ICP PGS, PGC, GPFM, GPCM, GPSM Installation Instructions Manual
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Installation Instructions
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PGF, PGC, PGS, GPFM, GPCM, GPSM
11/2to 5 TON
COMBINATION UNITS
GAS HEAT / ELECTRIC COOL
Models
PGF018K040F
PGF024K040F
PGF024K060F
PGF030K060F
PGF030K080F
PGF036K060F
PGF036K080F
PGF036K100F
PGF042K080F
PGF042K100F
PGF048K080F
PGF048K120F
PGF060K100F
PGF060K140E
PGC018K040F
PGC024K040F
PGC024K060F
PGC030K060F
PGC030K080F
PGC036K060F
PGC036K080F
PGC036K100F
PGC042K080F
PGC042K100F
PGC048K080F
PGC048K120F
PGC060K100F
PGC060K140F
PGS024K060F
PGS030K080F
PGS036K080F
PGS036K100F
PGS042K080F
PGS042K100F
PGS048K120F
PGS060K140E
GPFM18K040F
GPFM24K040F
GPFM24K060F
GPFM30K060F
GPFM30K080F
GPFM36K060F
GPFM36K080F
GPFM36K100F
GPFM42K080F
GPFM42K100F
GPFM48K080F
GPFM48K120F
GPFM60K100F
GPFM60K140E
GPCM18K040F
GPCM24K040F
GPCM24K060F
GPCM30K060F
GPCM30K080F
GPCM36K060F
GPCM36K080F
GPCM36K100F
GPCM42K080F
GPCM42K100F
GPCM48K080F
GPCM48K120F
GPCM60K100F
GPCM60K140F
GPSM24K060F
GPSM30K080F
GPSM36K080F
GPSM36K100F
GPSM42K080F
GPSM42K100F
GPSM48K120F
GPSM60K140E
462 01 1006 00 4-18-05
Printed in U.S.A.
[IJ_lliI]I LV4:1l [.,-'][I]l [.,-_
1-1/2 TO 3-1/2 TON
[ 4 TO 5 TON
I/lliI "A"
BASE PAN - CHASSIS
©
BASE RAIL
L_-k
BASE RAIL
12-1/4 --
191 SUPPLY _
I
M
2-3/16
19
12-1/4
RETURN
3-3/4
46 - 1/8"*
2-3/16
ALL DIMENSIONS IN INCHES
Connections Detail
AS /
ONNECTtON (
1/2 \
<F-1-3/4" VOLTAGE _
ELECTRICAL
POWER
CONDUIT
Condensate Drain
UNITSIZE A B C
1-112TO3-1/2 Ton 29-1/2 47-1/2 47-1/2
4 TO5 Ton* 37-1/2 47-1/2 51-1/2
** Measured from inside to inside on base rails.
D E F G H I J K L M
3 9-1/2 12 14 12 14 4-1/2 16 42-3/4 1-9/16
7-1/2 5-1/2 19 12 12 19 4-1/2 22 46-1/4 5-3/16
N
46-1/2
49-3/4
3. SAFE INSTALLATION REQUIREMENTS
FIRE, EXPLOSION, ELECTRICAL SHOCK, AND
CARBON MONOXIDE POISON HAZARD
Failure to carefully read and 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 ANSI Z223.1 and the National
Electrical Code NFPA70-1990 or in Canada the
National Standard CANiCGA 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.
• Do NOT use this furnace as a construction heater.
• Use only the Type of gas approved for this furnace (See
Rating Plate).
• Do NOT use open flame to test for gas leak.
• Seal supply and return air ducts.
• Check to see that filters are installed correctly and are
the proper type an size.
NOTE: It is 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.
NOTE: Units with available filter racks ( 3-1/2 to 5 ton), 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 in the 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.
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" (6" on large chassis models)
Condenser Inlet ................................... 30"
Blower Service (Side) .............................. 30"
Contro! 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"
I
FIGURE 1
Minimum Clearances and Access Panels
(B Chassis Shown)
Blower Compartment Panel
Small Chassis - 2"
Large Chassis
4. LOCATING THE UNIT
ACCESS PANELS
See FIGURE 1 for a general view of unit and location of
access panels.
CARBON MONOXIDE POISONING HAZARD.
Keep blower door closed.
Failure to keep blower door closed could result in bodily injury
and/or death.
CLEARANCES
Internal Filter Access
from Burner Compartment Side
26" (Large Chassis Units)
INSTALLATION
NOTICE
80-00-01
Burner Compartment
Panel
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.
Unit will NOT operate properly unless it is installed lev-
el 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.
131
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 con-
densate trap installation and drainage. See FIGURE 3
and associated text for more information about conden-
sate 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 sup-
port the weight of the unit or the roof MUST be
reinforced.
Check the weight of the unit in relation to the roof struc-
ture 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 plat-
form or a combination of platform and roof beams or
curb,
- See Hoisting section for hoisting instructions,
HOISTING
NOTE: All access panels MUST be secured in place 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 of the unit and that the slings will not allow
the unit to shift.
Refer to FIGURE 17 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.
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 di-
rections included with curb and all applicable building
codes in your installation.
Heating Vent Assembly
Refer to FIGURE 2 and assemble as shown.
FIGURE 2
Heating Vent Assembly
Atta£t?with 2 screws
Heen_ingi__ _
Flue Pipe
DO NOT OPERATE THE UNIT WITHOUT THE VENT
ASSEMBLY INSTALLED
Condensate Drain
The condensate drain outlet is a 3/4" (19.1 mm) female PVC
connection located at the bottom on the left hand side (see
FIGURE 3).
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, a field
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,
A3/4" (19.1mm) 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.
FIGURE 3 / Condensate Drain Information*
1
3/4" (19,1mm)
Female PVC
Fitting X
3/4" (19.1mm)
Drain Line
* Condensate trap MUST be installed.
80-31-32
141
5. PRE-EXISTING COMMON VENT CHECK
If the installation of the combination unit involves removing
an existing furnace from a common vent with other
appliances, the existing venting system will probably be too
large for the remaining appliances and they will not vent
properly. The existing venting system MUST be checked by
a qualified technician to ensure it is properly sized and
vents properly.
6. GAS SUPPLY AND PIPING
NOTE: Because there are many types of liquified petroleum
(LP) gases, the term LP as used in this manual refers to
propane gas. Ifyou intend to use any type of LP gas, proper
precautions MUST be used inthe handling, piping, and use
of such gas. NOTE: In Canada, installations MUST be
performed by licensed LP installers.
The UL/CSA Rating Plate located on the side panel on the
unit contains the model number, type of gas and gas input
rating, and other important information.
FIRE AND/OR EXPLOSION HAZARD
Failure to follow this warning could result in property damage,
_ersonal injury, and/or death.
Make certain the unit is equipped to operate on the type of gas
available. Models designated as natural gas are to be used with
natural gas only. Models designated for use with liquefied petro-
leum (LP) gas are shipped with orifices sized for commercially
pure propane gas. They MUST not be used with butane or a mix-
ture of butane and propane unless properly sized orifices are
installed by a licensed LP installer.
GAS PIPING
The gas supply line MUST beofadequate 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 4 or FIGURE 5. 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 ANSI Z223.1 or in
Canada the National Standard CAN/CGA B149-1 or
current editions.
FIGURE 4
Gas Pipe Size, Length and Btu/hr Capacity
for Schedule 40 Iron Pipe/En_llish)
NATURAL GAS
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
LP GAS
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
Gas Pipe Size, Length and Btu/hr Capacity
FIGURE 5
for Schedule 40 Iron Pipe (English)
Pipe Length
(Includes
Fittings)
6.1m
3/4" 2"
56 615
12.2m 38 425
18.3m 31 337
Pipe Length
(Includes
Fittings) 1/2" 11/2"
6.1m 55 674
12.2m 38 457
18.3m 30 374
**kW (Kilowatts) is the metric equivalent of Btu/hr.
NATURALGAS
kW**
1" 11/4" 11/2"
103 214 322
72 147 223
57 117 179
LP GAS
kW**
3/4" 1" 11/4"
115 215 438
78 148 305
64 120 244
PIPING AT UNIT
Connections
NOTE: The rules listed apply to natural and LP gas pipe
installations.
1. If installation is for LP gas, have LP gas installer use
TWO-STAGE REGULATION and make all connec-
tions from storage tank to unit.
2. Use black iron or steel pipe and fittings or other pipe ap-
proved by local code.
3. If copper tubing is used, it MUST comply with limitation
set in Fuel Gas Code.
NOTE: If a 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.
FIRE AND/OR EXPLOSION HAZARD
Failure to do so could result in property damage, bodily injury
or death.
Gas connector MUST be properly installed and can NOT be
used inside the furnace.
4. Use pipe joint compound on external (male) threads
ONLY. Joint compound MUST be resistant to any
chemical action of LP gases. Do NOT put pipe com-
pound on last 2 threads of pipe.
5. Use ground joint unions and install a drip leg no less
than 3 inches (76 mm) long to trap dirt and moisture be-
fore it can enter gas valve.
6. Use a wrench on gas valve when making connections
to prevent gas valve from turning. Do NOT use a pipe
wrench on the gas valve body.
7. Provide a 1/8 inch (3mm) National Pipe Thread (NPT)
plug for test gauge connection immediately upstream of
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