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 ......................................... 2 ELECTRICALWIRING................................... 8

SAFEINSTALLATIONREQUIREMENTS ......................... 3

LOCATINGTHE UNIT ....................................... 4

CLEARANCES ............................................ 4

INSTALLATION............................................ 4

GROUNDLEVELINSTALLATION .............................. 4

HOISTING................................................ 5

DOWNFLOWCONVERSION.................................. 5

HEATINGVENTASSEMBLY .................................. 5

CONDENSATEDRAIN....................................... 5

COMBUSTIONBLOWERPIPEINSTALLATION .................... 5

PRE-EXISTINGCOMMONVENTCHECK ......................... 5

GASSUPPLYAND PIPING ................................... 6

DUCTWORK......................................... 10

FILTERS ............................................ 10

AIRFLOWADJUSTMENT ............................... 11

START-UPPROCEDURES .............................. 12

GAS PRESSURES .................................... 12

HEATINGSTART-UPPROCEDURES ...................... 13

SEQUENCEOF OPERATION- COOLING ................... 14

OPERATION......................................... 14

MAINTENANCE ...................................... 15

INSPECTIONANDCLEANING............................ 15

RIGGING ........................................... 18

ORIFICES............................................ 7 WIRINGDIAGRAMS ................................ 19 - 22

CLIS_IEDUS

internationalComfort Products,LLC

Lewisburg,TN.37091 509 01 2501 00 8-1 0-06

Printed in U.S.A.

Key: PGF3

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ALL DIMENSIONSIN INCHES

Connections Detail

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CONNECTION

1/2" PIPE

LOW

4_ 1-3/4, VOLTAGE

1/2" CONDUI[

ELECTRICAL

POWER

CONDUIT

Condensate Drain

\2-3/16

UNITSIZE A B C

3 TO 3-1/2 Ton 37-1/2 47-1/2 47-1/2

4TO5Ton* 37-1/2 47-1/2 51

** Measuredfrominsideto insideon baserails.

DEF G H I JKL M N

3-1/2 6-1/2 19 12 12 19 4-1/2 21-1/2 42-3/4 1-9/16 46-1/2

7-1/2 6-1/2 19 12 12 19 4-1/2 21-1/2 46-1/4 5-3/16 49-3/4

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 inthe 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, AND

CARBON MONOXIDE POISON HAZARD

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, AND

CARBON MONOXIDE POISON HAZARD

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.

[o] lJiiKe] #IRecogniz_ 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 com-

mercially 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 al-

lowable 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 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 inthe 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

Failure to follow this caution may result in shorten life

of unit components.

Do NOT operate unit in a corrosive atmosphere

containing chlorine, fluorine, or any other corrosive

chemicals.

Minimum Clearances to Combustible Construction

Furnace Plenum ..................................... 2"

Duct Side ........................................... 2"

Condenser Inlet .................................... 30"

Blower Service (Side) ............................... 30"

Control Service Side

(Front Combustion Air Inlet) .............. 30"

Clearance between 3 Ft, Overhang

and Top of Unit ......................... 30"

Combustible Base

(Wood or Class A, B or C

roof covering material) ..................... 0"

InternalFilter BurnerCompartment

AccessPanel Panel

INSTALLATION

NOTICE

Unit will NOT operate properly unless it is installed lev-

el 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.

- Position platform separate from building foundation.

- 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.

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 theunitto

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 Pipe Installation

Heating Vent Assembly

Refer to FIGURE 3 and assemble as shown.

Combustion

Pipe

FIGURE 3 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,

A3/4" (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 _

MUST be installed.

4. PRE-EXISTING 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.

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 equippedto operate onthe 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 usedwith 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 5Gas Pipe Size, Length and Btu/hr Capacity

for Schedule 40 Iron Pipe/English/

NATURAL GAS

Pipe Length Btu/hr (in thousands)

(Includes

Fittings) 3/4" 1" 11/4" 11/2" 2"

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 Btu/hr (in thousands)

(Includes

Fittings) 1/2" 3/4" 1" 11/4 "

20' 189 393 732 1,496

40' 129 267 504 1,039

60' 103 217 409 834

11/2"

2,299

1,559

1,275

Gas Pipe Size, Length and Btu/hr Capacity

FIGURE 6 for Schedule 40 Iron Pipe (English)

Pipe Length

(Includes

Fittings)

6.1m

3/4" 2"

56 615

12.2m 38 425

18.3m 31 337

Pipe Length

(Includes

Fittings) 1/2" 11/2"

6.1m 55 674

12.2m 38 457

18.3m 30 374

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

NATURAL GAS

kW**

1" 11/4" 11/2"

103 214 322

72 147 223

57 117 179

LP GAS

kW**

3/4" 1" 11/4"

115 215 438

78 148 305

64 120 244

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.

Gasconnector 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,

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)

plugfortestgaugeconnectionimmediatelyupstreamof

thegassupplyconnectionto thefurnaceif noneis

suppliedwiththegasvalveofunit.

8. Installa manualshutoffvalveand tightenall joints

securely,

LEAKCHECK/PRESSURETESTING OF GAS SUPPLY

PIPING

FIRE OR EXPLOSION HAZARD

Failureto follow the safetywarningsexactlycouldresultinserious

injury,deathorpropertydamage.

Never testfor gas leakswithan open flame. Use a commercially

availablesoapsolutionmadespecificallyfor thedetectionof leaks

to check all connections. A fire or explosionmay result causing

propertydamage,personalinjuryorlossof 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

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 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/ft3 content has already been adjusted for altitude.

Check Table 1 & 2 for the proper orifice sizes.

Table 1NATURAL GAS ORIFICE SIZING

MEAN ELEVATION FEET ABOVE SEA LEVEL

0 to 2000 2001 to 4001 to 5001 to 6001 to 7001 to 8001 to 9001 to

4000 5000 6000 7000 8000 9000 10000

Orifice Kit Orifice Orifice Orifice Orifice Orifice Orifice Orifice

Nominal Heating Size Drill # Number Drill # Dril! # Dri!l # Drill # Drill # Drill # Dril! #

060, 080 44 1173863 45 46 47 47 48 48 49

100 41 1173865 43 43 48 44 44 45 46

120, 140 42 1173865 43 43 44 44 45 46 47

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

0to2000 2001to4000 4001to 7000 70011o9000 9001to 10,000

Nominal Heating Orifice Kit Orifice Kit Orifice Kit Orifice Kit Orifice Kit

Size Drill # Number Drill # Number Drill # Number Drill # Number Drill # Number

060, 080 55 1173857 55 1173857 56 1173859 56 1173859 57 1173861

100,120,140 54 1173855 55 1173857 55 1173857 56 1173859 56 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

Changing Orifices

ELECTRICAL SHOCK, FIRE AND/OR EXPLOSION

HAZARD

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 orifices requires a qualified service

technician.

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).

7, Remove the orifices from the manifold with a 7/t6" box

end or socket wrench.

8. Check to be sure that the size of each orifice is correct

for the Btu input desired,

FIGURE 8 Manifold/Orifice Measurement

Measure 13/16" from face of orifice

back edge of manifold pipe.

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.

Failure to follow this warning could result in per-

sonal 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.

Removing NOx Baffles

25-22-46a

ELECTRICAL 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. Failure to adhere to this

warning could result in serious injury or death.

181

REDUCED EQUIPMENT LIFE HAZARD

Failure to follow these precautions 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 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 lug connection 11 of the

compressor contactor.

4. Connect L2 to pressure lug connection 13 of the

compressor contactor.

5. Connect L3 to the bare Blue wire from the compressor

power plug, using a wire nut and insulate it with electric

tape.

Converting 230V Units to 208V

To convert 230V units to 208V:

1. Turn electric power OFE

2. Remove the electrical access panel.

3. Locate the 24V control transformer.

4. Remove wires from the terminal labeled "240V" on the

24V control transformer and reconnect them to the

208V terminal of the 24V control transformer.

5. 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 Connections

@ ,,,1_ Red

,,,_ hite

Yellow

@,,,1_ Green

Typical

Mechanical

Thermostat

Subbase

For 4 to 5 Ton Models Only:

(_ -I D.- Red

White

(_ .,,1_ Yellow

@ .,,1_ Green

@-I D.- Brown

Typical

Electronic

Thermostat

Subbase

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

,,1_ ed

White

Yellow

Pink

@,,1_ Green

Typical

Mechanical

Thermostat

Subbase

,,1_ Red

White

Y_ _Yellow

Pink

Typical

Electronic

Thermostat

Subbase

THERMOSTAT 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.

NOTE: Wiring MUST be installed so it is protected from

possible mechanical damage.

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 Connections

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 11and 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.

7. DUCTWORK

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.

REDUCED EQUIPMENT LIFE HAZARD

Failure to follow this caution may result in improper

unit operation.

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

Model

PGF336060

PGF336080

PGF336100

PGF342080

PGF342100

PGF348080

PGF348120

PGF354100

PGF354140

Disposable Filters

Nominal Size

(qty x w x d)

2 x 15" x 20"

2x18"x20"

2 x20" x20"

2 x20" x24"

2 x24" x24"

Minimum Area

(sq. inches)

576

720

672

720

768

785

960

1008

Nominal Size

(qty x w x d)

1 x 15" x 20"

1 x 18" x 20"

1 x 20" x 20"

1 x 20" x 24"

1 x 24" x 24"

Washable Filters'

Minimum Area

(sq. inches)

288

360

336

360

384

392.5

48O

5O4

1 Washable filter size based on an allowable face velocity of 600 ft/min. Refer to

filter manufacturer's specifications for allowable face velocity and required filter area.

8. AIRFLOW ADJUSTMENT

ELECTRICAL 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" .2" .3" .4" .5" .6" .7" .8"

Heatin Heating

Cooling input Rise Speed Heating Heating Heating Heating Heating Heating Heating Heating

Model Tons (Btu/hr) Range(°F Tap CFM Rise(°F) CFM Rise (°F) CFM Rise(°F) CFM Rise(°F) CFM Rise (°F) CFM Rise(°F) CFM Rise (°F) CFM Rise (°F)

4 t552 NA 1607 NA 1574 NA 1541 NA t500 NA t462 30 1426 3t t384 32

3 t529 NA 1484 30 1440 31 1402 32 t364 32 1325 33 1284 34 1238 35

PGF336060 3 50000 30-60 2 t278 35 1233 36 1191 37 1149 38 t108 40 1060 42 1005 44 943 47

1 t162 38 1118 40 1062 42 1014 44 958 46 892 50 826 54 780 57

4 t552 36 1607 37 1574 38 1541 38 t500 39 1462 40 1426 41 1384 43

3 t529 39 1484 40 1440 41 1402 42 t364 43 1325 45 1284 46 1238 48

PGF336080 3 80000 35-55 2 t278 46 1233 48 1191 50 1149 51 t108 53 1060 56 1005 59 943 63

1 t162 51 1118 53 1062 55 1014 58 958 52 892 NA 826 NA 780 NA

4 t552 44 1607 45 1574 45 154t 47 t500 48 1462 50 1426 51 1384 53

3 t529 48 1484 49 1440 50 1402 52 t364 53 1325 55 1284 57 1238 59

PGF336100 3 100000 35-55 2 t278 57 1233 59 1191 61 1149 53 t108 NA 1060 NA 1005 NA 943 NA

1 t162 53 1118 55 1062 NA 1014 NA 958 NA 892 NA 826 NA 780 NA

4 t543 36 1609 37 1577 37 1541 38 t509 39 1475 40 1439 41 t402 42

3 t505 39 1467 40 1431 41 1398 42 t363 43 1324 45 1283 46 t234 48

PGF342080 35 80000 35-65 2 t240 48 1189 50 1145 52 1104 54 t053 56 t010 59 952 52 891 NA

1 1138 52 1087 54 1041 57 989 50 940 53 865 NA 806 NA 752 NA

4 t543 44 1609 45 1577 45 1541 47 t509 48 1475 49 1439 51 t402 52

3 t505 48 1467 50 1431 51 1398 52 t363 53 1324 55 1283 57 t234 59

PGF342100 35 100000 35-65 2 t240 59 1189 51 1145 63 1104 NA t063 NA 1010 NA 952 NA 891 NA

1 t138 54 1087 NA 1041 NA 989 NA 940 NA 855 NA 806 NA 752 NA

4 t908 NA 1864 NA 1819 NA 1770 NA t720 NA t578 35 1632 36 t586 37

3 t750 34 1696 35 1543 35 1592 37 t547 38 1497 40 1443 41 1400 42

PGF348080 4 80000 35-55 2 t245 48 1170 51 1110 53 1034 57 972 51 924 64 875 NA 835 NA

1 t154 51 1084 55 1005 59 940 53 880 NA 832 NA 780 NA 713 NA

4 t908 47 1864 48 1819 49 1770 50 t720 52 1578 53 1632 54 t586 55

3 t750 5t 1696 52 1543 54 1592 56 t547 57 1497 59 1443 52 t400 63

PGF348120 4 120000 40-70 2 t245 NA 1170 NA 1110 NA 1034 NA 972 NA 924 NA 875 NA 835 NA

1 t154 NA 1084 NA 1005 NA 940 NA 880 NA 832 NA 780 NA 713 NA

4 2173 34 2113 35 2067 36 2032 36 2003 37 1962 38 1904 39 t822 41

3 2109 35 2052 36 2000 37 1952 38 t899 39 1847 40 1798 41 t750 42

PGF350100 5 100000 30-60 2 t449 51 1372 54 1318 55 1258 59 t195 NA 1130 NA 1086 NA t048 NA

1 1348 55 1274 58 1218 NA 115t NA t085 NA 1032 NA 989 NA 954 NA

4 2173 48 2113 49 2067 50 2032 5t 2003 52 1962 53 1904 54 t822 57

3 2109 49 2052 51 2000 52 1952 53 t899 55 1847 55 1798 58 t750 59

PGF350140 5 140000 35-55 2 t449 NA 1372 NA 1318 NA 1256 NA t195 NA 1130 NA 1086 NA t048 NA

1 1348 NA 1274 NA 1218 NA 115t NA t085 NA 1032 NA 989 NA 954 NA

NA = Not Allowed for Heatinq Speed.

CIRCULATING AIR BLOWER SPEEDS

FIGURE 12 I Factory-Shipped Blower Tap Connections

Model

PGF336060H

PGF336080H

PGF336100H

PGF342080H

PGF342100H

PGF348080H

PGF348100H

PGF354100H

PGF354140H

Blower Speed Tap Settings

Speed Tap 2 Speed Tap 3

Speed Tap 3 Speed Tap 4

Speed Tap 3 (Hi); 2 (Lo) Speed Tap 4 (Hi); 3 (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 _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:

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 cooling speed for 2

thru 3-1/2 ton models and at the low stage cooling speed for

4 and 5 ton models.

COOLING

1. Turn electric power OFF

2. Set thermostat Heat-Cool select to COOL.

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,

9. START-UP PROCEDURES

FIRE 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.

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.

FIRE OR EXPLOSION HAZARD.

Failure to follow this warning could result in

personal injury and/or death.

Turn OFF gas at shut off before connecting U-tube

manometer.

FIGURE i3

RegulatorAdjustment

UnderCa

Inlet

Pressure

Tap1/8NPT

Honeywell Gas Valve

HONEYWELL@

Outlet

Pressure

Tap

1/8NPT

OUTLET

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.

b2J

FIGURE 14 Gas Pressures

Natural Gas LP Gas

Minimum 4.5"W.C. (1120 Pa) 11" W.C. (2740 Pa)

Inlet

Recommended 7" W.C. (1740 Pa) 11" W.C. (2740 Pa)

Inlet

Maximum 13" W.C. (3230 Pa) 13" W.C. (3230 Pa)

Inlet

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 Manifold Pressure Settings

Gas Type 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.

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 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 light, the circulating

blower will begin to run.

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.

2. Turn off gas supply to unit and attach manifold

pressure gauge as instructed in the "Manifold

Pressure Adjustment" section.

3. With gas ON to the unit and the unit operating, record

the number of seconds for the gas meter dial to make

one revolution.

4. Divide number of seconds in Step 3 into 3600

(number of seconds in 1 hour).

5. 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.

6. 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 ther-

mometers in the supply and return air ducts as close to the

unit as possible.

Open ALL registers and duct dampers. Operate unit AT

LEAST 15 minutes before taking readings,

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 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 16 for more information.

4. Set thermostat Heat-Cool selector to OFF.

FAN CONTROL CHECK

FIGURE i6 ]Fan Delay DIP Switch Settings

180 _,; 186 146_

H_A! _£_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.

2. Operate the furnace and ensure that the blower turns

ON and OFF at the appropriate time to provide the

desired comfort level.

10. Sequence of OPERATION

ELECTRICAL 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.

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

ELECTRICAL 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 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

bid

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 60 additional seconds (2 to 3-1/2 ton models)

or 90 additional seconds (4 to 5 ton models).

12. MAINTENANCE

MONTHLY MAINTENANCE AND INSPECTION

CHECKS

Air Filters

REDUCED EQUIPMENT LIFE HAZARD

Normal Flame

Flame should be

Turbulator will glow stable and solid

orange when hot. blue.

Failure to follow this cautions may result in damage to

the unit being installed.

Do not operate the unit without 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

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.

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 Coil

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 Drain

Check for condensate drainage. Clean as required.

ANNUAL MAINTENANCE AND INSPECTION

ELECTRICAL 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.

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

BURN HAZARD.

Failure to follow this caution may result in personal

injury or property damage.

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 motor and

compartment.

1. Remove the blower access panel

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 Only

See FIGURE 18 for identification of parts.

1. Disconnect electrical power to unit.

2. Turn OFF gas at manual shut off valve.

3. Remove burner access panel.

4. Remove the vent assembly flue pipe.

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.

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 1 Component Locations

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

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

I Burners ]

,.."-I Rollout Switch I

..... Flame Sensor I

<//{

Secondary Limit Switch I

4 & 5 Ton Models I

Secondary Limit Switch l

2 to 3-1/2 Ton Models 1

...... J J ':' 2;

/IlFMandSpeed ISelector Leads

..........I PrimarYswitchLimit I

Gas Valve I

L!ZJ

I; R GG NG INSTRUCTIONS __

fAiLURETOfOLLOW .STRUC-r O S

,/_ WAR\ NO CAN RESULT IN PROPERTY DAMAGE,

ALL PANELS MUST BE IN PLACE WHEN RIGGING AND

HOOK RIGGING SHACKLES THROUGH HOLES IN BASE

USE SPREADER BARS, WHEN RIGGING, TO PREVENT

BE SURE RIGGING AND SHACKLES ARE SUFFICIENT TO

_SPREADER BARS

LENGTH_ WIDTH

CABINET

SMALL

LARGE

MAX.

52.00

75.00

LENGTH MAX.

MM IN

1219 48.00

1854 48.00

WIDTH

1219

LIFTING.

RAIL, AS SHOWN IN DETAIL-A.

UNIT DAMAGE.

HANDLE WEIGHT LISTED BELOW.

DETAIL-A

_OR _

MAX.

58,00

58.00

HEIGHT

965

MAX. WEIGHT

LB KG

500 227

900 409

Ill

3 to 3-1/2 Ton Wiring Diagram

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3 to 3-1/2 Ton Wiring Diagram

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201

4 to 5 Ton Wiring Diagram

!i_ I

................... ;L ..........

iSEEECONOMIZER

_ _ ACCESSORY

_STALLATION

'i:_i:ii° _°

PROPERWN_ ;

: C

....................................................................................

.......................... ...................................................... I;i _ii i

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4 to 5 Ton Wirina Diaaram

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ICP Package Units(both Units Combined) Manual L0611150

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