ICP PGN324, PGN330, PGN342, PGN348, PGN360 Installation Instructions Manual
...
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.
2
• 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
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.
3
*
FIGURE 3
PGN324--36 DIMENSIONS
REQUIRED CLEARANCE TO COMBUSTIBLE MATL
(
R
efe
r t
o
M
aximu
m
O
perating
C
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]
.
s
)
INCHES [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]
4
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]
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]
Z
5
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
WARNING
WARNING
6
!
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
1
y
4
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
2
x
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
3
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
7
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:
8
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
IN
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
9
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