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First Co First-Pak FPG Series Installation, Operation & Maintenance Manual

Vertical packaged gas heat / electric cooling unit
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Installation, Operation, & Maintenance Manual
IOM 8405
Rev. C 3/24
FPG SERIES
Vertical Packaged Gas Heat / Electric Cooling Unit
Category IV Type MSP Up to 96% AFUE
ATTENTION
:
Installer
Affix these instructions on or adjacent to the furnace.
Consumer
Read these instructions thoroughly and retain all manuals
for future reference.
WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow safety warning exactly could result in
serious injury, death or property damage.
– 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
 Do not try to light any appliance.
 Do not touch any electrical switch; do not use any
phone in your building.
 Leave the building immediately.
 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 fire
department.
– Installation and service must be performed by a
qualified installer, service agency or the gas supplier.

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  • Page 1 Installation, Operation, & Maintenance Manual IOM 8405 Rev. C 3/24 FPG SERIES Vertical Packaged Gas Heat / Electric Cooling Unit Category IV Type MSP Up to 96% AFUE ATTENTION Installer Affix these instructions on or adjacent to the furnace. Consumer Read these instructions thoroughly and retain all manuals for future reference.
  • Page 2 FIRST-PAK COPYRIGHT First Co. / AE-Air works to continuously improve its products and as a result, it reserves the right to change design and specifications without notice. The warranty may be void unless the Startup & Performance Checklist is completed and returned to the warrantor. If the FIRST- PAK Gas Furnace unit is not installed properly, the warranty will be void, as the manufacturer cannot be held accountable for problems that stem from improper installation.

  • Page 3: Table Of Contents

    FIRST-PAK TABLE OF CONTENTS SAFETY CONSIDERATIONS MODEL NOMENCLATURE GENERAL INFORMATION INTRODUCTION STORAGE SHIPPING & PACKAGE LIST UNIT INSPECTION CHECKLIST UNIT DIMENSIONAL DATA UNIT PHYSICAL DATA ELECTRICAL DATA INSTALLATION 13-25 REQUIREMENTS INSTALLATION PRECAUTIONS UNIT LOCATION UNIT CLEARANCE REQUIREMENTS VENT CLEARANCES REMOVAL OF A UNIT FROM A COMMON VENTING SYSTEM WALL SLEEVE INSTALLATION UNIT SUPPORT PACKAGED UNIT INSTALLATION...

  • Page 4: Safety Considerations

    1. This product should only be installed and serviced by a qualified, licensed installer or service agency. 2. Only use First Co. approved kits and accessories when modifying this product. Refer and follow instructions packaged with the kits or accessories when installing.
  • Page 5 FIRST-PAK SAFETY CONSIDERATIONS CONTINUED SAFETY RULES: 10. This furnace is equipped with a blocked vent shut-off system. If the furnace fails to operate, contact a qualified 1. This furnace is approved for use with Natural Gas only. service agency for repair. Refer to the FURNACE RATING PLATE.
  • Page 6 FIRST-PAK SAFETY CONSIDERATIONS CONTINUED 13. The following items should be inspected annually WARNING (minimum) before each heating season by a qualified service agency: a. HEAT EXCHANGER TUBES: make sure they are free HIGH VOLTAGE! from blockages, signs of carbon buildup or heavy Disconnect all power before servicing.

  • Page 7: Model Nomenclature

    FIRST-PAK MODEL NOMENCLATURE FIGURE 1 - MODEL NOMENCLATURE FPG SERIES – IOM (REV. C 3/24)

  • Page 8: General Information

    ELECTRIC SHOCK HAZARD INTRODUCTION Before servicing equipment, ALWAYS turn off all power FIRST-PAK FPG series are packaged gas heat / electric to the unit. There may be more than one disconnect cooling units. The unit design has been certified by Intertek switch.

  • Page 9: Storage

    FIRST-PAK STORAGE Equipment should be stored in a clean dry, conditioned area with maximum temperatures up to 120°F [48.89°C] and minimum temperatures to 32°F [0°C]. Units should be stored upright and in an indoor environment. It is recommended to leave packaging on the unit until the installation is to begin.

  • Page 10: Unit Inspection Checklist

    FIRST-PAK UNIT INSPECTION CHECKLIST Complete the inspection procedures below before preparing unit for installation: NOTE 1) Visually inspect unit for any shipping damage. Damage Check the unit nameplate for correct voltage with the must be reported immediately to the shipping plans before installing the equipment.

  • Page 11: Unit Dimensional Data

    FIRST-PAK UNIT DIMENSIONAL DATA FIGURE 5 - Unit Dimensions FPG SERIES – IOM (REV. C 3/24)

  • Page 12: Unit Physical Data

    FIRST-PAK UNIT PHYSICAL DATA PHYSICAL DATA FPG MODELS 22N9012C 33N9012C 44N9012C 22N9018C 33N9018C 44N9018C 55N9018C UNIT INFORMATION Compressor Type (Qty) Rotary (1) Rotary (1) Rotary (1) Rotary (1) Rotary (1) Rotary (1) Rotary (1) Compressor Capacitor 40MFD/370V 40MFD/370V 40MFD/370V 35MFD/370V 35MFD/370V 35MFD/370V 35MFD/370V...

  • Page 13: Electrical Data

    FIRST-PAK ELECTRICAL DATA ELECTRICAL DATA CONDENSOR INDOOR MIN. MAX. VOLTAGE-PH- COMPRESSOR MIN. MAX. MODEL NUMBER MOTOR MOTOR CIRCUIT CIRCUIT VOLTAGE VOLTAGE AMPACITY PROTECTION FPG22N9012C* 208/230-1-60 FPG33N9012C* 208/230-1-60 FPG44N9012C* 208/230-1-60 FPG22N9018C* 208/230-1-60 FPG33N9018C* 208/230-1-60 FPG44N9018C* 208/230-1-60 FPG55N9018C* 208/230-1-60 FPG33N9024C* 208/230-1-60 10.7 FPG44N9024C* 208/230-1-60 10.7...

  • Page 14: Unit Location

    This appliance is not CAUTION design certified for installation in mobile homes, recreational vehicles, or outdoors. A First Co. approved wall When the unit is in operation components are rotating sleeve must be used to install the FPG unit.

  • Page 15: Unit Clearance Requirements

    FIRST-PAK INSTALLATION CONTINUED UNIT CLEARANCE REQUIREMENTS The unit may be installed with zero clearances to adjacent combustible surfaces. This furnace shall not be installed directly on carpeting, tile, or other combustible material, other than wood flooring. Service clearance must be provided for future maintenance and service.

  • Page 16: Vent Clearances

    FIRST-PAK INSTALLATION CONTINUED VENT CLEARANCES FIGURE 9 - Location of Vent Termination Clearances VENT TERMINATION CLEARANCES CLEARANCE CANADIAN INSTALLATIONS¹ US INSTALLATIONS² A = Clearance above grade, veranda, porch, deck, or 12 in (30 cm) 12 in (30 cm) balcony (see 1.23.5-i(9)b.) B = Clearance to window or door that may be opened 6 in (15 cm) for appliances 10,000 Btuh (3 kW) 12 in (30cm) for appliances >10,000 Btuh(3 kW)

  • Page 17: Removal Of A Unit Froma Common Venting System

    FIRST-PAK INSTALLATION CONTINUED REMOVAL OF A UNIT FROM A COMMON VENTING SYSTEM WARNING When an existing furnace is removed from a common venting system serving other appliances, the venting ELECTRIC SHOCK HAZARD system is likely to be too large to properly vent the Disconnect all power supplies before servicing.

  • Page 18: Wall Sleeve Installation

    FIRST-PAK INSTALLATION CONTINUED WALL SLEEVE INSTALLATION Refer to installation instruction packed with the wall sleeve REAR INSTALLATION & DIMENSIONS to assemble and mount into the wall. Before unit installation, make sure sleeve components are not damaged; drain line is not obstructed and is leak free. Check all seals to ensure that they are in position and un- damaged.

  • Page 19: Unit Support

    INSTALLATION CONTINUED UNIT SUPPORT The FIRST-PAK wall sleeve is not intended or designed to Things to consider prior to build the support structure: provide complete support for the FIRST-PAK unit. Additional support is required. A field constructed platform 1. Accurately measure the unit and choose a strong may be used for this purpose and may also be constructed building material for the support structure.

  • Page 20: Packaged Unit Installation

    FIRST-PAK INSTALLATION CONTINUED PACKAGED UNIT INSTALLATION Insulation is used in indoor equipment to provide a barrier NOTE between outside air conditions surrounding the unit and the varying conditions inside the unit. If the insulating Locate the unit in an area that meets minimum barrier is damaged, the surrounding ambient air will affect clearance requirements for all service access panels the inside surface temperature of the cabinet;...
  • Page 21 FIRST-PAK INSTALLATION CONTINUED PACKAGED UNIT INSTALLATION 6. Ensure that the wall sleeve is installed squarely and is secured before installing the unit. NOTE 7. Inspect the sleeve seal, which is supplied with the sleeve, to ensure that it is properly secured and Check nameplate voltage, amperage and fuse size for aligned (see FIGURE 13 –...

  • Page 22: Ductwork And Duct Connections

    FIRST-PAK INSTALLATION CONTINUED DUCTWORK AND DUCT CONNECTIONS IMPORTANT Both supply and return air ducts must be attached to the unit. IMPORTANT The supply duct connection must be sized to a minimum of the same size as the unit discharge air opening.

  • Page 23: Venting

    FIRST-PAK INSTALLATION CONTINUED GAS HEAT CONDENSATE DRAINAGE AIR FILTER In addition to air conditioning condensation, the FPG**N9 The FIRST-PAK unit must not be operated without an air unit will produce condensation during the combustion filter in place. The unit is equipped with a factory installed process.

  • Page 24: Combustion Air

    FIRST-PAK INSTALLATION CONTINUED COMBUSTION AIR GAS PIPING & CONNECTION This is a direct vent furnace, which receives its combustion All gas piping and connections to this furnace must be air from outside and discharges the products of performed by a qualified installer. Installation methods and combustion outside.

  • Page 25: Leak Testing

    FIRST-PAK INSTALLATION CONTINUED GAS PIPING & CONNECTION CONTINUED WARNING FIRE OR EXPLOSION HAZARD WARNING Failure to follow the safety warnings exactly could In the State of Massachusetts: result in serious injury, death or property damage. This product must be installed by a licensed Plumber or Never test for leaks with an open flame.

  • Page 26: Electrical

    FIRST-PAK ELECTRICAL HIGH VOLTAGE LOW VOLTAGE THERMOSTAT WARNING A standard 24 VAC single stage heating and cooling thermostat is required to control this unit. For ELECTRIC SHOCK HAZARD FPG**N9030C units, a dual stage thermostat must be used Disconnect all power supplies before servicing. Lock in order to reach rated system performance.

  • Page 27: Controls

    FIRST-PAK CONTROLS CONTROL BOARD SIGNAL PROBLEM POSSIBLE CAUSE CHECKS & CORRECTIONS SLOW FLASH Stand-by mode, awaiting call from room Status = Stand-by mode; does not Status of stand-by mode displayed no thermostat indicate fault condition fault indicated RAPID FLASH Room thermostat is requesting heat Status = Thermostat requesting heat;...
  • Page 28 FIRST-PAK FIGURE 23 - Control Board COOLING OPERATION When the unit is given a "Y" input the unit will operate in steady state cooling mode. The compressor will FIGURE 24 – Electrical Component immediately come on after a "Y" input. After a 5s time delay the indoor fan will be energized.
  • Page 29 FIRST-PAK CONTROLS CONTINUED BLOWER CONTROL FPG gas heat units are equipped with a direct drive indoor blower motor.  All models have 5 fan speeds: T1 is the constant fan speed. T2 is used for freeze protection. T3 may be used for heating mode providing the speed selection allows the unit to operate within specified temperature rise range.

  • Page 30: Performance Data

    FIRST-PAK PERFORMANCE DATA FPG AIRFLOW PERFORMANCE DATA IWC STATIC PRESSURE RISE MOTOR MODEL RANGE SPEED RISE °F TEMP TEMP TEMP TEMP TEMP °F SCFM SCFM SCFM SCFM SCFM RISE °F RISE °F RISE °F RISE °F RISE °F 25-55 25-55 FPG22N9012C* 40.0 25-55...
  • Page 31 FIRST-PAK PERFORMANCE DATA FPG AIRFLOW PERFORMANCE DATA IWC STATIC PRESSURE RISE MOTOR MODEL RANGE SPEED RISE °F TEMP TEMP TEMP TEMP TEMP °F SCFM SCFM SCFM SCFM SCFM RISE °F RISE °F RISE °F RISE °F RISE °F 35-65 35-65 FPG33N9024C* 45.0 35-65...

  • Page 32: Heating Operations

    FIRST-PAK HEATING OPERATIONS FIGURE 26 - Heating Sequence of Operations FPG SERIES – IOM (REV. C 3/24)
  • Page 33 FIRST-PAK HEATING OPERATIONS CONTINUED TO LIGHT BURNERS 1. Turn off electrical power to the unit. 2. Turn the room thermostat to the lowest setting. Check that the position of the gas valve switch is in the “on” position (see FIGURE 28 – Gas Valve Check that the position of the manual gas shut-off valve is in the “on”...
  • Page 34 FIRST-PAK HEATING OPERATIONS CONTINUED GAS SUPPLY PRESSURE 4. Connect tubing and a manometer to the 1/4” hose barb connector. 1. Turn “off” the gas supply to the furnace using the manual gas valve. 2. Remove the inlet pressure port plug using a 3/16” hex wrench.

  • Page 35: Cooling Operations

    FIRST-PAK HEATING OPERATIONS CONTINUED TEMPERATURE RISE This gas furnace is designed to operate within a specific range of temperatures while in heating mode. The “Temperature Rise” range is shown on the rating plate. MEASURE Temperature rise is defined as the temperature difference SUPPLY TEMP between the air entering the furnace and the air leaving SUPPLY...

  • Page 36: Location Of Major Components

    FIRST-PAK LOCATION OF MAJOR COMPONENTS HEAT EXCHANGER ASSEMBLY CONDENSER COIL ASSEMBLY CHASSIS SLIDE-OUT COOLING ASSEMBLY BLOWER FAN ASSEMBLY FILTER RETENTION EVAPORATOR COIL DRAIN PAN ASSEMBLY FIGURE 32 – Slide Out Chassis Assembly MANIFOLD DRAFT INDUCER GAS VALVE FIGURE 33 – Heating Assembly FPG SERIES –...
  • Page 37 FIRST-PAK LOCATION OF MAJOR COMPONENTS CONTINUED FIGURE 34 – Cabinet Components FPG SERIES – IOM (REV. C 3/24)

  • Page 38: Wiring Diagrams

    FIRST-PAK WIRING DIAGRAMS FPG SERIES – IOM (REV. C 3/24)
  • Page 39 FIRST-PAK WIRING DIAGRAMS FPG SERIES – IOM (REV. C 3/24)
  • Page 40 FIRST-PAK WIRING DIAGRAMS FPG SERIES – IOM (REV. C 3/24)
  • Page 41 FIRST-PAK WIRING DIAGRAMS FPG SERIES – IOM (REV. C 3/24)

  • Page 42: Circuit Diagrams

    FIRST-PAK CIRCUIT SCHEMATIC FIGURE 39 - Circuit Diagram STARTUP INSTRUCTIONS PRE-STARTUP CHECKS: PRIOR TO THE STARTUP OF THE UNIT: 1. Ensure supply voltage matches nameplate data. 2. Ensure the unit is properly grounded. WARNING 3. With the power off, check blower wheel set screws for proper tightness and that the blower wheel Electrically ground the unit.
  • Page 43 FIRST-PAK STARTUP INSTRUCTIONS CONTINUED UNIT STARTUP: Example of input rate calculation using the typical heating 1. Ensure that power is connected to the unit and the valve of Natural Gas of 1,000 BTU cu/ft, and 90 seconds local disconnect is switched to ON position. time to complete one revolution of the 1 cu/ft dial on the 2.

  • Page 44: Troubleshooting

    FIRST-PAK TROUBLESHOOTING HEATING PROBLEM POSSIBLE CAUSE CHECKS & CORRECTIONS Open Circuit Fuse (Electrical Panel) Replace fuse Open Circuit Breaker (Electrical Panel) Re-set circuit breaker / fuse OPERATION Open Unit Power Switch Check position / electrical state of switch (External disconnect, adjacent to unit) Refer to LED &...

  • Page 45: Heating

    FIRST-PAK TROUBLESHOOTING CONTINUED HEATING Step 1 Thermostat calls for heat by energizing “W” terminal with 24 volts a/c Expected The room thermostat R terminal is constantly powered with 24 volts a/c by its connection to the control board R Operation terminal and the unit transformer.
  • Page 46 FIRST-PAK TROUBLESHOOTING CONTINUED HEATING Step 6 Control board energizes the spark ignitor & the gas valve (trial for ignition) Expected During trial for ignition, the draft inducer, & gas valve are energized. After 10 seconds, the spark ignitor is de- Operation energized &...

  • Page 47: Cooling

    FIRST-PAK TROUBLESHOOTING CONTINUED COOLING PROBLEM POSSIBLE CAUSE CHECKS & CORRECTIONS Power supply off Apply power; close disconnect. Blown Fuse Replace fuse or reset circuit breaker. Check for correct fuses. If voltage is below minimum voltage specified on unit data plate, Voltage supply low ENTIRE UNIT contact power company.
  • Page 48 FIRST-PAK MAINTENANCE & SERVICE - HEATING AIR FILTER(S) COMBUSTION AIR PROVING SWITCH Furnace filters should be checked monthly and replaced as necessary. Do not operate the furnace without filters in The combustion air-proving switch is a safety device which place. The Interval of filter replacement will vary with verifies operation of the combustion blower and that the environmental factors and the size and type of filters used.
  • Page 49 FIRST-PAK GAS HEAT CONDENSATE DRAIN &TRAP The heating condensate drain trap receives the water created by the combustion process. Water is carried to the trap by a drain tube which runs from the heat exchanger collector box to the drain trap located in the cooling chassis behind the evaporator coil.
  • Page 50 FIRST-PAK MAINTENANCE & SERVICE – HEATING CONTINUED INDOOR BLOWER MOTOR PERIODIC INSPECTIONS Check the openings on the end of the indoor blower motor The following items should be inspected annually to make sure they are not blocked and free from debris. (minimum) before each heating season by a qualified The indoor blower motor contains permanently sealed ball service agency:...
  • Page 51 FIRST-PAK MAINTENANCE & SERVICE – HEATING CONTINUED HEATING MODULE REMOVAL The entire gas heat section may be removed as a unit for service if required. 1) Turn off electrical power to furnace and disconnect low and high voltage field wiring at unit.
  • Page 52 FIRST-PAK FIGURE 43 – Heating Access Panel Removal FPG SERIES – IOM (REV. C 3/24)
  • Page 53 FIRST-PAK MAINTENANCE & SERVICE – COOLING AIR CONDITIONER MODULE REMOVAL FIGURE 49 – Drain Tube Disconnection The air-conditioning chassis may be removed as a unit for service if required. Turn off electrical power to refrigeration chassis. 1) Remove screws (2) from controls cover and remove panel.
  • Page 54 FIRST-PAK MAINTENANCE & SERVICE – COOLING CONTINUED 6) Slide-out refrigeration chassis FIGURE 48 – Slide AIR CONDITIONER MODULE REASSEMBLY Out Chassis 1) To put-back the chassis, make sure all the 7) Side panel can be removed from the evaporator refrigerant lines are in place and there are no section to service the TXV.
  • Page 55 FIRST-PAK PREVENTIVE MAINTENANCE To achieve maximum performance and service life of WARNING equipment, a formal schedule of regular maintenance should be established and followed. ELECTRIC SHOCK HAZARD Check motor connections to ensure they are secure WARNING and in accordance with the unit wiring diagram. It is illegal to discharge refrigerant into the ECM motors have line voltage power applied at all atmosphere.

  • Page 56: Replacement Parts

    FIRST-PAK REPLACEMENT PARTS Table 15 – Replacement Part For service part inquiries, please contact 8273 Moberly Lane Dallas, TX 75227 214-388-5751 FPG SERIES – IOM (REV. C 3/24)

  • Page 57: Startup & Performance Checklist

    FIRST-PAK STARTUP & PERFORMANCE CHECKLIST FIGURE 49 - Startup and Performance Checklist (1 of 2) FPG SERIES – IOM (REV. C 3/24)
  • Page 58 FIRST-PAK STARTUP & PERFORMANCE CHECKLIST CONTINUED FIGURE 50 - Startup and Performance Checklist (2 of 2) NOTES FPG SERIES – IOM (REV. C 3/24)
  • Page 59 P.O. Box 270969 Dallas, TX 75227 www.firstco.com or www.ae-air.com The manufacturer works to continually improve its products. It reserves the right to change design and specifications without notice. ©2023 First Co., Applied Environmental Air...

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