Page 1: Table Of Contents
INSTALLATION INSTRUCTIONS 14 SEER Single- -Packaged Air Conditioner and Gas Furnace System with R- -410A Refrigerant Single Phase 2- -5 Nominal Tons (Sizes 24- -60) Three Phase 3- -5 Nominal Tons (Sizes 36- -60) PGD4 and PGS4 Series E, WPG4 Series B IMPORTANT: Effective January 1, 2015, all split system and packaged air conditioners must be installed pursuant to applicable regional efficiency standards issued by the Department of Energy.
Page 2: Introduction
RECEIVING AND INSTALLATION In Canada refer to the current editions of the National Standards of Canada CAN/CSA- -B149.1 and .2 Natural Gas and Propane Step 1 — Check Equipment Installation codes, and Canadian Electrical Code CSA C22.1 Identify Unit Recognize safety information. This is the safety- -alert symbol The unit model number and serial number are stamped on the unit When you see this symbol on the unit and in instructions or manu- information plate.
Page 3: Field Fabricate Ductwork
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. OPTIONAL OPTIONAL RETURN SUPPLY Training for operators of the lifting equipment should include, but OPENING OPENING not be limited to, the following:...
Page 4 A150559 Fig. 3 - - PGD4 and PGS4 24- -36 Unit Dimensions 46201200402 Specifications are subject to change without notice.
Page 5 A150548 Fig. 4 - - WPG4 24- -36 Unit Dimensions 46201200402 Specifications are subject to change without notice.
Page 6 A150560 Fig. 5 - - PGD4 and PGS4 42- -60 Unit Dimensions 46201200402 Specifications are subject to change without notice.
Page 7 A150549 Fig. 6 - - WPG4 42- -60 Unit Dimensions 46201200402 Specifications are subject to change without notice.
Page 8 Dashed lines show cross support location for large basepan units. HVAC unit HVAC unit basepan base rails Sealing Gasket Roofcurb Anchor screw Wood nailer* Flashing field supplied Roofcurb* Insulation (field supplied) Roofing material field supplied Cant strip field supplied SMALL/COMMON CURB A09413 *Provided with roofcurb A09090...
Page 9 CAUTION - NOTICE TO RIGGERS PRUDENCE - AVIS AUX MANIPULATEUR ACCESS PANELS MUST BE IN PLACE WHEN RIGGING. PANNEAUX D'ACCES DOIT ÊTRE EN PLACE POUR MANIPULATION. Use top skid as spreader bar. / Utiliser la palette du haut comme barre de répartition DUCTS MINIMUM HEIGHT: 36"...
Page 10: Connect Condensate Drain
Table 1—Physical Data Con’t UNIT SIZE 48090 48115 48130 60090 60115 60130 NOMINAL CAPACITY (ton) SHIPPING WEIGHT lb SHIPPING WEIGHT kg COMPRESSOR / QUANTITY Scroll / 1 REFRIGERANT (R --- 410A) Quantity lb Quantity (kg.) REFRIGERANT METERING DEVICE Orifice ORIFICE ID in./mm .080 / 2.03 .084 / 2.14 OUTDOOR COIL...
Page 11: Install Flue Hood
Step 7 — Install Flue Hood 4. The use of copper tubing for gas piping is NOT approved by the state of Massachusetts. The flue assembly is secured and shipped in the return air duct. In the absence of local building codes, adhere to the following Remove duct cover to locate the assembly (See Fig.
Page 12: Install Duct Connections
tion, and only the piece over the downshot knockout needs WARNING to be removed. Discard insulation. 4. To remove the downshot (plastic) knockouts for both sup- FIRE OR EXPLOSION HAZARD ply and returns, break front and right side connecting tabs with a screwdriver and hammer.
Page 13: Install Electrical Connections
5. Size all ductwork for maximum required airflow (either codes for maximum fuse/circuit breaker size and minimum circuit heating or cooling) for unit being installed. Avoid abrupt amps (ampacity) for wire sizing. duct size increases or decreases or performance may be The field- -supplied disconnect switch box may be mounted on the affected.
Page 14: Standard Connection
Standard Connection PRE- - START- -UP Run the low- -voltage leads from the thermostat, through the inlet WARNING hole, and into unit low- -voltage splice box. Locate six (seven for 3- -phase) 18- -gage wires leaving control box. These low- -voltage connection leads can be identified by the colors ENVIRONMENTAL, FIRE, EXPLOSION,...
Page 15: Check For Refrigerant Leaks
4. Verify the following conditions: a. Make sure gas line is free of air. Before lighting the unit for the first time, perform the following with the gas valve in the OFF position: NOTE: If the gas supply pipe was not purged before connecting the unit, it will be full of air.
Page 16 S The rated gas inputs shown in Table 6 are for altitudes from sea IN CANADA: The input rating for altitudes from 2,000 (610 m) to 4,500 ft (1372 level to 2000 ft (610 m) above sea level. These inputs are based m) above sea level must be derated 10% by an authorized Gas on natural gas with a heating value of 1025 Btu/ft at 0.60...
Page 17: Adjust Gas Input
Table 6 – Heating Inputs GAS SUPPLY PRESSURE (IN. W.C.) MANIFOLD PRESSURE MANIFOLD PRESSURE HEATING INPUT NUMBER OF NUMBER OF (IN. W.C.) Natural{ Propane*{ (BTUH) ORIFICES ORIFICES Natural{ Propane*† 40,000 13.0 11.0 13.0 3.23.8 10.0 60,000 13.0 11.0 13.0 3.23.8 10.0...
Page 18 A150502 Fig. 16 - - 208/230- -1- -60 Connection Wiring Diagram 46201200402 Specifications are subject to change without notice.
Page 19 A150510 Fig. 14 Cont. - - 208/230- -1- -60 Ladder Wiring Diagram 46201200402 Specifications are subject to change without notice.
Page 20 A150508 Fig. 17 - - 208/230- -3- -60 Connection Wiring Diagram 46201200402 Specifications are subject to change without notice.
Page 21 A150511 Fig. 15 Cont. - - 208/230- -3- -60 Ladder Wiring Diagram 46201200402 Specifications are subject to change without notice.
Page 22 A150509 Fig. 18 - - 460- -3- -60 Connection Wiring Diagram 46201200402 Specifications are subject to change without notice.
Page 23 A150512 Fig. 16 Cont. - - 460- -3- -60 Ladder Wiring Diagram 46201200402 Specifications are subject to change without notice.
Page 24: Normal Operation
Normal Operation Table 7 – LED Indications STATUS CODE LED INDICATION An LED (light- -emitting diode) indicator is provided on the Normal Operation integrated gas unit controller (IGC) to monitor operation. The IGC No Power or Hardware Failure is located by removing the control access panel (see Fig. 22). Check fuse, low voltage circuit 1 Flash During normal operation, the LED is continuously on (See Table 7...
Page 25: Checking & Adjusting Refrigerant Charge
turning backwards, the difference between compressor suction and (psig) to determine desired system operating liquid line discharge pressures will be minimal. temperature (See Table 9). 6. Compare actual liquid line temperature with desired liquid Checking and Adjusting Refrigerant Charge line temperature. Using a tolerance of  2F (1.1C), add The refrigerant system is fully charged with R- -410A refrigerant refrigerant if actual temperature is more than 2F (1.1C) and is tested and factory sealed.
Page 26: Cooling Sequence Of Operation
a given static pressure. Make sure that the speed chosen speed in Table 11 or NO TAG that will deliver the nominal delivers a temperature rise within the rise range listed on the cooling airflow as listed in Table 1 for each size. unit rating plate.
Page 27 HEAT HIGH OILL AB A15 R3 R5 R6 C 24VAC SSTZ-8 DH G A09058 Fig. 20 - - Interface Fan Board (IFB) Shunt in no Shunt in dehumidification dehumidification position position A14399 Fig. 19 - - Single Phase IGC Board 46201200402 Specifications are subject to change without notice.
Page 28 Table 9 – Cooling Charging Chart Superheat charging table is derived from optimum performance point. (95_F [35_C] outdoor ambient and (80_F [27_C] dry bulb; 67_F [19_C] wet bulb indoor condition.) Where a dash( --- ---) appears do not attempt to check charge or charge unit under these conditions using the superheat method. (Weigh in method should be used.) A150625 To properly check or adjust charge, conditions must be favorable for subcooling charging.
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Page 53: Maintenance
MAINTENANCE 3. Inspect blower motor and wheel for cleanliness at the beginning of each heating and cooling season. Clean when To ensure continuing high performance and to minimize the necessary. For first heating and cooling season, inspect possibility of premature equipment failure, periodic maintenance blower wheel bi- -monthly to determine proper cleaning must be performed on this equipment.
Page 54: Induced Draft (Combustion Air) Blower
f. Connect 5 pin plug and 4 pin plug to indoor blower 6. Remove wires connected to gas valve. Mark each wire. motor. 7. Remove the mounting screw that attaches the burner rack to g. Reinstall blower access panel (see Fig. 22). the unit base (See Fig.
Page 55: Outdoor Fan
A07680 Fig. 24 - - Burner Rack Removed Outdoor Fan CAUTION CONTROL ACCESS BLOWER PANEL ACCESS COMPRESSOR UNIT OPERATION HAZARD PANEL ACCESS PANEL Failure to follow this caution may result in damage to unit A09207 components. Fig. 22 - - Unit Access Panels Keep the condenser fan free from all obstructions to ensure proper cooling operation.
Page 56: Refrigerant Circuit
FAN GRILLE MOTOR MOTOR SHAFT A08505 MAX DISTANCE BETWEEN TOP OF FAN GRILLE AND BOTTOM OF FAN BLADE “A” SIZE Fig. 25 - - Fan Blade Position Refrigerant Circuit Pressure Switches Annually inspect all refrigerant tubing connections. Pressure switches are protective devices wired into control circuit (low voltage).
Page 57: Troubleshooting
Servicing Systems on Roofs with Synthetic Materials The compressor is an electrical (as well as mechanical) device. Exercise extreme caution when working near compressors. Power POE (polyolester) compressor lubricants are known to cause long should be shut off, if possible, for most troubleshooting techniques. term damage to some synthetic roofing materials.
Page 58 R- -410A QUICK REFERENCE GUIDE S R- -410A refrigerant operates at 50- -70 percent higher pressures than R- -22. Be sure that servicing equipment and replacement components are designed to operate with R- -410A S R- -410A refrigerant cylinders are rose colored. S Recovery cylinder service pressure rating must be 400 psig, DOT 4BA400 or DOT BW400.
Page 59 Table 16 – Troubleshooting Chart 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--pressure, Replace component loss--of--charge or low--pressure switch Compressor and condenser fan will not start. Insufficient line voltage Determine cause and correct Incorrect or faulty wiring...
Page 60 Table 17 – Troubleshooting Guide–Heating SYMPTOM CAUSE REMEDY Water in gas line Drain. Install drip leg. No power to furnace Check power supply fuses, wiring or circuit breaker. Check transformer. No 24--v power supply to control circuit NOTE: Some transformers have internal over--current protection that requires a cool--down period to reset.
Page 61 START- -UP CHECKLIST (Remove and Store in Job Files) I. PRELIMINARY INFORMATION MODEL NO.: SERIAL NO.: DATE: TECHNICIAN: II. PRESTART- -UP (Insert check mark in box as each item is completed) ( ) VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT ( ) REMOVE ALL SHIPPING HOLD DOWN BOLTS AND BRACKETS PER INSTALLATION INSTRUCTIONS ( ) CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS ( ) CHECK GAS PIPING FOR LEAKS (WHERE APPLICABLE)
Page 62 Copyright 2015 International Comfort Products Replaces: NEW Lewisburg, TN 37091 USA 46201200402 Specifications are subject to change without notice.

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