ICP PGD536, PGS560, PGD524, PGD548, PG524040 Owner's Manual

Packaged Gas Heat/Electric Cooling Units

Owner's Guide to Operating and

Maintaining Your Gas/Electric Unit

ELECTRICAL SHOCK HAZARD.

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

Disconnect power at fuse box or service panel
before performing recommended maintenance.

FIRE, EXPLOSION, ELECTRICAL SHOCK
HAZARD.

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

Do not use this unit if any part has been under

water. Immediately call a qualified service
technician to inspect the unit and to replace any

part of the control system which has been under

water.

FIRE OR EXPLOSION HAZARD

Failure to follow safety warnings exactly could
result in serious injury, death, and/or property
damage.

Information in this manual MUST be followed
exactly.

Do not store or use gasoline or other flammable

vapors and liquids in the vicinity of this or any

other appliance.

WHAT TO DO IF YOU SMELL GAS

• Leave the building immediately.

• Do not try to light any appliance.

• Do touch any electrical switch; do not use any

phone in the building.

• Immediately call your gas supplier from a

neighbors phone. Follow the gas suppliers
instructions.

• If you cannot reach your gas supplier, call the
fire department.

Installation and service must be performed by a
qualified installer, service agency or the gas

supplier.

This manual should be left with the owner.

04/28/09 462 02 2102 00

SAFETYCONSIDERATIONS

Improper installation, adjustment, alteration, service
maintenance, or use can cause explosion, fire, electrical

shock, or other conditions which may cause death,

personal injury, or property damage. Consult a qualified
installer, service agency, or your distributor or branch for
information or assistance. The qualified installer or

agency must use factory-authorized kits or accessories
when modifying this product. Refer to the individual

instructions packaged with the kits or accessories when
installing.

Follow all safety codes. Wear safety glasses, protective

clothing, and work gloves. Have a fire extinguisher
available. Read these instructions thoroughly and follow

all warnings or cautions included in literature and
attached to the unit. consult local building codes, the

current editions of the National Fuel Gas Code (NFGC)

NFPA 54/ANSI Z223.1, and the National Electrical Code
(NEC) NFPA 70.

In Canada refer to the current editions of the National
Standards of Canada CAN/CSA-B149.1 and .2 Natural
Gas and Propane Installation codes, and Canadian

Electrical Code CSA C22.1

Recognize safety information. This is the safety-alert
symbol /_. When you see this symbol on the unit and in

instructions or manuals, be alertto the potential for personal

injury. Understand these signal words: DANGER,
WARNING, and CAUTION. These words are used with the

safety-alert symbol. DANGER identifies the most serious

hazards which will result in severe personal injury or death.
WARNING signifies hazards which could result in personal

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.

Note: Installer: This manual should be left with the
equipment user.

FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal
injury, death or property damage.

Installation and servicing of this equipment can be
hazardous due to mechanical and electrical

components. Only trained and qualified personnel
should install, repair, or service this equipment.

CUT HAZARD

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

When removing access panels or performing
maintenance functions inside your unit, be aware of sharp

sheet metal parts and screws. Although special care is
taken to reduce sharp edges to a minimum, be extremely

careful when handling parts or reaching into the unit.

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury

and/or death.

Before performing recommended maintenance, be sure the

main power switch to unit is turned off and lock-out tag is

installed.

FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD

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

1. Do not turn off the electrical power to unit without first

turning off the gas supply.

2. Before attempting to start the gas heating section,
familiarize yourself with all the procedures that must be

followed.

FIRE, EXPLOSION HAZARD

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

Do not attempt to light by hand.

UNIT INTRODUCTION

This unit is a small packaged gas heat/electric cooling
system that can utilize the comfort of gas heating packaged

along with efficient electric air conditioning.

Starting or Shutting Unit Off:

Note: Your combination heating/cooling unit is equipped

with an automatic direct spark ignition and power
combustion blower.

To Start Unit Gas Heat:

Refer to Figure 1 for location of unit access panel. Refer to
Figure 2 for location of gas valve. Refer to Figure 3 while

proceeding with the following steps.

1. Set the temperature selector on room thermostat to the
lowest temperature setting and set system switch to

HEAT.

2. Close the external manual gas shutoff valve.

3. Turn off the electrical supply to the unit.

4. Remove the control access panel with a 5/16" nut
driver. See Fig. 1.

5. Move the selector switch on the internal gas valve tothe
OFF position and wait 5 minutes. See Fig. 2.

6. Move the selector switch on the internal gas valve tothe
ON position.

7. Replace the control access panel.

8. Turn on the electrical supply to unit.

9. Open the external manual gas shutoff valve.

10. Set the temperature selector on room thermostat
slightly above room temperature to start unit. The

induced-draft combustion air fan will start. Main gas

valve will open and main burners should ignite within 5
seconds. If the burner does not light within 5 seconds,

theignitionmodulewillgointoa RetryModeaftera

periodof approximately22seconds(followingthe5

secondignitionperiod).Iftheburnersdonotlightwithin

15minutesoftheinitialcallforheat,thereisalockout.

11.Setthetemperatureselectoronroomthermostatto
desiredsetting.

FIRE AND EXPLOSION HAZARD

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

1. If the main burners fail to light, or the blower fails to start,
shut down gas heating section and call your dealer for

service.

2. Never attempt to manually light the main burners on unit
with a match, lighter, or any other flame. If the electric
sparking device fails to light the main burners, refer to the

following shutdown procedures, then call your dealer as

soon as possible.

FIGURE 1 J Unit Access Panels

Filter

Access

Panel

FIGURE 2 Access Panel Removed

Gas Heating / Electric Cooling Unit with

Flue Hood

Burners Gas Valve

To Shut Off Unit Gas Heat:

FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD

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

Do not turn off the electrical power to unit without first
turning off the gas supply.

Note: If the unit is being shut down because of a
malfunction, call your dealer as soon as possible.

Should overheating occur or the gas supply fail to shut off,
shut off the manual gas valve to the unit before shutting off

the electrical supply. Do not use this unit ifany part has been

under water. Immediately call a qualified service technician

to inspect the unit and to replace any part of the control
system and any gas control which has been under water.

Refer to Figure 4 while proceeding with the following steps.

1. Set the temperature selector on room thermostat to
lowest temperature setting and set system switch to

OFF.

2. Close the external manual gas shutoff valve.

3. Turn off the electrical power supply to the unit.

4. Remove the control access panel. See Fig. 1.

5. Move the selector switch on the internal gas valve tothe

OFF position. See Fig. 2.

6. Replace the control access panel.

To Start Unit Electric Cooling:

Refer to Figure 5 while proceeding with the following steps.

1. Set the temperature selector on room thermostat to
highest temperature setting and set system SWITCH to

OFF.

2. Close the external manual gas shutoff valve, if not

already closed.

3. Turn ON the electrical power supply to the unit.

4. Set system switch to COOL.

5. Set the temperature selector on room thermostat

slightly below the room temperature to start unit.

To Shut OFF Unit Electric Cooling:

Refer to Figure 6 while proceeding with the following steps.

1. Set the temperature selector on room thermostat to
highest temperature setting and set system SWITCH to

OFF.

2. Close the external manual gas shutoff valve, if not

already closed.

3. Turn OFF the electrical power supply to the unit.
OPERATING YOUR UNIT

The operation of your system is controlled by the indoor
temperature control (Thermostat). Your gas heating /

electric cooling unit requires a thermostat with 2 stages of
cooling and 1 stage of heating. You simply adjust the

thermostat and it maintains the indoor temperature at the

level you select. Most thermostats of heating and cooling

systems have 3 controls: a temperature control selector, a

FAN control, and a System or MODE control. Refer to your

thermostat owner's manual for more information.

To better protectyour investmentand to eliminate

unnecessaryservicecalls,familiarizeyourselfwiththe

followingfacts:

Cooling Mode

With the SYSTEM or MODE control set to COOL, your unit
will run in cooling mode until the indoor temperature is

lowered to the level you have selected. On extremely hot

days, your unit will run more often on the high capacity
stage. On mild days, your unit will run more often on low
capacity stage for even greater energy savings.

Gas Heating Mode

With the SYSTEM or MODE control of your indoor
thermostat set to HEAT, your unit will run in heating mode

until the room temperature is raised to the level you have

selected. On cold days and nights, your system will typically

run for longer periods of time and have shorter "off" periods

than on moderate days.

MAINTENANCE AND SERVICE

This section discusses maintenance that should be

performed on your system. Most maintenance should be
performed by your dealer. You, as the owner, may wish to

handle some minor maintenance for your new unit.

Routine Maintenance

All routine maintenance should be handled by skilled,
experienced personnel. Your dealer can help you establish

a standard procedure.

For your safety, keep the unit area clear and free of

combustible materials, gasoline, and other flammable

liquids and vapors.

To assure proper functioning of the unit, flow of condenser
air must not be obstructed from reaching the unit.

Clearance from the top of the unit is 48" (1219 mm).
Clearance of at least 36" (914 mm) is required on sides

except the power entryside (42" (1067 mm) clearance) and
the duct side (12" (305 mm) clearance).

Maintenance and Care for the Equipment Owner
Before proceeding with those things you might want to

maintain yourself, please carefully consider the following:

FIRE, EXPLOSION, ELECTRICAL SHOCK AND CUT
HAZARD

Failure to follow this warning could result in personal injury,
death or property damage.

1. Turn off gas supply first, then all electrical power to your
unit and install lock-out tag before servicing or per-

forming maintenance.

2. When removing access panels or performing
maintenance functions inside your unit, be aware of

sharp sheet metal parts and screws. Although special
care is taken to reduce sharp edges to a minimum, be

extremely careful when handling parts or reaching into
the unit. Wear safety glasses, gloves, and appropriate

protective clothing.

Air Filters
The air filter(s) should be checked every 3 or 4 weeks and

changed or cleaned whenever it becomes dirty. Dirty filters

produce excessive stress on the blower motor and can

cause the motor to overheat and shut down.
This unit must have air filters in place before it can be

operated. These filters can be located inone of at least two

places. In many applications, the installer will provide return

air filter grilles mounted on the wall or ceiling of the
conditioned structure. In the instance of filter grilles, the

filters can simply be removed from the grille and replaced.
The other typical application is an accessory filter rack

installed inside the unit itself. The following information is

given to assist in changing filters used inthese internal filter

racks.

Table 1 indicates the minimum indoor filter size for your unit.

Table l--Indoor Air Filter Data

Return Air Filter Size

Unit Model

PG(D,S)524040
PG(D,S)524060

PG(D,S)536060

in,

20x20x1
20x24x1

24x30x1

mm

508x508x25
508x610x25

610x762x25

PG(D,S)536090
PG(D,S)548090

PG(D,S)548115
PG(D,S)548130

24x36x1

610x914x25

PG(D,S)560090
PG(D,S)560115

PG(D,S)560130

When installing the new filter(s), note the direction of the
airflow arrows on the filter frame.

If you have difficulty locating your air filter(s) or have

questions concerning proper filter maintenance, contact
your dealer for instructions. When replacing filters, always

use the same size and type of filter that was supplied,

originally, by the installer.

If using an Accessory Filter Rack, refer to the Installation

Instructions provided with it for correct filter sizes and
quantities. Refer to Figure 1to access filters installed in the
accessory filter rack.

To replace / inspect filters in accessory filter rack.
See Figure 1

1. Remove the filter access panel using a 5/16" (8mm) nut
driver.

2. Remove the filter(s) by pulling it out of the unit. If the
filter(s) is dirty, clean or replace with a new one.

UNIT OPERATION HAZARD
Failure to follow this caution could result in personal

injury, death or unit damage.
Never operate your unit without filters in place. An

accumulation of dust and lint on internal parts of your unit
can cause loss of efficiency.

FIGURE 3 J To Start Unit Gas Heat

@

STEP1 STEP 2

MAIN

O_,

,,1,-.-..-

STEP 3

STEP6

MAIN

STEP4 STEP 5

STEP 7

I

STEP 8

STEP 9

STEP 10

12

FIGURE 4 ] To Shut OFF Unit Gas Heat

MAIN

!

l

°
!

STEP1

1

STEP 4

STEP2

STEP 3

STEP 5

STEP 6

161

FIGURE 5 J To Start Unit Electric Cooling

STEP 1 STEP 2 STEP 3 STEP 4 & 5

FIGURE 6 J To Shut OFF Unit Electric Cooling

MAIN

ON_

OFF

MAIN

STEP 1

STEP2

STEP3

ILl

Fans and Fan Motors
Periodically check the condition of fan wheels and housings

and fan-motor shaft bearings. Contact your dealer for the

required annual maintenance.
Heat Exchanger

To ensure dependable and efficient heating operation, the

heat exchanger should be checked by a qualified
maintenance person before each heating season, and

cleaned when necessary. This checkout should not be
attempted by anyone not having the required expertise and

equipments to properly do the job. Contact your dealer for
the required periodic maintenance.

Indoor and Outdoor Coils

Cleaning of the coils should only be done by qualified
service personnel. Contact your dealer for the required

annual maintenance.
Condensate Drain

The drain pan and condensate drain line should be checked
and cleaned atthe same time the cooling coils are checked

by your dealer.

Compressor
All compressors are factory shipped with a normal charge

of the correct type of refrigeration grade oil. A compressor
should rarely require additional oil.

Condenser Fan

Unit Panels

After performing any maintenance or service on the unit, be
sure all panels are fastened securely in place to prevent rain
from entering unit cabinet and to prevent disruption of the

correct unit airflow pattern.
Combustion Area and Vent System

The combustion area and vent system should be inspected
visually before each heating season. The normal

accumulation of dirt, soot, rust, and scale can result in loss
of efficiency and improper performance if allowed to build

up. this inspection should be done by a trained service
person.

FIRE, EXPLOSION HAZARD

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

If your unit makes an especially loud noise when the main
burners are ignited, shut down the heating section and call
your dealer.

BURN HAZARD

Failure to follow this caution may result in personal injury.

Components in heating section may be hot after unit has
been started up. When observing flame, be careful not to

get close to or touch heating components.

PERSONAL INJURY AND UNIT DAMAGE HAZARD

Failure to follow this warning could result in personal
injury, death or property damage.

Do not insert sticks, screwdrivers, or any other object
into revolving fan blades.

The fan must be kept free of all obstructions to ensure

proper cooling. Contact your dealer for any required

service.

Electrical Controls and Wiring
Electrical controls are difficult to check without proper

instrumentation. If there are any discrepancies in the

operating cycle, contact your local dealer and request
service.

Refrigerant Circuit

The refrigerant circuit is difficult to check for leaks without
the proper equipment. If inadequate cooling is suspected,

contact your local dealer for service.

EXPLOSION AND ENVIRONMENTAL HAZARD

Failure to follow this warning could result in personal
injury, death or property damage.

System under pressure. Relieve pressure and recover
all refrigerant before system repair or final unit disposal.
Use all service ports and open all flow-control devices,

including solenoid valves.

Regular Dealer Maintenance

In addition to the type of routine maintenance you might be

willing to perform, your unit should be inspected regularly by
a properly trained service technician. An inspection

(preferably each year, but at least every other year) should
include the following:

1. Inspection of all flue product passages-including the

burners, heat exchanger, and flue collector box. Make
sure the burner flames are blue in color and in proper
adjustment. Refer to Figure 7 for burner flame.

FIGURE 7 I Monoport Burner

J

BURNER FLAME

.... ......../.....t.......

2. Inspection of all combustion-and ventilation-air
passages and openings.

3. Close inspection of all gas pipes leading to and inside of
your unit.

4. Inspection and, if required, cleaning of the outdoor and
indoor coils.

5.Inspectionand,ifrequired,cleaningoftheindoorcoil
condensatedrain.

6.Inspectionandcleaningofblowerwheelhousingand

motor.

7.Inspectionofall supply-airandreturn-airductsfor

leaks, obstructions,and insulationintegrity.Any
problemsfoundshouldberesolvedatthistime.

8.Inspectionoftheunitbaseto ensurethatnocracks,
gaps, etc., exist which may causea hazardous

condition.

9.Inspectionoftheunitcasingforsignsofdeterioration.

10.Inspectionofallelectricalwiringandcomponentsto
ensureproperconnection.

11.Inspectionfor leaks in the refrigerantcircuit.

Pressure-checktodetermineappropriaterefrigerant

charge.

12.Operationalcheckof theunitto determineworking
conditions.Repairoradjustmentshouldbemadeatthis

time.

Yourservicingdealermayofferan economicalservice
contractthatcoversseasonalinspections.Askforfurther

details.
Completeserviceinstructionscanbefoundin the unit

Installation,Start-upandServiceInstructions.

WarrantyCertificate
Yourheatingandairconditioningunithasalimitedwarranty.

Besureto readthewarrantycarefullyto determinethe

coverageforyourunit.

Beforeyoucallforservice...

...checkforseveraleasily-solvedproblems.

If insufficient heating or cooling is suspected:

( ) Check the air filter for dirt.
( ) Check for blocked return-air or supply-air grilles. Be

sure they are open and unobstructed. Ifthese checks do not
reveal the cause, call your servicing dealer.

If your unit is not operating at all, check the following
list for easy solutions:

( ) Check to be sure that your thermostat temperature
selector is set below the indoor temperature during the
cooling season or above the indoor temperature during

heating season. Be sure the SYSTEM switch or MODE
control is in the COOL or HEAT position and not in the OFF

position.

( ) Ifyour unit still fails to operate, call your servicing dealer
for troubleshooting and repairs. Specify the model and

serial numbers of your unit. (Record them in this manual in
the space provided.) If the dealer knows exactly which unit

you have, he may be able to offer suggestions over the
phone, or save valuable time through knowledgeable

preparation for the service call.

In Case of Trouble

If you perform the steps above and unit performance is still

unsatisfactory, shut off the unit and call your dealer.

NOTE TO EQUIPMENT OWNER:

For your convenience, please record the model and serial numbers of your new equipment in the spaces
provided. This information, along with the installation data and dealer contact information, will be helpful
should your system require maintenance or service.

UNIT INFORMATION

Model #
Serial #

ACCESSORIES (List type and model #)

NOTE TO INSTALLER:

This manual must be left with the equipment owner.

INSTALLATION INFORMATION

Date Installed
DEALERSHIP CONTACT INFORMATION

Company Name
Address

Phone Number

Technician Name