Installation guide

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Installation Instructions

PDX4 Series

PACKAGED DUAL FUEL UNITS

TABLEOF CONTENTS

UNITDIMENSIONS ...................................... 2 - 4

SAFEINSTALLATIONREQUIREMENTS ......................... 5

LOCATINGTHE UNIT ....................................... 6

CLEARANCES ............................................ 6

INSTALLATION............................................ 6

GROUNDLEVELINSTALLATION .............................. 7

HOISTING................................................ 7

DOWNFLOWCONVERSION.................................. 7

HEATINGVENTASSEMBLY.................................. 7

CONDENSATEDRAIN....................................... 8

PRE-EXISTINGCOMMONVENTCHECK......................... 8

GASSUPPLYAND PIPING ................................... 8

ORIFICES............................................... 9

ELECTRICALWIRtNG.................................. 11

DUCTWORK ......................................... 13

FILTERS ............................................ 14

AIRFLOWADJUSTMENT ............................... 15

START-UPPROCEDURES .............................. 16

GAS PRESSURES .................................... 16

GAS HEATINGSTART-UPPROCEDURES .................. 17

OPERATION ......................................... 18

MAINTENANCE ...................................... 20

INSPECTIONANDCLEANING............................ 21

COMPONENTLOCATION ............................... 22

RIGGING ........................................... 23

WIRINGDIAGRAMS ................................ 24- 25

CQUS

LISTED

InternationalComfortProducts,LLC

Lewisburg,TN. 37091

518 01 1801 00 12-08-06

Printed in U.S.A.

Code: PDX4

Summary of content (25 pages)

PAGE 1
Installation Instructions PDX4 Series PACKAGED DUAL FUEL UNITS TABLEOF CONTENTS UNITDIMENSIONS ...................................... 2-4 ELECTRICALWIRtNG.................................. 11 SAFEINSTALLATIONREQUIREMENTS ......................... 5 DUCTWORK ......................................... 13 LOCATINGTHE UNIT ....................................... 6 FILTERS ............................................ 14 CLEARANCES ............................................ 6 AIRFLOWADJUSTMENT ..
PAGE 2
"B" CHASSIS UNIT DIMENSIONS 1. Unit Dimensions Units COMBINATION GAS/ ELECTRIC UNITS "B" Chassis in "B" PDX424 Chassis Configuration - 30 z A DIM. A B C D E F G H I J K L M N P Q R S 32-1/2 47-3/8 1203 79 283 _" _ 363 363 L_ _ I 3-1/8 I 11-1/8 12 I I I J _ _ 3,4 I19 28 _,_,_-_"_._"_. f(_d((_'_%_ J _ _ _N_.._.___._/ _"___ _ _ _ 308 4 _ _ 12 I 308 14-1/4 14-1/4 _. 4-1/4I lO8 4-3/8 14-1/2 111 368 12-1/4 12-1/8 14-1/4 I I _ "_ _ _ 1-3/8" A [ _ ..
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"C" CHASSIS UNIT DIMENSIONS ECTRICAL CONDUIT POWER ('l(" DIM.) 2-3/8" W 1/2" GAS 1/2" 3i (75) VOLTAGE (12.7) CONDUIT CONNECTION (12.7) PIPE 1-3/8" 25-1/16" (97.
PAGE 4
"C+" CHASSIS UNIT DIMENSIONS ECTRICAL CONDUIT POWER ('K" W _/2" DIM.) VOLTAGE (12.7) CONDUIT 3" (75) GAS 1/2" l CONNECTION (12.7) PIPE 1-3/8" 31-1/16" (789 4) 1 "C" (97.
PAGE 5
2. SAFE INSTALLATION REQUIREMENTS Installation and servicing of air-conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualified personnel should install, repair, or service air-conditioning equipment. Untrained personnel can perform basic maintenance functions of cleaning coils and filters. All other operations should be performed by trained service personnel.
PAGE 6
Unitsmaybeinstalledeitherona rooftop,cementslab,or directlyonthegroundiflocalcodespermit. Modelswitha'l" inthetwelfthpositionofthemodelnumber are dedicatedLow NOx units designedfor California installations. Theemissions ofthesemodelsdonotexceed 40nanograms ofnitrogen oxideemissions perjouleofheat outputasshippedfromthefactory,andmustbeinstalledin CaliforniaAir QualityManagement Districtsor anyother regionsin NorthAmericawherea LowNOxruleexists. 3. LOCATING roof covering material) FIGURE 1 \ I ..........
PAGE 7
NOTE: All access panels MUST be secured in place before hoisting. The unit should be hoisted with two lifting slings. Attach the slings to rigging shackles that have been hooked through holes in the base rail, Two spreader bars MUST be placed on top of the unit to protect the unit from damage from the pressure exerted by the slings.
PAGE 8
4. PRE-EXISTING COMMON VENT CHECK If the installation of this new combination gas heat/electric cool unit involves removing an existing gas-fired furnace from a common vent system with other gas-fired appliances (gas-fired hot water heater, etc.), the existing vent system must be checked and inspected by a qualified technician. The qualified technician can determine if the existing vent system will properly vent the flue products of the remaining gas-fired appliances.
PAGE 9
previously serviced another gas appliance. Always use a new listed connector. FIRE OR EXPLOSION HAZARD FIRE OR EXPLOSION Failure to do so could result in personal injury, death and/or property damage. Gas connector MUST be properly installed and can NOT be used inside the furnace. 4. Use pipe joint compound on external (male) threads ONLY. Joint compound MUST be resistant to any chemical action of propane (LP) gases. Do NOT put pipe compound on last 2 threads of pipe. 5.
PAGE 10
Table I NATURAL GAS MANIFOLD PRESSURE ("w c ) MEAN ELEVATION FEET ABOVE SEA LEVEL HEATING VALUE at ALTITUDE Odfic_ BTU/CU. FT No 0 to 2001 to 300I to 4001 to 500I to 6001 to 700I to 6001 to 2000 3000 4000 5000 6000 7000 8000 9000 MnfldPress Hi Orlfic_ Lo No MnfldPress Hi Odfic_ MnfldPress Lo No Hi Lo Odfic_ MnfldPress No Hi Lo Oriflc_ No MnfldPress Hi Orifice Lo No MnfldPress Hi Lo 700 9dflc_ No.
PAGE 11
6. ELECTRICAL FIGURE 7 i Removing WIRING NOx Baffles ELECTRICAL SHOCK HAZARD. or Failure to follow this warning could result in personal injury, death, and/or property damage. 25-22-46a 7. Remove the orifices from the manifold with a end or socket wrench. 7/t6" box 8. Check to be sure that the size of each orifice is correct for the Btu input desired. FIGURE 8 Manifold/Orifice Measurement _lpi°l_e°rifiee 9. Install the correct orifices.
PAGE 12
LineVoltageWiring Connections forlinevoltagearemadeintheunitcontrolbox area.RefertowiringdiagramlocatedontheBurnerAccess panel.Foraccess,removetheburneraccesspanel. 1.Runthehighvoltage(L1,L2)andgroundleadsintothe controlbox. 2. Connectgroundleadtochassisgroundconnection. 3. ConnectL1 to pressurelug connection11 of the compressor contactor. 4. ConnectL2 to pressurelug connection23 of the compressor contactor. Thermostat/ Low Voltage Wiring Location of the thermostat has an important effect on home comfort.
PAGE 13
Example: A PDX442080 is installed in a residence where the electrical utility cost is 9 cents per kilowatt-hour and the gas cost is 90 cents per therm. Proceed as follows: 1. $.09/$.90 = .1 2. Using Figure 10, a PDX342080 with a .1 cost ratio => Economic Balance Point Temperature = 20°F Some utilities have asliding cost based on consumption. In this case, take the total bill and divide by the total consumption to determine the average utility cost.
PAGE 14
sidecasingofthe unitanddonotinterferewithremovalof thetopofthe unit. FILTERS AllreturnairMUSTpassthroughafilterbeforeenteringthe unit.Anelectronic aircleaner,optionalfilterracks,orother accessible filterarrangement mustbeinstalledinthereturn airductwork.Minimum recommended filtersizesarelisted inFIGURE12andarebasedonmaximum facevelocities of 300ft/minfordisposable filtersand600ft/minforwashable (highvelocity)filters.Seefigure10forfiltersizes.
PAGE 15
8. AIRFLOW ADJUSTMENT Figure 13 Airflow Adjustment High Stage Heating Low Stage Heating Ext. Static Pressure (in we) Model PDX424040 PDX430050 PDX448100 Heating Rise CFM Heating Rise (°F) 904 33 791 37 .1" ~ .
PAGE 16
CIRCULATING AIR BLOWER SPEEDS ELECTRICAL CHECK BEFORE STARTING 1. Check that the blower motor speed terminal block is running the correct heating and cooling speeds. SHOCK HAZARD. Failure to follow this warning could result in personal injury, death and/or property damage. Turn off electric power supply at disconnect switch or service panel before removing access or service panels from unit. 2. Check to see that clean, properly sized air filters are installed.
PAGE 17
2.Turn gas ON. Temporarilyset balance point GAS HEATING START-UP PROCEDURE temperaturewarm enoughto lock out heat pump 1. Temporarily set balance point warm enough to lock out operation. Changethermostatto HEATmodeand heat pump. Adjust thermostat setting above room adjusttemperature setpointtoatleast7degreesabove temperature and set thermostat selector to HEAT. The roomtemperature.Makesurethatthethird(3rd)dip combustion air blower will energize on high speed.
PAGE 18
5, Divide number of seconds in step 4 into 3600 (number of seconds in 1 hour). 6. Multiply result of step 5 by the number of cubic feet shown for one revolution of the meter dial to obtain the cubic feet of gas flow per hour. 7, Multiply result of step 6 by Btu heating value of gas to obtain total measured input in Btu/hr. Compare this with the unit rating plate and make any adjustments as needed according to the "Manifold Pressure Adjustments" section.
PAGE 19
AlertTM Diagnostics device provides around-the-clock monitoring for common electrical problems, compressor defects, and broad system faults. If trouble is detected, an alert code is displayed with a flashing LED indicator. Alert codes are listed in Figure 17. The device is factory wired and requires no modification. Low voltage lead wires are provided in the control box for connection to thermostat wires (use wire nuts).
PAGE 20
1.The backup defrost terminate minutes. time is fixed at 10 2. The compressor recycle delay timer is 5 minutes. 3. The power interrupt response is minimum 17 msec. to maximum 35 msec. 4. Quite shift compressor recycle delay is 30 seconds. In normal defrost mode, the following sequence will occur after the set delay: 1. Condenser fan off. 2. Reversing valve energized to cooling and auxiliary gas heat (W1) is energized. 3.
PAGE 21
Condenser Fan Motor Note: The condenser fan motor is permanently lubricated. No further lubrication is required. Do not attempt to lubricate the condenser fan motor. INSPECTION AND CLEANING OF BURNER ASSEMBLY/HEAT EXCHANGERS/FLUE GAS PASSAGES For Qualified Service Technician Only See Figure 19 for identification of parts. VENT ASSEMBLY 1. Disconnect electrical power to unit. 2. Turn OFF gas at manual shut off valve. BURN HAZARD. Failure to follow this caution injury. may result in personal 5.
PAGE 22
Figure 19 Component Locations I Remote Sparker Unit I .... i ....
PAGE 23
12. Rigging Instructions 1 Figure 20 Rigging Instructions w _ CO o xi o z 0 Z_ P--_ <::_ z c_ co ___ z --J L-LJ 0 F_ _-- F-- L..._ L._ co ._ _: iI . '' ___1 @=:7>-- _._ z 222) _ 0 z xi .
PAGE 24
USE COPPER FIELD CONDUCTORS SUPPLY ONlY IB_ _os/2soVAC 60HZ, /PN !I_ Y_ _BK m "_j_l, I -1 \, y OFM CONTACPS CRANKCASE BEATER C M,/vv, R B_ COMFORT A ERT BOARD o HP81 J LPS ......................................................................................................... o DE ROST BOARD 24 _ 30 S]ZE UN1TS ONL_ 0 Y ET_ NA_UAL RESEI -R / ....................
PAGE 25
All Models Wiring L/\}[}/R Diagram W/I:R}N{} DIAG/i/\M ! L1 USE COPPERCONDUCTORS ONLY FIE [) SUPP Y 208/250 VAC, 60 PZ, P/! BK 11( ) CONTACTS81 2 G/'Y .... | CRANKCASE HEATER CAP t_ 23 CONTACTS -- S @C2_d2_E_ _R @ ¢A8 O DC MOTOR ,y_ I1 ,12 P23 ,,,_ LOW VOL]AGE IERM]NAT[ON }COM,FCB RQ BR R 00 0 TB2,00 _'_ _ Y Tt2, w20 112 Y/ 0 ..................BY........ W f_s© RVS B_ C P22 6 BK D}MO P1 !O,FCB TAP SELECT INTERFACE BOARD CAB v20 .....