Table of Contents
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Installation Instructions
PACKAGED GAS/ELECTRIC UNIT
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Dimensions
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Install Flue Hood
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Start--Up Heating & Make Adjustments
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Start--Up Cooling & Make Adjustments
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Airflow
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Printed in U.S.A.
PGD3 Series
TABLE OF CONTENTS
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International Comfort Products, LLC
Indoor Blower and Motor
Outdoor & Indoor Coil, Condensate Drain Pan 23
AIRFLOW CHART
COOLING TROUBLESHOOTING GUIDE
HEATING TROUBLESHOOTING GUIDE
LED ERROR CODES GUIDE
CHECKLIST FORM
Lewisburg, TN. 37091
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01- -28- -08
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Related Manuals for International comfort products PGD3 Series
Summary of Contents for International comfort products PGD3 Series
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Page 1: Table Of Contents
........Sequence of Operation ....International Comfort Products, LLC Lewisburg, TN. 37091 509 01 3401 01 01- -28- -08 Printed in U.S.A. -
Page 2: Safe Installation Requirements
SAFE INSTALLATION REQUIREMENTS PACKAGED GAS / ELECTRIC UNIT FIGURE 1 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. -
Page 3: Receiving And Installation
RECEIVING AND INSTALLATION STEP 1 — Check Equipment Slab Mounting Details FIGURE 2 Identify Unit The unit model number and serial number are stamped on the unit information plate. Check this information against OPTIONAL OPTIONAL shipping papers. RETURN SUPPLY Inspect Shipment OPENING OPENING Inspect for shipping damage while unit is still on shipping... -
Page 4: Unit Center Of Gravity
FIGURE 3 MODEL SIZE 24- -36 DIMENSIONS REQUIRED CLEARANCE TO COMBUSTIBLE MATL. REQUIRED CLEARANCE FOR OPERATION AND SERVICING INCHES [mm] (R efer to M aximum O perating C learances ) INCHES [mm] EVAP. COIL ACCESS SIDE............36.00 [914.0] TOP OF UNIT...................14.00 [355.6] POWER ENTRY SIDE..............42.00 [1066.8] DUCT SIDE OF UNIT.................2.00 [50.8] (EXCEPT FOR NEC REQUIREMENTS) - Page 5 FIGURE 4 MODEL SIZE 42- -60 DIMENSIONS REQUIRED CLEARANCE TO COMBUSTIBLE MATL. REQUIRED CLEARANCE FOR OPERATION AND SERVICING INCHES [mm] INCHES [mm] TOP OF UNIT...................14.00 [355.6] EVAP. COIL ACCESS SIDE............36.00 [914.0] DUCT SIDE OF UNIT.................2.00 [50.8] POWER ENTRY SIDE..............42.00 [1066.8] SIDE OPPOSITE DUCTS ..............14.00 [355.6] (EXCEPT FOR NEC REQUIREMENTS) UNIT TOP ..................48.00 [1219.2]...
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Page 6: Provide Clearances
STEP 4 — Provide Clearances wear at hoist hooking points and load support areas. Brackets or straps showing any kind of wear in these areas The required minimum operating and service clearances must not be used and should be discarded. are shown in Figures 3 and 4. -
Page 7: Connect Condensate Drain
4. After unit is securely in place detach rigging straps. After the unit is placed on the roof curb or mounting pad, Remove corner posts screws, and rigging brackets remove the top crating. then reinstall screws. FIGURE 5 Unit Corner Weight (lbs) and Rigging Rigging Brackets are factory installed on 3---phase units only. -
Page 8: Install Gas Piping
inches water column maximum pressure drop. Never use WARNING pipe smaller than the 2” FPT gas inlet on the unit gas valve. For natural gas applications, the gas pressure at unit gas CARBON MONOXIDE POISONING HAZARD connection must not be less than 4.0 inches water column Failure to follow this warning could result in personal or greater than 13 inches water column while the unit is injury or death. -
Page 9: Install Duct Connections
have been completed. Use soap--and--water solution NOTE: Pressure test the gas supply system after the gas (or method specified by local codes and/or regulations). supply piping is connected to the gas valve. The supply piping must be disconnected from the gas valve during the Sediment Trap FIGURE 7 testing of the piping systems when test pressure is in... -
Page 10: Install Electrical Connections
5. It is recommended that the base insulation around the minute for throwaway type or 450 feet per minute for perimeter of the vertical return--air opening be secured high--capacity type. filter pressure drop to the base with aluminum tape. Applicable local codes non--standard filters must not exceed 0.08 inches water may require aluminum tape to prevent exposed column. - Page 11 See unit wiring label and Figure 10 for reference when Remove knockout hole located in the flue panel adjacent to making high voltage connections. Proceed as follows to the control access panel (see Figures 3 and 4). Remove the complete the high--voltage connections to the unit. rubber grommet from the installer’s packet (included with unit) and install grommet in the knockout opening.
- Page 12 FIGURE 11 208/230 - - 1 - - 60 WIRING DIAGRAM...
- Page 13 FIGURE 12 208/230 - - 3 - - 60 WIRING DIAGRAM...
- Page 14 FIGURE 13 460 - - 3 - - 60 WIRING DIAGRAM...
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Page 15: Pre- -Startup
PRE- -STARTUP Inspect for oil at all refrigerant tubing connections WARNING and on unit base. Detecting oil generally indicates a refrigerant leak. FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD Leak--test all refrigerant tubing connections using electronic leak detector, or liquid--soap solution. If Failure to follow this warning could result in personal a refrigerant leak is detected, see following Check injury or death. -
Page 16: Gas Input
Altitude Derate Multiplier for U.S.A. operation my occur when the burner orifices in the manifold Table 3 - - are misaligned. PERCENT OF ALTITUDE (ft) DE---RATE MULTIPLIER * DERATE Follow the lighting instructions on the heating section operation label (located inside the burner or blower access 0--- 2000 1.00 door) to start the heating section. - Page 17 Proceed as follows: Burner Assembly FIGURE 14 1. Turn off gas supply to unit. 2. Remove pipe plug on manifold (see Figure 14) and connect manometer. Turn on gas supply to unit. 3. Record number of seconds for gas meter test dial to make one revolution.
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Page 18: Airflow And Temperature Rise
5. Adjust regulator adjustment screw to the correct temperature rises. The heating operation airflow must manifold pressure, as specified in Table 3. Turn produce a temperature rise that falls within the approved adjusting screw clockwise to increase manifold range. pressure, or turn adjusting screw counterclockwise to Refer to Indoor Airflow and Airflow Adjustments section to decrease manifold pressure. -
Page 19: R--410A Charge
Limit Switches NOTE:Adjustment of the refrigerant charge is not required unless the unit is suspected of not having the proper Normally closed limit switch (LS) completes the control R--410A charge. circuit. Should the leaving--air temperature rise above the maximum allowable temperature, the limit switch opens The charging label and the tables shown refer to system and the control circuit “breaks.”... - Page 20 Table 6 - - Cooling Charging Chart...
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Page 21: Sequence Of Operation
Indoor Airflow and Airflow Adjustments Continuous Fan Operation The continuous fan operates at the same fan speed as CAUTION cooling operation. Cooling Sequence of Operation UNIT OPERATION HAZARD With the room thermostat SYSTEM switch in the COOL Failure to follow this caution may result in unit damage. position and the FAN switch in the AUTO position, the cooling sequence of operation is as follows: For cooling operation, the recommended airflow is 350... -
Page 22: Air Filter
For longer life, operating economy, and continuing WARNING efficiency, clean accumulated dirt and grease from the blower wheel and motor annually. ELECTRICAL SHOCK HAZARD WARNING Failure to follow these warnings could result in personal injury or death: ELECTRICAL SHOCK HAZARD 1. -
Page 23: Flue Gas Passageways
2. Remove the 5 screws that attach induced--draft motor 7. Remove the mounting screw that attaches the burner mounting plate to blower housing (see Figure 19). rack to the unit base (see Figure 18). 3. Slide the assembly out of the blower housing (see 8. -
Page 24: Outdoor Fan
Burner Rack Removed Unit Access Panel FIGURE 20 FIGURE 17 FRONT ACCESS PANEL Blower Housing and Flue Collector Box FIGURE 18 INDUCED DRAFT MOTOR MOUNT IGNITION MODULE Outdoor Fan CAUTION UNIT OPERATION HAZARD Failure to follow this caution may result in damage to unit components. -
Page 25: Refrigeration Circuit
component with the proper electrical instrumentation. Refer loss of charge, low airflow across indoor coil, dirty filters, to the unit wiring label when making these checks. etc. It opens on a pressure drop at about 20 psig. If system pressure is above this, switch should be closed. NOTE: Refer to the Cooling Sequence of Operation in this To check switch: document to understand proper control operation. -
Page 26: Troubleshooting
leakage include, but are not limited to, compressor WARNING replacement, repairing refrigerant leaks, replacing refrigerant components such as filter drier, pressure EXPLOSION, ENVIRONMENTAL SAFETY switch, metering device, coil, accumulator, or reversing HAZARD valve. Failure to follow this warning could result in personal Synthetic Roof Precautionary Procedure injury, death or equipment damage. - Page 27 Table 8—Dry Coil Air Delivery* - - Horizontal and Downflow Discharge (Deduct 10% for 208 Volts) External Static Pressure (Inches Water Column) Heating Motor Model Rise Range Speed Watts --- --- --- --- Heating Rise °F °C Watts 1195 1155 1100 1028 20 --- 50...
- Page 28 External Static Pressure (Inches Water Column) Heating Motor Heating Motor Model Model Rise Range Speed Rise Range Speed Watts 1242 1170 1089 Heating Rise °F °C Watts 1320 1244 1162 1081 1005 40 --- 70 PGD336090 Medium (22 --- 39) Heating Rise °F °C...
- Page 29 External Static Pressure (Inches Water Column) Heating Motor Heating Motor Model Model Rise Range Speed Rise Range Speed Watts 2027 1960 1901 1821 1759 1693 1616 1513 1354 Heating Rise °F °C Watts 2095 2026 1962 1887 1817 1748 1679 1583 1439 25 --- 55...
- Page 30 Table 11—Troubleshooting Guide - - Cooling SYMPTOM CAUSE REMEDY Power failure Call power company Fuse blown or circuit breaker tripped Replace fuse or reset circuit breaker Defective contactor, transformer, or high--pres- Replace component sure, loss--of--charge or low--pressure switch Compressor and condenser fan will not start.
- Page 31 Table 12—Troubleshooting Guide–Heating SYMPTOM CAUSE REMEDY Water in gas line Drain. Install drip leg. Check power supply fuses, wiring or No power to furnace circuit breaker. Check transformer. NOTE: Some transformers have inter- No 20--v power supply to control circuit nal over--current protection that re- quires a cool--down period to reset.
- Page 32 Table 13—Troubleshooting Guide–LED Error Codes SYMPTOM CAUSE REMEDY Check 5--amp fuse son IGC*, power to unit, 24--v circuit breaker, and transformer. Units Hardware failure without a 24--v circuit breaker have an internal Loss of power to control module (IGC)*. (LED OFF) overload in the 24--v transformer.
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Page 33: R--410A Quick Reference Guide
R- -410A QUICK REFERENCE GUIDE • R--410A refrigerant operates at 50% -- 70% higher pressures than R--22. Be sure that servicing equipment and replacement components are designed to operate with R--410A. • R--410A refrigerant cylinders are rose colored. • Recovery cylinder service pressure rating must be 400 psig, DOT 4BA400 or DOT BW400. •... - Page 34 START- -UP CHECKLIST (Remove and Store in Job File) 1. Preliminary Information Model Number: Serial Number: Date: Technician: 2. Pre--Start--Up ____ Verify that all packing materials have been removed from unit ____ Check all electrical connections and terminals for tightness ____ Check gas piping for leaks ____ Check that the indoor (evaporator) air filter is clean and in place ____ Verify that the unit installation is level...