Allied Air Enterprises 506271-01 User Manual

INSTALLATION INSTRUCTIONS
RPGE/RGE Series
Gas Heating/Electric Cooling Package Unit
Save these instructions for future reference
WARNING
Improper installation, adjustment, alteration, service, or maintenance can cause injury or property damage. Refer to this manual. For assistance or additional information, consult a qualified installer , service agency , or the gas supplier.
W ARNING
Do not store combustible materials, including gasoline and other flammable vapors and liquids, near the furnace, vent pipe, or warm air ducts. Such actions could cause property damage, personal injury , or death.
W ARNING
Never use a flame to check for gas leaks. Explosion causing injury or death may occur.
W ARNING
If this unit is to be installed in a mobile or manufactured home application, the ductwork must be sized to achieve static pressures within the manufacturer’s guidelines. All other installation guidelines must also be followed. Failure to do so may result in equipment damage, personal injury , and improper performance of the unit.
T ABLE OF CONTENTS
INSTALLATION ...................................... 2
START-UP.............................................. 8
OPERATION ........................................ 10
Cooling System............................... 1 0
Heating System............................... 10
MAINTENANCE ....................................11
CONTROL SYSTEM DIAGNOSTICS .. 12
WIRING DIAGRAM.............................. 13
Manufactured By
Allied Air Enterprises, Inc.
A Lennox International Company
215 Metropolitan Drive
West Columbia, SC 29170
*506271-01*
CAUTION
The installation of the furnace, wiring, warm air ducts, venting, etc. must conform to the requirements of the National Fire Protection Association; the National Fuel Gas Code, ANSI Z223.1 (latest edition) and the National Electrical Code, ANSI/ NFP A No. 70 (latest edition) in the United States; the Canadian Installation Codes CAN/CGA-B149.1 & .2 (latest edition) and the Canadian Electrical Code Part 1, CSA 22.1 (latest edition) in Canada; and any state or provincial laws, local ordinances, or local gas utility requirements. Local authorities having jurisdiction should be consulted before installation is made. Such applicable regulations or requirements take precedence over the general instructions in this manual.
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INSTALLATION
These instructions must be hung on or near the furnace in a
conspicuous place. These furnace units are single package air conditioners with
gas heat designed for outdoor installation on a rooftop or a slab.
The units are completely assembled. All piping, refrigerant charge, and electrical wiring are factory installed and tested. The units require only electric power, gas piping, condensate drain, and duct connections, plus instruction of the vent cover at the point of installation.
If components are to be added to a unit to meet local codes, they are to be installed at the dealer’s and/or customer’s expense.
The size of unit for the proposed installation should be based on heat loss/heat gain calculation made according to the methods of Air Conditioning Contractors of America (ACCA). See Table 1 for application limitations.
Inspection
As soon as the unit is received, it should be inspected for possible damage during transit. If damage is evident, the extent of the damage should be noted on the carrier’s freight bill. A sep arate request for inspection by the carrier’s agent should be made in writing.
Location
Use the following guidelines to select a suitable location for these units.
1. Unit is designed for outdoor installation only. Unit must be installed so all electrical components are protected from water.
2. Condenser coils must have an unlimited supply of air.
3. For ground level installation, use a level prefabricated pad or use a level concrete slab. Do not tie the slab to the building foundation.
4. Maintain level within a tolerance of 1/4" maximum across the entire length or width of the unit.
WARNING
In the State of Massachusett s:
This product must be installed by a licensed Plumber or Gas Fitter. When flexible connectors are used, the maximum length shall not exceed 36". When lever-type gas shutoffs are used, they shall be T -handle type.
These installation instructions are intended as a general guide only, for use by an experienced, qualified contractor.
These units are certified by E.T.L. T esting Laboratories, Inc.:
For use as a forced air furnace with cooling unit.
For outdoor installation only .
For installation on combustible material.
For use with natural gas or propane gas. (Conversion kit required for propane gas application.)
5. Do not locate the unit where the combustion air supply will be exposed to any of the following substances:
Permanent wave solutions
Chlorinated waxes and cleaners
Chlorine-based swimming pool chemicals
Water softening chemicals
Deicing salts or chemicals
Carbon tetrachloride
Halogen-type refrigerants
Cleaning solvents (such as perchloroethylene)
Printing inks, paint removers, varnishes, etc.
Cements and glues
Antistatic fabric softeners for clothes dryers
Masonry acid washing materials
These units are not suitable for use with conventional venting systems.
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Chlorinated laundry products
Hydrochloric acid
CAUTION
Before lifting a unit, make sure that the weight is distributed equally on the cables so that it will lift evenly .
Clearances
All units require certain clearances for proper operation and service. Refer to Table 2 for the minimum clearances to combustibles required for construction, servicing, and proper unit operation.
Exercise care when moving the unit. Do not remove any packaging until the unit is near the place of installation. An accessory lift kit can be purchased to aid in rigging. Spreaders whose length exceed the largest dimension across the unit
must be used across the top of the unit.
Units may also be moved or lifted with a forklift while still in the factory supplied packaging. The lengths of the forks
of the forklift must be a minimum of 42".
Roof Curb Installation
If a roof curb is used, follow the manufacturer’s Installation Instructions and be sure that all required clearances are observed (see Clearances section on this page).
This unit is shipped with four corner brackets in place on the underside of the unit (see Figure 1). All four brackets must
be removed before unit is installed onto roof curb assembly.
To avoid interference with roof curb remove the outer most screw attaching the outdoor coil filler panel to the unit base, and calk the open hole.
Clearance to combustibles below the unit flue is 10" since the flue points down.
Do not permit overhanging structures or shrubs to obstruct condenser air discharge outlet, combustion air inlet, or vent outlet.
Minimum Clearances to Combustibles
Front of Unit
Back of Unit
Left Side
Right Side (from Vent Cover)
Below Unit *
* Minimum clearance to combustible material below the flue
is 10" to allow proper dissipation of flue gasses and temperatures.
24”
2”
12”
15”
0”
T able 1
Corner Brackets
Bracket
Return
Coil Close Off
Bracket
Remove all four (4) corner brackets before installing on roof curb.
Bracket
Supply
Bracket
Figure 1
In the U.S., units may be installed on combustible floors made from wood or class A, B, or C roof covering material. In Canada, units may be installed on combustible floors. Units must be installed outdoors.
Service Access
Access to all serviceable components is provided by four removable panels: blower compartment, evoporator coil/filter compartment, burner compartment, and main control box.
Combustion Discharge
The vent outlet must be installed in a location as to prevent building degradation and must be consistent with the National Fuel Gas Code, Z223.1 or CAN/CGA-B149.1 & .2.
The products of combustion are discharged through a screened opening on the gas heat side panel. The horizontal vent system shall terminate at least 4' below, 4' horizontally from, or 1' above any door, window , or gravity air inlet into the building. The vent system shall terminate at least 3' above any forced air inlet located within 10'.
The unit shall be installed in a manner such that snow accumulation will not restrict the flow of flue products.
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Minimum horizontal clearance of 4' from electric meters, gas meters, regulator, and relief equipment is required.
In addition to the above requirements, consideration must be given to prevent unwanted ice buildup from the vent condensate. The vent should not be located on the side of a building where the prevailing winter winds could trap the moisture, causing it to freeze on the walls or on overhangs (under eaves). The vent location should not discharge over a sidewalk, patio, or other walkway where the condensate could cause the surface to become slippery .
The products of combustion must not be allowed to accumulate within a confined space and recirculate.
NOTE:
If a gas furnace that’s connected to a common venting system is being removed when this package unit is installed, then read and follow the instructions in the “Removal of Unit from Common Venting System” section that follows. Otherwise, you
may skip this section.
Removal of Unit from Common Venting System
When an existing furnace is removed from a common venting system serving other appliances, the venting system is likely to be too large to properly vent the remaining attached appliances. The following test should be conducted with each appliance while the other appliances connected to the common venting system are not in operation.
Vent Cover
For shipping purposes, the unit is shipped with the vent cover packaged in the unit supply air compartment. Retrieve the vent cover from the supply air compartment.
To attach the vent cover to the unit:
1. Locate the vent screen. It is packed in the plastic bag that contains these Installation Instructions.
2. Remove the two screws that will be used to attach the screen to the unit (see Figure 2).
3. Center the screen over the hole and re-insert the screws removed in Step 2.
4. Remove the 4 screws that will be used to attach the vent cover (see Fig. 3). Install the vent cover using these screws. A properly installed vent cover will not extend above the top of the unit.
Installing the V ent Cover
Screen
1. Seal any unused openings in the common venting system.
2. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion, or other deficiencies which could cause an unsafe condition.
3. Insofar as is practical, close all building doors and windows between the space in which the appliances remaining connected to the common venting system are located and other spaces in the building. T urn on clothes dryers and any appliance not connected to the common venting system. Turn on exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.
4. Following the lighting instructions, place the unit being inspected in operation. Adjust the thermostat so the appliance will operate continuously .
5. T est for spillage at the draft control relief opening af ter 5 minutes of main burner operation. Use the flame of a match or candle.
Screen attachment screws
Vent Cover Attachment Screws (Plus 2 on other side)
Vent Cover
Figure 2
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6. Follow the preceding steps for each appliance connected to the common venting system.
7. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers, and any other fuel burning appliance to their previous condition of use.
8. If improper venting is observed during any of the above tests, the common venting system must be corrected.
See
National Fuel Gas Code, ANSI Z223.1 (latest edition) or CAN/CGA B149.1 & .2 Canadian Installation Codes to correct improper operation of common venting system.
Ductwork
Ductwork should be designed and sized according to the methods in Manual Q of the Air Conditioning Contractors of America (ACCA).
A closed return duct system shall be used. This shall not preclude use of economizers or outdoor fresh air intake. It is recommended that supply and return duct connections at the unit be made with flexible joints.
The supply and return air duct systems should be designed for the CFM and static requirements of the job. They should
not be sized by matching the dimensions of the duct connections on the unit. Filters
Filters are not supplied with the unit. Filters must always be installed ahead of the evaporator coil and must be kept clean or replaced. Dirty filters will reduce the airflow of the unit. Filters should be sized in accordance with Table 3.
Minimum Required Surface Area
for Disposable Filters
This unit is equipped with an internal filter clip which is located in the indoor coil compartment attached to the side of the unit drain pan.
CAUTION
When fastening ductwork to the side duct flanges on unit, insert screws through duct flanges only. Do not insert screws through the casing. Outdoor ductwork must be insulated and waterproofed.
Condensate Drain
This package unit is equipped with a 3/4" FPT coupling for condensate line connection. Plumbing must conform to local codes. Use a sealing compound on male pipe threads.
The condensate drain line must be properly trapped and routed to a suitable drain. See Figure 3 for proper drain
arrangement. The drain line must pitch to an open drain or pump to prevent clogging of the line. Seal around the drain connection with suitable material to prevent air leakage into the return air system.
T able 2
Gas Piping
Proper sizing of a gas piping depends on the cubic feet per hour of gas flow required, specific gravity of the gas, and length of run. National Fuel Gas Code Z223.1 latest edition should be followed in all cases unless superseded by local codes or gas company requirements. In Canada, refer to CAN/CGA B.149.1 & .2 (latest edition).
The heating value of the gas may differ with locality. The value should be checked with the local gas utility. For temperature rise of unit, see unit rating plate.
T ypical Condensate Drain Connection
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Figure 3
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