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PGAD47D1K5
Owner’s Manual
22 pgs3.9 Mb0

ICP PGAD47D1K5, PGAD47D1K1, PGAD42E1K5, PGAD42E1K1, PGAD42D1K5 Owner’s Manual

...
Installation
Instructions
Three Phase 3 to 5 Ton
Direct Drive Blower
COMBINATIONUNITS
Contents
Unit Dimensions ............ 2-3
1. Safety Labeling / Signal Words . 4
2. Safe Installation Requirements . 4
3. Locating the Unit .............. 5
4. Gas Supply and Piping ........ 8
10. Maintenance ................ 15
11. Rigging Instructions ........ 20
GASHEAT/ELECTRICCOOL
Printed in U,S.A. 509 01 1102 02 1/6/04
_ Installation Instructions Combination Units I
"B" CHASSIS UNIT DIMENSIONS
COMBINATION GAS/
ELECTRIC UNITS
"B" Chassis / A
(473/8 X 473/8)
,,o,Es M,UL,M_E,8 "C."--____"E"B"
A
82-i/2 828 / _ __'-._
B
47-3/8 I 1203 _ _ _ _((_(_(_(_-._)_)_)_) ))))})// _. _.
C
47-3/8 I 1208 _ _ _._____________________/////_ _t
D
3-1/8 I 79 _ / __/ _. _
E
11-1/8 I 283 _ _ /_
F G H I J K L
M N P
Q
R
S
12 I 306 _" _/
14-1/4 I 363 _ //
14-1/4I 363 _ _
12 I 306 "_ _ /t "A"
4 102 'T'/"
3/4&1 19&25 #_ _ _ _._'l"_j
4-1/4I lO8 (_ _ _ .i'E'_'_
12-1/8 308 / / _ 'D'_" _ "H" -"J / / 14-1/4 363 / / _ // _0_
12_1 4I 318
2-i/2" :_ I
(635) ELECTRICAL POWER
:, _ co.o_,T_"_"o,_.) _ _<.</_J _ _..'-._>_ / "
_7o_ , _ --.._--._.__ .__ ..>___
1-1/2" J
I _>_
(53975) _""_ "L''_ _ _ _.. /_ \
I i L_ 1/2"<12#)PIPE / _ _ _ "_'_'_" /._,,_,/_ \
ROOF CURB PA RATg LY
forunitsin TO BLLU8YRAYE BOY=TOM
"B"Chassis # U CT 0 P E N BN G S
(473/8 x 473/8)
BNCHE8 MBLLBMETER8
A
42-3/4 1086
B
39-3/4 1010 // /_....
C D
E F G H K*
18 457 // _ _ 18 457 //- /v
3-3/4 95 // / .././'_2..._
42-3/4 1086 _ / // _ 3913/4 10;O _ _ __ "-._'_
/q_ROOF CURB8 gNg ALSO AVAILANLE IN 8"{2Q3) AND 24"{610) HN_GHT8 {K D_MNNS_@N}=
E_ 50901 110202
I Combination Units Installation Instructions
"C" CHASSIS UNIT DIMENSIONS
2-1/2"
3" (762) ("K" DIM.)
1- 1/2"
21-1/4"
(539.75) GAS CONNECTION
11-1/8"
COMBINATION GAS/
ELECTRIC UNITS
LOW VOLTAGE 1/2" (12.7) CONDUIT
(101.6)
"C" Chassis
(473/8 x 73)
_IM. INCHES M_LLIM_T_RS
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 ] 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
"C"
"G"
"R"
,,p,,
UNIT BASE SHOWN SEPARAT
TO ILLUSTRATE BOTTOM DUCT OPENINGS
ROOF CURB
for
"C" Chassis
(473/8 x 73)
DIM. _NCHE8 MILLIMETER8
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
_ROOF OURB8 ARE AL80 AVAILABLE IN 8"(208) AND Z4"(610) HEIGHT8 (K DIMENSION).
"F\
80-t0-11
50901 110202 E_]
I Installation Instructions Combination Units I
1. Safety Labeling and Signal Words
Danger, Warning and Caution
The signal words DANGER, WARNING and CAUTION are used to identify levels of hazard seriousness. The signal word DAN-
GER is only used on product labels to signify an immediate haz- ard. The signal words WARNING and CAUTION will be used on product labels and throughout this manual and other manuals that may apply to the product.
Signal Words
DANGER - immediate hazards which WILL result in severe per-
sonal injury or death. WARNING - Hazards or unsafe practices which COULD result in
severe personal injury or death.
2. Safe Installation Requirements
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 ANSI Z223.1-1990 National Fuel
Gas Code and the National Electrical Code
NFPA70-1990 or in Canada the National Standard CAN/
CGA B149.1 and CSA C.22.1 - Canadian Electrical Code Part 1.
CAUTION - Hazards or unsafe practices which COULD result in minor personal injury or product or property damage.
Signal Words in Manuals
The signal word WARNING is used throughout this manual in the following manner:
The signal word CAUTION is used throughout this manual in the following manner:
CAUTION
NOTE: It is the personal responsibility and obligation of the cus-
tomer to contact a qualified installer to ensure that the installation
is adequate and conforms to governing codes and ordinances.
CAUTION
It is recommended that a qualified service technician check the heat exchanger integrity every two (2) years, after the first
four (4) years of operation.
Check Pre-existing Common Vent From Old Furnace
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.
Failure to carefully read and follow all instructions in this manual can result in furnace malfunction, property damage, personal injury and/or death.
• Installation MUST conform to the most current version of the following standards or a superseding standard.
In the USA:
•. ANSI Z223.1-1990 National Fue! Gas Code
• National Electrical Code NFPA70-1990 In Canada:
• National Standard CAN/CGA B149.1
• CSA C.22.1 - Canadian Electrical Code Part 1.
• Do NOT use this furnace as a construction heater.
• Use only the type of gas approved for this furnace (see rat-
ing plate).
• Do NOT use open flame to test for gas leak.
• Seal supply and return air ducts.
If the installation of the combination unit involves removing an ex- isting furnace from a common vent with other appliances, the
venting system will probably be too large for the remaining ap-
pliances and they will not vent properly. The venting system MUST be checked according to the following procedure.
NOTE: The following steps shall be followed with each appliance remaining connected tothe common venting system placed in op- eration, while the other appliances remaining connected to the common venting system are not in operation.
1. Seal any unused openings in the common venting system.
Visually inspect the venting system for proper size and hor- izontal pitch to ensure there is no blockage or restriction,
leakage, corrosion or other deficiencies which could cause an unsafe condition.
insofar as is practical, close all doors and windows and all doors between the space in which the appliances remain-
ing connected to the common venting system are located and other spaces of the building
Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any 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.
Follow the lighting instructions, Place the appliance being inspected in operation. Adjust thermostat so appliance wil! operate continuously.
Test for spillage at the draft hood relief opening after 5 min- utes of main burner operation. Use the flame of a match or
E_I 50901 110202
I Combination Units
Installation Instructions
candle. (see FIGURE 1). Flame or smoke should drawto- wards vent pipe.
After it has been determined that each appliance remaining connected to the common venting system properly vents
when tested as outlined, return doors, windows, exhaust fans, fireplace dampers and any other gas-burning ap-
pliance to their previous condition of use.
If improper venting is observed during any of the above
tests, the common venting system MUST be corrected us-
ing the appropriate tables in Appendix G in the National Fuel Gas Code, ANSI Z223.1, 1990.
3. Locating the Unit
The unit is designed for outdoor installation only. The unit may be
installed on a concrete mounting base at ground level, or on a rooftop with an adequate platform or if using as a downflow model,
with a roof curb.
FIGURE 1 Vent Check
Vent Pipe--___ Draft Hood
Typical Gas _/
WaterHeaterx [ I I _ v--Match
I j
NOTE: If flame pulls towards draft hood, this indicates adequate
venting.
I FIGURE 2
Access Panels
CAUTION
Do NOT operate unit in a corrosive atmosphere containing
chlorine, fluorine, or any other corrosive chemicals.
Do NOT install the unit in a location that will permit discharged air
from the condenser to recirculate to the condenser inlet.
Access Panels
See FIGU RE 2 below for a general view of unit and location of ac- cess panels.
Carbon monoxide poisoning hazard.
Keep blower door closed.
Failure to keep blower door closed can result in bodily injury and/or death.
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 5). In addition,
local codes MUST be observed.
Clearances MUST be maintained from adjacent structures to pro-
vide adequate fire protection, adequate combustion air, and room for service personnel.
NOTE: Filter racks need a 26" minimum clearance at front of unit
for removal offilters. See chart below if unit is going to be placed
near combustible construction or materials.
While minimum clearances are acceptable for safety reasons, they may not allow adequate air circulation around the unit for
proper operation in the cooling mode. Whenever possible, it is de- sirable to allow additional clearance, especially around the con- denser inlet and discharge openings.
50901 110202 E_]
I Installation Instructions Combination Units I
The unit MUST be situated to provide safe access for ser-
FIGURE 3 (C Chassis Shown)
Minimum Clearances and Access Panels
sk>_r _ Pmww
Bcm.+,m,:
/+++++za_'
vicing. Platform may be made of either concrete or pressure
treated wood and MUST be level and strong enough to sup- port 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 conden- sate trap installation and drainage. See Figure 9 and asso- ciated text for more information about condensate
drainage.
Rooftop Installation
30"
80-00-01A
Minimum Clearances to Combustible Construction
Furnace Plenum .................................... 2"
Duct Side ................ 2" (6" on large chassis models)
Condenser Inlet Side ............................... 30"
Blower Service (Rear) .............................. 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"
Installation
Rooftop platform requirements:
• The unit MUST be situated to provide safe access for ser- vicing.
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 ifnecessary. See FIGURE 25 on the back cover of this manual for unit weights and corner weights.
• Support for the unit MUST be level and strong enough to carry unit weight. The support may consist ofa platform or a combination of platform and roof beams or curb.
The platform may be constructed of pressure treated wood and may be covered with Class A, B or C roof covering.
• Platform MUST allow for proper condensate trap installa- tion and drainage. See FIGURE 6 and associated text for more information about condensate drainage.
NOTE: Cardboard covers on downflow supply and return duct openings MUST be removed before starting unit.
Hoisting
CAUTION
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 control box side MUST always be lower.
Ground Level Installation
Ground level platform requirements:
NOTE: All access panels MUST be secured in place before hoist- ing.
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 of
the unit and that the slings will not allow the unit to shift.
Refer to FIGURE 25 on the back cover of this manual for illus-
trated rigging instructions and weight chart.
E_ 50901 110202
I Combination Units Installation Instructions
Downflow Conversion
FIGURE 5 J Heating Vent Assembly
These units are adaptable to downflow use. To convert to down- flow use, follow these steps:
1. Remove the blockoff plates found in the return air compart- ment and the supply air compartment. See FIGURE 4 for plate location.
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.
2. Install the removed plates on the horizontal return and sup- ply air openings.
3. Install roof curb on your building. Be sure to follow all direc-
tions included with curb and all applicable building codes.
4. Install unit on the appropriate roof curb.
Flue Support
(Shipped moume(:lto unit)
Flue Cover
/
NOTE: It is the installer's personal responsibility to follow all local
codes and ordinances and instructions contained herein, as well as instructions included with accessory items when installing unit.
Blockoff Plate (Return Air Compartment)
Condensate Drain
A3/4" O.D. condensate drain connection is located at the front end
of the unit. A 3/4" drain line MUST be installed if required by local codes or location of unit, and run to an open drain or other suitable disposal point. A condensate trap MUST be installed as near the unit as possible for proper drainage.
Condensate Trap
Condensate trap MUST have proper height and fall as shown in FIGURE 6,
FIGURE 6 ] Condensate Trap
25-1/2 ("B" Chassis)
("C" Chassis)
3/4" (19.1mm)
Threaded Female PVC Fitting
_(25.4mm)
Heating Vent Assembly
The flue cover is packed with screws in the return air compart- ment. Refer to FIGURE 5 and assemble as shown.
CAUTION
DO NOT OPERATE THE UNIT WITHOUT THE VENT AS-
SEMBLY INSTALLED
4-1/2
\
3/4" (19.1mm) '
Drain Line
* Condensate trap MUST be installed.
50901 110202 [_]
)
2" (50.8mm)
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