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PGME60G1505
Owner’s Manual
18 pgs2.44 Mb0

ICP PGME60G1505 Owner’s Manual

Installation Instructions
PGAA / PGAD / PGMD / PGME
11/2 to 5 TON
Single Phase, Combination Units
Gas Heat / Electric Cool
TABLEOFCONTENTS
1. SAFETY LABELING AND SIGNAL WORDS .................... 2
DANGER,WARNING AND CAUTION ............................... 2
SIGNALWORDS ............................................... 2
PRODUCTLABELING ........................................... 2
WarningLabel ............................................... 2
2. UNIT DIMENSIONS .................................... 3-4
3. SAFE INSTALLATION REQUIREMENTS ...................... 5
4. LOCATING THE UNIT .................................... 5
ACCESSPANELS .............................................. 5
CLEARANCES................................................. 5
GROUNDLEVEL INSTALLATION ................................... 5
ROOFTOPINSTALLATION........................................ 6
HOISTING.................................................... 6
Downflew Conversion ........................................... 6
5, PRE- EXISTING COMMON VENT CHECK ..................... 7
6. GAS SUPPLY AND PIPING ................................ 7
GABPIPING .................................................. 7
PIPINGATUNIT ................................................ 7
ORIFICES .................................................... 8
7, ELECTRICAL WIRING ................................... 9
THERMOSTAT/HEATANTICIPATOR............................... 9
8. DUCTWORK .......................................... 10
DustworkInsulation ........................................... 10
DustworkConnections......................................... 10
FILTERS .................................................... 10
9. START- UP PROCEDURES ............................... 10
CHECKBEFORESTARTING..................................... 10
ReverseRotation(ScrotlCompressorsOnly) ......................... 10
ManifoldGas PressureAdjustment................................ 10
GAB PRESSURES............................................. 11
CIRCULATINGAIR BLOWER ..................................... 11
HEATINGSTAR-UPPROCEDURES................................ 11
TemperatureRiseCheck ....................................... t2
FANCONTROLCHECK ......................................... 12
SPEEDTAPS ................................................. 12
CONTINUOUSFANOPERATION .................................. 12
COOLING ................................................... 13
10, OPERATION ......................................... 13
COMBUSTION/INDOORFANCONTROL............................. 13
SCROLLANTI-CYCLE TIMER .................................... 14
11. MAINTENANCE ...................................... 14
MONTHLYMAINTENANCEAND INSPECTIONCHECKS................. 14
Air Fitters .................................................. 14
HEATINGSEASONCHECKS (MONTHLY)........................... 14
Pilot Flame ................................................. 14
MainBurnerFlame ........................................... 14
ANNUALMAINTENANCEANDINSPECTION ......................... 14
CondenserFan Motor ......................................... 15
VENTASSEMBLY ............................................. 15
BLOWERMOTORACCESS ...................................... 15
Method1 .................................................. 15
Motorremovatandreplacement .................................. 15
Method2 .................................................. 15
Burners/ HeatExchangers/ FlueGas Passages ...................... 15
INSPECTIONAND CLEANINGOF BURNERASSEMBLY
/HEATEXCHANGERS/FLUEGAS PASSAGES........................ 16
ForQualifiedServiceTechnicianOnly .............................. 16
12. RIGGING INSTRUCTIONS .............................. 17
13, NOTES ............................................. 18
Printed in U.S.A.
462 O1 1OO4 03 4-18-O5
1. Safety Labelinq and Siqnal Words
explanations of the colors used.
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 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 per-
sonal 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 inthe
following manner:
i,'A'l'._ 1t=*1 I_[c '_1
Danger Label
White lettering on a black background except the word DANGER which is white with a red background.
O
Warning Label White lettering on a black background except the word WARN-
ING 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.
,_ CAUTION
The signal word CAUTION is used throughout this manual inthe following manner:
CAUTION
Product Labeling
Signal words are used incombination with colors and/or pictures on product labels. Following are examples of product labels with
2. Unit Dimensions "B" CHASSIS UNIT DIMENSIONS
COMBINATION GAS/
ELECTRIC UNITS PGAA18-42 / PGMD18-42
"B" Chassis PGAD24-36 / PGME24-36 _ _. _
D_M,
(473/8 x 473/8)
A
82-1/2 828 /_
B
47-3/8 I 1208 _ _ __&_)_)>P))>))bb _
C
47-3/8 I 1203 J _ _ ._\_._-_ Y////// _ "_1
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 3o8 _ _/
14-1/4 I 363 _ // 14-1/4 I 363 _ //
12 I 308 "_ // /4 A
4 102 'T'/
3/4&1 19&25 y _'_ _ _[ j'l"_
4-1/4I lO8 { _ _ _ j E_
4-3/8 111
14-1/2 368 A _ "_. _/ "G'/_'_ ¢_.
12-1/4 I 311 //\ _Y .x_'_ / _ .
12-1/8 308 / / _ 'D" // "H" -""Jz / 14-1/4 363 / / _ // _ __0_0_0_0_0_0_0_0_0/_
_, 1/2" {12Z7) CONDUIT \ _/ ,_, ,,. ___/ _ _/ XO._"_x
1-1/2" "d"
Units in "B" Chassis Configuration
(53975) _"'_ "L"'<"- _ _ _ ///"'_-_-_-_S \
ROOFCURB TO _LLUSTRATE BOTTOM
for units in #ucT OPENING8
"B" Chassis
(473/8 x 47 /8) Units m B Chassm Configuration /_.
_0M,
,*CriES M,LC,_*_ PGAA18-42 / PGMD18-42 _ _
A
42-3/4 1086 PGAD24-36 / PGME24-36 _
B C
39-3/418 ;05170 _ __
D E
3-3/4
F
42-3/4 1086 _ / // _
G H 14"
14 356
8NPARATNLY
\
_ROOF CU_8 A_ ALSO AVAILA_L_ I_ 8"{_0_) AN# _4"(810} H_GHT8 {_ D_M_N8_O_},
80-10-12
COMBINATION GAS/
ELECTRIC UNITS
"C" Chassis
(473/8 x 73)
[_IM. INOHE8 M,LLIMETER8
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)
_IM. _NCHES 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" CHASSIS UNIT DIMENSIONS
ELECTRICAL POWER
CONDUIT ("K" DIM.)
VOLTAGE
1/2" (12.7) CONDUIT
GAE CONNECTION
1/2" (12.7) PIPE
(IOl.e)
"R"
,,p,,
UNIT BASE SHOWN EEPARAT
TO ILLUSTRATE BOTTOM DUCT OPENINGS
Units in "C" Chassis Configuration PGAA48-60 / PGMD48-60
PGAD42-60 / PGME42-60
"F\
-_ROOF CURBS ARE ALSO AVAILABLE IN 8'(208) AND 24"(610) HEIGHTS (K DIMENEtON),
80-10-1t
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 Elec-
trical Code NFPA70-current edition or in Canada the
National Standard CAN/CGA B149-1 and CSA C.22.1 - Canadian Electrical Code Part 1.
Failure to carefully read and follow all instructions in
this manual could result in furnace malfunction, prop-
erty damage, personal injury and/or death.
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 and size.
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.
NOTE: Units with built in filter racks ( "C" Chassis 48 x 73 mod- els), need a 26" minimum clearance at front of unit for removal of filters. See chart below if unit is going to be placed near combus-
tible 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 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.
REDUCED UNIT LIFE HAZARD Failure to follow this warning could result in
property damage, personal injury and/or death.
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 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"
FIRE, EXPLOSION, OR CARBON MONOXIDE POISONING HAZARDS
Failure to have the furnace inspected and maintained could result in death, bodily injury, and/or property damage.
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
ACCESS PANELS
See FIGURE 1 for a general view of unit and location of access panels.
CARBON MONOXIDE POISONING HAZARD.
Failure to keep blower door closed could result in
bodily injury and/or death.
Keep blower door closed.
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 1). In addition,
local codes MUST be observed.
FIGURE 1
I Minimum Clearances and Access Panels
(B Chassis Shown)
I Blower Compartment Panel
\
80-00-01
Internal Filter Access from Burner Compartment Side
26" (C Chassis Units)
INSTALLATION
NOTICE
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 drain side MUST always be lower.
Panel
Burner Compartment
Ground Level Installation
Ground level platform requirements:
- The unit MUST be situated to provide safe access for servic-
ing.
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 condensate
trap installation and drainage. See FIGURE 4 and associated text for more information about condensate
drainage.
Rooftop Installation Rooftop platform requirements:
- The unit MUST be situated to provide safe access for servic-
ing.
- 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 21 in the back cover 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 platform or a combination of platform and roof beams or curb.
- See Hoisting section below for hoisting instructions.
HOISTING
FIGURE 2 Blockoff Plate (Return Air Compartment)
Heating Vent Assembly
The flue cover is packed with screws in the return air compart- ment, Refer to FIGURE 3 and assemble as shown.
FIGURE 3 _ Heating Vent Assembly
1
Flue Support
(Shipped mounted to unil
Flue Cover
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 21 on the back cover of this manual for illus-
trated rigging instructions and weight chart.
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 2.
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 direc- tions included with curb and all applicable building codes in your installation. (See Pages 2 or 3 for appropriate curb to use with your model.)
\
Condensate Drain The condensate drain outlet is a 3/4" (19.1 mm) threaded female
PVC connection located atthe bottom of the unit to the right ofthe
filter access panel (see FIGURE 4). Condensate drain outlet MUST be held with wrench when installing trap and drain line.
The circulating blower creates a negative pressure on the con- densate drain line that can prevent the condensate from draining
properly. To combat this negative pressure, a field supplied con- densate 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. A 3/4" (19.1 mm) 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.
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