ICP PGD4 E Series - User Manual

46201200402 12/2015
Specifications are subject to change without notice.
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)
PGD4andPGS4SeriesE,WPG4SeriesB
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.
NOTE: Read the entire instruction manual before starting the
installation.
NOTE: Installer: Make sure the Owner’s Manual and Service
Instructions are left with the unit after installation.
TABLE OF CONTENTS
PAGE
SAFETY CONSIDERATIONS 1.........................
INTRODUCTION 2...................................
RECEIVING AND INST ALLATION 2--14.................
Check Equipment 2..................................
Identify Unit 2....................................
Inspect Shipment 2.................................
Provide Unit Support 2...............................
Roof Curb 2......................................
Slab Mount 2.....................................
Field Fabricate Ductwork 3............................
Provide Clearances 3.................................
Rig and Place Unit 3.................................
Inspection 3......................................
Rigging/Lifting of Unit 3............................
Connect Condensate Drain 10..........................
Install Flue Hood 11..................................
Install Gas Piping 11.................................
Install Duct Connections 12............................
Configuring Units for Downflow (Vertical)
Discharge 12.....................................
Install Electrical Connections 13........................
High-- Voltage Connections 13........................
Special Procedures for 208--V Operation 13..............
Control Voltage Connections 13.......................
Standard Connection 14.............................
Heat Anticipator Setting 14..........................
Transformer Protection 14...........................
PRE-- START --UP 14...................................
START--UP 15--26.....................................
Check for Refrigerant Leaks 15.........................
Start--Up Heating & Make Adjustments 15................
Check Heating Control 15...........................
Check Gas Input 15................................
Adjust Gas Input 17................................
Check Burner Flame 17.............................
Normal Operation 24...............................
Airflow and Temperature Rise 24......................
Heating Sequence of Operation 24.....................
Limit Switches 24.................................
Rollout Switch 24.................................
Start-- Up Cooling & Make Adjustments 24................
Checking Cooling Control Operation 24................
Checking & Adjusting Refrigerant Charge 25............
Indoor Airflow and Airflow Adjustments 25.............
Cooling Sequence of Operation 26.....................
MAINTENANCE 53--56................................
A09044
Fig. 1 -- Unit PGD4, PGS4, WPG4
(Low NOx Model Available)
Air Filter 53......................................
Indoor Blower and Motor 53.........................
Induced Draft (Combustion Air) Blower 54..............
Flue Gas Passageways 54............................
Limit Switch 54...................................
Burner Ignition 54.................................
Main Burners 54...................................
Removal of Gas Train 54............................
Outdoor Coil, Indoor Coil, & Condensate Drain Pan 54....
Outdoor Fan 55...................................
Electrical Controls and Wiring 55.....................
Refrigerant Circuit 56...............................
Gas Input 56......................................
Evaporator Airflow 56..............................
R--410A Items 56..................................
TROUBLESHOOTING 57..............................
START--UP CHECKLIST 57............................
SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service maintenance,
or use can cause explosion, fire, electrical shock, or other
conditions which may cause death, personal injury, or property
damage. Consult a qualified installer, service agency, or your
distributor or branch for information or assistance. The qualified
installer or agency must use factory--authorized kits or accessories
when modifying this product. Refer to the individual instructions
packaged with the kits or accessories when installing.
Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Have a fire extinguisher available. Read these
instructions thoroughly and follow all warnings or cautions
included in literature and attached to the unit. consult local
building codes, the current editions of the National Fuel Gas Code
(NFGC) NFPA 54/ANSI Z223.1, and the National Electrical Code
(NEC) NFPA 70.

Summary

SAFETY CONSIDERATIONS

Unit Introduction and System Overview

Provides an overview of the unit's capabilities, design, and specifications.

Unit Receiving and Installation Procedures

Covers unpacking, inspection, and placement of the unit.

Inspecting and Identifying the Unit

Details how to identify the unit and inspect for shipping damage.

Unit Mounting and Support Requirements

Covers requirements for securing and supporting the unit on curbs or slabs.

Ductwork Fabrication and Installation

Instructions for fabricating and connecting ductwork to the unit.

Ensuring Proper Unit Clearances

Specifies required clearances around the unit for airflow and servicing.

Safe Rigging and Unit Placement

Guidelines for safely lifting and positioning the unit during installation.

Condensate Drain Connection Procedure

Instructions for properly connecting the condensate drain line.

Flue Hood Installation and Venting

Details on installing the flue hood for proper venting of combustion gases.

Gas Piping Installation and Connection

Covers the installation and connection of the gas supply piping.

Duct Connection Procedures

Instructions for connecting supply and return air ducts to the unit.

Electrical Connections and Wiring

Guidance on making high-voltage and control voltage wiring connections.

Pre-Start-Up Safety Checks and Procedures

Details pre-operation checks and safety precautions before starting the unit.

Unit Start-Up and Adjustment Procedures

Outlines the procedures for initial unit operation and adjustments.

Refrigerant Leak Detection and Repair

Procedures for identifying and repairing refrigerant leaks.

Heating Start-Up and Adjustments

Covers initial heating operation and necessary adjustments.

Cooling Start-Up and Adjustments

Details procedures for starting the unit in cooling mode and making adjustments.

Refrigerant Charge Check and Adjustment

How to check and adjust the refrigerant charge for optimal performance.

Indoor Airflow Adjustment Procedures

Instructions for checking and adjusting indoor airflow for heating and cooling.

Routine Maintenance Procedures

Describes routine checks and cleaning procedures for optimal performance.

Air Filter Inspection and Replacement

Guidelines for inspecting, cleaning, and replacing air filters.

Indoor Blower and Motor Cleaning

Instructions for cleaning the indoor blower motor and wheel.

Inducer Blower Assembly Inspection and Cleaning

Procedures for inspecting and cleaning the induced-draft blower assembly.

Flue Gas Passageway Inspection

Instructions for inspecting the flue collector box and heat exchanger areas.

Limit Switch and Burner Ignition Checks

How to check the limit switch and burner ignition system.

Main Burner and Gas Train Servicing

Procedures for inspecting main burners and servicing the gas train.

Coil and Drain Pan Cleaning

Guidelines for cleaning the unit's coils and condensate drain pan.

TROUBLESHOOTING

Troubleshooting Common Unit Issues

A chart listing common symptoms, causes, and remedies for unit problems.

Heating System Troubleshooting Guide

Specific troubleshooting steps for heating-related issues and symptoms.

Troubleshooting Unit LED Status Codes

Interpreting LED codes for identifying and resolving unit faults.

START-UP CHECKLIST

Preliminary Information and Pre-Start-Up Checks

Gathering unit information and performing initial pre-start-up inspections.

Unit Start-Up Procedures and Measurements

Recording electrical, temperature, and pressure readings during unit start-up.

ICP PGD4 E Series Specifications

General

Brand	ICP
Model	PGD4 E Series
Category	Air Conditioner
Language	English