ICP PGX436080K01A, PGX436080K00A, PGX430060K01A, PGX436060K01A, PGX442080K00A Owner's Manual

Packaged Gas/Electric Units

Owner's Guide to Operating and

Maintaining Your Gas/Electric Unit

ELECTRICAL SHOCK HAZARD.

Failure to follow this warning could result in

personal injury, death, and/or property damage.

Disconnect power at fuse box or service panel

before performing recommended maintenance.

FIRE, EXPLOSION, ELECTRICAL SHOCK
HAZARD.

Failure to follow this warning could result in

personal injury, death, and/or property damage.

Do not use this unit if any part has been under
water. Immediately call a qualified service
technician to inspect the unit and to replace any
part of the control system which has been under

water.

FIRE OR EXPLOSION HAZARD

Failure to follow safety warnings exactly could
result in serious injury, death, and/or property

damage.

--Information in this manual MUST be followed
exactly.

--Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any
other appliance.

--WHAT TO DO IF YOU SMELL GAS

• Leave the building immediately.

• Do not try to light any appliance.

• Do touch any electrical switch; do not use any

phone in the building.

• Immediately call your gas supplier from a

neighbors phone. Follow the gas suppliers
instructions.

• If you cannot reach your gas supplier, call the

fire department.

m Installation and service must be performed by a

qualified installer, service agency or the gas
supplier.

This manual should be left with the owner.

Printed in U.S.A.

Code:PGX4 12/6/06 462 02 1801 00

UNIT DAMAGE HAZARD
Failure to follow this caution may result in the shorten

life of unit components.

Do NOT operate unit in a corrosive atmosphere
containing chlorine, fluorine, or any other corrosive

chemicals.

TO LIGHT UNIT

Your combination heating/cooling unit is equipped with an
automatic direct spark ignition and power combustion

blower.

FIRE AND/OR EXPLOSION HAZARD

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

Do not attempt to light by hand, personal injury may

result.

FIRE AND/OR EXPLOSION HAZARD

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

1. If the main burners fail to light, or the blower fails to

start, shut down gas heating section and call your
dealer for service.

2. Never attempt to manually light the main burners on
unit with a match, lighter, or any other flame. If the

electric sparking device fails to light the main burners,

refer to the following shutdown procedures, then call

your dealer as soon as possible.

TO SHUT UNIT OFF

FIRE AND/OR EXPLOSION HAZARD

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

Do not turn off the electrical power to unit without first

turning off the gas supply.

FIRE AND/OR EXPLOSION HAZARD

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

Do not turn off the electrical power to unit without first

turning off the gas supply.

Before attempting to start the gas heating section,

familiarize yourself with all the procedures that must be
followed.

Refer to Figure 2 for gas valve location.

1. Set the temperature selector on room thermostat to the
lowest temperature setting and set system switch to

HEAT.

2. Close the external manual shutoff valve.

3. Turn off the electrical supply to the unit.

4. Remove the front access panel with a 5/16 -in. nut
driver.

5. Move the selector switch on the internal gas valve to the
OFF position and wait 5 minutes.

6. Move the selector switch on the internal gas valve to the
ON position.

7. Replace the front access panel.

8. Turn on the electrical supply to unit.

9. Open the external manual shutoff valve.

10. Set the temperature selector on room thermostat
slightly above room temperature to start unit. The
induced-draft combustion-air fan will start. Main gas

valve will open and burners should ignite the gas

within 25 seconds. If burners do not light within 25
seconds, the ignition control will go into a Retry Mode

that will take another 25 seconds. If the burners fail to

ignite the gas in 4 consecutive attempts, the unit will
lockout for 3 hours.

11. Set the temperature selector on room thermostat to
desired setting.

NOTE: If unit is being shut down because the heating

season has ended, make sure to turn on power to cooling
system.

Ifunit is being shut down because of a malfunction, call your

dealer as soon as possible.

Should the gas supply fail to shut off or if overheating

occurs, shut off the manual gas valve to the unit before
shutting off the electrical supply.

Do not use this furnace if any part has been under water. A

flood-damaged furnace is extremely dangerous. Attempts
to use the furnace can result in fire or explosion. A qualified

service agency should be contacted to inspect the furnace
and to replace all gas controls, control system parts,

electrical parts that have been wet orthe furnace if deemed
necessary.

Refer to Fig. 2 while proceeding with the following steps.

1. Set the temperature selector on room thermostat to
lowest temperature setting and set system switch to

OFE

2. Close the external manual shutoff valve.

3. Turn off the electrical power supply to the unit.

4. Remove the front access panel.

5. Move the selector switch on the internal gas valve to the
OFF position.

6. Replace the burner access panel.

7. Restore electrical power to the unit and set system
switch to COOL to ensure operation of the cooling
system during the cooling season.

Figure 2 Access to Gas Valve

I IFM and Speed ISelector Leads

Switch

Primary Limit I

I Remote Sparker Unit I

I Burners ]

Sparker ]

I asValvel

Regulator

Adjustment

I Flame Sensor I

IRe,,e°tSwitch]

E

[

Joo.EYw

[

tntlet Pressure

Tap 1/8 NPT

GasValve

SEQUENCE OF OPERATION

Cooling Mode:

1.Adjust thermostat setting below room temperature and
set thermostat selector to COOL.

2.The compressor and condenser fan will immediately
energize.

&The evaporator motor will either immediately start on full

speed or wait approximately 30 seconds to reach full
speed (field-selectable).

Outlet Pressure
Tap 1/8 NPT

The air conditioner has 2 stages of cooling and will
automatically pick the correct cooling stage based on the
difference between the actual indoor temperature and the
set point temperature on the thermostat. For maximum

efficiency, avoid frequent changes to the set point

temperature.

4.When the cooling setpoint has been satisfied
a.The compressor and condenser fan will de-energize

immediately.

b. The evaporator motor will either immediately turn off

or run for an additional 90 seconds before turning off

(field-selectable).

Cooling Cycle - When operating in the cooling cycle, your

air conditioner will run until the indoor temperature is

lowered to the level you have selected. On extremely hot
days, your air conditioner will run for longer periods at a time
and have shorter "off' periods than on moderate days.

The following are typical conditions that add extra heat
and/or humidity to your home. Your air conditioner will work

longer to keep your home comfortable under these
conditions:

• Entrance doors are frequently opened and closed

• Laundry appliances are being operated

• A shower is running

• More than the usual number of people are present in the
home

• More than the normal number of electric lights are in use

• Drapes are open on the sunny side of the home

HEATING MODE

1. Adjust thermostat setting above room temperature and

set thermostat selector to HEAT. The combustion air
blower will energize on high speed.

2. The combustion air blower will run on high speed for 15
seconds to purge the combustion chamber.

3. After the 15 second purge, the combustion air blower
will remain on. The sparker will turn on to ignite the gas
at the same time the gas valve is energized on low
stage. Make sure the gas valve is in the "ON" position

(Refer to Figure 2 and the instruction label located on

the inside of the burner access panel.

4. The sparker will remain energized for 7 seconds or until
a flame is detected by the flame sensor. It may take
several ignition attempts to purge the air out of the gas
line at the initial start-up of the unit.

5. Once flame is proven, the ignition control will monitor
the thermostat to see whether low stage gas heat or
high stage gas heat is needed.

a. If low stage gas heat is needed, the combustion air

blower will be changed to low speed, while keeping

the low stage gas valve operation energized.

b. If high stage gas heat is needed, the combustion air

blower will remain on high speed, and the high stage

gas valve operation is energized.

6.30 seconds after the burners light, the circulating air
blower will begin to run.

NOTE: Regardless of whether the thermostat is calling for
low stage gas heat or high stage gas heat, the unit will

always start with the high inducer speed and low stage gas
valve operation.

131

The gas heating system has 2 stages of heating and will
automatically pick the correct heating stage based on the

difference between the actual indoor temperature and the
set point temperature on the thermostat. For maximum

efficiency, avoid frequent changes to the set point

temperature.

7. When the heating setpoint has been satisfied:
a. The gas valve will turn immediately off.

b. The combustion air blower will run for an additional

15 seconds to purge exhaust gas.
c. The circulating air motor will continue to run an
additional 60, 100, 140, or 180 seconds

(field-selectable) before turning offto extract additional

heat from the heat exchanger.

FIRE AND/OR EXPLOSION HAZARD

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

Do NOT attempt to light the pilot or burner with amatch
or flame of any kind.

ROUTINE MAINTENANCE

All routine maintenance should be handled by skilled,

experienced personnel. Your dealer can help you establish

a standard procedure.

For your safety, keep the unit area clear and free of

combustible materials, gasoline, and other flammable

liquids and vapors.

To assure proper functioning of the unit, flow of combustion
and ventilating air must not be obstructed from reaching the

TABLE 1

Filter Data

I

I Disposable Filters Washable Filters'

unit. Clearance of at least 30 in. is required on all sides
except the duct side.

MAINTENANCE AND CARE FOR THE
EQUIPMENT OWNER

Before proceeding with those things you might want to
maintain yourself, please carefully consider the following:

• TURN OFF GAS SUPPLY AND ELECTRICAL
POWER TO YOUR UNIT BEFORE SERVICING OR

PERFORMING MAINTENANCE.

• Do not turn off electrical power to this unit without first

turning off the gas supply.
When removing access panels or performing

maintenance functions inside your unit, be aware of

sharp sheet metal parts and screws. Although special
care is taken to reduce sharp edges to a minimum, be

extremely careful when handling parts or reaching
into the unit.

AIR FILTERS - Air filter(s) should be checked at least every
3 or 4 weeks and changed orcleaned whenever it becomes

dirty. Dirty filters produce excessive stress on the blower

motor and can cause the motor to overheat and shut down.

Table 1 indicates the correct filter size for your unit.
When installing the new filter(s), note the direction of the

airflow arrows on the filter frame.

If you have difficulty in locating your air filter(s), or if you
have questions concerning proper filter maintenance,

contact your dealer for instructions. When replacing filters,
always use the same size and type offilter that was supplied

originally by the installer. NEVER OPERATE THE UNIT
WITHOUT FILTERS IN PLACE. FAILURE TO OPERATE

WITHOUT FILTERS COULD RESULT IN DAMAGE TO
THE BLOWER MOTOR AND/OR COMPRESSOR,

Nominal Size Minimum Area Nominal Size (w Minimum Area

Model (qty x w x d) (sq. inches) x d) (inches) (sq. inches)
PGX424040 1 x 20" x 20" 384 1 x 10" x 20" 192
PGX424060 1 x 20" x 24" 432 1 x 12" x 20" 216

PGX430040 1 x 20" x 24" 480 1 x 12" x 20" 240
PGX430060 1 x 20" x 24" 480 1 x 12" x 20" 240
PGX436060 2 x 15"x 20" 576 1 x 15" x 20" 288

PGX436080 2 x 15"x 20" 576 1 x 15" x 20" 288
PGX442080 2x 18" x 20" 672 1 x 18" x 20" 336
PGX448100 2 x 20" x 20" 768 1x 20" x 20" 384
PGX448120 2 x 20" x 20" 785 1x 20" x 20" 393

PGX460100 2 x 20" x 24" 960 1x 20" x 24" 480
PGX460120 2 x 20" x 24" 960 1x 20" x 24" 480

1Washable filter size is based on an allowable face velocity of 600 ft/min. Refer to

filter manufacturer's specifications for allowable face velocity and required filter area.

HEAT EXCHANGER - To ensure dependable and efficient
heating operation, the heat exchanger should be checked

by a qualified maintenance person before each heating

season, and cleaned when necessary. This checkout
should not be attempted by anyone not having the required

expertise and equipment to properly do the job. Checking

and/or cleaning the heat exchanger involves removing the

141

gas controls assembly and the flue collector box cover and,
when completed, reinstalling the gas controls assembly for

proper operation. Also, the flue collector box cover must be
replaced correctly so that a proper seal is maintained.

Contact your dealer for the required periodic maintenance.

FANS AND FAN MOTOR - Periodically check the condition

of fan wheels and housings and fan-motor shaft bearings.

No lubrication of condenser- or evaporator-fan bearings or
motors is required or recommended.

EVAPORATOR AND CONDENSER COILS - Cleaning of

the coils should only be done byqualified service personnel.

Contact your dealer for the required annual maintenance.
CONDENSATE DRAIN - The drain pan and condensate

drain line should be checked and cleaned at the same time
the cooling coils are checked by your dealer.

COMPRESSOR - All compressors are factory-shipped

with a normal charge of the correct type refrigeration grade
oil in them and should rarely require additional oil. The

service person must be certain the proper oil level is

maintained in the compressor when it is installed and
running.

CONDENSER FAN -The fan must be kept free of all

obstructions to ensure proper cooling. Contact your dealer
for any required service.

ELECTRICAL CONTROLS and WIRING - Electrical

controls are difficult to check without proper

instrumentation; therefore, if there are any discrepancies in

the operating cycle, contact your dealer and request
service.

REFRIGERATION CIRCUIT - The refrigerant circuit is

difficult to check for leaks without the proper equipment;
therefore, if inadequate cooling is suspected, contact your

local dealer for service.
COMBUSTION AREA and VENT SYSTEM - The

combustion area and vent system should be inspected
visually before each heating season. The normal

accumulation of dirt, soot, rust, and scale can result in loss
of efficiency and improper performance if allowed to build.

UNIT PANELS - After performing any maintenance or

service on the unit, be sure all panels are fastened securely

in place to prevent rain from entering unit cabinet and to
prevent disruption of the correct unit airflow pattern.

REGULAR DEALER MAINTENANCE
In addition to the type of routine maintenance you might be

willing to perform, your unit should be inspected regularly by
a properly trained service technician. An inspection

(preferably each year, but at least every other year) should
include the following:

1. Inspection of all flue product passages - including the
burners, heat exchanger, and flue collector box.

2. Inspection of all combustion- and ventilation-air
passages and openings.

3. Close inspection of all gas pipes leading to and inside of
your unit.

4. Inspection and, if required, cleaning of the condenser
and evaporator coils.

5. Inspection and, if required, cleaning of the evaporator
drain pan.

6. Inspection and cleaning of blower wheel housing and
motor.

7. Inspection of all supply-air and return-air ducts for
leaks, obstructions, and insulation integrity. Any
problems found should be resolved at this time.

8, Inspection of the unit base to ensure that no cracks,

gaps, etc., exist which may cause a hazardous
condition.

9, Inspection of the unit casing for signs of deterioration.
10, Inspection of all electrical wiring and components to

assure proper connection.

11, Inspection for leaks in the refrigerant circuit.

Pressure-check to determine appropriate refrigerant

charge.

12. Inspection of compressor oil level.
13, Operational check of the unit to determine working

conditions. Repair or adjustment should be made at
this time.

Your servicing dealer may offer an economical service
contract that covers seasonal inspections. Ask for further

details.

Complete service instructions can be found in the unit
Installation, Start-Up and Service Instructions,

BEFORE YOU CALL FOR SERVICE, CHECK FOR

THESE EASILY SOLVED PROBLEMS

Check the indoor and outdoor disconnect switches, Verify

that circuit breakers are ON.

Check for sufficient airflow. Check the air filter(s) for any

accumulations of dirt. Check for blocked return-air or
supply-air grilles. Be sure grilles are open and

unobstructed.
Check the settings on your indoor thermostat. If you desire

cooling, see that the temperature control selector is set

below room temperature and the SYSTEM switch is on the
COOL or AUTO position. If you require warmth, be sure the

temperature control selector is set above room temperature
and the SYSTEM switch is at HEAT or AUTO. The FAN

switch should be set at ON for continuous blower operation
or AUTO ifyou wish the blower to function only while the unit

is operating.

If your comfort system still fails to operate, contact your
servicing dealer for troubleshooting and repairs. Specify
your apparent problem, and state the model and serial

numbers of your equipment. (You should have them

recorded on page 4 of this booklet.) With this information,
your dealer may be able to offer helpful suggestions over
the phone, or save valuable time through knowledgeable

preparation for the service call.

INSTALLATION DATA

Date Installed

Dealer Name
Address

City

State
Telephone

Zip

UNIT DATA

Product No,

Model No.

Serial No,

151