International Comfort Products PGD324040, PGD324060, PGD330040, PGD330060, PGD336060 TECHNICAL MANUAL

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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 BTU/h 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.

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.

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.

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).

Airflow can be changed by changing the lead connections of the blower motor. Refer to Table 3 for motor lead color coding (208/230V).

Model sizes 24, 36, 42 and 60 are factory wired for low speed. Model sizes 30 and 48 are factory wired for medium speed.

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.

WARNING

Continuous Fan Operation

The continuous fan operates at the same fan speed as cooling operation.

Cooling Sequence of

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.

NOTE: 3--phase, scroll compressors will run backwards if not wired correctly. Unit must be checked to ensure proper compressor 3--phase power lead orientation. If not corrected within 5 minutes, the internal protector will shut off the compressor. To change the rotation of the compressor, swap any two of the three power leads. When turning backwards, the difference between compressor suction and discharge pressures will be minimal.

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

NOTE: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 second delay, the blower motor stops. The unit is in a standby condition, waiting for the next call for cooling from the room thermostat.

Operation

Table 3 -- Color Coding for 208/230V Motor Leads

Black = High Speed

Blue = Medium Speed

Red = Low Speed

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 Tables 11, 12, and 13 -- Troubleshooting Charts.

NOTE TOEQUIPMENT OWNER:Consult your localdealer 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

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.

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 inspectheating section before each heating season. Clean and adjust when necessary.

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

Air

Filter

NOTE: 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 2 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.

Evaporator (Indoor) Motor and

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

lubricate these motors.

WARNING

CAUTION

Blower

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.

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 yellow lead from terminal L2 of the contactor.

c. On all units remove blower assembly from unit.

Remove screwssecuring blower toblower 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 set screw(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 abrush. Remove lint and/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. Connect motor lead to blower relay (BM). Connect

yellow lead to terminal L2 of the contactor

g. Reinstall unit access panel.

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

Induced Draft (Combustion Air)

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 Figure 17).

WARNING

Blower

2. Remove the 5 screws that attach induced--draft motor mounting plate to blower housing (see Figure 19).

3. Slide the assembly out of the blower housing (see Figure 19). Clean the blower wheel. If additional cleaning is required, continue with Steps 4 and 5.

4. To remove blower wheel, 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.

Flue Gas

Passageways

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

1. Remove the induced draft blower assembly according to directions in the Induced Draft Blower Assembly section.

2. Remove the 11 screws holding the flue collector box cover (see Figure 18) to the heat exchanger assembly. Inspect the heat exchangers.

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

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 Figure 18). Module contains a self--diagnostic LED. During servicing, refer to Table 5 or unit 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.

Burners

Main

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 Figure 17).

4. Disconnect gas piping at unit gas valve.

5. Remove wires connectedto gas valve. Mark each wire.

6. Remove ignitor and sensor wires a t the ignitor module.

7. Remove the mounting screw that attaches the burner rack to the unit base (see Figure 18).

8. Slide the burner rackout of the unit (see Figures 18 and

20).

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 airflowthrough 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 17

Unit Access Panel

FRONT ACCESS PANEL

FIGURE 20

Burner Rack Removed

FIGURE 18

FIGURE 19

Blower Housing and Flue Collector Box

IGNITION MODULE

FLUE COLLECTOR BOX

INDUCED DRAFT MOTOR MOUNT

BLOWER HOUSING

BURNER RACK

MOUNTING SCREW

Removal of Motor and Blower Wheel

BLOWER HOUSING

2 SETSCREWS (HIDDEN)

ROLLOU SWITCH

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 discharge 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 8” (3.2mm) away from the motor end (8” (3.2mm) of motor shaft will be visible).

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

7. Replace grille.

Electrical Controls and W

iring

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 theparts, re--strip the wireend 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 withthe proper electricalinstrumentation. Refer to the unit wiring label when making these checks.

NOTE: Refer to the Cooling Sequence of Operation in this document to understand proper control operation.

Items

Circuit

WARNING

)

Refrigeration

Annually inspect all refrigerant tubing connections and the unit base for oil accumulations. Detecting oil generally indicates a refrigerant leak.

EXPLOSION, SAFETY AND ENVIRONMENT AL 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.

If oil is detected or if low cooling performance is suspected, leak--test all refrigerant tubing using an electronic leak--detector, halide torch, or liquid--soap solution. If a refrigerant leak is detected, refer to the Check for Refrigerant Leaks section.

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

Input

Gas

The gas input does not require checking unless improper heating performance is suspected. If a problem exists, refer to the Start--Up section.

Evaporator 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. When necessary, refer to the Indoor Airflow and Airflow Adjustments section to check the system airflow.

R--410A Metering Device (Thermostatic Expansion Valve

This metering device is a hard shutoff, balance port TXV. The TXV maintains a constant superheat at the evaporator exit resulting in higher overall system efficiency.

Pressure Switches

Pressure switches are protective devices wired into control circuit (low voltage). They shut off compressor if abnormally high or low pressures are present in the refrigeration circuit. These pressure switches are specifically designed to operate with R--410A systems. R--22 pressure switches must not be used as replacements for the R--410A system.

Loss of Charge Switch

This switch is located on the liquid line and protects against low suction pressures caused by such events as

loss of charge, low airflow across indoor coil, dirty filters, etc. It opens on a pressure drop at about 20 psig. If system pressure is above this, switch should be closed. To check switch:

1. Turn off all power to unit.

2. Disconnect leads on switch.

3. Apply ohm meter leads across switch. You should have continuity on a good switch.

NOTE:Because these switches are attached to refrigeration system under pressure, it is not advisable to remove this device for troubleshooting unless you are reasonably certain that a problem exists. If switch must be removed, remove and recover all system charge so that pressure gauges read 0 psi. Never open system without breaking vacuum with dry nitrogen.

Switch

Refrigerant)

WARNING

High--Pressure

The high--pressure switch is located in the discharge line and protects against excessive condenser coil pressure. It opens at 650 psig.

High pressure may be caused by a dirty outdoor coil, failed fan motor, or outdoor air recirculation. To check switch:

1. Turn off all power to unit.

2. Disconnect leads on switch.

3. Apply ohm meter leads across switch. You should have continuity on a good switch.

Copeland Scroll Compressor (R--410A

The compressor used in this product is specifically designed to operate with R--410A refrigerant and cannot be interchanged.

The compressor is an electrical (as well as mechanical) device. Exercise extreme caution when working near compressors. Power should be shut off, if possible, for most troubleshooting techniques. Refrigerants present additional safety hazards.

FIRE/EXPLOSION HAZARD

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

Wear safety glasses and gloves when handling refrigerants. Keep torches and other ignition sources away from refrigerants and oils.

The scroll compressor pumps refrigerant throughout the system by the interaction of a stationary and an orbiting scroll. The scroll compressor has no dynamic suction or discharge valves, and it is more tolerant of stresses caused by debris, liquid slugging, and flooded starts. The compressor is equipped with an anti--rotational device and an internal pressure relief port. The anti--rotational device prevents the scroll from turning backwards and replaces the need for a cycle protector. The pressure relief port is a safety device, designed to protect against extreme high pressure. The relief port has an operating range between 550 psi (26.34 kPa) and 625 psi (29.93 kPa) differential p ressure.

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