National Comfort Products CPG Installation Manual

Thru-the-Wall Packaged Heating & Cooling

Installation
Guide

Comfort Pack

Universal Series

NATIONAL

®

COMFORT

PRODUCTS

HEATING & A/C EQUIPMENT

80% THERMAL EFFICIENCY

This unit should be installed in an

OUTSIDE WALL for THRU-THE-WALL
INSTALLATION ONLY!

CPG

CPG

U-Models

U-Models

Gas

Heating

Electric

Cooling

Read Installation Guide prior to starting the installation.

National Comfort Products

A Division of National Refrigeration & Air Conditioning Products, Inc.

539 Dunksferry Road | Bensalem, PA 19020 | [phone] | 1-800-523-7138 | Fax: [phone]

®

.

Table of Contents

Safety First ................................................................................................. page 5-6

Before You Start ......................................................................................... page 6

Installation .................................................................................................. page 8

Drainage ...................................................................................................... page 8

Clearance ................................................................................................... page 9

Unit Location Considerations ..................................................................... page 10

Vent Termination Clearances ..................................................................... page 11

Electrical ..................................................................................................... page 12-14

Dimensions ................................................................................................ page 15

Gas Furnace Specifications ......................................................................... page 16

Sequence of Operations (Gas Heat) ............................................................ page 16

Abnormal Functions ................................................................................... page 17

Installation Guide for Comfort Pack (CPG) Units

High Altitude Operation .............................................................................. page 17-18

Gas Piping, Venting & Pressures ............................................................... page 19-20

Ignition System........................................................................................... page 21

Start up ....................................................................................................... page 22-23

Special Notes for Extremely Cold Weather Areas ........................................ page 23-24

Gas Control Valve ........................................................................................ page 24

Maintenance and Service ............................................................................ page 24-29

Slide Out Furnace Instructions .................................................................... page 29-30

Equipment Specifications ............................................................................ page 31

Air Flow ...................................................................................................... page 32-34

Wiring Diagram .......................................................................................... page 36-38

Trouble Shooting ....................................................................................... page 39-40

Replacement Parts Guide ........................................................................... page 41-42

Warranty .................................................................................................... page 43-45

Notes ......................................................................................................... page 46-47

IMPORTANT NOTE: DO NOT DESTROY OR THROW AWAY THIS MANUAL.

IT SHOULD BE KEPT IN A SAFE PLACE FOR FUTURE REFERENCE.

3

Installation Guide for Comfort Pack (CPG) Units

Example: CPG41838-U

Comfort Pack Nomenclature

Note: Standard units (with no options) will have no letter after the “U” in the name. Example: CPG41838-U

CP=Comfort

Pack

G =Gas

E=Electric

4=410A

Refrigerant

Nominal
Cooling Capacity

12=12,000Btu
18=18,000Btu
24=24,000Btu
30=30,000Btu

Model Number

C P G 4 1 8 3 8 - U

Heating Capacity

Gas Input

28=28,000Btu
38=38,000Btu
51=51,000Btu
64=64,000Btu

Electric
05=5

Kilowatt
Kilowatt

07=7

Kilowatt

10=10

Kilowatt

15=15

Options

(if used)

* *

*

U=Universal Chassis

Last 2 Digits
for factory use

= Edition

*

= Generation

*

A=No Grille
B=Slotted Filter Door
C=No Grille, with

Slotted Filter Door

4

Installation Guide for Comfort Pack (CPG) Units

Safety First!

!

HAZARD INTENSITY LEVELS

1. DANGER: FAILURE TO COMPLY WITH WILL RESULT
IN SEVERE PERSONAL INJURY OR DEATH AND/ OR
PROPERTY DAMAGE.

2. WARNING: FAILURE TO COMPLY COULD RESULT
IN SEVERE PERSONAL INJURY OR DEATH AND/ OR
PROPERTY DAMAGE.

3. CAUTION: FAILURE TO COMPLY COULD RESULT
IN MINOR PERSONAL INJURY AND/OR PROPERTY
DAMAGE.

!

WARNING

FOR YOUR SAFETY, DO NOT STORE OR USE GASOLINE
OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE
VICINITY OF THIS OR ANY OTHER APPLIANCE. SUCH
ACTIONS COULD RESULT IN PROPERTY DAMAGE,
PERSONAL INJURY, OR DEATH.

!

CAUTION

SHOULD OVERHEATING OCCUR, OR THE GAS SUPPLY
FAIL TO SHUT OFF, SHUT OFF THE MANUAL GAS VALVE
TO THE APPLIANCE BEFORE SHUTTING OFF THE
ELECTRICAL SUPPLY.

!

CAUTION

SCROLL COMPRESSORS SHOULD NEVER BE USED TO
EVACUATE THE AIR CONDITIONING SYSTEM. VACUUMS
THIS LOW CAN CAUSE INTERNAL ELECTRICAL ARCING
RESULTING IN A DAMAGED OR FAILED COMPRESSOR.

!

WARNING

THE UNIT MUST BE PERMANENTLY GROUNDED.
FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK
RESULTING IN SEVERE PERSONAL INJURY OR DEATH.

“USE COPPER SUPPLY WIRES ONLY”

WARNING

!

IF THE INFORMATION IN THIS MANUAL
IS NOT FOLLOWED EXACTLY, A FIRE
OR EXPLOSION MAY RESULT CAUSING
PROPERTY DAMAGE, PERSONAL INJURY
OR LOSS OF LIFE.

Do NOT store or use gasoline or other ammable
vapors and liquids in the vicinity of this or any other
appliance.

!

WARNING

WARNING: DO NOT USE THIS APPLIANCE IF ANY PART
HAS BEEN UNDER WATER. IMMEDIATELY CALL A
QUALIFIED SERVICE TECHNICIAN TO INSPECT THE
APPLIANCE AND REPLACE ANY GAS CONTROL THAT
HAS BEEN UNDER WATER.

!

WARNING

INSTALLATION AND REPAIR OF THIS UNIT SHOULD
BE PERFORMED ONLY BY INDIVIDUALS MEETING THE
REQUIREMENTS OF AN “ENTRY LEVEL TECHNICIAN”
AS SPECIFIED BY NATIONAL CODES. ATTEMPTING
TO INSTALL OR REPAIR THIS UNIT WITHOUT SUCH
BACKGROUND MAY RESULT IN PRODUCT DAMAGE,
PERSONAL INJURY OR DEATH.

!

WARNING

HIGH VOLTAGE!
DISCONNECT ALL POWER BEFORE SERVING.
FAILURE TO DO SO MAY RESULT IN PROPERTY
DAMAGE, PERSONAL INJURY OR DEATH.

!

CAUTION

USE CARE WHEN HANDLING SCROLL COMPRESSORS.
SOME TEMPERATURES COULD BE HOT!

WHAT TO DO IF YOU SMELL GAS:

• Do NOT try to light any appliance.

• Do NOT touch any electrical switch; do not use any

phone in your building.

• Immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the re
department.

Installation and service must be performed by a
qualied installer, service agency or the gas supplier.

WARNING

!

IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION,
SERVICE, OR MAINTENANCE CAN CAUSE PROPERTY
DAMAGE, PERSONAL INJURY OR LOSS OF LIFE. REFER
TO THE USER’S INFORMATION MANUAL PROVIDED
WITH THIS FURNACE. INSTALLATION AND MATERIALS,
SERVICE MUST BE PERFORMED BY A QUALIFIED
INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.

This furnace must be installed in accordance with the
manufacturer’s instructions and local codes. In the absence of

local codes, follow the National Fuel Gas Code, ANSI Z223.1 or
the CAN/CGA-B149 Installation Codes.

To be installed without alteration.

5

Installation Guide for Comfort Pack (CPG) Units

Safety First!

!

WARNING

IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE
FURNACE MUST BE REPLACED, IT MUST BE REPLACED
WITH WIRING MATERIAL HAVING A TEMPERATURE
RATING OF AT LEAST 90°C.

THIS FURNACE MUST BE INSTALLED SO THERE ARE
PROVISIONS FOR VENTILATING AIR.

SHOULD OVERHEATING OCCUR, OR THE GAS SUPPLY
FAIL TO SHUT OFF, SHUT OFF THE MANUAL GAS
VALVE TO THE FURNACE BEFORE SHUTTING OFF THE
ELECTRICAL SUPPLY.

!

CAUTION

THESE UNITS ARE NOT APPROVED FOR MOBILE
HOME APPLICATIONS. SUCH USE COULD RESULT IN
PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH.

!

WARNING

THESE INSTRUCTIONS ARE INTENDED AS AN AID TO
QUALIFIED, LICENSED SERVICE PERSONNEL FOR
PROPER INSTALLATION, ADJUSTMENT AND OPERATION
OF THIS UNIT. READ THESE INSTRUCTIONS THOROUGHLY
BEFORE ATTEMPTING INSTALLATION OR OPERATION.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
RESULT IN IMPROPER INSTALLATION, ADJUSTMENT,
SERVICE OR MAINTENANCE POSSIBLY RESULTING
IN FIRE, ELECTRICAL SHOCK, PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH.

!

WARNING

DO NOT USE OXYGEN TO PURGE LINES OR PRESSURIZE
SYSTEM FOR LEAK TEST. OXYGEN REACTS VIOLENTLY
WITH OIL, WHICH CAN CAUSE AN EXPLOSION
RESULTING IN SEVERE PERSONAL INJURY OR DEATH.

!

WARNING

GAS-FIRED APPLIANCES ARE NOT DESIGNED FOR
USE IN HAZARDOUS ATMOSPHERES CONTAINING
FLAMMABLE VAPORS OR COMBUSTIBLE DUST,
IN ATMOSPHERES CONTAINING CHLORINATED
OR HALOGENATED HYDROCARBONS, OR IN
APPLICATIONS WITH AIRBORNE SILICONE
SUBSTANCES. SEE HAZARD LEVELS BELOW.

Before You Start

This unit is shipped with a cooling chassis installed in the
cabinet. Prior to installing the unit in the wall opening, the
shipping bolts located at the bottom on both sides of the cabinet
must be removed to allow for removal of the cooling chassis.
1/4" hole plugs provided with the unit should be installed in the
holes to prevent air leakage. Shipping bolts are located on both
sides below this sticker:

THE SHIPPING BOLTS MUST BE REMOVED PRIOR
TO INSTALLATION OF THE CABINET TO PERMIT
REMOVAL OF THE CHASSIS. INSTALL THE HOLE
PLUGS PROVIDED.

14299588

This unit is designed and approved for through-the-wall
installation only. The unit must be installed a minimum of 8”
above finish floor. If this unit is installed in a residential
garage, it must be installed so that the ignition source and
burners are located not less than 18 inches (457 mm) above
the floor, and it must be located or protected to avoid physical
damage by vehicles. The entire unit must not be installed
outside. The grille side of the unit should extend 3/4" beyond the

exterior wall to allow moisture that may enter the outdoor
section to drain. The pitch of the internal drain pans toward the
outside will assure proper drainage when the cabinet is installed
level. Masonry walls must have a lintel to support the wall.

The interior of the unit may be installed with zero clearances to
adjacent combustible surfaces. The unit shall not be installed

directly on carpeting, tile or other combustible material,
except wood flooring. In order to be able to remove the chassis,

29" of open area must be left unobstructed in front of the access
panels. The 3/4" O.D. drain pan connection should be connected
to the building drain using the flexible tubing included and
a trap. The secondary drain offers protection from overflow.
The secondary drain feature is piped into the base of the unit
and drains through the weep holes outside. Reconnect 3” piece
of clear flexible tubing to secondary drain on drain pan. Position
secondary drain through grommet of chassis and connect to
flexible tubing (prime trap prior to operating).

The grille side must be kept free of any obstructions that
will reduce or alter the air flow pattern. The unit must be

installed at least 4 feet (1.22 m) from electric meters, gas
meters, regulators, and relief equipment. The vent of the
unit is located at the front grille. Distances from adjacent
public walkways, adjacent buildings, openable windows, and
building openings must be consistent with the National Fuel
Gas Code ANSI Z223.1 and/or CAN/CGA-B149 installation
codes, as well as local codes.

If an optional architectural grille is to be used on standard units,
the stamped and louvered grille provided must be removed.
Consult the factory prior to ordering product(s) that require an
optional architectural grille.

6

Installation Guide for Comfort Pack (CPG) Units

THE CHASSIS BASE AND EVAPORATOR DRAIN PAN, NOT

!

THE INSTALLATION OF THIS APPLIANCE
MUST CONFORM TO THE REQUIREMENTS
OF THE NATIONAL FIRE PROTECTION
ASSOCIATION; THE NATIONAL ELECTRIC
CODE, ANSI/NFPA NO. 70 (LATEST EDITION)
IN THE UNITED STATES; THE CANADIAN
ELECTRICAL CODE PART 1, CSA 22.1 (LATEST
EDITION) IN CANADA; AND ANY STATE OR
PROVINCIAL LAWS OR LOCAL ORDINANCES.
LOCAL AUTHORITIES HAVING JURISDICTION
SHOULD BE CONSULTED BEFORE
INSTALLATION IS MADE. SUCH APPLICABLE
REGULATIONS OR REQUIREMENTS TAKE
PRECEDENCE OVER THE GENERAL
INSTRUCTIONS IN THE MANUAL.

TO REMOVE THE CHASSIS FROM THE CABINET:
TURN OFF POWER TO THE UNIT. REMOVE THE LOWER

ACCESS PANEL FROM THE CABINET. DISCONNECT
THE DRAIN LINE FROM THE EVAPORATOR COIL DRAIN
CONNECTION. DISCONNECT THE SECONDARY DRAIN
FLEXIBLE TUBING & TRAP TO AVOID DAMAGE (PRIME TRAP
WHEN REINSTALLING). DEPRESS AND HOLD THE RELEASE
LATCH ON THE CHASSIS POWER WIRING CONNECTOR
AND UNPLUG IT FROM THE CABINET POWER WIRING
CONNECTOR. DEPRESS AND HOLD THE RELEASE LATCH
ON THE CONTROL WIRING CONNECTOR AND UNPLUG IT
FROM THE CABINET CONTROL WIRING CONNECTOR.

REMOVE THE SCREWS ATTACHING THE CONTROLS
ENCLOSURE TO THE INDOOR COIL COVER. REMOVE THE
SCREWS FROM THE INDOOR BLOWER COVER PLATE.
REMOVE THE PLATE FROM THE UNIT. TEMPORARILY
SECURE THE CHASSIS POWER AND CONTROL WIRING AND
CONNECTORS TO THE TOP OF THE INDOOR COIL COVER
TO PREVENT DAMAGE DURING CHASSIS REMOVAL.

CAREFULLY SLIDE THE CHASSIS OUT OF THE CABINET BY
GRASPING BOTH SIDES OF THE EVAPORATOR COIL DRAIN
PAN AND PULLING TOWARD YOU WHILE KEEPING THE
CHASSIS CENTERED IN THE CABINET. AS THE CHASSIS IS
REMOVED, KEEP THE CHASSIS LEVEL UNTIL THE OUTDOOR
FAN COVER PASSES THE CABINET SEALS. DAMAGE TO

THE CABINET SEALS WILL RESULT IF THE CHASSIS IS
NOT KEPT LEVEL UNTIL THE OUTDOOR FAN COVER HAS
PASSED THE CABINET SEALS. AFTER THE CHASSIS IS

REMOVED, IT SHOULD BE HANDLED USING

CAUTION

BY USING REFRIGERANT PIPING OR THE OUTDOOR FAN
MOUNT. THE BOTTOM OF THE CHASSIS IS NOT SMOOTH
AND WILL DAMAGE FLOORS IF SLID.

TO INSTALL THE CHASSIS INTO THE CABINET:

TURN OFF POWER TO THE UNIT. TEMPORARILY SECURE

THE CHASSIS POWER AND CONTROL WIRING AND TURN
OFF POWER TO THE UNIT. TEMPORARILY SECURE
THE CHASSIS POWER AND CONTROL WIRING AND
CONNECTORS TO THE TOP OF THE INDOOR COIL COVER
TO PREVENT DAMAGE DURING CHASSIS INSTALLATION.
PLACE THE OUTDOOR COIL SECTION OF THE CHASSIS
ONTO THE CABINET RAILS. LIFT THE REAR OF THE CHASSIS
USING THE EVAPORATOR COIL DRAIN PAN SO THAT THE
CHASSIS IS LEVEL AND CENTERED AS IT IS PUSHED IN THE
CABINET. DAMAGE TO THE CABINET SEALS WILL RESULT

IF THE CHASSIS IS NOT KEPT LEVEL UNTIL THE OUTDOOR
FAN COVER HAS PASSED THE CABINET SEALS, AND THE
CHASSIS KEPT CENTERED IN THE CABINET. AFTER THE

CHASSIS IS ALL THE WAY IN THE CABINET, CHECK THAT
THE CHASSIS IS CENTERED IN THE CABINET BY VERIFYING
THAT IT IS IN CONTACT WITH THE CABINET SEALS ON BOTH
SIDES.

INSTALL THE INDOOR BLOWER COVER PLATE AND SECURE
IT WITH SCREWS. INSTALL THE CHASSIS POWER WIRE
CONNECTOR AND THE CONTROL WIRING CONNECTOR
INTO THEIR RESPECTIVE CABINET WIRING CONNECTORS
SO THAT THE CONNECTORS LATCH. POSITION THE
CONTROLS ENCLOSURE AND SECURE IT TO THE INDOOR
COIL COVER WITH SCREWS. CONNECT THE DRAIN LINE TO
THE EVAPORATOR COIL DRAIN CONNECTION. RECONNECT
3” PIECE OF CLEAR FLEXIBLE TUBING TO SECONDARY
DRAIN ON DRAIN PAN. POSITION SECONDARY DRAIN
THROUGH GROMMET OF CHASSIS AND CONNECT TO
FLEXIBLE TUBING (PRIME TRAP PRIOR TO OPERATING).
INSTALL THE LOWER ACCESS PANEL ON THE CABINET.
TURN ON POWER TO THE UNIT.

ALL phases of this installation must comply with NATIONAL,
STATE AND LOCAL CODES. The manufacturer assumes no
responsibility for equipment installed in violation of any code
requirements.

Be sure that the electrical data specified on the unit rating
plate corresponds to what is available at the installation site
and NEC for installation requirements.

This unit MUST be installed in an outside wall for thru-the-wall
installation ONLY.

7

Installation Guide for Comfort Pack (CPG) Units

Be sure that the electrical service provided to the building can
handle the load imposed by the unit.

IMPORTANT — This Document is customer property and is to
remain with this unit. Please refer to service information pack
upon completion of work to register the unit’s warranty. These
instructions do not cover all variations in systems or provide
for every possible contingency to be met in connection with the
installation. Should further information be desired or should
particular problems arise which are not covered sufficiently
for the purchaser’s purposes, the matter should be referred to
your installing dealer or local distributor before contacting the
manufacture.

NOTE: THE UNIT MUST NEVER BE PLACED
ON ITS SIDE OR UPSIDE DOWN AS THE
COMPRESSOR OIL WILL RUN IN THE COOLING
CIRCUIT AND SERIOUSLY DAMAGE THE UNIT.

Installation

NOTE: THESE INSTALLATION AND
MAINTENANCE INSTRUCTIONS SHOULD
BE LEFT WITH THE UNIT FOR FUTURE
REFERENCE.

This unit must be installed in accordance with all applicable
codes. This unit is not to be used for temporary heating of
buildings or structures under construction.

FOR MAXIMUM PERFORMANCE, IT IS IMPERATIVE THAT
THE COOLING CHASSIS AIR DIVIDER BE SEALED TO THE
CABINET AIR SEAL. ANY LEAKAGE WILL ALLOW OUTSIDE
UNCONDITIONED AIR TO INFILTRATE AND MIX WITH THE
CONDITIONED AIR. THIS CONDITION WILL DEGRADE UNIT
PERFORMANCE. ALL UNITS SHOULD BE INSPECTED FOR
THIS CONDITION, AS DURING TRANSPORTATION AND
INSTALLATION THE SEALS CAN BE DISTURBED. IF REQUIRED,
A LIGHT BEAD OF CAULKING IS RECOMMENDED TO SEAL THE
CHASSIS, TO THE AIR SEAL TO ELIMINATE LEAKAGE.

OUTSIDE/UNCONDITIONED AIR MUST NOT BE INTRODUCED
INTO THE RETURN AIR STREAM OF THIS UNIT. THIS
CONDITION WILL ALSO DEGRADE THE PERFORMANCE
OF THE UNIT AND MAY VOID EQUIPMENT WARRANTY.

the possible transmission of sound and vibration, a resilient
material such as rubber or cork should be installed between the
support and the base of the unit. All spaces around the top, sides
and bottom of the exterior grille area should be caulked and
sealed to the wall, making sure that the openings for drainage in
the bottom edge are not blocked.

If the optional wall sleeve is used, caulk the spaces between the
sleeve and the wall. Completely fill the clearance on all sides
between the unit and the wall sleeve with a polyurethane foam
sealant (follow manufacturer’s suggested application manual).
Provide the unit with support inside the building in the area of
the return air opening. Slide the unit into the wall sleeve and
fasten the unit to the sleeve with the five screws provided with
the sleeve.

NOTE: FOR EASE OF INSTALLATION, INSTALL
THE CABINET INTO THE WALL SLEEVE FIRST
WITHOUT THE COOLING CHASSIS. THEN SLIDE
COOLING CHASSIS IN AFTER CABINET IS IN
PLACE.

Drainage

The 3/4" I.D. flexible tubing included should be connected to the
Comfort Pack primary drain connection so that it can easily be
disconnected if the cooling chassis must be removed. A trap
at least 2" deep should be provided close to the drain pan. The
tubing should not be higher than the bottom of the unit drain
pan at any point to assure proper drainage and allow chassis
removal. The drain line should pitch downward at least 1" per
10 ft. to an open building drain trap.

Drain Pan

SECONDARY DRAIN TRAP
MUST BE INSTALLED

3/4” O.D. Drain Connection
(Primary Drain)

3/4” I.D. Flexible Tubing Included

2”

min.

Shaded Area Represents Components

Provided and Installed By Others

Highest Point Must Not Be Above
Bottom of Drain Pan

Pitch Downward 1” per 10ft.

The unit should be provided with support inside the building in
the area of the return air opening. The support should be high
enough to allow for return air provisions to the unit. To reduce

8