ICP PGAD42D1K5, PGAD47D1K5, PGAD24B1K5, PGAD42E1K5, PGAD47F1K1 Installation Instructions Manual

Installation

Instructions

Three Phase 3 to 5 Ton

Direct Drive Blower

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

5. Electrical Wiring .............. 11

6. Ductwork .................... 11

7. Economizer .................. 12

8. Start-up Procedures .......... 13

9. Operation .................... 14

10. Maintenance ................ 15

11. Rigging Instructions ........ 20

COMBINATIONUNITS

GASHEAT/ELECTRICCOOL

Printed in U,S.A. 509 01 1102 02 1/6/04

_ Installation Instructions Combination Units I

"B" CHASSIS UNIT DIMENSIONS

A
B
C
D
E

F
G
H
I
J
K
L

M
N
P

Q

R

S

A
B
C

D
E
F
G
H
K*

COMBINATION GAS/

ELECTRIC UNITS

"B" Chassis / A

(473/8 X 473/8)

,,o,Es M,UL,M_E,8 "C."--____"E"B"

82-i/2 828 / _ __'-._

47-3/8 I 1203 _ _ _ _((_(_(_(_-._)_)_)_) ))))})// _. _.

47-3/8 I 1208 _ _ _._____________________/////_ _t

3-1/8 I 79 _ / __/ _. _

11-1/8 I 283 _ _ /_

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

42-3/4 1086

39-3/4 1010 // /_....

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.)

LOW VOLTAGE
1/2" (12.7) CONDUIT

1- 1/2"

21-1/4"

(539.75) GAS CONNECTION

11-1/8"

(101.6)

COMBINATION GAS/

ELECTRIC UNITS

"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

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

"C"

"G"

,,p,,

"R"

UNIT BASE SHOWN SEPARAT

TO ILLUSTRATE BOTTOM
DUCT OPENINGS

"F\

_ROOF OURB8 ARE AL80 AVAILABLE IN 8"(208) AND Z4"(610) HEIGHT8 (K DIMENSION).

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

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

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.

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.

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

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

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.

Installation Instructions

FIGURE 1 Vent Check

Vent Pipe--___ Draft Hood

Typical Gas _/

WaterHeaterx [ I I _ v--Match

I j

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.

NOTE: If flame pulls towards draft hood, this indicates adequate

venting.

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.

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.

I FIGURE 2

Access Panels

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, itis de-
sirable to allow additional clearance, especially around the con-
denser inlet and discharge openings.

50901 110202 E_]

I Installation Instructions Combination Units I

Minimum Clearances and Access Panels

FIGURE 3 (C Chassis Shown)

sk>_r _ Pmww

Bcm.+,m,:

/+++++za_'

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

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:

The unit MUST be situated to provide safe access for ser-
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

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 if necessary. 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

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

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.

FIGURE 5 J Heating Vent Assembly

Flue Support

(Shipped moume(:lto unit)

Flue Cover

/

4. Install unit on the appropriate roof curb.

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)

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

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

4-1/2

_(25.4mm)

)

2" (50.8mm)

\

3/4" (19.1mm) '

Drain Line

* Condensate trap MUST be installed.

50901 110202 [_]