ICP PDX424040K00A1, PDX424040K01A1, PDX430060K00A1, PDX430060K01A1, PDX436080K00A1 Installation Guide

Installation Instructions

PDX4 Series

PACKAGED DUAL FUEL UNITS

TABLEOFCONTENTS

UNITDIMENSIONS ...................................... 2 - 4

SAFEINSTALLATIONREQUIREMENTS ......................... 5

LOCATINGTHE UNIT ....................................... 6

CLEARANCES ............................................ 6

INSTALLATION............................................ 6

GROUNDLEVELINSTALLATION .............................. 7

HOISTING................................................ 7

DOWNFLOWCONVERSION .................................. 7

HEATINGVENTASSEMBLY.................................. 7

CONDENSATEDRAIN....................................... 8

PRE-EXISTINGCOMMONVENTCHECK......................... 8

GASSUPPLYAND PIPING ................................... 8

ORIFICES............................................... 9

ELECTRICALWIRtNG.................................. 11

DUCTWORK ......................................... 13

FILTERS ............................................ 14

AIRFLOWADJUSTMENT ............................... 15

START-UPPROCEDURES .............................. 16

GAS PRESSURES .................................... 16

GAS HEATINGSTART-UPPROCEDURES .................. 17

OPERATION......................................... 18

MAINTENANCE ...................................... 20

INSPECTIONANDCLEANING............................ 21

COMPONENTLOCATION............................... 22

RIGGING ........................................... 23

WIRINGDIAGRAMS ................................ 24- 25

CQUS

LISTED

Printed in U.S.A.

Code: PDX4

InternationalComfortProducts,LLC
Lewisburg,TN. 37091

518 01 1801 00 12-08-06

1. Unit Dimensions "B" CHASSIS UNIT DIMENSIONS

COMBINATION GAS/

ELECTRIC UNITS

"B" Chassis z A

DIM.

A

32-1/2 826 _ _ _ _,_,_-_"_._"_.

B

47-3/8I 1203 _ _ f(_d((_'_%_ _

C

47-3/8 I 1203 J J _ _N_.._.___._/ _. "_

D

3-1/8 I 79 _" _ _"___ _ ./i"

E

11-1/8 283 _ _

F
G
H
I
J
K

L

M
N

P

Q

R

S

12 I 308 _

14-1/4 I 363 L_ _
14-1/4 I 363 _ _

12 I 308 "_ _ _ 'w'

4 102 "1''j

3,4 I19 28

4-1/4I lO8 [ _ _ _ "E'_

4-3/8 111 .._ _ __ ....._-_ < .

14-1/2 I 368 _ ["1 _"""_/_ ...../ f "_

12-1/4 I 311 y/ _, _ )-d .... ,._ |,L--4 _ ,_

12-1/8 308 j / _ "D" _ "H" _"-_/
14-1/4 363 / / *" _ _"

12-1/4 I 318 _" / _. I _>_. _

Units in "B" Chassis Configuration
PDX424 - 30

I "F"

f 1-3/8" _ _NDUIT k _ _ _ S_'_-_

A ,. I '2"3'1123]16,PIP E

ROOF CURB Unit Base shown separately to

for units in illustrate bottom of duct openings,

"B" Chassis

(473/8 x 473/8) Units in "B" Chassis Configuration_

DIM.

,NC,E_ M......... 8 PDX424 - 30 _ _.

A

42-3/4 1086 .,._v

B

39-3/4 1010 J_ _

C
D
E
F
G
H
K*

18 457 _ _ _

18 457 _ j

3-3/4 98 _ _ _.....-_

42-3/4 1086 _ J _ _._
39-3/4 1010 _ _ J_ _ _.

18 457 __ _<'_ _- _- _ /'-_l

_ ..... __ _ _._ _,,B:_ A

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

2-3/8"

3i (75) 1-3/8"

25-1/16"

COMBINATION GAS/

ELECTRIC UNITS

"C" Chassis

(473/8 x 73)

DIN INCHE8 _41LLOMEYER8

A 36 914

B 47-3/8 1203

C 73 1354

D 4-5/8 117
E 15 361

F 12 307

G 18-3/4 476

H 18-3/4 476
I 12 306

J 4 102

K 1 &1-1/4 25&31
L 4-1/4 108
M 5-1/4 133
N 12-1/4 311

P 19 483

Q 15 381

R 19 483

S 12-1/4 318
T 16-7/8 429

ROOF CURB

for

"C" Chassis

(473/8 x 73)

IM INCHES MgLLIM_T_RS

A 67-3/4 1721

B 64-3/4 1645

C 23 584

D 23 584
E 2-1/2 64
F 42-3/4 1086

G 39-3/4 1010

H 23 584
I 12 305

J 12 305

K* 14 356

"C" CHASSIS UNIT DIMENSIONS

ECTRICAL POWER

CONDUIT ('l(" DIM.)

W VOLTAGE

1/2" (12.7) CONDUIT

GAS CONNECTION

1/2" (12.7) PIPE

(97.1)

3-13/16"

,,p,,

Unit Base shown separately to

illustrate bottom of duct openings,

Units in "C" Chassis Configuration
PDX436-42

"F'L

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

13

3" (75)

l 1-3/8"

31-1/16"

(789 4)

"C+" CHASSIS UNIT DIMENSIONS

ECTRICAL POWER

CONDUIT ('K" DIM.)

W VOLTAGE

_/2" (12.7) CONDUIT

GAS CONNECTION

1/2" (12.7) PIPE

"C"

1 (2_79,7) 3-13/16"

COMBINATION GAS/

ELECTRIC UNITS

"C" Chassis

(473/8 x 73)

DIM

INOHE8 MILL_MEYER8

A

B

C

D
E
F

G

H
I

J

K
L
M
N

P

Q

R
S
T

42 1067

47-3/8 1203

73 1354

4-5/8 117

15 361

12 307
18-3/4 476
18-3/4 476

12 306

4 102

1 &1-1/4 25&31

4-1/4 108
5-1/4 133

12-1/4 311

19 483

15 381

19 483
12-1/4 318

16-7/8 429

ROOF CURB

for

"C" Chassis

(473/8 x 73)

IM INCHES MOLLIM_T_RS

A 67-3/4 1721

B 64-3/4 1645

C 23 584

D 23 584
E 2-1/2 64
F 42-3/4 1086

G 39-3/4 1010

H 23 584
I 12 305

J 12 305

K* 14 356

(97.1)

,,p,,

Unit Base shown separately to

illustrate bottom of duct openings,

Units in "C" Chassis Configuration
PDX448-60

141

"F'L

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

2. SAFE INSTALLATION REQUIREMENTS

Installation and servicing of air-conditioning equipment can
be hazardous due to system pressure and electrical

components. Only trained and qualified personnel should

install, repair, or service air-conditioning equipment.

Untrained personnel can perform basic maintenance
functions of cleaning coils and filters. All other operations
should be performed by trained service personnel. When
working on air-conditioning equipment, observe

precautions 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 could result in
personal injury or unit damage. Consult a qualified

installer, service agency, or gas supplier for information

or assistance. The qualified installer or agency must use
only factory-authorized kits or accessories when

modifying this product.

FIRE, EXPLOSION, ELECTRICAL SHOCK, 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.

Recogniz_ safety information. This is the safety-alert

symbol/.rk. 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 readand 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

orocedures 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: Itis 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
Failureto follow this caution may reduceunit reliability.

It is recommended that a qualified service technician
check the heat exchanger integrity everytwo (2)years,
after the first four (4) years of operation.

INTRODUCTION

The PDX4 unit is a fully self-contained, combination

Category Igas heating/electric heat pump unit designed for

outdoor installation (See pages 2 to 4 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.

Unitsmaybeinstalledeitherona rooftop,cementslab,or

directlyonthegroundiflocalcodespermit.

Modelswitha'l" inthetwelfthpositionofthemodelnumber

are dedicatedLowNOxunitsdesignedfor California

installations.Theemissionsofthesemodelsdonotexceed

40nanogramsofnitrogenoxideemissionsperjouleofheat
outputasshippedfromthefactory,andmustbeinstalledin

CaliforniaAirQualityManagementDistrictsor anyother
regionsinNorthAmericawherea LowNOxruleexists.

3. LOCATING THE UNIT

ACCESS PANELS

See Figure 1 for a general view of unit and location of

access panels.

CARBON MONOXIDE POISONING HAZARD.

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

Keep blower door closed.

CLEARANCES

The location MUST allow for minimum clearances and
should not be adjacent to a patio or other area where the

unit's operating sound level might be objectionable. The

combustion air inlet openings MUST not be obstructed (see

Figure 1). In addition, local codes MUST be observed.
NOTE: Units with available filter racks (3-1/2 to 5ton), need

a 26" minimum clearance at side of unit for removal of
filters. See chart below if unit is going to be placed near

combustible construction or materials.
While minimum clearances are acceptable for safety

reasons, they may not allow adequate air circulation around

the unit for proper operation 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"

FIGURE 1

I Minimum Clearances and Access Panels

B Chassis Shown)

\

80-00-01

Internat Filter Access
from Burner Compartment Side

26" (C Chassis Units)

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.

- 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 acombination of platform and roof beams or

curb.

- See Hoisting section for hoisting instructions.

HOISTING

Burner Compartment

Panel

161

NOTE: All access panels MUST be secured inplace before
hoisting.

The unit should be hoisted with two lifting slings. Attach the
slings to rigging shackles that have been hooked through

holes in the base rail,

Two spreader bars MUST be placed on top of the unit to

protect the unit from damage from the pressure exerted by

the slings. Make sure that all equipment is adequate to

handle the weight ofthe unit and that the slings will not allow

the unit to shift,

Refer to Figure 20 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: Blockoff plate in the supply air compartment only

contains one screw. If reinstalling plate, back part of plate

MUST fit into mating dimples on flange. To reinstall, slant
plate into dimples, then put plate into position and fasten

with screw,

I FIGURE 2 I Heating vent Assembly I

Screwsfor

"B" Chassis

(473/8 x 473/8)

/

FIGURE 3 1 Heating Vent Assembly

Flue Support

(Shipped mounted to unit

Flue Cover

Condensate Drain

The condensate drain outlet is a 3/4" (19.1mm) female PVC
connection located atthe bottom of the unit tothe right of the

filter access panel (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, afield
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,

2. Install the removed plates on the horizontal return and
supply air openings.

3, Install roof curb on the building. Be sure to follow all

directions included with curb and all applicable building
codes in your installation. See page 2 or 3 for
appropriate roof curb to use.

Heating Vent Assembly

The flue cover is packed with installation screws in the
return air compartment, Refer to FIGURE 3 and assemble
as shown,

FIGURE 4

3/4" (19.1mm)
Threaded Female

* Condensate trap MUST be installed.

/ Condensate Drain Information*

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

(25.4mm)

2" (50.8mm)

171

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

existing vent system may be oversized for the remaining

appliances.

5. GAS SUPPLY AND PIPING

NOTE: Because there are many types of liquified petroleum
(propane (LP)) gases, the term propane (LP) as used inthis

manual refers to propane gas. Ifyou intend to use any type
of propane (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

propane (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.

Makecertainthe unitisequippedtooperateonthetype of
gasavailable.Models designatedasnatural gas areto be

used with natural gas only. Models designated for use
with liquefied petroleum (propane (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 propane (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 beconsidered
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 5 for Schedule 40 Iron Pipe tEn_llish/

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

Pipe Length Btu/hr (in thousands)

(includes

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

FIGURE 6 for Schedule 40 Iron Pipe (English)

Pipe Length kW**

(includes

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

6.1m 56 103 214 322 615

12.2m 38 72 147 223 425

18.3m 31 57 117 179 337

Pipe Length kW**

(includes

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

6.1m 55 115 215 438 674

12.2m 38 78 148 305 457

18.3m 30 64 120 244 374

I Gas Pipe Size, Length and Btu/hr Capacity

NATURAL GAS

propane (LP) GAS

I Gas Pipe Size, Length and Btu/hr Capacity

NATURAL GAS

Propane (LP) GAS

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

PIPING AT UNIT
Connections

In the state of Massachusetts:

- This product must be installed by a licensed Plumber or
Gas Fitter.

- When flexible connections are used, the maximum
length shall not exceed 36 inches.

- When lever type gas shutoffs are used they shall be
T-handle type.

- The use of copper tubing for gas piping is not approved
by the state of Massachusetts.

NOTE: The rules listed apply to natural and propane (LP)

gas pipe installations.

1. Ifinstallation is for propane (LP) gas, have propane 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. tf 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

181