ICP PGN324, PGN330, PGN342, PGN348, PGN360 Installation Instructions Manual

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Installation Instructions

PGN3 Series

Single Phase

PACKAGED GAS / ELECTRIC UNITS

TABLE OF CONTENTS

Page

SAFE INSTALLATION REQUIREMENTS 2........

INTRODUCTION 3.............................

RECEIVING AND INSTALLATION 3...............

Check Equipment 3.............................

Provide Unit Support 3..........................

Field Fabricate Ductwork 3.......................

Dimensions 4 -- 5...............................

Provide Clearances 6...........................

Rig and Place Unit 6............................

Connect Condensate Drain 8.....................

Install Flue Hood 8..............................

Install Gas Piping 8.............................

Install Duct Connections 10......................

Install Electrical Connections 1 1..................

PRE--START--UP 12............................

START--UP 13..................................

Check for Refrigerant Leaks 13...................

Start--Up Heating & Make Adjustments 13..........

Start--Up Cooling & Make Adjustments 17..........

MAINTENANCE 19.............................

Air Filter 20....................................

Indoor Blower and Motor 20......................

Flue Gas Passageways 20.......................

Induced Draft (Combustion Air) Blower 20..........

Limit Switch 20.................................

Burner Ignition 21...............................

Main Burners 21................................

Outdoor & Indoor Coil, & Condensate Drain Pan 21.

Outdoor Fan 22.................................

Electrical Controls and Wiring 22..................

Indoor Airflow 22................................

Metering Devices--Fixed Orifice 22................

TROUBLESHOOTING 26--28....................

START--UP CHECKLIST 29......................

Printed in U.S.A.

International Comfort Products, LLC Lewisburg, TN. 37091

462 01 1901 01 01--28--08

SAFE INSTALLATION REQUIREMENTS

FIGURE 1

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.

Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations must be performed by trained service personnel. When working on this equipment, observe precautions in the literature, ontags, and on labels attached to or shipped with the unit and other safety precautions that may apply.

Follow all safety codes. Installation must be in compliance with local and national building codes. Wear safety glasses, protective clothing, and work gloves. Have fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit.

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON MONOXIDE POISON HAZARD

Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon monoxide poisoning, fire, or an explosion which could result in personal injury or unit damage. Consult a qualified installer, service agency, or gas supplier for information or assistance. The qualified installer or agency must use only factory--authorized kits or accessories when modifying this product.

PGN3 GAS / ELECTRIC UNIT

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON MONOXIDE POISON HAZARD

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

Before performing service or maintenance operations on unit, turn off gas supply to unit.Then turn off unitmain power switch and install lockout tag.

Recognize safety information. This is the safety--alert symbol . When you see this symbol in instructions or

manuals, be alert to the potential for personal injury.

Understand the signal words DANGER, WARNING, CAUTION, and NOTE. These words are used with the safety--alert symbol. DANGER identifies the most serious hazards which will result in serious injury or death. WARNING signifies a hazard which could result in serious 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.

These instructions cover minimum requirements and conform to existing national standards and safety codes. In some instances, these instructions exceed certain local codes and ordinances, especially those that may not have kept up with changing residential construction practices. We require these instructions as a minimum for a safe installation.

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 National Fuel Gas Code NFPA 54--2006/ANSI Z223.1--2006 and the National Electrical Code NFPA70--2005 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.

SAFETY CONSIDERATIONS

• Use only with type of gas approved for this unit. Refer to unit rating plate.

• Install this unit only in a location and position as specified in this manual.

• Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections.

• Always install unit to operate within the unit’s intended temperature--rise r ange with a duct system, which has an external static pressure within the allowable range. Refer to unit rating plate for the allowable external static pressures.

• All connecting ductwork to the unit (supply and return) must be sealed to the unit casing as specified in section 7.

• Do NOT use this furnace as a construction heater.

• 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.

UNIT SAFETY Failure to follow this caution may reduce unit reliability.

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.

CAUTION

INTRODUCTION

The PGN3 unit is a fully self--contained, combination Category I gas heating/electric cooling unit designed for outdoor installation (See Fig 3 and 4 for unit dimensions). All unit sizes have return and discharge openings for both horizontal and downflow configurations, and are factory--shipped with all downflow duct openings covered.

Units may be installed either on a rooftop or at ground level. Models with a ”1” in the twelfth position of the model number

are dedicated Low NOx units designed for California installations. The emissions of these models do not exceed 40 nanograms of nitrogen oxide emissions per joule of heat output as shipped from the factory, and must be installed in California Air Quality Management Districts or any other regions in North America where a Low NOx rule exists.

RECEIVING AND INSTALLATION

Step 1—Check Equipment

IDENTIFY UNIT The unit model number and serial number are stamped on the unit information plate. Check this information against shipping papers.

INSPECT SHIPMENT

Inspect for shipping damage while unit is still on shipping pallet. If unit appears to be damaged or is torn loose from its anchorage, have it examined by transportation inspectors before removal. Forward claim papers directlyto transportation company. Manufacturer is not responsible for any damage incurred in transit. Check all items against shipping list. Immediately notify the nearest equipment distribution office if any item is missing. To prevent loss or damage, leave all parts in original packages until installation.

Step 2—Provide Unit Support

For hurricane tie downs, contact distributor for details and PE (Professional Engineering) Certificate if required.

ROOFCURB

Install accessory roof curb in accordance with instructions shipped with curb. Install insulation,cant strips, roofing, and flashing. Ductwork must be attached to curb.

IMPORT ANT: The gasketing of the unit to the roof curb is critical for a water tight seal. Install gasketing material supplied with the roof curb. Improperly applied gasketing also can result in air leaks and poor unit performance.

Curb should be level to within 1/4 in. (6mm) This is necessary for unit drain to function properly. Refer to accessory roof curb installation instructions for additional information as required.

SLAB MOUNT

Place the unit on a solid, level concrete pad that is a minimum of 4 in. (102mm) thick with 2 in. (51mm) above grade (See Fig. 2). The slab should extend approximately 2 in. beyond the casing on a ll 4 sides of the unit. Do not secure the unit to the slab except when required by local codes.

FIGURE 2

EVAP. COIL COND. COIL

Slab Mounting Details

OPTIONAL

RETURN

AIR

OPENING

OPTIONAL

SUPPLY

AIR

OPENING

ADDITIONAL GROUND LEVEL PLATFORM REQUIREMENTS

The unit MUST be situated to provide safe access for servicing. The unit must be level and supported above grade by beams, platform, or a pad. Platform or pad can be of open or solid construction but should be of permanent materials such as concrete, bricks, blocks, steel, or pressure--treated timbers approved for ground contact. Soil conditions must be considered so that the platform or pad does not shift or settle and leave the unit partially supported. 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.

Step 3—Field Fabricate Ductwork

Secure all ducts to roof curb and building structure on vertical discharge units. Do not connect ductwork to unit. For horizontal applications, unit is provided with flanges on the horizontal openings. All ductwork should be secured to the flanges. Insulate and weatherproof all external ductwork, joints, and roof openings with counter flashing and mastic in accordance with applicable codes.

Ducts passing through an unconditioned space must be insulated and covered with a vapor barrier.

If a plenum return isused on a vertical unit,the return should be ducted through the roof deck to comply with applicable fire codes.

A minimum clearance is not required around ductwork. Cabinet return--air static shall not exceed --.25 in. wc.

FIGURE 3

PGN324--36 DIMENSIONS

REQUIRED CLEARANCE TO COMBUSTIBLE MATL (

efe

r t

aximu

perating

learance

TOP OF UNIT...................................................................................14.00 [355.6]

DUCT SIDE OF UNIT.........................................................................2.00 [50.8]

SIDE OPPOSITE DUCTS ................................................................14.00 [355.6]

BOTTOM OF UNIT.............................................................................0.50 [12.7]

NEC. REQUIRED CLEARANCES.

BETWEEN UNITS, POWER ENTRY SIDE....................................42.00 [1066.8]

UNIT AND UNGROUNDED SURFACES, POWER ENTRY SIDE.36.00 [914.0] UNIT AND BLOCK OR CONCRETE WALLS AND OTHER

GROUNDED SURFACES, POWER ENTRY SIDE.........................42.00 [1066.8]

LEGEND

CG - Center of Gravity COND - Condensor EVAP - Evaporator NEC - National Electrical Code REQ’D - Required

NOTE: Dimensions are in in. [mm]

)

INCHES [mm]

REQUIRED CLEARANCE FOR OPERATION AND SERVICING

EVAP. COIL ACCESS SIDE............................................................36.00 [914.0]

POWER ENTRY SIDE....................................................................42.00 [1066.8]

(EXCEPT FOR NEC REQUIREMENTS)

UNIT TOP.......................................................................................48.00 [1219.2]

SIDE OPPOSITE DUCTS ..............................................................36.00 [914.0]

DUCT PANEL .................................................................................12.00 [304.8]

*MINIMUM DISTANCES: IF UNIT IS PLACED LESS THAN 12.00 [304.8] FROM WALL SYSTEM, THEN SYSTEM PERFORMANCE MAYBE COMPROMISE.

INCHES [mm]

UNIT

ELECTRICAL

CHARACTERISTICS

PGN324 208/230--1--60 343 156 37 [940] 20.0 [508] 17.0 [432] 17.6 [447] PGN330 208/230--1--60 355 161 39 [991] 20.0 [508] 19.3 [490] 13.0 [330] PGN336 208/230--1--60 360 163 41 [1042] 21.0 [533] 21.0 [533] 16.6 [422]

UNIT WEIGHT

lb kg X Y Z

UNIT HEIGHT IN. [MM]

“A”

CENTER OF GRAVITY

IN. [MM]

FIGURE 4

PGN342--60 DIMENSIONS

REQUIRED CLEARANCE TO COMBUSTIBLE MATL

TOP OF UNIT...................................................................................14.00 [355.6]

DUCT SIDE OF UNIT.........................................................................2.00 [50.8]

SIDE OPPOSITE DUCTS ................................................................14.00 [355.6]

BOTTOM OF UNIT.............................................................................0.50 [12.7]

ELECTRIC HEAT PANEL .................................................................36.00 [914.4]

NEC. REQUIRED CLEARANCES.

BETWEEN UNITS, POWER ENTRY SIDE....................................42.00 [1066.8]

UNIT AND UNGROUNDED SURFACES, POWER ENTRY SIDE .36.00 [914.0] UNIT AND BLOCK OR CONCRETE WALLS AND OTHER

GROUNDED SURFACES, POWER ENTRY SIDE.........................42.00 [1066.8]

INCHES [mm]

REQUIRED CLEARANCE FOR OPERATION AND SERVICING

EVAP. COIL ACCESS SIDE............................................................36.00 [914.0]

POWER ENTRY SIDE....................................................................42.00 [1066.8]

(EXCEPT FOR NEC REQUIREMENTS)

UNIT TOP.......................................................................................48.00 [1219.2]

SIDE OPPOSITE DUCTS ..............................................................36.00 [914.0]

DUCT PANEL .................................................................................12.00 [304.8] *

*MINIMUM DISTANCES: IF UNIT IS PLACED LESS THAN 12.00 [304.8] FROM WALL SYSTEM, THEN SYSTEM PERFORMANCE MAYBE COMPROMISE.

LEGEND CG - Center of Gravity COND - Condensor EVAP - Evaporator NEC - National Electrical Code REQ’D - Required

NOTE: Dimensions are in in. [mm]

INCHES [mm]

UNIT

ELECTRICAL

CHARACTERISTICS

PGN342 208/230--1--60 450 204.1 40.98 [1041] 21.0 [533] 21.0 [533] 17.1 [434] PGN348 208/230--1--60 480 217.7 46.98 [1193] 21.0 [533] 20.0 [508] 17.4 [442] PGN360 208/230--1--60 484 219.5 46.98 [1193] 21.0 [533] 20.0 [508] 17.6 [447]

UNIT WEIGHT

lb kg X Y

UNIT HEIGHT IN. [MM]

“A”

CENTER OF GRAVITY

IN. [MM]

Table 1—Filter Data-- PGN324--60

UNIT SIZE 024040 024060 030040 030060 036060 036090 042060 042090 RETURN--AIR FILTERS (in.)†

Throwaway

UNIT SIZE 048090 048115 048130 060090 060115 060130 RETURN--AIR FILTERS (in.)†

Throwaway

{ Required filter sizes shown are based on the larger of the ARI (Air Conditioning and Refrigeration Institute) rated cooling

airflow or the heating airflow velocity of 300 ft/minute for throwaway type or 450 ft/minute for high--capacity type. Air filter pressure drop for non--standard filters must not exceed 0.08 in. wc.

Step 4—Provide Clearances

The required minimum operating and service clearances are shown in Fig. 3 and 4. Adequate combustion, ventilation and condenser air must be provided in accordance with section 9.3, Air for Combustion and Ventilation, of the National Fuel Gas Code ANSI (American National Standards Institute) Z223.1 or applicable provisions of local building code. In Canada, follow sections 8.2, 8.3, or 8.4 or Can/CGA (Canadian Gas Association) B149 Installation Codes or applicable provisions of local building code.

IMPORT ANT: Do not restrict outdoor airflow. An air restriction at either the outdoor--air inlet or the fan discharge may be detrimental to compressor life.

The condenser fan pulls air through the condenser coil and discharges it through the top grille. Be sure that the fan discharge does not recirculate to the condenser coil. Do not locate the unit in either a corner or under an overhead obstruction. The minimum clearance under a partial overhang (such as a normal house overhang) is 48--in (1219mm). above the unit top. The maximum horizontal extension of a partial overhang must not exceed 48--in (1219mm).

Do not place the unit where water, ice, or snow from an overhang or roof will damage or flood the unit. Do not install the unit on carpeting or other combustible materials. Slab--mounted units should be at least 4 in. (102mm) above the highest expected water and runoff levels. Do not use unit if it has been under water.

Step 5—Rig and Place Unit

Rigging and handling of this equipment can be hazardous for many reasons due to the installation location (roofs, elevated structures, etc.).

Only trained, qualified crane operators and ground support staff should handle and install this equipment.

When working with this equipment, observe precautions in the literature, on tags, stickers, and labels attached to the equipment, and any other safety precautions that might apply.

Training for operators of the lifting equipment should include, but not be limited to, the following:

1. Application of the lifter to the load, and adjustment of the lifts to adapt to various sizes or kinds of loads.

2. Instruction in any special operation or precaution.

3. Condition of the load as it relates to operation of the lifting kit, such as balance, temperature, etc.

Follow all applicable safety codes. Wear safety shoes and work gloves.

20x24x1 20x24x1 20x24x1 20x24x1 20x24x1 20x24x1 24x36x1 24x36x1

24x36x1 24x36x1 24x36x1 24x36x1 24x36x1 24x36x1

INSPECTION The lifting/rigging bracket is engineered and designed to

be installed only on Small Packaged Products. This bracket is to be used to rig/lift a Small Packaged Product onto roofs or other elevated structures.

Prior to initial use, and at monthly intervals, all rigging

brackets and straps should be visually inspected for any damage, evidence of wear, structural deformation, or cracks. Particular attention should be paid to excessive wear at hoist hooking points and load support areas. Brackets or straps showing any kind of wear in these areas must not be used and should be discarded.

UNIT FALLING HAZARD

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

Never stand beneath rigged units or lift over people.

PROPERTY DAMAGE HAZARD

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

Rigging brackets for one unit use only. When removing a unit at the end of its useful life, use a new set of brackets.

USE OF RIGGING BRACKET

NOTE: Rigging brackets are factory installed on 3--phase units only. Single--Phase units require accessory kit NPLIFTBK003A10.

Field Installation of Rigging Bracket (if not already installed)

1. Remove unit from shipping carton. Leave top shipping skid on the unit for use as a spreader bar to prevent the rigging straps from damaging the unit. If the skid is not available, use a spreader bar of sufficient length to protect the unit from damage.

2. Remove 4 screws in unit corner posts.

3. Attach each of the 4 metal rigging brackets under the panel rain lip (See Fig. 5). Use the screws removed in step 2 above to secure the brackets to the unit.

PROPERTY DAMAGE HAZARD

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

Rigging bracket MUST be under the rain lip to provide adequate lifting.

WARNING

PROPERTY DAMAGE HAZARD

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

Do not strip screws when re--securing the unit. If a screw is stripped, replace the stripped one with a larger diameter screw (included). When straps are taut, the clevis should be a minimum of 36 in. (914mm) above the unit top cover.

WARNING

Rigging/Lifting of Unit

1. Bend top of brackets down approximately 30 degrees from the corner posts.

2. Attach straps of equal length to the rigging brackets at opposite ends of the unit. Be sure straps are rated to hold the weight of the unit (See Fig. 5).

3. Attach a clevis of sufficient strength in the middle of the straps. Adjust the clevis location to ensure unit is lifted level with the ground.

4. After unit is securely in place detach rigging straps. Remove corner posts screws, and rigging brackets then reinstall screws.

After the unit is placed on the roof curb or mounting pad, remove the top crating.

FIGURE 5

CORNER WEIGHTS (SMALL CABINET) CORNER WEIGHTS (LARGE CABINET)

PGN324

Unit

Total Weight 343 156 Corner Weight 1 69 31 Corner Weight 2 53 24 Corner Weight 3 83 38 Corner Weight 4 138 63

Rigging Weight 353 160

Shipping Weight 383 173

lb kg

Unit Corner Weight (lbs) and Rigging

PGN330 PGN336

lb kg lb kg

355 161 360 163

75 34 74 34 56 25 55 25

81 37 86 39 143 65 145 66 365 166 370 168 395 179 400 181

Rigging Brackets are factory installed on 3--- phase units only. Single ---phase units require accessory kit NPLIFTBK003A10

PGN342 PGN348 PGN360

Unit

Total Weight 450 204 480 218 484 220 Corner Weight 1 90 41 97 44 98 45 Corner Weight 2 72 33 74 34 75 34 Corner Weight 3 110 50 116 53 118 54 Corner Weight 4 176 81 193 88 193 88

Rigging Weight 465 211 495 225 499 226

Shipping Weight 510 231 540 245 544 247

lb kg lb kg lb kg

Step 6—Connect Condensate Drain

NOTE: When installing condensate drain connection be

sure to comply with local codes and restrictions.

The PGN3 disposes of condensate water through a 3/4 in. NPT fitting which exits through the base on the evaporator coil access side. See Fig. 3 & 4 for location.

Condensate water can be drained directly onto the roof in rooftop installations (where permitted) or onto a gravel apron in ground level installations. Install a field--supplied 2--in. (51mm) condensate trap at the end of condensate connection to ensure proper drainage. Make sure that the outlet of the trap is at least 1 in. (24mm) lower than the drain--pan condensate connection to prevent the pan from overflowing (See Fig. 6). Prime the trap with water. When using a gravel apron, make sure it slopes away from the unit.

Connect a drain tube using a minimum of 3/4--in. PVC or 3/4--in. copper pipe (all field--supplied) at the outlet end of the 2--in. (51mm) trap. Do not undersize the tube. Pitch the drain tube downward at a slope of at least 1--in (25mm). for every 10 ft (3048mm) of horizontal run. Be sure to check the drain tube for leaks.

FIGURE 6

1" min.

Condensate Drain

TRAP OUTLET

2" min.

Step 7—Install Flue Hood

The flue assembly is secured and shipped in the return air duct. Remove duct cover to locate the assembly (See Fig. 8 and 9).

NOTE: Dedicated low NOx models MUST be installed in California Air Quality Management Districts where a Low NOx rule exists.

These models meet the California maximum oxides of nitrogen (NOx) emissions requirements of 40 nanograms/joule or less as shipped from the factory.

NOTE: Low NOx requirements apply only to natural gas installations.

CARBON MONOXIDE POISONING HAZARD

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

The venting system is designed to ensure proper venting. The flue hood assembly must be installed as indicted in this section of the unit installation instructions.

WARNING

Install the flue hood as follows:

1. This installation must conform with local building codes and with the National Fuel Gas Code (NFGC), ANSI Z223.1 (in Canada, CAN/CGA B149.1, and B149.2) or NFPA (National Fire Protection Association) latest revision. Refer to Provincial and local plumbing or wastewater codes and other applicable local codes.

2. Remove flue hood from shipping location (inside the return section of the blower compartment--see Fig. 8 &

9). Remove the return duct cover to locate the flue hood. Place flue hood assembly over flue panel. Orient screw holes in flue hood with holes in the flue panel.

3. Secure flue hood to flue panel by inserting a single screw on the right side and the left side of the hood.

Step 8—Install Gas Piping

The gas supply pipe enters the unit through the access hole provided. The gas connection to the unit is made to the 1/2--in. FPT gas inlet on the gas valve.

Install a gas supply line that runs to the heating section. Refer to Table 2 and the NFGC for gas pipe sizing. Do not use cast--iron pipe. It is recommended that a black iron pipe is used. Check the local utility for recommendations concerning existing lines. Size gas supply piping for 0.5 in. wc maximum pressure drop. Never use pipe smaller than the 1/2--in. FPT gas inlet on the unit gas valve.

For natural gas applications, the gas pressure at unit gas connection must not be less than 4.0 in. wc or greater than 13 in. wc while the unit is operating. For propane applications, the gas pressure must not be less than 7.0 in. wc or greater than 13 in. wc at the unit connection.

A 1/8--in. NPT plugged tapping, accessible for test gauge connection, must be installed immediately upstream of the gas supply connection to the gas valve.

When installing the gas supply line, observe local codes pertaining to gas pipe installations. Refer to theNFGC ANSI Z223.1--2005 NFPA latest edition (in Canada, CAN/CGA B149.1).

NOTE:In the state of Massachusetts:

1. Gas supply connections MUST be performed by a licensed plumber or gas fitter.

2. When flexible connectors are used, the maximum length shall not exceed 36 inches (915 mm).

3. When lever handle type manual equipment shutoff valves are used, they shall be T--handle valves.

4. The use of copper tubing for gas piping is NOT approved by the state of Massachusetts.

In the absence of local building codes, adhere to the following pertinent recommendations:

1. Avoid low spots in long runs of pipe. Grade all pipe 1/4 in. (6mm) for every 15 ft (4572mm) of length to prevent traps. Grade all horizontal runs downward to risers. Use risers to connect to heating section and to meter.

2. Protect all segments of piping system against physical and thermal damage. Support all piping with appropriate straps, hangers,etc. Use aminimum of one hanger every 6 ft. (1829mm) For pipe sizes larger than 1/2 in., follow recommendations of national codes.

3. Apply joint compound (pipe dope) sparingly and only to male threads of joint when making pipe connections.

Use only pipe dope that is resistant to action of liquefied petroleum gases as specified by local and/or national codes. Never use Teflon tape.

FIGURE 7

Sediment Trap

4. Install sediment trap in riser leading to heating section (See Fig. 7). This drip leg functions as a trap for dirt and condensate.

5. Install an accessible, external, manual main shutoff valve in gas supply pipe within 6 ft (1829mm) of heating section.

6. Install ground--joint union close to heating section between unit manual shutoff and external manual main shut--off valve.

OUT

TEE

NIPPLE

CAP

7. Pressure test all gas piping in accordance with local and national plumbing and gas codes before connecting piping to unit.

8. Check for gas leaks at the field--installed and factory--installed gas lines after all piping connections have been completed. Use soap--and--water solution (or method specifiedby local codes and/orregulations).

NOTE: Pressure test the gas supply system after the gas supply piping is connected to the gas valve. The supply piping must be disconnected from the gas valve during the testing of the piping systems when test pressure is in excess of 0.5 psig. Pressure test the gas supply piping system at pressures equal to or less than 0.5 psig. The unit heating section must be isolatedfrom the gas piping system by closing the external main manual shutoff valve and slightly opening the ground--joint union.

Table 1

NOMINAL

IRON PIPE

SIZE (IN.)

1/2 .622 175 120 97 82 73 66 61 57 53 50 44 40 — — 3/4 .824 360 250 200 170 151 138 125 11 8 110 103 93 84 77 72

1 1.049 680 465 375 320 285 260 240 220 205 195 175 160 145 135 1--1/4 1.380 1400 950 770 600 580 530 490 460 430 400 360 325 300 280 1--1/2 1.610 2100 1460 1180 990 900 810 750 690 650 620 550 500 460 430

*Capacity of pipe in cu ft of gas per hr for gas pressure of 0.5 psig or less. Pressure drop of 0.5--in. wc (based on a 0.60 specific gravity gas). Refer to Table, National Fire Protection Association NFPA 54.

{ This length includes an ordinary number of fittings.

INTERNAL

DIAMETER

(IN.)

10 20 30 40 50 60 70 80 90 100 125 150 175 200

—PIPING SIZES

LENGTH OF PIPE (FT)†

FIRE OR EXPLOSION HAZARD

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

--Connect gas pipe to unit using a backup wrench to avoid damaging gas controls.

--Never purge a gas line into a combustion chamber. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections.

--Use proper length of pipe to avoid stress on gas control manifold.

--If a flexible connector is required or allowed by authority having jurisdiction, black iron pipe shall be installed at furnace gas valve and extend a minimum of 2 in. (51mm) outside furnace casing.

--If codes allow a flexible connector , always use a new connector. do not use a connector which has previously serviced another gas appliance.

WARNING

Step 9—Install Duct Connections

The unit has duct flanges on the supply-- and return--air openings on the side and bottom of the unit. For downshot applications, the ductwork connects to the roof curb (See Fig. 3 and 4 for connection sizes and locations).

CONFIGURING UNITS FOR DOWNFLOW (VERTICAL) DISCHARGE

FIGURE 8

Supply and Return Duct Opening

ELECTRICAL SHOCK HAZARD

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

Before installing or servicing system, always turn off main power to system. There may be more than one disconnect switch. Turn off power supply to the unit and install lockout tag.

WARNING

1. Open all electrical disconnects before starting any service work.

2. Remove horizontal (metal) duct covers to access vertical (downflow) discharge duct knockouts in unit base.

3. Use a screwdriver and hammer to remove the panels in the bottom of the unit base (See Fig. 9).

4. If unit ductwork is to be attached to vertical opening flanges on the unit base (jackstand applications only), do so at this time.

CAUTION

PROPERTY DAMAGE HAZARD

Failure to follow this caution may result in property damage.

Collect ALL screws that were removed. Do not leave screws on rooftop as permanent damage to the roof may occur.

5. It is recommended that the base insulation around the perimeter of the vertical return--air opening be secured to the base with aluminum tape. Applicable local codes may require aluminum tape to prevent exposed fiberglass.

6. Cover both horizontal duct openings with the provided duct covers. Ensure opening is air and water tight.

7. After completing unit conversion, perform all safety checks and power up unit.

NOTE: The design and installation of the duct system must be in accordance with the standards of the NFPA for installation of nonresidence--type air conditioning and ventilating systems, NFPA 90A or residence--type, NFPA 90B; and/or local codes and ordinances.

SUPPLY DUCT OPENING

FIGURE 9

Vertical Duct Cover Removed

DUCT COVERS REMOVED

RETURN DUCT OPENING

VENT HOOD SHIPPING LOCATION

Adhere to the following criteria when selecting, sizing, and installing the duct system:

1. Units are shipped for horizontal duct installation (by removing duct covers).

2. Select and size ductwork, supply--air registers, and return--air grilles according to American Society of Heating, Refrigeration and Air Conditioning Engineers (ASHRAE) recommendations.

3. Use flexible transition between rigid ductwork and unit to prevent transmission of vibration. The transition may be screwed or bolted to duct flanges. Use suitable gaskets to ensure weather--tight and airtight seal.

4. All units must have field--supplied filters or accessory filter rack installed in the return--air side of the unit. Recommended sizes for filters are shown in Table 1.

5. Size all ductwork for maximum required airflow (either heating or cooling) for unit being installed. Avoid abrupt duct size increases or decreases or performance may be affected.

6. Adequately insulate and weatherproof all ductwork located outdoors. Insulate ducts passing through unconditioned space, and use vapor barrier in accordance with latest issue of Sheet Metal and Air

Conditioning Contractors National Association

(SMACNA) and Air Conditioning Contractors of America (ACCA) minimum installation standards for heating and air conditioning systems. Secure all ducts to building structure.

7. Flash, weatherproof, and vibration isolate all openings in building structure in accordance with local codes and good building practices.

Step 10—Install Electrical Connections

ELECTRICAL SHOCK HAZARD

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

The unit cabinet must have an uninterrupted, unbroken electrical ground. This ground may consist of an electrical wire connected to the unit ground screw in the control compartment, or conduit approved for electrical ground when installed in accordance with NEC, ANSI/NFPA American National Standards Institute/National Fire Protection Association (latest edition) (in Canada, Canadian Electrical Code CSA C22.1) and local electrical codes.

UNIT COMPONENT DAMAGE HAZARD

Failure to follow this caution may result in damage to the unit being installed.

1. Make all electrical connections in accordance with NEC ANSI/NFPA (latest edition) and local electrical codes governing such wiring. In Canada, all electrical connections must be in accordance with CSA standard C22.1 Canadian Electrical Code Part 1 and applicable local codes. Refer to unit wiring diagram.

2. Use only copper conductor for connections between field--supplied electrical disconnect switch and unit. DO NOT USE ALUMINUM WIRE.

3. Be sure that high--voltage power to unit is within operating voltage range indicated on unit rating plate. On 3--phase units, ensure phases are balanced within 2 percent. Consult local power company for correction of improper voltage and/or phase imbalance.

4. Insulate low--voltage wires for highest voltage contained within conduit when low--voltage control wires are in same conduit as high--voltage wires.

5. Do not damage internal components when drilling through any panel to mount electrical hardware, conduit, etc.

WARNING

CAUTION

The field--supplied disconnect switch box may be mounted on the unit over the high--voltage inlet hole when the standard power and low--voltage entry points are used (See Fig. 3 and 4 for acceptable location).

See unit wiring label and Fig. 14 for reference when making high voltage connections. Proceed as follows to complete the high--voltage connections to the unit.

1. Run the high--voltage (L1, L2) and ground lead into the control box.

2. Connect ground lead to chassis ground connection.

3. Locate the black and yellow wires connected to the line side of the contactor.

4. Connect field L1 to black wire on connection 11 of the compressor contactor.

5. Connect field wire L2 to yellow wire on connection 23 of the compressor contactor.

ELECTRICAL SHOCK HAZARD

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

Before making any wiring changes, make sure the gas supply is switched off first. Then switch off the power supply to the unit and install lockout tag.

WARNING

CONTROL VOLTAGE CONNECTIONS

Do not use any type of power--stealing thermostat. Unit control problems may result.

Use no. 18 American Wire Gage (AWG) color--coded, insulated (35_C minimum) wires to make the control voltage connections between the thermostat and the unit. If the thermostat is located more than 100 ft from the unit (as measured along the control voltage wires), use no. 16 AWG color--coded, insulated (35_C minimum) wires.

Standard

Connection

Remove knockout hole located in the flue panel adjacent to the control access panel (See Fig. 3 and 4). Remove the rubber grommet from the installer’s packet (included with unit) and install grommet in the knockout opening. Provide a drip loop before running wire through panel.

FIGURE 10

HIGH VOLTAGE POWER LEADS (SEE UNIT WIRING LABEL)

High and Control Voltage Connections

POWER SUPPLY

HIGH--VOLTAGE CONNECTIONS

When routing power leads into unit, use only copper wire between disconnect and unit. The high voltage leads should be in a conduit until they enter the duct panel; conduit termination at the duct panel must be watertight.

The unit must have a separate electrical service with a field--supplied, waterproofdisconnect switch mountedat, or within sight from, the unit. Refer to the unit rating plate, NEC and local codes for maximum fuse/circuit breaker size and minimum circuit amps (ampacity) for wire sizing.

FIELD-SUPPLIED

CONTROL BOX

LOW-VOLTAGE POWER LEADS (SEE UNIT WIRING LABEL)

SPLICE BOX

FUSED DISCONNECT

WHT(W1)

YEL(Y)

GRN(G)

RED(R)

BRN(C)

THERMOSTA (TYPICAL)

Run the low--voltage leads from the thermostat, through the inlet hole, and into unit low--voltage splice box.

Locate five 18--gage wires leaving control box. These low--voltage connection leads can be identified by the colors red, green, yellow, brown, and white (See Fig. 10). Ensure the leads are long enough to be routed into the low--voltage splice box (located below right side of control box). Route leads through hole in bottom of control box and make low--voltage connections (See Fig. 10). Secure all cut wires, so that they do not interfere with operation of unit.

HEAT ANTICIPATOR SETTING

The room thermostat heat anticipator must be properly adjusted to ensure proper heating performance. Set the heat anticipator, using an ammeter between the W and R terminals to determine the exact required setting.

NOTE: For thermostat selection purposes, use 0.18 amp for the approximate required setting. Failure to make a proper heat anticipator adjustment will result in improper operation, discomfort to the occupants of the conditioned space, and inefficient energy utilization; however, the required setting may be changed slightly to provide a greater degree of comfort for a particular installation.

TRANSFORMER PROTECTION

The transformer is of the energy--limiting type. It is set to withstand a 30--sec. overload or shorted secondary condition. If an overload or short is present, correct overload condition and check for blown fuse on gas control board. Replace fuse as required with correct size.

PRE--START--UP

FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD

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

1. Follow recognized safety practices and wear protective goggles when checking or servicing refrigerant system.

2. Do not operate compressor or provide any electric power to unit unless compressor terminal cover is in place and secured.

3. Do not remove compressor terminal cover until all electrical sources are disconnected and tagged.

4. Relieve and recover all refrigerant from system before touching or disturbing anything inside terminal box if refrigerant leak is suspected around compressor terminals.

5. Never attempt to repair soldered connection while refrigerant system is under pressure.

6. Do not use torch to remove any component. System contains oil and refrigerant under pressure. To remove a component, wear protective goggles and proceed as follows:

a. Shut off electrical power to unit and install

lockout tag.

b. Relieve and reclaim all refrigerant from

system using both high-- and low--pressure ports.

c. Cut component connecting tubing with tubing

cutter and remove component from unit.

d. Carefully unsweat remaining tubing stubs

when necessary. Oil can ignite when exposed to torch flame.

WARNING

Use the Start--Up Checklist supplied at the end of this book and proceed as follows to inspect and prepare the unit for initial start--up:

1. Remove access panel.

2. Read and follow instructions on all DANGER, WARNING, CAUTION, and INFORMATION labels attached to, or shipped with unit.

3. Make the following inspections:

a. Inspect for shipping and handling damage, such as

broken lines, loose parts, disconnected wires, etc.

b. Inspect for oil at all refrigerant tubing connections

and on unit base. Detecting oil generally indicates a refrigerant leak.

c. Leak--test all refrigerant tubing connections using

electronic leak detector, or liquid--soap solution. If a refrigerant leak is detected, see following Check for Refrigerant Leaks section.

d. Inspect all field-- and factory--wiring connections.

Be sure that connections are completed and tight.

e. Ensure wires do not touch refrigerant tubing or

sharp sheet metal edges.

f. Inspect coil fins. If damaged during shipping and

handling, carefully straighten fins with a fin comb.

FIRE, EXPLOSION HAZARD

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

Do not purge gas supply into the combustion chamber. Do not use a match or other open flame to check for gas leaks.

WARNING

4. Verify the following conditions:

a. Make sure gas line is free of air. Before lighting the

unit for the first time, perform the following with the gas valve in the OFF position:

NOTE: If the gas supply pipe was not purged before connecting the unit, it will be full of air. It is recommended that the ground joint union be loosened, and the supply line be allowed to purge until the odor of gas is detected. Never purge gas lines into a combustion chamber. Immediately upon detection of gas odor, retighten the union. Allow 5 minutes to elapse, then light unit.

b. Make sure that condenser--fan blade is correctly

positioned in fan orifice. Top 1/3 of condenser--fan blade should be within fan orifice venturi.

c. Ensure fan hub is positioned correctly with respect

to motor housing (See Fig. 11).

d. Make sure that air filter(s) is in place. e. Make sure that condensate drain trap is filled with

water to ensure proper drainage.

f. Make sure that all tools and miscellaneous loose

parts have been removed.

5. Charge unit with R--22 refrigerant, using a volumetric charging cylinder or accurate scale. Refer to unit rating plate for required charge. Be sure to add extra refrigerant to compensate for internal volume of filter drier.

STEP 2—START--UP HEATING AND MAKE ADJUSTMENTS

Complete the r equired procedures given in the Pre--Start--Up section before starting the unit. Do not jumper any safety devices when operating the unit. Make sure that burner orifices are properly aligned. Unstable operation my occur when the burner orifices in the manifold are misaligned.

Follow the lighting instructions on the heating section operation label (located inside the burner or blower access door) to start the heating section.

NOTE: Make sure that gas supply has been purged, and that all gas piping has been checked for leaks.

FIGURE 12

Burner Assembly

FIGURE 11

MOTOR

1/8" MAX BETWEEN MOTOR AND FAN HUB

Fan Blade Clearance

FAN GRILLE

1/2ý

MOTOR SHAFT

START--UP

Step 1—CHECK FOR REFRIGERANT LEAKS

Proceed as follows to locate and repair a refrigerant leak and to charge the unit:

1. Locate leak and make sure that refrigerant system pressure has been relieved and reclaimed from both high-- and low--pressure ports.

2. Repair leak following accepted practices.

NOTE: Install a filter drier whenever the system has been opened for repair.

3. Add a small charge of R--22 refrigerant vapor to system and leak--test unit.

4. Recover refrigerant from refrigerant system and evacuate to 500 microns if no additional leaks are found.

MANIFOLD PIPE PLUG

FIGURE 13

Monoport Burner

BURNER FLAME

BURNER

MANIFOLD

CHECK HEATING CONTROL

NUMBER

MANIFOLD

PRESSURE

(IN.WC)

ORIFICES

Start and check the unit for proper heating control operation as follows (see furnace lighting instructions located inside burner or blower access panel):

1. Place room thermostat SYSTEM switch in the HEAT position and the fan switch is placed in AUTO position.

2. Set the heating temperature control of the thermostat above room temperature.

3. The induced--draft motor will start.

4. After a call for heating, the main burner should light within 5 sec. If the burners do not light, there is a 22--sec. delay before another 5--sec. try. If the burners still do not light, this sequence is repeated. If the burners do not light within15 minutes from the initial call for heat, there is a lockout. To reset the control, break the 24--v power to W.

5. The evaporator fan will turn on 45 sec. after the flame has been established. The evaporator fan will turn off 45 sec. after the thermostat has been satisfied.

CHECK GAS INPUT

Check gas input and manifold pressure after unit start--up (See Table 3). If adjustment is required proceed as follows:

-- The rated gas inputs shown in Table 3 are for altitudes from sea level to 2000 ft above sea level. These inputs are based on natural gas with a heating value of 1050

Btu/ft heating value of 2500 Btu/ft

at 0.65 specific gravity, or propane gas with a

at 1.5 specific gravity.

-- For elevations above 2000 ft, reduce input 4% for each 1000 ft above sea level. For example at 2001 ft. a 12% total derate is required.

-- When the gas supply being used has a differentheating value or specific gravity, refer to national and local codes, or contact your distributor to determine the required orifice size.

CAUTION

ADJUST GAS INPUT

The gas inputto the unit is determined bymeasuring the gas flow at the meter or by measuring the manifold pressure. Measuring the gas flow at the meter is recommended for natural gas units. The manifoldpressure must be measured to determine the input of propane gas units.

Measure Gas Flow (Natural Gas

Units)

Minor adjustment to the gas flow can be made by changing the manifold pressure. The manifold pressure must be maintained between 3.4 and 3.6 in. wc.

If larger adjustments are required, change main burner orifices following the recommendations of national and local codes.

NOTE: All other appliances that use the same meter must be turned off when gas flow is measured at the meter.

Proceed as follows:

1. Turn off gas supply to unit.

2. Remove pipe plug on manifold (See Fig. 12) and connect manometer. Turn on gas supply to unit.

3. Record number of seconds for gas meter test dial to make one revolution.

4. Divide number of seconds in Step 3 into 3600 (number of seconds in one hr).

5. Multiply result of Step 4 by the number of (cubic feet) cu ft shown for one revolution of test dial to obtain cu ft of gas flow per hour.

6. Multiply result of Step 5 by Btu heating value of gas to obtain total measured input inBtuh. Compare this value with heating input shown in Table 3 (Consult the local gas supplier if the heating value of gas is not known).

EXAMPLE: Assume that the size of test dial is 1 cu ft, one revolution takes 32 sec., and the heating value of the gas is 1050 Btu/ft

. Proceed as follows:

UNIT DAMAGE HAZARD

Failure to follow this caution may result in reduced unit and/or component life.

Do Not redrill an orifice. Improper drilling (burrs, out--of--round holes, etc.) can cause excessive burner noise and misdirection of burner flame. If orifice hole appears damaged or it is suspected to have been redrilled, check orifice hole with a numbered drill bit of correct size.

Table 2—Heating Inputs

HEATING INPUT

(BTUH)

40,000 2 4.0 13.0 4.0 13.0 3.5 3.5 60,000 2 4.0 13.0 4.0 13.0 3.5 3.5

90,000 3 4.0 13.0 4.0 13.0 3.5 3.4 115,000 3 4.0 13.0 4.0 13.0 3.5 3.7 130,000 3 4.0 13.0 4.0 13.0 3.5 3.5

*When a unit is converted to propane, different size orifices must be used. See separate, natural--to--propane conversion kit instructions.

{Based on altitudes from sea level to 2000 ft above sea level. For altitudes above 2000 ft, reduce input rating 4 percent for each

additional 1000 ft above sea level. In Canada, from 2000 ft above sea level to 4500 ft above sea level, derate the unit 10 percent.

Min Max Min Max

GAS SUPPLY PRESSURE (IN. WC)

Natural{ Propane*{

Natural{

Propane*†

1. 32 sec. to complete one revolution.

2. 3600 P 32 = 112.5.

3. 112.5 x 1 =112.5 ft

4. 112.5 x 1050 = 118,125 Btuh input.

If the desiredgas input is115,000Btuh, only a minor change in the manifold pressure is required.

Observe manifold pressure and proceed as follows to adjust gas input:

1. Remove cover screw over regulator adjustment screw on gas valve.

2. Turn regulator adjustment screw clockwise to increase gas input, or turn regulator adjustment screw counterclockwise to decrease input. Manifold pressure must be between 3.4 and 3.6 in. wc.

FIRE AND UNIT DAMAGE HAZARD

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

Unsafe operation of the unit may result if manifold pressure is outside this range.

3. Replace cover screw cap on gas valve.

4. Turn off gas supply to unit. Remove manometer from pressure tap and replace pipe plug on gas valve. Turn on gas to unit and check for leaks.

Measure Manifold Pressure (Propane

The main burner orifices on a propane gas unit are sized for the unit rated input when the manifold pressure reading matches the level specified in Table 3.

Proceed as follows to adjust gas input on a propane gas unit:

1. Turn off gas to unit.

2. Remove pipe plug on manifold and connect manometer (See Fig. 12).

3. Turn on gas to unit.

4. Remove cover screw over regulator adjustment screw on gas valve.

of gas flow/hr.

WARNING

Units)

5. Adjust regulator adjustment screw to the correct manifold pressure, as specified in Table 3. Turn adjusting screw clockwise to increase manifold pressure, or turn adjusting screw counterclockwise to decrease manifold pressure.

6. Replace cover screw.

7. Turn off gas to unit. Remove manometer from pressure tap. Replace pipe plug on gas valve, then turn on gas to unit. Check for leaks.

CHECK BURNER FLAME

With burner access panel removed, observe the unit heating operation. Watch the burner flames to see if they are light blue and soft in appearance, and that the flames are approximately the same for each burner. Propane will have blue flame (See Fig. 13). Refer to the Maintenance section for information on burner removal.

AIRFLOW AND TEMPERATURE RISE

The heating section for each size unit is designed and approved for heating operation within the temperature--rise range stamped on the unit rating plate.

Table 8 shows the approved temperature rise range for each heating input, and the air delivery cfm at various temperature rises. The heating operation airflow must produce a temperature rise that falls within the approved range.

Refer to Indoor Airflow and Airflow Adjustments section to adjust heating airflow when required.

HEATING SEQUENCE OF OPERATION

(See Fig. 14 and unit wiring label.)

On a call for heating, terminal W of the thermostat is energized, starting the induced--draft motor. When the hall--effect sensor on the induced --draft motor senses that it has reached the required speed, the burner sequence begins. This function is performed by the integrated gas control (IGC). The indoor (evaporator)--fan motor is energized 45 sec. after flame is established. When the thermostat is satisfied and W is de--energized, the burners stop firing and the indoor (evaporator) fan motor shuts off after a 45--sec. time--off delay.

FIGURE 14

PGN324--60 Wiring Diagram

LED MONITOR An LED (light--emitting diode) indicator is provided on the

control board to monitor operation. The control board is located by removing the burner access panel. During normal operation, the LED is continuously on (See Table 4 for error codes).

Tab le 3 — LED Indications

ERROR CODE LED INDICATION

Normal Operation On

Hardware Failure Off

Fan On/Off Delay Modified 1Flash

Limit Switch Fault 2 Flashes

Flame Sense Fault 3 Flashes

Four Consecutive Limit Faults 4 Flashes

Ignition Lockout Fault 5 Flashes

Induced--Draft Motor Fault 6 Flashes

Rollout Switch Fault 7 Flashes

Internal Control Fault 8 Flashes

Temporary Lock--Out (1 hr) 9 Flashes

NOTES:

1. There is a 3 sec. pause between error code displays.

2. If more than one error code exists, all applicable error codes will be displayed in numerical sequence.

3. This chart is on the wiring diagram located inside the burner access panel.

LIMIT SWITCHES

Normally closed limit switch (LS) completes the control circuit. Should the leaving--air temperature rise above the maximum allowable temperature, the limit switch opens and the control circuit “breaks.” Any interruption in the control circuit instantly closes the gas valve and stops gas flow to the burners and pilot. The blower motor continues to run until LS resets.

When the air temperature at the limit switch drops to the low--temperature setting of the limit switch, the switch closes and completes the control circuit. The direct--spark ignition system cyclesand the unit returns to normal heating operation.

ROLLOUT SWITCH

The function of the rollout switch is to close the main gas valve in the event of flame rollout. The switch is located above the main burners. When the temperature at the rollout switch reaches the maximum allowable temperature, the control circuit trips, closing the gas valve and stopping gas flow to the burners. The indoor (evaporator) fan motor (IFM) and induced draft motor continue to run until switch is reset. The IGC LED will display FAULT CODE 7.

Step 3—START--UP COOLING AND MAKE ADJUSTMENTS

Complete the r equired procedures given in the Pre--Start--Up section before starting the unit. Do not jumper any safety devices when operating the unit. Do not operate the compressor when the outdoor temperature is below 40°F(4.4°C) (unless accessory low--ambient kit is installed). Do not rapid--cycle the compressor. Allow 5 minutes between on cycles to prevent compressor damage.

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.

WARNING

CHECKING COOLING CONTROL OPERATION

Start and check the unit for proper cooling control operation as follows:

1. Place room thermostat SYSTEM switch in OFF position. Observe that blower motor starts when FAN switch is placed in ON position and shuts down when FANswitchisplacedinAUTOposition.

2. Place SYSTEM switch in COOL position and FAN switch in AUTO position. Set cooling control below room temperature. Observe that compressor, condenser fan, and evaporator blower motors start. Observe that cooling cycle shuts down when control setting is satisfied. The evaporator fan will continue to run for 30 sec.

3. When using an auto--changeover room thermostat, place both SYSTEM and FAN switches in AUTO positions. Observe that uni t operates in Heating mode when temperature control is set to call for heating (above room temperature) and operates in Cooling mode when temperature control is set to call for cooling (below room temperature).

CHECKING AND ADJUSTING REFRIGERANT CHARGE

The refrigerant system is fully charged with R--22 refrigerant and is tested and factory sealed. Allow system to operate a minimum of 15 minutes before checking or adjusting charge.

NOTE:Adjustment of the refrigerant charge is not required unless the unit is suspected of not having the proper R--22 charge.

A refrigerant charging label is attached to the outside of the service access door. The chart includes the required suction line temperature at given suction line pressures and outdoor ambient temperatures.

An accurate superheat, thermocouple-- or thermistor--type thermometer, and a gauge manifold are required when using the superheat charging method for evaluating the unit charge. Do not use mercury or small dial--type thermometers because they are not adequate for this type of measurement.

UNIT DAMAGE AND ENVIRONMENTAL HAZARD

Failure to follow this caution may result in unit damage.

When evaluating the refrigerant charge, an indicated adjustment to the specified factory charge must always be very minimal. If a substantial adjustment is indicated, an abnormal condition exists somewhere in the cooling system, such as insufficient airflow across either coil or both coils. Always recover refrigerant, never vent to the atmosphere.

Proceed as follows:

1. Remove cap from low--pressure service fittings.

2. Using hoses with valve core depressors, attach low--pressure gauge hose to low--pressure service fitting.

CAUTION

Tab le 4 — Cooling Charging Chart

3. Start unit in Cooling Mode and let unit run until system pressures stabilize.

4. Measure and record the following:

a. Outdoor ambient--air temperature (°F(°C)db).

b. Suction line temperature (°F(°C)). c. Suction (low--side) pressure (psig).

5. Using “Cooling Charging Charts,” compare outdoor--air temperature(°F(°C) db) with the suction line pressure (psig) to determine desired system operating suction line temperature (See Table 5).

6. Compare actual suction line temperature with desired suction line temperature. Using a tolerance of +/-- 3°F (1.7°C), add refrigerant if actual temperature is higher than proper suction line temperature, or remove refrigerant if actual temperature is lower than required suction line temperature.

NOTE: If the problem causing the inaccurate readings is a refrigerant leak, refer to the Check for Refrigerant Leaks section.

INDOOR AIRFLOW AND AIRFLOW ADJUSTMENTS

CAUTION

UNIT OPERATION HAZARD

Failure to follow this caution may result in unit damage.

For cooling operation, the recommended airflow is 350 to 450 cfm for each 12,000 Btuh of rated cooling capacity. For heating operation, the airflow must produce a temperature rise that falls within the range stamped on the unit rating plate.

Table 8 shows the temperature rise in each heating mode. Refer to these tables to determine the desired heating airflow for the system being installed. (See Table 9 for wet coil pressure drop).

NOTE: Be sure that all supply--and return--air grilles are open, free from obstructions, and adjusted properly. Airflow can be changed using the User Interface.

ELECTRICAL SHOCK HAZARD

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

Disconnect electrical power to the unit and install lockout tag before changing blower speed.

Airflow can be changed by changing the lead connections of the blower motor.

All PGN3 units are factory wired for low speed, except the 030 through 048 sizes, which are wired for medium speed.

FOR 208/230V

For color coding on the 208/230V motor leads, see Table 6.

Tab le 5 — Color Coding for 208/230V Motor Leads

WARNING

BLACK = HIGH SPEED

Blue = Medium Speed

Red = Low Speed

3. The set of normally open contacts of energized relay BM close and complete the circuit through evaporator blower (indoor) fan motor (IFM).

NOTE: Once the compressor has started and then stopped, it should not be started again until 5 minutes have elapsed. The cooling cycle remains on until the room temperature drops to a point that is slightly below the cooling control setting of the room thermostat. At this point, the thermostat breaks the circuit between thermostat terminal R to terminals Y and G. These open circuits deenergize contactor coil C. The condenser and compressor motors stop. After a 30--sec. delay,the blower motor stops. The unit is in a standby condition, waiting for the next call for cooling from the room thermostat.

MAINTENANCE

To ensure continuing high performance and to minimize the possibility of premature equipment failure, periodic maintenance must be performed on this equipment. This unit should be inspected at least once each year by a qualified service person. To troubleshoot unit, refer to Table 10, Troubleshooting Chart.

NOTE TO EQUIPMENT OWNER: Consult your local dealer about the availability of a maintenance contract.

PERSONAL INJURY AND UNIT DAMAGE HAZARD

Failure to follow this warning could result in personal injury or death and unit component damage.

The ability to properly perform maintenance on this equipment requires certain expertise, mechanical skills, tools and equipment. If you do not possess these, do not attempt to perform any maintenance on this equipment, other than those procedures recommended in the Owner’s Manual.

WARNING

To change the speed of the indoor fan motor (IFM), remove the fan motor speed leg lead from the blower relay (BR). This wire is attached to terminal blower motor (BM) of the integrated gas control (IGC) board for single--phase units. To change the speed, remove and replace with lead for desired blower motor speed. Insulate the removed lead to avoid contact with chassis parts.

COOLING SEQUENCE OF OPERATION

With the room thermostat SYSTEM switch in the COOL position and the FAN switch in the AUTO position, the cooling sequence of operation is as follows:

1. When the room temperature rises to a point that is slightly above the cooling control setting of the thermostat, the thermostat completes the circuit between thermostat terminal R to terminals Y and G.

2. The normally open contacts of energized contactor (C) close and complete the circuit through compressor motor (COMP) to condenser (outdoor) fan motor (OFM). Both motors start instantly.

ELECTRICAL SHOCK HAZARD

Failure to follow these warnings could result in personal injury or death:

1. Turn off electrical power to the unit before performing any maintenance or service on this unit. Install lockout tag.

2. Use extreme caution when removing panels and parts.

3. Never place anything combustible either on or in contact with the unit.

UNIT OPERATION HAZARD

Failure to follow this caution may result in improper operation.

Errors made when reconnecting wires may cause improper and dangerous operation. Label all wires prior to disconnecting when servicing.

CAUTION

The minimum maintenance requirements for this equipment are as follows:

1. Inspect air filter(s) each month. Clean or replace when necessary.

2. Inspect indoor coil, drain pan, and condensate drain each cooling season for cleanliness. Clean when necessary.

3. Inspect blower motor and wheel for cleanliness at the beginning of each heating and cooling season. Clean when necessary. For first heating and cooling season, inspect blower wheel bi--monthly to determine proper cleaning frequency.

4. Check electrical connections for tightness and controls for proper operation each heating and cooling season. Service when necessary.

5. Ensure electric wires are not in contact with refrigerant tubing or sharp metal edges.

6. Check and inspect heating section before each heating season. Clean and adjust when necessary.

7. Check flue hood and remove any obstructions, if necessary.

AIR FILTER

IMPORT ANT: Never operate the unit without a suitable air filter in the return--air duct system. Always replace the filter with the same dimensional size and type as originally installed. See Table 1 for recommended filter sizes.

Inspect air filter(s) at least once each month and replace (throwaway--type) or clean (cleanable--type) at least twice during each cooling season and twice during the heating season, or whenever the filter becomes clogged with dust and lint.

INDOOR BLOWER AND MOTOR

NOTE: All motors are pre--lubricated. Do not attempt to lubricate these motors.

For longer life, operating economy, and continuing efficiency, clean accumulated dirt and grease from the blower wheel and motor annually.

ELECTRICAL SHOCK HAZARD

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

Disconnect and tag electrical power to the unit before cleaning and lubricating the blower motor and wheel.

WARNING

To clean the blower motor and wheel:

1. Remove and disassemble blower assembly as follows:

a. Remove unit access panel. b. Disconnect motor lead from blower relay (BM).

Disconnect ytellow lead from terminal L2 of the contactor.

c. On all units remove blower assembly from unit.

Remove screws securing blower to blower partition and slide assembly out. Be careful not to tear insulation in blower compartment.

d. Ensure proper reassembly by marking blower

wheel and motor in relation to blower housing before disassembly.

e. Loosen setscrew(s) that secures wheel to motor

shaft, remove screws that secure motor mount brackets to housing, and slide motor and motor mount out of housing.

2. Remove and clean blower wheel as follows:

a. Ensure proper reassembly by marking wheel

orientation.

b. Lift wheel from housing. When handling and/or

cleaning blower wheel, be sure not to disturb balance weights (clips) on blower wheel vanes.

c. Remove caked--on dirt from wheel and housing

with a brush. Remove lintand/or dirt accumulations from wheel and housing with vacuum cleaner, using soft brush attachment. Remove grease and oil with mild solvent.

d. Reassemble wheel into housing. e. Reassemble motor into housing. Be sure

setscrews are tightened on motor shaft flats and not on round part of shaft.

f. Reinstall unit access panel.

3. Restore electrical power to unit. Start unit and check for proper blower rotation and motor speeds during heating and cooling cycles.

FLUE GAS PASSAGEWAYS

To inspect the flue collector box and upper areas of the heat exchanger:

1. Remove the combustion blower wheel and motor assembly according to directions in the Combustion--Air Blower section.

2. Remove the 3 screws holding the blower housing to the flue collector box cover (See Fig. 15--18).

3. Remove the 12 screws holding the flue collector box cover (See Fig. 17--18) to the heat exchanger assembly. Inspect the heat exchangers.

4. Clean all surfaces, as required, using a wire brush.

INDUCED DRAFT (COMBUSTION AIR) BLOWER

Clean periodically to assure proper airflow and heating efficiency. Inspect blower wheel every fall and periodically during the heating season. For the first heating season, inspect blower wheel bimonthly to determine proper cleaning frequency.

To inspect blower wheel, remove draft hood assembly. Shine a flashlight into opening to inspect wheel. If cleaning is required, remove motor and wheel as follows:

1. Remove unit access panel (See Fig. 16).

2. Remove the 7 screws that attach induced--draft motor mounting plate to blower housing (See Fig. 17).

3. Slide the motor and blower wheel assembly out of the blower housing (See Fig. 17). Clean the blower wheel. If additional cleaning is required, continue with Steps 4 and 5.

4. To remove blower, remove 2 setscrews.

5. To remove motor and cooling fan assembly, remove 4 screws that hold blower housing to mounting plate.

6. To reinstall, reverse the procedure outlined above.

LIMIT SWITCH

Remove unit access panel. Limit switch is located on the blower partition.

BURNER IGNITION

Unit is equipped with a direct spark ignition 100 percent lockout system. Ignition module is located in the control box (See Fig. 15).Module contains a self--diagnostic LED. During servicing, refer to label diagram for LED interpretation.

If lockout occurs, unit may be reset by either momentarily interrupting power supply to unit or by turning selector switch to OFF position at the thermostat.

MAIN BURNERS

At the beginning of each heating season, inspect for deterioration or blockage due to corrosion or other causes. Observe the main burner flames and adjust, if necessary.

Removal of Gas T

rain

To remove the gas train for servicing:

1. Shut off main gas valve.

2. Shut off power to unit and install lockout tag.

3. Remove unit access panel (See Fig. 16).

4. Disconnect gas piping at unit gas valve.

5. Remove wires connected to gas valve. Mark each wire.

6. Remove ignitor and sensor wires at the ignitor module.

7. Remove the mounting screw that attaches the burner rack to the unit base (See Fig. 15).

8. Slide the burner rack out of the unit (See Fig. 15 and

18).

9. To reinstall, reverse the procedure outlined above.

OUTDOOR COIL, INDOOR COIL, AND CONDENSATE DRAIN PAN

Inspect the condenser coil, evaporator coil, and condensate drain pan at least once each year.

The coils are easily cleaned when dry; therefore, inspect and clean the coils either before or after each cooling season. Remove all obstructions, including weeds and shrubs, that interfere with the airflow through the condenser coil.

Straighten bent fins with a fin comb. If coated with dirt or lint, clean the coils with a vacuum cleaner, using the soft brush attachment. Be careful not to bend the fins. If coated with oil or grease, clean the coils with a mild detergent and water solution. Rinse coils with clear water, using a garden hose. Be careful not to splash water on motors, insulation, wiring, or air filter(s). For best results, spray condenser coil fins from inside to outside the unit. On units with an outer and inner condenser coil, be sure to clean between the coils. Be sure to flush all dirt and debris from the unit base.

Inspect the drain pan and condensate drain line when inspecting the coils. Clean the drain pan and condensate drain by removing all foreign matter from the pan. Flush the pan and drain trough with clear water. Do not splash water on the insulation, motor, wiring, or air filter(s). If the drain trough is restricted, clear it with a “plumbers snake” or similar probe device.

FIGURE 15

FIGURE 16

FIGURE 17

Blower Housing and Flue Collector Box

IGNITION MODULE

FLUE COLLECTOR BOX

INDUCED DRAFT MOTOR MOUNT

BLOWER HOUSING

BURNER RACK

MOUNTING SCREW

Unit Access Panel

FRONT ACCESS PANEL

Removal of Motor and Blower Wheel

ROLLOU SWITCH

BLOWER HOUSING

2 SETSCREWS (HIDDEN)

FIGURE 18

Burner Rack Removed

OUTDOOR FAN

CAUTION

UNIT OPERATION HAZARD

Failure to follow this caution may result in damage to unit components.

Keep the condenser fan free from all obstructions to ensure proper cooling operation. Never place articles on top of the unit.

1. Remove 6 screws holding outdoor grille and motor to top cover.

2. Turn motor/grille assembly upside down on top cover to expose fan blade.

3. Inspect the fan blades for cracks or bends.

4. If fan needs to be removed, loosen setscrew and slide fan off motor shaft.

5. When replacing fan blade, position blade so that the hub is 1/8 in. away from the motor end (1/8 in. of motor shaft will be visible) (See Fig. 11).

6. Ensure that setscrew engages the flat area on the motor shaft when tightening.

7. Replace grille.

ELECTRICAL CONTROLS AND WIRING

Inspect and check the electrical controls and wiring annually. Be sure to turn off the electrical power to the unit.

Remove access panel to locate all the electrical controls and wiring. Check all electrical connections for tightness. Tighten all screw connections. If any smoky or burned connections are noticed, disassemble the connection, clean all the parts, re--strip the wire end and reassemble the connection properly and securely.

After inspecting the electrical controls and wiring, replace all the panels. Start the unit, and observe at least one complete cooling cycle to ensure proper operation. If discrepancies are observed in operating cycle, or if a suspected malfunction has occurred, check each electrical component with the proper electrical instrumentation. Refer to the unit wiring label when making these checks.

If no refrigerant leaks are found and low performance is suspected, refer to Checking and Adjusting Refrigerant Charge section.

INDOOR AIRFLOW

The heating and/or cooling airflow does not require checking unless improper performance is suspected. If a problem exists, be sure that all supply-- and return--air grilles are open and free from obstructions, and that the air filter is clean.

METERING DEVICES

Refrigerant metering device is a fixed orifice and is located in the distributor assembly to the indoor coil.

LIQUID LINE STRAINER

The liquid line strainer (to protect metering device) is made of wire mesh and is located in the liquid line on the inlet side of the metering device.

TROUBLESHOOTING

Refer to the Troubleshooting Chart (Table 10--12) for troubleshooting information.

START--UP CHECKLIST

Use the Start--Up Checklist at the back of this manual.

FILTER SIZE

20X20X1 0.05 0.07 0.08 0.1 0.12 0.13 0.14 0.15 — — — — — — — — — — — 20X24X1 — — — — 0.09 0.1 0.11 0.13 0.14 0.15 0.16 — — — — — — — — 24X30X1 — — — — — — — 0.07 0.08 0.09 0.1 0.11 0.12 0.13 0.14 0.15 0.16 0.17 0.18

500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300

Tab le 6 — Filter Pressure Drop Table (in. wc)

CFM

Unit

PGN324040

PGN324060

PGN330040

PGN330060

PGN336060

Heating

Rise

RangeoF

(_C)

20 -- 50

(11 -- 28)

35 -- 65

(19 -- 36)

20 -- 50

(11 -- 28)

35 -- 65

(19 -- 36)

25 -- 55

(14 -- 31)

Table 7—Dry Coil Air Delivery* -- Horizontal and Downflow Discharge --

Unit PGN324--060 (Deduct 10% for 208 Volts)

Motor Speed

Low

Medium

High

Low

Medium

High

Low

Medium

High

Low

Medium

High

Low

Medium

High

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

Watts 311 309 304 301 286 290 286 280 -- -- -- -- -CFM 935 885 820 757 686 583 423 263 -- -- -- -- --

Heating Rise

oF(_C)

(18)34(19)37(20)40(22)44(24) Watts 411 405 398 390 379 357 357 345 327 CFM 1195 1155 1100 1028 957 868 769 647 365 Heating Rise

oF(_C)

(14)26(14)27(15)29(16)31(17)35(19)39(22)46(26) Watts 528 518 509 492 477 467 447 435 421 CFM 1484 1421 1368 1279 1185 1088 970 853 712 Heating Rise

oF(_C)

(11)21(12)22(12)23(13)25(14)28(15)31(17)35(20) Watts 311 309 304 301 286 290 286 280 -- -- -- -- -CFM 935 885 820 757 686 583 423 263 -- -- -- -- --

Heating Rise

oF(_C)

(27)51(28)55(30)59(33) Watts 411 405 398 390 379 357 357 345 327 CFM 1195 1155 1100 1028 957 868 769 647 365 Heating Rise

oF(_C)

(21)39(22)41(23)44(24)47(26)52(29)59(33) Watts 528 518 509 492 477 467 447 435 421 CFM 1484 1421 1368 1279 1185 1088 970 853 712 Heating Rise

oF(_C)

NA NA NA

Watts 311 309 304 301 286 290 286 280 -- -- -- -- -CFM 935 885 820 757 686 583 423 263 -- -- -- -- -Heating Rise

oF(_C)

(18)34(19)37(20)40(22)44(24) Watts 411 405 398 390 379 357 357 345 327 CFM 1195 1155 1100 1028 957 868 769 647 365

Heating Rise

oF(_C)

(14)26(14)27(15)29(16)31(17)35(19)39(22)46(26) Watts 528 518 509 492 477 467 447 435 421 CFM 1484 1421 1368 1279 1185 1088 970 853 712 Heating Rise

oF(_C)

(11)21(12)22(12)23(13)25(14)28(15)31(17)35(20) Watts 311 309 304 301 286 290 286 280 -- -- -- -- -CFM 935 885 820 757 686 583 423 263 -- -- -- -- -Heating Rise

oF(_C)

(27)51(28)55(30)59(33) Watts 411 405 398 390 379 357 357 345 327 CFM 1195 1155 1100 1028 957 868 769 647 365

Heating Rise

oF(_C)

(21)39(22)41(23)44(24)47(26)52(29)59(33) Watts 528 518 509 492 477 467 447 435 421 CFM 1484 1421 1368 1279 1185 1088 970 853 712 Heating Rise

oF(_C)

NA NA NA

Watts 439 429 415 401 395 380 356 339 329 CFM 1242 1170 1089 994 917 837 702 570 442 Heating Rise

oF(_C)

(20)38(21)41(23)45(25)49(27)54(30) Watts 503 491 479 461 450 436 418 404 389 CFM 1320 1244 1162 1081 1005 897 767 662 541

Heating Rise

oF(_C)

(19)36(20)39(22)42(23)45(25)50(28) Watts 641 627 623 609 601 588 571 559 548 CFM 1362 1288 1205 1119 1033 933 826 714 580 Heating Rise

oF(_C)

(18)35(19)37(21)40(22)44(24)48(27)54(30)

External Static Pressure (in. wc)

NA NA NA NA

NA NA NA NA NA

(20)38(21)41(23)46(26)53(29)

NA NA NA NA

NA NA NA NA NA

(20)38(21)41(23)46(26)53(29)

(23)

NA NA

(35)

(23)

NA NA

(35)

NA NA NA

NA NA

Unit

PGN336090

PGN342060

PGN342090

PGN348090

PGN348115

PGN348130

Table 8 Con’t—Dry Coil Air Delivery* -- Horizontal and Downflow Discharge --

Unit PGN324--060 (Deduct 10% for 208 Volts)

Heating

Rise

RangeoF

(_C)

40 -- 70

(22 -- 39 )

25 -- 55

(14 -- 31)

40 -- 70

(22 -- 39)

25 -- 55

(14 -- 31)

35 -- 65

(19 -- 36)

40 -- 70

(22 -- 39)

Motor Speed

Low

Medium

High

Low

Medium

High

Low

Medium

High

Low

Medium

High

Low

Medium

High

Low

Medium

High

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

Watts 439 429 415 401 395 380 356 339 329 CFM 1242 1170 1089 994 917 837 702 570 442 Heating Rise

oF(_C)

(30)58(32)62(34)68(38) Watts 503 491 479 461 450 436 418 404 389 CFM 1320 1244 1162 1081 1005 897 767 662 541

Heating Rise

oF(_C)

(28)54(30)58(32)62(35)67(37) Watts 641 627 623 609 601 588 571 559 548 CFM 1362 1288 1205 1119 1033 933 826 714 580 Heating Rise

oF(_C)

(28)52(29)56(31)60(34)65(36) Watts 434 428 422 403 404 390 375 360 344 CFM 1282 1241 1206 1160 1109 1040 967 890 813 Heating Rise

oF(_C)

(20)36(20)37(21)39(22)41(23)43(24)47(26)51(28) Watts 560 548 535 526 511 496 478 460 439 CFM 1526 1482 1437 1398 1344 1281 1205 1125 1029

Heating Rise

oF(_C)

(16)30(17)31(17)32(18)33(19)35(20)37(21)40(22) Watts 765 746 730 709 690 664 642 624 600 CFM 1860 1805 1751 1685 1620 1541 1468 1370 1265 Heating Rise

oF(_C)

(14)26(14)27(15)28(15)29(16)31(17)33(18) Watts 434 428 422 403 404 390 375 360 344 CFM 1282 1241 1206 1160 1109 1040 967 890 813 Heating Rise

oF(_C)

(29)54(30)56(31)58(32)61(34)65(36)70(39) Watts 560 548 535 526 511 496 478 460 439 CFM 1526 1482 1437 1398 1344 1281 1205 1125 1029

Heating Rise

oF(_C)

(25)46(25)47(26)48(27)50(28)53(29)56(31)60(33) Watts 765 746 730 709 690 664 642 624 600 CFM 1860 1805 1751 1685 1620 1541 1468 1370 1265 Heating Rise

oF(_C)

NA NA NA

Watts 627 617 607 584 567 548 528 503 480 CFM 1550 1530 1493 1461 1414 1361 1320 1250 1177 Heating Rise

oF(_C)

(24)44(24)45(25)46(26)48(27)50(28)51(28)54(30) Watts 771 755 734 711 690 665 639 607 572 CFM 1798 1771 1734 1687 1645 1595 1530 1449 1355

Heating Rise

oF(_C)

(21)38(21)39(22)40(22)41(23)42(24)44(25)47(26) Watts 969 941 908 887 858 827 804 767 748 CFM 2124 2071 2000 1944 1876 1811 1735 1647 1555 Heating Rise

oF(_C)

(18)33(18)34(19)35(19)36(20)37(21)39(22)41(23) Watts 627 617 607 584 567 548 528 503 480 CFM 1550 1530 1493 1461 1414 1361 1320 1250 1177 Heating Rise

oF(_C)

(31)56(31)58(32)59(33)61(34)63(35)65(36) Watts 771 755 734 711 690 665 639 607 572 CFM 1798 1771 1734 1687 1645 1595 1530 1449 1355

Heating Rise

oF(_C)

(27)49(27)50(28)51(28)52(29)54(30)56(31)60(33) Watts 969 941 908 887 858 827 804 767 748 CFM 2124 2071 2000 1944 1876 1811 1735 1647 1555 Heating Rise

oF(_C)

(23)42(23)43(24)44(25)46(26)48(26)50(28)52(29) Watts 627 617 607 584 567 548 528 503 480 CFM 1550 1530 1493 1461 1414 1361 1320 1250 1177 Heating Rise

oF(_C)

(35)64(35)65(36)67(37)69(38) Watts 771 755 734 711 690 665 639 607 572 CFM 1798 1771 1734 1687 1645 1595 1530 1449 1355

Heating Rise

oF(_C)

(30)55(31)56(31)58(32)59(33)61(34)64(35)67(37) Watts 969 941 908 887 858 827 804 767 748 CFM 2124 2071 2000 1944 1876 1811 1735 1647 1555 Heating Rise

oF(_C)

(26)47(26)49(27)50(28)52(29)54(30)56(31)59(33)

External Static Pressure (in. wc)

NA NA NA NA NA

NA NA NA NA

(22)42(23)44(24)46(26)49(27)

NA NA NA NA

(31)

(24)

(20)

NA NA

(36)

(30)

(28)

(24)

NA NA

(35)

(31)

(35)

Table 8 Con’t—Dry Coil Air Delivery* -- Horizontal and Downflow Discharge --

Unit PGN324--060 (Deduct 10% for 208 Volts)

Heating

Unit

Rise

RangeoF

(_C)

Motor Speed

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

Watts 786 769 754 736 722 705 684 658 616

Low

Heating Rise

oF(_C)

(19)34(19)36(20)37(21)38(21)40(22)42(23)45(25)

CFM 2027 1960 1901 1821 1759 1693 1616 1513 1354

Watts 873 849 833 815 798 782 763 748 704

PGN360090

25 -- 55

(14 -- 31)

Medium

CFM 2095 2026 1962 1887 1817 1748 1679 1583 1439 Heating Rise

oF(_C)

(18)33(19)34(19)36(20)37(21)39(21)40(22)43(24) Watts 1012 993 981 963 948 927 904 886 846

High

CFM 2184 2109 2036 1963 1886 1812 1729 1647 1496 Heating Rise

oF(_C)

(17)32(18)33(18)34(19)36(20)37(21)39(22)41(23) Watts 786 769 754 736 722 705 684 658 616

Low

Heating Rise

oF(_C)

(24)44(24)45(25)47(26)49(27)51(28)53(30)57(32)

CFM 2027 1960 1901 1821 1759 1693 1616 1513 1354

Watts 873 849 833 815 798 782 763 748 704

PGN360115

35 -- 65

(19 -- 36)

Medium

CFM 2095 2026 1962 1887 1817 1748 1679 1583 1439 Heating Rise

oF(_C)

(23)43(24)44(24)46(25)47(26)49(27)51(29)54(30) Watts 1012 993 981 963 948 927 904 886 846

High

CFM 2184 2109 2036 1963 1886 1812 1729 1647 1496 Heating Rise

oF(_C)

(22)41(23)42(24)44(24)46(25)48(26)50(28)52(29) Watts 786 769 754 736 722 705 684 658 616

Low

Heating Rise

oF(_C)

(27)50(28)51(28)54(30)55(31)58(32)60(34)64(36)

CFM 2027 1960 1901 1821 1759 1693 1616 1513 1354

Watts 873 849 833 815 798 782 763 748 704

PGN360130

40 -- 70

(22 -- 39)

Medium

CFM 2095 2026 1962 1887 1817 1748 1679 1583 1439 Heating Rise

oF(_C)

(26)48(27)50(28)52(29)54(30)56(31)58(32)62(34) Watts 1012 993 981 963 948 927 904 886 846

High

*Air delivery values are without air filter and are for dry coil (see Wet Coil Pressure Drop table).

Factory--shipped heating/cooling speed

CFM 2184 2109 2036 1963 1886 1812 1729 1647 1496 Heating Rise

oF(_C)

(25)46(26)48(27)50(28)52(29)54(30)56(31)59(33)

“NA” = Not allowed for heating speed Note: Deduct field--supplied air filter pressure drop and wet coil pressure drop to obtain external static pressure available for ducting.

Tab le 8 — PGN3 Wet Coil Pressure Drop

UNIT SIZE

600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 024 0.030 0.037 0.044 0.053 0.063 -- -- -- -- -- -- -- -- -- -030 -- 0.037 0.044 0.053 0.063 0.072 0.081 0.105 -- -- -- -- -- -- -036 -- -- -- 0.05 0.061 0.072 0.08 0.09 0.11 -- -- -- -- -- -042 -- -- -- -- 0.044 0.051 0.059 0.065 0.072 0.080 0.088 0.095 0.105 -- -048 -- -- -- -- -- -- 0.044 0.050 0.053 0.059 0.066 0.072 0.077 0.086 -060 -- -- -- -- -- -- -- -- -- 0.079 0.087 0.095 0.102 0.113 0.123

STANDARD CFM (S.C.F.M.)

External Static Pressure (in. wc)

(28)

(26)

(25)

(35)

(33)

(32)

(38)

(36)

SYMPTOM CAUSE REMEDY

Compressor and condenser fan will not start.

Compressor will not start but condenser fan runs

Compressor cycles (other than normally satisfying UI)

Compressor operates continuously

Excessive head pressure

Head pressure too low

Excessive suction pressure

Suction pressure too low

Tab le 9 — Troubleshooting Chart

Power failure Call power company Fuse blown or circuit breaker tripped Replace fuse or reset circuit breaker Defective contactor, transformer, or high--pres-

sure, loss--of--charge or low--pressure switch Insufficient line voltage Determine cause and correct Incorrect or faulty wiring Check wiring diagram and rewire correctly

Thermostat setting too high

Faulty wiring or loose connections in compressor circuit

Compressor motor burned out, seized, or Determine cause internal overload open Replace compressor Defective run/start capacitor, overload, start relay Determine cause and replace

One leg of 3--phase power dead

Low input voltage (20% low) Determine cause and correct

Refrigerant overcharge or undercharge

Defective compressor Replace and determine cause Insufficient line voltage Determine cause and correct Blocked outdoor coil Determine cause and correct Defective run/start capacitor Determine cause and replace Faulty outdoor fan motor or capacitor Replace Restriction in refrigerant system Locate restriction and remove Dirty air filter Replace filter Unit undersized for load Decrease load or increase unit size Thermostat temperature set too low Reset Thermostat Low refrigerant charge Locate leak, repair, and recharge

Air in system

Outdoor coil dirty or restricted Clean coil or remove restriction Dirty air filter Replace filter Dirty condenser coil Clean coil Refrigerant overcharged Recover excess refrigerant

Air in system

Condenser air restricted or air short--cycling Determine cause and correct Low refrigerant charge Check for leaks, repair, and recharge.

Restriction in liquid tube Remove restriction

High heat load Check f or source and eliminate

Compressor valves leaking Replace compressor Refrigerant overcharged Recover excess refrigerant

Dirty air filter Replace filter Low refrigerant charge Check for leaks, repair and recharge Metering device or low side restricted Remove source of restriction

Insufficient evaporator airflow

Temperature too low in conditioned area Reset Thermostat Outdoor ambient below 55°F (12.7°C) Install low--ambient kit Filter drier restricted Replace filter

Replace component

Lower Thermostat temperature setting below room temperature

Check wiring and repair or replace

Replace fuse or reset circuit breaker Determine cause

Recover refrigerant, evacuate system, and recharge to capacities shown on rating plate

Recover refrigerant, evacuate system, and recharge

Increase air quantity Check filter–replace if necessary

SYMPTOM CAUSE REMEDY

Burners will not ignite

Inadequate heating

Poor flame characteristics

Table 10—Troubleshooting Guide–Heating

Water in gas line Drain. Install drip leg.

No power to furnace

No 20--v power supply to control circuit

Mis--wired or loose connections Check all wiring and wire nut connections

Misaligned spark electrodes

No gas at main burners

Dirty air filter Clean or replace filter as necessary

Gas input to furnace too low

Unit undersized for application

Restricted airflow

Limit switch cycles main burners

Incomplete combustion results in: Aldehyde odors, carbon monoxide, sooting flame, floating flame

Check power supply fuses, wiring or circuit breaker.

Check transformer. NOTE: Some transformers have internal over--current protection that requires a cool-down period to reset.

Check flame ignition and sense electrode positioning. Adjust as necessary.

1. Check gas line for air. Purge as necessary. NOTE: After purging gas line of air, wait at least 5 minutes for any gas to dissipate before attempting to light unit.

2. Check gas valve.

Check gas pressure at manifold match with that on unit nameplate

Replace with proper unit or add additional

unit Clean or replace filter. Remove any restric-

tion. Check rotation of blower, temperature rise of

unit. Adjust as necessary.

1. Tighten all screws around burner compartment

2. Cracked heat exchanger. Replace.

3. Unit over--fired. Reduce input (change orifices or adjust gas line or manifold pressure).

4. Check burner alignment.

5. Inspect heat exchanger for blockage. Clean as necessary.

SYMPTOM CAUSE REMEDY

Hardware failure (LED OFF)

Fan ON/OFF delay modified (LED/FLASH)

Limit switch faults (LED 2 flashes)

Flame sense fault (LED 3 flashes)

4 consecutive limit switch faults (LED 4 flashes)

Ignition lockout (LED 5 flashes)

Induced--draft motor fault (LED 6 flashes)

Tab le 11— Troubleshooting Guide–LED Error Codes

Check 5--amp fue son IGC*, power to unit, 24--v circuit breaker, and transformer. Units without a 24--v

Loss of power to control module (IGC)*.

High limit switch opens during heat exchanger warm--up period before fan--on delay expires. Limit switch opens within three minutes after blower--off delay timing in heating mode.

High temperature limit switch is open.

The IGC* sensed flame that should not be present.

Inadequate airflow to unit.

Unit unsuccessfully attempted ignition for 15 minutes.

IGC does not sense that induced--draft motor is operating.*

circuit breaker have an internal overload in the 24--v transformer. If the overload trips, allow 10 minutes for automatic reset.

Ensure unit is fired on rate; ensure temperature rise is correct. Ensure unit’s external static pressure is within application guidelines.

Check the operation of the indoor (evaporator) fan motor. Ensure that the supply--air temperature rise is in accordance with the range on the unit nameplate. Clean or replace filters.

Reset unit. If problem persists, replace control board.

Check the operation of the indoor (evaporator) fan motor and that supply--air temperature rise agrees with range on unit nameplate information.

Check ignitor and flame sensor electrode spacing, gaps, etc. Ensure that fame sense and ignition wires are properly terminated. Verify that unit is obtaining proper amount of gas.

Check for proper voltage. If motor is operating, check the speed sensor plug/IGC Terminal J2 connection. Proper connection: PIN 1 -- White PIN 2 -- Red PIN 3 -- Black

SYMPTOM CAUSE REMEDY

Rollout switch will automatically reset, but IGC* will

Rollout switch fault (LED 7 flashes)

Rollout switch has opened.

continue to lockout unit. Check gas valve operation. Ensure that induced--draft blower wheel is properly secured to motor shaft. Inspect heat exchanger. Re set unit at unit disconnect.

Internal control fault (LED 8 flashes)

Temporary software lockout (LED 9 flashes)

*WARNING : If the IGC must be replaced, be sure to ground yourself to dissipate any electrical charge that my be present before handling new control board. The IGC is sensitive to static electricity and my be damaged if the necessary precautions are not taken.

IMPORTANT: Refer to Table 12--Troubleshooting Guide--Heating for additional troubleshooting analysis. LEGEND

IGC—Integrated Gas Unit Controller LED—Light--Emitting Diode

Microprocessor has sensed an error in the software or hardware.

Electrical interference impeding IGC software

If error code is not cleared by resetting unit power, replace the IGC*.

Reset 24--v. to control board or turn thermostat off, then on again. Fault will automatically reset itself in one (1) hr.

START-UP CHECKLIST

(Remove and Store in Job File)

I. Preliminary Information

MODEL NO.:_________________________________ SERIAL NO.:__________________________________ DATE:_______________________________________ TECHNICIAN:_________________________________

II. PRE-START-UP (Insert checkmark in box as each item is completed)

( ) VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT ( ) REMOVE ALL SHIPPING HOLD DOWN BOLTS AND BRACKETS PER INSTALLATION INSTRUCTIONS ( ) CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS ( ) CHECK GAS PIPING FOR LEAKS (WHERE APPLICABLE) ( ) CHECK THAT INDOOR (EVAPORATOR) AIR FILTER IS CLEAN AND IN PLACE ( ) VERIFY THAT UNIT INSTALLATION IS LEVEL ( ) CHECK FAN WHEEL, AND PROPELLER FOR LOCATION IN HOUSING/ORIFICE AND SETSCREW TIGHTNESS

III. START-UP ELECTRICAL

SUPPLY VOLTAGE __________________________________ COMPRESSOR AMPS_________________________________ INDOOR (EVAPORATOR) FAN AMPS___________

TEMPERATURES

OUTDOOR (CONDENSER) AIR TEMPERATURE ___________DB RETURN-AIR TEMPERATURE ___________DB ___________WB COOLING SUPPLY AIR ___________DB ___________WB GAS HEAT SUPPLY AIR ___________

PRESSURES

GAS INLET PRESSURE GAS MANIFOLD PRESSURE REFRIGERANT SUCTION ___________PSIG SUCTION LINE TEMP*___________ REFRIGERANT DISCHARGE ___________PSIG DISCHARGE TEMP†___________ ( ) VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS GAS HEAT TEMPERATURE RISE TEMPERATURE RISE (See Literature) RANGE

MEASURED TEMPERATURE RISE

*Measured at suction inlet to compressor

†Measured at liquid line leavin

___________

condenser.

IN.WG

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ICP PGN324, PGN330, PGN342, PGN348, PGN360 Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual