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Installation Instructions
PGX3 Series
PACKAGED GAS / ELECTRIC UNITS
TABLEOF CONTENTS
UNITDIMENSIONS ......................................
2 - 3
SAFEINSTALLATIONREQUIREMENTS .........................
4
LOCATING THE UNIT .......................................
5
CLEARANCES ............................................
5
INSTALLATION............................................
5
GROUNDLEVELINSTALLATION ..............................
5
HOISTING................................................
6
DOWNFLOWCONVERSION ..................................
6
HEATINGVENTASSEMBLY ..................................
6
CONDENSATEDRAIN.......................................
7
PRE-EXISTINGCOMMONVENTCHECK .........................
7
GAS SUPPLYAND PIPING ...................................
7
ORIFICES ...............................................
8
ELECTRICALWIRtNG..................................
10
DUCTWORK.........................................
11
FILTERS ............................................
11
AIRFLOWADJUSTMENT ...............................
12
START-UPPROCEDURES ..............................
13
GAS PRESSURES ....................................
14
HEATINGSTART-UPPROCEDURES ......................
14
OPERATION.........................................
16
MAINTENANCE ......................................
16
INSPECTIONAND CLEANING............................
17
COMPONENTLOCATION ...............................
18
RIGGING ...........................................
19
WIRING DIAGRAMS ................................
20 - 21
CQUS
LISTED
InternationalComfortProducts,LLC
Lewisburg,TN. 37091
462 01 1201 00
1-10-06
Printed in U.S.A.
Code: PGX3
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Summary of Contents for ICP PGX3 Series
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Page 1: Table Of Contents
Installation Instructions PGX3 Series PACKAGED GAS / ELECTRIC UNITS TABLEOF CONTENTS UNITDIMENSIONS ........2 - 3 ELECTRICALWIRtNG........DUCTWORK......... SAFEINSTALLATIONREQUIREMENTS ......LOCATING THE UNIT ........FILTERS ..........CLEARANCES ..........AIRFLOWADJUSTMENT ....... INSTALLATION..........START-UPPROCEDURES ......GROUNDLEVELINSTALLATION ......GAS PRESSURES ........HOISTING..........HEATINGSTART-UPPROCEDURES ...... DOWNFLOWCONVERSION ........ -
Page 2: Unitdimensions
"B" CHASSIS UNIT DIMENSIONS 1. Unit Dimensions Units in "B" Chassis Configuration COMBINATION GAS/ ELECTRIC UNITS PGX324 - 36 "B" Chassis (473/8 x 473/8) "0" _ "B" DIM= INCHES MILLOMETERS 47-3/8 1203 47-3/8 1203 3-1/8 32-1/2 11-1/8 14-1/4 14-1/4 "4 314 I 19 28 "1''/ 4-1/4... - Page 3 "C" CHASSIS UNIT DIMENSIONS POWER CONDUIT ('K" DIM.) VOLTAGE 1/2" (12.7) CONDUIT CONNECTION 1/2" (12,7) PIPE 1/2" COMBINATION GAS/ ELECTRIC UNITS "C" Chassis (473/8 x 73) INCHES MILLOMETERS 47-3/8 1203 1354 4-5/8 18-3/4 18-3/4 1 &1-1/4 25&31 4-1/4 5-1/4 12-1/4 12-1/4 ,,p,, 16-7/8...
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Page 4: Safeinstallationrequirements
2. SAFE INSTALLATION REQUIREMENTS FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON Installation and servicing of air-conditioning equipment can MONOXIDE POISON HAZARD be hazardous due to system pressure and electrical Failure to carefully read and follow all instructions in this components. Only trained and qualified personnel should manual could result in furnace malfunction, property install, repair, or service air-conditioning equipment. -
Page 5: Locating The Unit
3. LOCATING THE UNIT FiGuRE i Minimum Clearances Panels(B Chassis and Access Shown) ACCESS PANELS I Blower Compartment Panel See Figure 1 for a general view of unit and location of access panels. B Chassis - 2" C Chassis - 6" CLEARANCES The location MUST allow for minimum clearances should not be adjacent to a patio or other area where the... -
Page 6: Hoisting
Rooftop Installation FIGURE2 Heating Vent Assembly Rooftop platform requirements: Screws for Screw for - The unit MUST be situated to provide safe access for "B" Chassis "C" Chassis servicing. (473/8 x 473/8) (473/8 x 73) - The existing roof structure MUST be adequate support the weight of the unit or the roof MUST be reinforced. -
Page 7: Condensatedrain
Condensate Drain 5. GAS SUPPLY AND PIPING The condensate drain outlet is (19.1 mm) female PVC a 3/4" NOTE: Because there are many types of liquified petroleum connection located atthe bottom ofthe unit to the right ofthe (LP) gases, the term LP as used in this manual refers to filter access panel (see FIGURE 4). -
Page 8: Orifices
FIGURE 6 Gas Pipe Size, Length and Btu/hr Capacity for Schedule 40 Iron Pipe (English) UNIT OPERATION AND COMPONENT DAMAGE HAZARD NATURAL GAS Failure to follow this caution may result in misaligned Pipe Length kW** burners, flame rollout and or unit damage. (includes Fittings) 3/4"... - Page 9 NOTE: The orifice sizes in the chart above derate the input rate at 4% per 1000 feet above sea level for altitudes exceeding 2000 feet above sea level. If converting from LP gas to Natural Gas at altitudes exceeding 2000 feet above sea level, part number...
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Page 10: Electricalwirtng
have a calipers, you can use an adjustable wrench and the electrical service panel or a properly driven and measure between the face of the jaws. electrically grounded ground rod. See warning above. 10. Reassemble in reverse order. Line Voltage Wiring Connections for line voltage are made in the unit control box 6. -
Page 11: Ductwork
7. DUCTWORK permitted. If flexible connectors are used, they should be protected from potential mechanical damage such as Ductwork Sizing punctures and tears. The maximum recommended velocity in trunk ducts is 1000 NOTE: When connecting the supply and return plenums to feet per minute. -
Page 12: Airflowadjustment
8. AIRFLOW ADJUSTMENT PGX3 SERIES HEATING CHART External Static Pressure (in H20) .1" 2" .3" .4" .5" .6" 8" Cooling Hea6n0 Input Heating Hise Speed Heating Heatrng Heating Heatln 0 Heating Heating Heating Heating Model Tuns (8tuih0 Range(_F) Rise (°F) Rise(_F) Rise (°F) Rise(_F) -
Page 13: Start-Upprocedures
CIRCULATING AIR BLOWER SPEEDS FIGURE 11 Factory-Shipped Blower Tap Connections Factory-Shipped BlowerTap Connections Coofing Heatinglnput Heating Rise Heating SpeedTap High Stage Coofing Low Stage Cooling SpeedTap(Violet) Model Tons (Btu/hr) Range(°F) (Red) Speed Tap (Black) PGX32404OK..40000 35-65 PGX32406OK..60000 35-65 PGX32408OK.. -
Page 14: Gaspressures
NOTE: Adjustment screw cover MUST be placed on gas valve before reading manifold pressure and operating furnace. FIREOR EXPLOSION HAZARD. Failureto follow this warning could resultin personalinjury and/ordeath. FIREAND/OREXPLOSION HAZARD TurnOFFgasat shutoffbeforeconnecting U-tubemanometer. Failureto follow this warning couldresultin personalinjury, deathand/or propertydamage. FIGURE i2 Honeywell Gas Valve... - Page 15 will normally be obtained when the unit is operating at rated input with the recommended blower speed. FIRE AND/OR EXPLOSION HAZARD The temperature rise must be within the specifications marked on the unit rating plate. Failure to follow this warning could result in personal To check the temperature rise through the unit, place ther- injury, death, and/or property damage.
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Page 16: Operation
10. OPERATION directly into the heat exchanger tubes and the turbulators should glow orange (after about five minutes of operation). Main burner flame should be inspected monthly. FIGURE i6 Normal Flame ELECTRICAL SHOCK HAZARD. Failure to follow this warning could result in personal injury, death and/or property damage. -
Page 17: Inspectionand Cleaning
VENT ASSEMBLY 1. Disconnect electrical power to unit. 2. Turn OFF gas at manual shut off valve. 3. Remove burner access panel. BURN HAZARD. 4. Remove the vent assembly flue pipe. 5. Disconnect gas pipe at union. Failure to follow this caution may result in personal 6. -
Page 18: Componentlocation
FIGURE 17 Component Locations I Remote Sparker Unit I Sensor I I Flame I GasValve I I Rollout Switch ©© [ 'FM and Speed Selector Leads Switch Primary Limit I... -
Page 19: Rigging
RIGGING INSTRUCTIONS 10962_,,_-A FAILURE TO FOLLOW THESE INSTRUCTIONS /K WARNING CAN RESULT IN PROPERTY DAMAGE, BODILY INJURY OR DEATH. - ALL PANELS MUST BE IN PLACE WHEN RIGGING AND LIFTING. - HOOK RIGGING SHACKLES THROUGH HOLES IN BASE RAIL, AS SHOWN IN DETAIL-A. -
Page 20: Wiring Diagrams
All Models Wiring Diagram I_PS1 IF £1iY OF Thee ORKIINA! W RE AS SUPP HD _?I" _,qUST8 REFLACED, THai @_LIAH{Z I:{EFLA£ 0 wr/ TYPt: A?_NI05"C OR NS E©S vat I/ , !_SIA IA bS R;CTIONS FOR PHOP[R NEA iIcG ANI} COO/IN6 (:Olq!ECI_ONS l_]i _)(0,_/}'!{ Ab... - Page 21 All Models Wiring Diagram ISUL/L Wl _[F' b A(} AF _, I_. / ..C,_AIaG E}<: El EC] t:_/iCiSi S_iOC!'t s_,_n ,_ E>] S CU,I _cC ..F!VI¢ N6 "[ USE COPPER_O_sUC*' "OR_oS 0 I_[" //YI B' SUP t¥ m ¸¸_ _" ©...