dril! #

Dri!l #

Drill #

Dril! #

Nominal Heating Size

Drill #

060, 080

1173863

100

1173865

120, 140

1173865

NOTE: The orifice sizes in the chart above derate the input rate at 4% per 1000 feet above sea level for altitudes exceeding 2000 feet
above sea level. If converting from LP gas to Natural Gas at altitudes exceeding 2000 feet above sea level, use part number
330732-401, plus the required orifice size # shown in Table 1. Natural Gas data is based on 0.60 specific gravity, a heating value of 1030
Btu/Cu.Ft., 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, Natural Gas and Propane Installation Code CSA B149.1-05.
Table2

LPGASORIFICESIZING
MEANELEVATIONFEETABOVESEA LEVEL
0 to2000
Kit
Number

2001 to4000
Orifice
Drill #

Kit
Number

4001to 7000
Orifice
Drill #

Kit
Number

70011o9000
Orifice
Drill #

Kit
Number

9001to 10,000

Nominal Heating
Size

Orifice
Drill #

Kit
Number

060, 080

1173857

1173859

1173861

100,120,140

1173855

1173857

1173859

NOTE: The orifice sizes in the chart above derate the input rate at 4% per 1000 feet above sea level for altitudes exceeding 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 Gas and Propane Installation Code CSA B149.1-05.

171

7, Remove the orifices from the manifold with
end or socket wrench.

Changing Orifices

a 7/t6"

box

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

SHOCK,

FIRE AND/OR

EXPLOSION
FIGURE 8

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

Manifold/Orifice

Measurement

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

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

9. Install the correct orifices. Gauge the size of the orifices
with a new twist drill bit of the correct size.
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
have a calipers, you can use an adjustable wrench and
measure between the face of the jaws,
10. Reassemble in reverse order,
6. ELECTRICAL

WIRING

CARBON MONOXIDE HAZARD.

ELECTRICAL

Failure to follow this warning could result in personal injury, death and/or property damage.
NOx baffles for use with Natural Gas units ONLY. If
LP Gas is required, NOx inserts must be removed.

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

Removing

NOx Baffles

25-22-46a

181

SHOCK HAZARD.

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.
Failure to adhere to this
warning could result in serious injury or death.

REDUCED

EQUIPMENT

could

result

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 i8 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.

For access, remove the burner access panel. See
FIGURE 1 for access panel location. Wiring MUST be
protected from possible mechanical damage.
Disconnect Switch
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.
Ground Connections
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
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 L3) and ground leads
into the control box.
2. Connect ground lead to chassis ground connection.
3. Connect L1 to pressure
compressor contactor.

lug connection

4. Connect L2 to pressure lug connection
compressor contactor.

11 of the
13 of the

5. Connect L3 to the bare Blue wire from the compressor
power plug, using a wire nut and insulate it with electric
tape.

Replace the electrical access panel.

Accessory Economizer

Wiring

This unit has factory-routed wiring required for using an
accessory economizer.
(Refer to product specification
sheets for an accessory economizer that is compatible with
this unit.)
The factory-routed

economizer wiring consists of:

There are 8 wires in the low voltage connection area. These
wires must be stripped and connected to thermostat and/or
unit pigtail connections per the economizer accessory
installation instructions.
There are two gray wires with 1/4" quick connects wire-tied
to the indoor blower motor harness above the blower
housing. These two gray wires must be connected to the
mixed-air sensor shipped with the accessory economizer.
The mixed air sensor must be mounted per the economizer
accessory installation instructions.
There is a 12 pin plug connection above the return opening.
The economizer accessory comes with two wire harnesses
connected with a 12 pin plug. Unplug these two harnesses
and connect the one to the 12 pin plug connection found
above the return opening. Discard the unused harness.
Refer to the economizer accessory installation instructions
for proper installation.
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.
For 3 to 3-1/2 Ton Models Only:
A single stage thermostat is required for proper operation.
Thermostat must have the following terminals: "R", "W",
"Y", and "G'. Some electronic thermostats 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 9 for proper
connections:
FIGURE 9

3 to 3-1/2 Ton Thermostat

Turn electric power OFE
Remove the electrical access panel.
Locate the 24V control transformer.

Connections

@ ,,,1_ Red
,,,_

hite
Yellow

@ ,,,1_ Green
Typical
Mechanical
Thermostat
Subbase

230V Units to 208V

To convert 230V units to 208V:
1.
2.
3.

Remove wires from the terminal labeled "240V" on the
24V control transformer and reconnect them to the
208V terminal of the 24V control transformer.

LIFE HAZARD

Failure to follow these precautions
damage to the unit being installed.

Converting

-I D.- Red
White

.,,1_ Yellow

@ .,,1_ Green
@ -I D.- Brown
Typical
Electronic
Thermostat
Subbase

For 4 to 5 Ton Models Only:
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

191

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 10

4 to 5 Ton Thermostat

Connections

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

,,1_ Red
White

White
,,1_
@,,1_

Yellow
ed
Pink

Y_ _

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.

Yellow
Pink

Green

Typical
Mechanical
Thermostat
Subbase

THERMOSTAT

Ductwork Connections

Typical
Electronic
Thermostat
Subbase

HEAT ANTICIPATOR

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.
Final Electrical Check
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.

The use of flexible, non-combustible connectors between
main trunk ducts and supply and return air plenums is
permitted. If flexible connectors are used, they should be
protected from potential mechanical damage such as
punctures and tears.
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 FIGURE 11 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.

NOTE: Wiring MUST be installed so it is protected from
possible mechanical damage.
REDUCED EQUIPMENT

LIFE HAZARD

7. DUCTWORK
Failure to follow this caution may result in improper
unit operation.

Ductwork 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.

Do not operate the unit without a filter.

Ductwork sizing affects the discharge temperature, airflow
velocity, and efficiency of the system. Be sure to properly
FIGURE il

Filter Sizes
Disposable Filters
Nominal Size
Minimum

Model

Washable
Area

Nominal

Size

Filters'
Minimum

Area

(qty x w x d)

(sq. inches)

(qty x w x d)

(sq. inches)

PGF336060

2 x 15" x 20"

576

1 x 15" x 20"

288

PGF336080

2 x 15" x 20"

576

1 x 15" x 20"

288

PGF336100

2x18"x20"

720

1 x 18" x 20"

360

PGF342080

2x18"x20"

672

1 x 18" x 20"

336

PGF342100

2x18"x20"

720

1 x 18" x 20"

360

PGF348080

2 x20"

x20"

768

1 x 20" x 20"

384

PGF348120

2 x20"

x20"

785

1 x 20" x 20"

392.5

PGF354100

2 x20"

x24"

960

1 x 20" x 24"

48O

PGF354140

2 x24"

x24"

1008

1 x 24" x 24"

1 Washable

filter size based

filter manufacturer's

on an allowable

specifications

face velocity

for allowable

of 600 ft/min.

face velocity

and required

5O4
Refer to
filter area.

8. AIRFLOW

ELECTRICAL

ADJUSTMENT

SHOCK HAZARD.

Failure to follow

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

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

External Static Pressure (in H20 )
.1"

Heatin
input

Model

Tons

(Btu/hr)

Range(°F

PGF336060

50000

30-60

PGF336100

PGF342080

PGF342100

PGF348080

PGF348120

PGF350100

PGF350140

80000

100000

80000

100000

80000

120000

100000

140000

.3"

.4"

.5"

Rise

35-55

Speed

Heating

Tap

CFM

Rise(°F)

CFM

Rise (°F)

CFM

Rise(°F)

.8"

t552

1607

1574

t529

1484

1440

t278

1233

t162

1118

t552

t529

Heating

Rise(°F)

CFM

Rise (°F)

CFM

Rise(°F)

CFM

Rise (°F)

CFM

Rise (°F)

1541

t500

t462

1426

t384

1402

t364

1325

1284

1238

1191

1149

t108

1060

1005

943

1062

1014

958

892

826

780

1607

1574

1541

t500

1462

1426

1384

1484

1440

1402

t364

1325

1284

1238

t278

1233

1191

1149

t108

1060

1005

943

t162

1118

1062

1014

958

892

826

780

t552

1607

1574

154t

t500

1462

1426

1384

t529

1484

1440

1402

t364

1325

1284

1238

t278

1233

1191

1149

t108

1060

1005

943

35-55

35-65

t162

1118

1062

1014

958

892

826

780

t543

1609

1577

1541

t509

1475

1439

t402

t505

1467

1431

1398

t363

1324

1283

t234

t240

1189

1145

1104

t053

t010

952

891

1138

1087

1041

989

940

865

806

752

t543

1609

1577

1541

t509

1475

1439

t402

t505

1467

1431

1398

t363

1324

1283

t234

t240

1189

1145

1104

t063

1010

952

891

35-65

35-55

40-70

t138

1087

1041

989

940

855

806

752

t908

1864

1819

1770

t720

t578

1632

t586

t750

1696

1543

1592

t547

1497

1443

1400

t245

1170

1110

1034

972

924

875

835

t154

1084

1005

940

880

832

780

713

t908

1864

1819

1770

t720

1578

1632

t586

t750

1696

1543

1592

t547

1497

1443

t400

t245

1170

1110

1034

972

924

875

835

t154

1084

1005

940

880

832

780

713

2173

2113

2067

2032

2003

1962

1904

t822

2109

2052

2000

1952

t899

1847

1798

t750

t449

1372

1318

1258

t195

1130

1086

t048

30-60

35-55

1348

1274

1218

115t

t085

1032

989

954

2173

2113

2067

2032

2003

1962

1904

t822

2109

2052

2000

1952

t899

1847

1798

t750

t449

1372

1318

1256

t195

1130

1086

t048

1348

1274

1218

115t

t085

1032

989

954

CIRCULATING AIR BLOWER SPEEDS
I Factory-Shipped

Blower

Tap Connections

Blower Speed Tap Settings
Model
PGF336060H
PGF336080H
PGF336100H
PGF342080H
PGF342100H
PGF348080H
PGF348100H
PGF354100H
PGF354140H

.7"

CFM

NA = Not Allowed for Heatinq Speed.

FIGURE 12

.6"

Heating

Cooling

PGF336080

.2"

Speed
Speed
Speed
Speed
Speed
Speed
Speed
Speed
Speed

Tap
Tap
Tap
Tap
Tap
Tap
Tap
Tap
Tap

2
2
2
3
3
3
3
3
3

(Hi);
(Hi);
(Hi);
(Hi);

2
2
2
2

(Lo)
(Lo)
(Lo)
(Lo)

Speed
Speed
Speed
Speed
Speed
Speed
Speed
Speed
Speed

Tap
Tap
Tap
Tap
Tap
Tap
Tap
Tap
Tap

3
3
3
4
4
4
4
4
4

(Hi);
(Hi);
(Hi);
(Hi);

3
3
3
3

(Lo)
(Lo)
(Lo)
(Lo)

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 4 speeds numbered "1", "2", "3", and "4". The wires for
the speed selection are as follows:
Red

9. START-UP

PROCEDURES

FIRE OR EXPLOSION

HAZARD

Heating

Black _

High Stage Cooling

Violet _

Low Stage Cooling (4 & 5 ton only)

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 "COOL" (3 - 3.5 Ton models)
or "HI" (4 - 5 Ton Models) on Blower Interface Board.
Tape end of Black lead using electrical tape.
3. Jumper the Red wire to both the "Heat" terminal and
either the "COOL" (3 - 3.5 Ton models) or'HI" (4 - 5Ton
Models) terminal on the Blower Interface Board.
If the same speed is required for heating and low stage
cooling (4 & 5 Ton models only), the following procedure
must be used:

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.
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.
Manifold Gas Pressure Adjustment
NOTE: Make adjustment to manifold pressure with burners
operating.

1. Set Red wire on proper speed selection on blower
motor.

FIRE OR EXPLOSION

2. Remove Violet wire from "LO" on Blower Interface
Board. Tape end of Violet lead using electrical tape.

Failure to follow this warning
personal injury and/or death.

3. Jumper the Red wire to both the "Heat" terminal and the
"LO" terminal on the Blower Interface Board.

Turn OFF gas at shut off before connecting U-tube
manometer.

CONTINUOUS

HAZARD.
could

FAN OPERATION
FIGURE i3

Continuous fan speed operates at the cooling speed for 2
thru 3-1/2 ton models and at the low stage cooling speed for
4 and 5 ton models.

Honeywell

Gas Valve

RegulatorAdjustment
UnderCa

Outlet
Pressure

COOLING
1. Turn electric power OFF
2. Set thermostat Heat-Cool

Tap
1/8NPT
J

select to COOL.

HONEYWELL@

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 OFE check the following:
a. Contactor contacts opening.
b. Compressor - OFF
c. Condenser fan motor - OFF
d. Circulating blower - OFF after a 60 second delay for
3 thru 3-1/2 ton models and a 90 second delay for 4
and 5 ton models,

b2J

result

OUTLET
Inlet
Pressure
Tap 1/8NPT

25-24-98a

GAS PRESSURES
1. Do NOT allow gas supply pressure to fall below the
listed minimums. Doing so will decrease input to
furnace. Refer to FIGURE 14 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 14.

HEATING START-UP
FIGURE 14

Natural Gas
Minimum
Inlet
Recommended

4.5"W.C.

7" W.C.

(1120

(1740

1. Adjust thermostat setting above room temperature and
set thermostat selector to HEAT. The combustion air
blower should come ON.

LP Gas
Pa)

Pa)

11" W.C.

(2740

Pa)

11" W.C.

(2740

Pa)

Inlet
Maximum
Inlet

13" W.C. (3230 Pa)

Manifold

3.5" W.C. (870 Pa)

10" W.C. (2490 Pa)

Pressure

Manifold Pressures
Manifold pressures are covered in the startup procedure
section. See Figure 15.
1. With gas OFF, Connect U-Tube manometer to tapped
opening on gas valve. Use manometer with a 0 to 12
inches water column range.
FIGURE i5

PROCEDURE

Gas Pressures

Manifold Pressure

Gas Type

Settings

2. The combustion air blower wil 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.

FIRE AND/OR EXPLOSION

light, the circulating

HAZARD

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

FIRE AND/OR EXPLOSION

HAZARD

Failure to follow this warning
could result in
personal injury, death and/or property damage.
Do NOT adjust manifold pressure more than _+0.3
inches water column to obtain rated input.

3. Set pressure to value shown in FIGURE 15, +_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.
3. Turn electric power ON. Nothing should start running.
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.

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. Consult with local gas supplier
if the heating value of gas is not known.

Example: Assume that the size of the meter dial is 1 cu. ft.,
one revolution takes 38 seconds, and the heating value of
the gas is 1020 Btu/ft3. Proceed as follows:
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

1131

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
will normally be obtained when the unit is operating at rated
input with the recommended blower speed.
1.

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,

10. Sequence

ELECTRICAL

of OPERATION

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.

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.
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 OFF. 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.
3, Adjust the thermostat setting below room temperature.
Main burners and combustion
OFF.

2. Operate the furnace and ensure that the blower turns
ON and OFF at the appropriate time to provide the
desired comfort level.

air blower should go

The circulating air blower should continue to run for 60,
100, 140 or 180 seconds. This time is adjustable. See
FIGURE 16 for more information.
4. Set thermostat Heat-Cool selector to OFF.

Cooling Operation (036 - 042):
With a call for cooling (Y), the indoor fan energizes
immediately whereas the contactor energizes after a 5
minute time delay (incase of an initial start up) starting the
compressor and the outdoor fan motor. When the cooling
demand is met, (Y) de-energizes, shutting the compressor,
indoor fan and the outdoor fan.
Cooling Operation (048 - 054):
These units utilize a 2 stage indoor thermostat. With a first
stage call for cooling (Y1), the indoor fan (low stage)
energizes immediately whereas the contactor energizes
after a 5 minute time delay (incase of an initial start up)
starting the compressor (low stage) and the outdoor fan
motor. If the low stage operation cannot satisfy the cooling
demand, the second stage cooling (Y2) energizes
switching the compressor into high stage cooling through
energizing an internal solenoid valve inside the scroll
compressor and switching the indoor fan into high stage.
When second stage cooling is satisfied, Y2 de-energizes
switching the compressor and the indoor fan into low stage
cooling. When the low stage cooling demand is met, Y1
de-energizes shutting the compressor, indoor fan and the
outdoor fan.

11. OPERATION

FAN CONTROL CHECK
FIGURE i6

] Fan Delay DIP Switch

Settings

ELECTRICAL

180

_,;

186

146_

H_A!

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

_£_F

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 16 for proper DIP switch settings.

bid

SHOCK HAZARD.

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

COMBUSTION / INDOOR FAN CONTROL
All functions of the combustion and indoor blower are
controlled by the 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.

Normal Flame

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 60 additional seconds (2 to 3-1/2 ton models)
or 90 additional seconds (4 to 5 ton models).

Turbulator will glow
orange when hot.

stable and solid
blue.
Flame should be

12. MAINTENANCE

MONTHLY MAINTENANCE
CHECKS

AND INSPECTION

Air Filters

REDUCED EQUIPMENT

LIFE HAZARD

Failure to follow this cautions may result in damage to
the unit being installed.
Do not operate the unit without a filter.

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)

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.

Condenser Coil

HEATING SEASON CHECKS

Check for condensate drainage.

(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
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.

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

ANNUAL

Drain

MAINTENANCE

ELECTRICAL

Clean as required.

AND INSPECTION

SHOCK HAZARD.

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.
Failure to follow this caution
injury or property damage.

may result in personal

5. Disconnect gas pipe at union.

Flue cover may be hot! Allow adequate time for flue
cover to cool.
Clean the surrounding area and the condenser and
evaporator coils. Use caution to avoid damage to coil fins.
BLOWER MOTOR ACCESS
Refer to Figure 18 for a view of blower
compartment.
1. Remove the blower access panel

motor and

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
and remove the limit switch.
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 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

4. Remove the vent assembly flue pipe.

Only

See FIGURE 18 for identification of parts.

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

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.

FiGURE18

Component

Locations

.....
'-- [ Secondary Limit Switch I

................
I Primary Limit Switch I

I Burners

]

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Create Date                     : Fri Apr 20 15:34:41 2007
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ICP Package Units(both Units Combined) Manual L0611150

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