ICP PGF060K140A, PGF048K120A, PGF042K100A, PGF036K100A, PGF036K060A Owner’s Manual

...

Installation Instructions

PGF, PGC, PGS, GPFM, GPCM, GPSM

COMBINATION UNITS

GAS HEAT / ELECTRIC COOL

11/2 to 5 TON

Printed in U.S.A.

462 01 1003 01 1-6-04

1. Safety Labelinq and Siqnal Words

Danger,Warning and Caution

The signal words DANGER, WARNING and CAUTION are

used to identify levels of hazard seriousness. The signal

word DANGER is only used on product labels to signify an

immediate hazard. 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 personal injury or death. WARNING - Hazards or unsafe practices which COULD

result in severe personal injury or death. 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:

Danger Label

White lettering on a black background except the word

DANGER which is white with a red background,

Warning Label White lettering on a black background except the word

WARNING which is black with an orange background,

Caution Label White lettering on a black background except the word

CAUTION which is black with a yellow background,

The signal word CAUTION is used throughout this manual

in the following manner:

CAUTION

Product Labeling

Signal words are used in combination with colors and/or pictures on product labels. Following are examples of

product labels with explanations of the colors used.

J2J 462 01 1003 01

[IJ_lli I]I LV4:1l [.,-'][I]l [.,-_

1-1/2 TO 3-1/2 TON

BASE RAIL

BASE PAN - CHASSIS

L_-k

[ 4 TO 5 TON

I/lliI "A"

ALL DIMENSIONS IN INCHES

Connections Detail

BASE RAIL

AS /

ONNECTtON (

1/2 \

<F-1-3/4" VOLTAGE _

12-1/4 --

191 SUPPLY _

2-3/16

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.

46 - 1/8"*

Condensate Drain

12-1/4

RETURN

2-3/16

3-3/4

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

ELECTRICAL POWER

CONDUIT

N 46-1/2 49-3/4

46201100301 131

3. 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 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 proce-

dures and equipped with the proper tools and test instru- ments.

Failure to carefully read and follow all instructions in this

manual can result in furnace malfunction, property damage, personal injury and/or death.

• 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.

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.

4. LOCATING THE UNIT

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.

CAUTION

Do NOT operate unit in a corrosive atmosphere con- taining 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"

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 i Minimum Clearances(BChassisandshown)ACcessPanels

Blower Compartment Panel

Large Chassis

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 can result in bodily injury

and/or death.

CLEARANCES

Internal Filter Access from Burner Compartment Side

26" (Large Chassis Units)

INSTALLATION

Burner Compartment

NOTICE

80-00-01

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.

141 462 01 1003 01

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.

80 _

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__ _

CAUTION

DO NOT OPERATE THE UNIT WITHOUT THE VENT AS- SEMBLY 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.

Flue Pipe

3 | Condensateora ninformation*

3/4" (19,1mm)

Female PVC

Fitting X

(25.4mm)

80-31-32

(

2" (50.8mm)

3/4" (19.1mm) Drain Line

* Condensate trap MUST be installed.

462 01 1003 01 151

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. If you intend to use any type of 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 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.

Make certain the unit is equippedto operate onthe type of gas

available. Models designated as natural gas are to be usedwith

naturalgas only.Modelsdesignated for use with liquefiedpetro- leum (LP) gas are shipped with orifices sized for commercially

pure propanegas. They MUST not beusedwith butane or a mix-

ture of butane and propane unless properly sized orifices are

installed by a licensed LP installer. Failure to follow this warning can result in property damage,

_ersonal injury,and/or death.

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 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 be considered 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

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"

20' 189 393 732 1,496

40' 129 267 504 1,039

60' 103 217 409 834

Gas Pipe Size, Length and Btu/hr Capacity for Schedule 40 Iron Pipe (English)

NATURAL GAS

LP GAS

11/2"

2,299 1,559 1,275

FIGURE 5

Pipe Length

(Includes

Fittings)

6.1m

12.2m 38 425

18.3m 31 337

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

Gas Pipe Size, Length and Btu/hr Capacity for Schedule 40 Iron Pipe (English)

NATURAL GAS

kW**

3/4" 2"

56 615

1" 11/4" 11/2"

103 214 322

72 147 223 57 117 179

LP GAS

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.

Gas connector MUST be properly installed and can NOT be used inside the furnace.

Failure to do so can result in property damage, bodily injury or death.

4. Use pipe joint compound on external (male) threads ONLY. Joint compound MUST be resistant to any chemical action of LP gases (NO TAG). Do NOT put pipe compound 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.

CAUTION

Overtightening assembly may cause damage to the

gas valve and/or wiring and may misalign the burners,

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 the gas supply connection to the furnace ifnone is sup- plied with the gas valve of unit.

462 01 1003 01

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