International comfort products PGD/S524?60 Installation Instructions Manual
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International comfort products PGD/S524?60 Installation Instructions Manual

International comfort products PGD/S524?60 Installation Instructions Manual

R−410a single package gas/electric units
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INSTALLATION INSTRUCTIONS

R−410A Single Package Gas/Electric Units
These instructions must be read and understood completely before attempting installation
DANGER, WARNING, CAUTION, and NOTE
The signal words DANGER, WARNING,
CAUTION, and NOTE are used to identify levels of
hazard seriousness. The signal word DANGER is only
used on product labels to signify an immediate hazard.
The signal words WARNING, CAUTION, and NOTE will
be used on product labels and throughout this manual
and other manual that may apply to the product.
DANGER − Immediate hazards which will result in
severe personal injury or death.
WARNING −Hazards or unsafe practices which could
result in severe personal injury or death.
CAUTION − Hazards or unsafe practices which may
result in minor personal injury or product or property
damage.
NOTE − Used to highlight suggestions which will result
in enhanced installation, reliability, or operation.

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PGD/S524−60
Single Phase

Safety Labeling and Signal Words

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Signal Words in Manuals
The signal word WARNING is used throughout
this manual in the following manner:
WARNING
!
The signal word CAUTION is used throughout
this manual in the following manner:
!
Signal Words on Product Labeling
Signal words are used in combination with colors
and/or pictures or product labels.
!
2
2
2
PERSONAL INJURY, AND/OR PROPERTY
DAMAGE HAZARD
3
Failure to carefully read and follow this warning
3
could result in equipment malfunction, property
7
damage, personal injury and/or death.
7
Installation or repairs made by unqualified
11
persons could result in equipment malfunction,
11
property damage, personal injury and/or death.
11
The information contained in this manual is
12
intended for use by a qualified service technician
13
familiar with safety procedures and equipped
15
with proper tools and test instruments.
17
Installation must conform with local building
17
codes and with the national Electrical Code
17
NFPA70 current edition or Canadian Electrical
Code part 1 CSA C.22.1.
17
20
23
26
34
CAUTION
WARNING
462 01 2103 01
07−09−13

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  • Page 1: Table Of Contents

    INSTALLATION INSTRUCTIONS R−410A Single Package Gas/Electric Units PGD/S524−60 Single Phase These instructions must be read and understood completely before attempting installation Safety Labeling and Signal Words DANGER, WARNING, CAUTION, and NOTE The signal words DANGER, WARNING, CAUTION, and NOTE are used to identify levels of hazard seriousness.

  • Page 2: Safety Considerations

    SAFE INSTALLATION REQUIREMENTS manuals, be alert to the potential for personal injury. Understand PACKAGED GAS / ELECTRIC UNIT FIGURE 1 these signal words: DANGER, WARNING, and CAUTION. These words are used with the safety−alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death.

  • Page 3: Receiving And Installation

    RECEIVING AND INSTALLATION STEP 1 — Check Equipment Slab Mount Place the unit on a solid, level concrete pad that is a minimum of 4” Identify Unit (102mm) thick with 2” (51mm) above grade (see Figure 2). The slab The unit model number and serial number are stamped on the unit should extend approximately 2”...
  • Page 4 FIGURE 3 Model Size 24 Dimensions Unit WT. Unit HT. Center of Gravity Electrical Characteristics Unit 24040 208/230-1-60 189.9 44-3/4 1136.7 22-13/16 579.4 15-5/16 388.9 17-5/8 447.7 24060 208/230-1-60 193.1 44-3/4 1136.7 22-13/16 579.4 15-5/16 388.9 17-5/8 447.7 Corner Weight LB/KG UNIT Voltage 24040...
  • Page 5 FIGURE 4 Model Size 36−60 Dimensions Unit WT. Unit HT. Center of Gravity Electrical Characteristics Unit 36060 208/230-1-60 513 232.8 48-5/8 1235.1 22-13/16 579.4 457.2 16-5/8 422.3 36090 208/230-1-60 521 236.4 48-5/8 1235.1 22-13/16 579.4 457.2 16-5/8 422.3 48090 / 115 / 130 208/230-1-60 549 249.1 50-5/8...
  • Page 6 Roof Curb Dimensions FIGURE 5 Dashed lines show cross support location for large basepan units. HVAC unit HVAC unit basepan base rails Sealing Gasket Roofcurb Anchor screw field supplied Wood nailer* Flashing field supplied (field supplied) Roofing material field supplied Cant strip field supplied SMALL/COMMON CURB...

  • Page 7: Step 4 - Provide Clearances

    STEP 4 — Provide Clearances INSPECTION The required minimum operating and service clearances are Prior to initial use, and at monthly intervals, all rigging shackles, shown in Fig. 3 and 4. Adequate combustion, ventilation and clevis pins, and straps should be visually inspected for any condenser air must be provided.
  • Page 8 FIGURE 6 Unit Corner Weight (lbs) and Rigging 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 9 Table 1 − PHYSICAL DATA PG(D,S)524−36 UNIT SIZE 24040 24060 36060 36090 NOMINAL COOLING CAPACITY (ton) NOMINAL HEATING CAPACITY (Btu) 40,000 60,000 60,000 90,000 SHIPPING WEIGHT (lb) (kg) 2−Stage Scroll COMPRESSORS Quantity REFRIGERANT: R−410A Quantity (lb) 10.1 10.1 (kg) REFRIGERANT METERING DEVICE Size 2 Ton 2 Ton...
  • Page 10 Table 2—Physical Data PG(D,S)548−60 UNIT SIZE 48090 48115 48130 60090 60115 60130 NOMINAL HEATING CAPACITY (Btu) 90,000 115,000 130,000 90,000 115,000 130,000 SHIPPING WEIGHT (lb) (kg) 2−Stage Scroll COMPRESSORS Quantity REFRIGERANT: R−410A Quantity (lb) 15.3 15.3 15.3 15.8 15.8 15.8 (kg) REFRIGERANT METERING DEVICE Size...

  • Page 11: Step 6 - Connect Condensate Drain

    STEP 6 — Connect Condensate Drain Step 8 — Install Gas Piping NOTE: When installing condensate drain connection be sure to The gas supply pipe enters the unit through the access hole comply with local codes and restrictions. provided. The gas connection to the unit is made to the 1/2−in. Unit disposes of condensate water through a 3/4 in.

  • Page 12: Step 9 - Install Duct Connections

    Table 3—Maximum Gas Flow Capacity* NOMINAL INTERNAL LENGTH OF PIPE FT (m)† IRON PIPE DIAMETER SIZE (IN.) (IN.) (12) (15) (18) (21) (24) (27) (30) (38) (46) (53) (61) .622 — — .824 1.049 1−1/4 1.380 1400 1−1/2 1.610 2100 1460 1180 *Capacity of pipe in cu ft of gas per hr for gas pressure of 0.5 psig or less.

  • Page 13: Step 10 - Install Electrical Connections

    NOTE:These panels are held in place with tabs similar to an CAUTION electrical knockout. Reinstall horizontal duct covers (Fig. 9) shipped on unit from factory. Insure openings are air and UNIT COMPONENT DAMAGE HAZARD watertight. Failure to follow this caution may result in damage to the unit NOTE:The design and installation of the duct system must be in being installed.
  • Page 14 Special Procedures For 208 Volt Operation Run the low−voltage leads from the thermostat, through the inlet hole, and into unit low−voltage splice box. WARNING Locate six 18−gage wires leaving control box. These low−voltage connection leads can be identified by the colors red, green, yellow, ELECTRICAL SHOCK HAZARD brown, pink, and white (see Figure 10).

  • Page 15: Wiring Diagrams

    208/230−1−60 ALL UNITS FIGURE 11 CONNECTION WIRING DIAGRAM DANGER: ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING NOTES: 1. IF ANY OF THE ORIGINAL WIRES FURNISHED ARE SCHEMATIC IF USED REPLACED, THEY MUST BE REPLACED WITH TYPE 208/230−1−60 90 DEG. C WIRE OR ITS EQUIVALENT. 2.
  • Page 16 Fig. 11 (Cont.) 208/230-1-60 All Units LADDER WIRING DIAGRAM DANGER: ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING USE COPPER CONDUCTORS ONLY FIELD SUPPLY 208/230 VAC, 60 HZ, 1PH UNIT COMPONENT ARRANGEMENT IF USED OUTDOOR FAN SECTION COMPRESSOR INDOOR FAN CONTROL BOX AREA SECTION SECTION TRAN...

  • Page 17: Pre−Startup

    PRE−STARTUP c. Leak−test all refrigerant tubing connections using WARNING electronic leak detector, or liquid−soap solution. If a refrigerant leak is detected, see following Check for Refrigerant Leaks section. FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD d. Inspect all field− and factory−wiring connections. Be sure Failure to follow this warning could result in personal injury or that connections are completed and tight.
  • Page 18 Altitude Derate Multiplier for U.S.A. 1. Place room thermostat SYSTEM switch in the HEAT position Table 4 − and the fan switch in the AUTO position. PERCENT OF DERATE MULTIPLIER 2. Set the heating temperature control of the thermostat above DERATE FACTOR{ ALTITUDE FT (M)
  • Page 19 Adjust Gas Input If larger adjustments are required, change main burner orifices following the recommendations of national and local codes. The gas input to the unit is determined by measuring the gas flow at the meter or by measuring the manifold pressure. NOTE: All other appliances that use the same meter must be turned Measuring the gas flow at the meter is recommended for natural off when gas flow is measured at the meter.

  • Page 20: Step 3 − Start−Up Cooling And Adjustments

    Airflow and Temperature Rise On a call for heating, thermostat closes R to W, starting the induced−draft motor. When the pressure switch senses that the The heating section for each size unit is designed and approved for induced−draft motor is moving sufficient combustion air, the burner heating operation within the temperature−rise range marked on the sequence begins.
  • Page 21 CAUTION below room temperature (to allow time to check charge). Observe that compressor, outdoor (condenser) fan, and indoor (evaporator) blower motors start. Observe that cooling UNIT DAMAGE HAZARD cycle shuts down when temperature setting is satisfied. The Failure to follow this caution may result in unit damage. indoor (evaporator) fan motor will continue to run for 90 seconds.
  • Page 22 wire to the “HIGH COOL” or “LOW COOL” terminal on the IFB. NOTE:Once the compressor has started and then stopped, it For optimum performance, add the wet coil pressure drop in should not be started again until 5 minutes have elapsed. The Table 10 to the system static to determine the correct cooling cooling cycle remains on until the room temperature drops to a point airflow speed in Table 9, that will deliver the nominal cooling...

  • Page 23: Maintenance

    MAINTENANCE To ensure continuing high performance and to minimize the 7. Check flue hood and remove any obstructions, if necessary. possibility of premature equipment failure, periodic maintenance Air Filter must be performed on this equipment. This unit should be IMPORTANT: Never operate the unit without a suitable air filter in inspected at least once each year by a qualified service person.
  • Page 24 To inspect blower wheel, remove draft hood assembly. Shine a 10. To reinstall, reverse the procedure outlined above. flashlight into opening to inspect wheel. If cleaning is required, Outdoor Coil, Indoor Coil, and Condensate Drain Pan remove motor and wheel as follows: Inspect the condenser coil, evaporator coil, and condensate drain 1.
  • Page 25 Electrical Controls and Wiring Removal of Motor and Blower Wheel FIGURE 18 Inspect and check the electrical controls and wiring annually. Be sure to turn off the electrical power to the unit. Remove access panels to locate all the electrical controls and wiring.

  • Page 26: Troubleshooting

    Loss of Charge Switch WARNING This switch is located on the liquid line and protects against low suction pressures caused by such events as loss of charge, low EXPLOSION, ENVIRONMENTAL SAFETY airflow across indoor coil, dirty filters, etc. It opens on a pressure HAZARD drop at about 20 psig.
  • Page 27 Table 9 − Dry Coil Air Delivery* − Horizontal and Downflow Discharge (Deduct 10% for 208 Volts) External Static Pressure ("WC) Heating Motor Wire Rise Range Speed Color Unit Heating Rise (°F) Low1 Blue Heating Rise (°C) Heating Rise (°F) Med-Low Pink Heating Rise (°C)
  • Page 28 Table 9 − Dry Coil Air Delivery* − Horizontal and Downflow Discharge (Deduct 10% for 208 Volts) External Static Pressure ("WC) Heating Motor Wire Rise Range Speed Color Unit 1201 1159 1101 1062 1004 Heating Rise (°F) Low1 Blue Heating Rise (°C) 1419 1364 1318...
  • Page 29 Table 9 − Dry Coil Air Delivery* − Horizontal and Downflow Discharge (Deduct 10% for 208 Volts) External Static Pressure ("WC) Heating Motor Wire Rise Range Speed Color Unit 1320 1256 1211 1142 1096 1028 Heating Rise (°F) Low1 Blue Heating Rise (°C) 1351 1295...
  • Page 30 Table 12—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 Compressor and condenser sure, loss−of−charge or low−pressure switch fan will not start.
  • Page 31 Table 13—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 internal No 20−v power supply to control circuit over−current protection that requires a cool−down period to reset.
  • Page 32 Table 14—Troubleshooting Guide–LED Error Codes SYMPTOM CAUSE REMEDY Check 5−amp fuse son IGC*, power to unit, 24−v circuit breaker, and transformer. Units No Power or 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.
  • Page 33 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

    Gas inlet pressure (inches water column): Gas manifold pressure (inches water column): Refrigerant suction pressure during cooling (psi): Refrigerant discharge pressure during cooling (psi): ____ Verify proper refrigerant charge using charging chart 462 01 2103 01 Copyright 2013 International Comfort Products Lewisburg, TN 37091 USA...

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