ICP PDX436080K01A1 User manual

Packaged Dual Fuel Units
Owner's Guide to Operating and
Maintaining Your Gas/Electric Unit
ELECTRICAL SHOCK HAZARD.
Failure to follow this warning could result in
personal injury, death, and/or property damage.
Disconnect power at fuse box or service panel
before performing recommended maintenance.
FIRE, EXPLOSION, ELECTRICAL SHOCK
HAZARD.
Failure to follow this warning could result in
personal injury, death, and/or property damage.
Do not use this unit if any part has been under
water. Immediately call a qualified service
technician to inspect the unit and to replace any
part of the control system which has been under
water.
FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could
result in serious injury, death, and/or property
damage.
--Information in this manual MUST be followed
exactly.
--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
• Leave the building immediately.
•Do not try to light any appliance.
•Do touch any electrical switch; do not use any
phone in the building.
•Immediately call your gas supplier from a
neighbors phone. Follow the gas suppliers
instructions.
•If you cannot reach your gas supplier, call the
fire department.
mInstallation and service must be performed by a
qualified installer, service agency or the gas
supplier.
This manual should be left with the owner.
Printed in U.S.A.
Code:PDX4 12/7/06 518 02 1801 O0

SAFETY CONSIDERATIONS
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. When
working on air-conditioning equipment, observe
precautions inthe literature, tags, and labels attached to the
unit, and other safety precautions that may apply.
Follow all safety codes. Wear safety glasses and work
gloves. Use quenching cloth for unbrazing operations.
Have fire extinguisher available for all brazing operations.
FIRE AND ELECTRICAL SHOCK HAZARD
Improper installation, adjustment, alteration, service,
maintenance, or use can cause fire or an explosion
which could result in personal injury or unit damage.
Consult a qualified installer, service agency, or gas
supplier for information or assistance. The qualified
installer or agency must use only factory-authorized kits
or accessories when modifying this product.
FIRE, AND ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage.
Before performing service or maintenance operations
on unit, turn off gas supply to unit. Then turn off unit main
power switch and install lockout tag.
Recognize safety information. This is the safety-alert
symboIZ_. When you see this symbol in instructions or
manuals, be alert to the potential for personal injury.
Understand the signal words DANGER, WARNING,
CAUTION, and NOTE. These words are used with the
safety-alert symbol. DANGER identifies the most serious
hazards which will result in serious injury or death.
WARNING signifies a hazard which could result in serious
injury or death. CAUTION is used to identify unsafe
practices which may result in minor personal injury or
product and property damage. NOTE is used to highlight
suggestions which will result in enhanced installation,
reliability, or operation.
It is the personal responsibility and obligation of the
customer to contact a qualified installer to ensure that the
installation is adequate and conforms to governing codes
and ordinances.
TO LIGHT UNIT
Your combination heating!cooling unit is equipped with an
automatic direct spark ignition and power combustion
blower.
FIRE AND/OR EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage.
Do not attempt to light by hand, personal injury may
result.
FIRE AND/OR EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
Do not turn off the electrical power to unit without first
turning off the gas supply.
Before attempting to start the gas heating section,
familiarize yourself with all the procedures that must be
followed.
Refer to Figure 2 for gas valve location.
1. Set the temperature selector on room thermostat to the
lowest temperature setting and set system switch to
HEAT.
2. Close the external manual shutoff valve.
3. Turn off the electrical supply to the unit.
4. Remove the front access panel with a 5/16 -in. nut
driver.
5. Move the selector switch on the internal gas valve to the
OFF position and wait 5 minutes.
6. Move the selector switch on the internal gas valve to the
ON position.
7. Replace the front access panel.
8. Turn on the electrical supply to unit.
9. Open the external manual shutoff valve.
10. Set the temperature selector on room thermostat 7
degrees above room temperature to start unit. The
induced-draft combustion-air fan will start. Main gas
valve will open and burners should ignite the gas
within 25 seconds. If burners do not light within 25
seconds, the ignition control will go into a Retry Mode
that will take another 25 seconds. If the burners fail to
ignite the gas in 4 consecutive attempts, the unit will
lockout for 3 hours.
11. Set the temperature selector on room thermostat to
desired setting.
UNIT DAMAGE HAZARD
Failure to follow this caution may result in the shorten
life of unit components.
Do NOT operate unit in a corrosive atmosphere
containing chlorine, fluorine, or any other corrosive
chemicals.
W

FIRE AND/OR EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
1. If the main burners fail to light, or the blower fails to
start, shut down gas heating section and call your
dealer for service.
2. Never attempt to manually light the main burners on
unit with a match, lighter, or any other flame. If the
electric sparking device fails to light the main burners,
refer to the following shutdown procedures, then call
your dealer as soon as possible.
TO SHUT UNIT OFF
FIRE AND/OR EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
Do not turn off the electrical power to unit without first
turning off the gas supply.
NOTE: If unit is being shut down because the heating
season has ended, make sure to turn on power to cooling
system.
Ifunit is being shut down because of a malfunction, call your
dealer as soon as possible.
Should the gas supply fail to shut off or if overheating
occurs, shut off the manual gas valve to the unit before
shutting off the electrical supply.
Do not use this furnace if any part has been under water. A
flood-damaged furnace is extremely dangerous. Attempts
to use the furnace can result in fire or explosion. A qualified
service agency should be contacted to inspect the furnace
and to replace all gas controls, control system parts,
electrical parts that have been wet or the furnace if deemed
necessary.
Refer to Fig. 2 while proceeding with the following steps.
1. Set the temperature selector on room thermostat to
lowest temperature setting and set system switch to
OFR
2. Close the external manual shutoff valve.
3. Turn off the electrical power supply to the unit.
4. Remove the front access panel.
5. Move the selector switch on the internal gas valve to the
OFF position.
6. Replace the burner access panel.
7. Restore electrical power to the unit and set system
switch to COOL to ensure operation of the cooling
system during the cooling season.
Figure 2Access to Gas Valve
L2...j
iIFM and Speed ISelector Leads
[ Remote Sparker Unit I
JPrimary LimitSwitch I
IBurners ]
Sparker
Regulator
Adjustment
E
E
E
tntlet Pressure
Tap 1/8 NPT
Gas Valve ]I Flame Sensor I
Rollout Switch ]
GasValve
SEQUENCE OF OPERATION
Outlet Pressure
Tap 1/8 NPT
Cooling Mode:
1.Adjust thermostat setting below room temperature and
set thermostat selector to COOL.
2.The compressor and condenser fan will immediately
energize.
&The evaporator motor will either immediately start on full
speed or wait approximately 30 seconds to reach full
speed (field-selectable).
131

The air conditioner has 2 stages of cooling and will
automatically pick the correct cooling stage based on the
difference between the actual indoor temperature and the
set point temperature on the thermostat. For maximum
efficiency, avoid frequent changes to the set point
temperature.
4.When the cooling setpoint has been satisfied
a. The compressor and condenser fan will de-energize
immediately.
b. The evaporator motor will either immediately turn off
or run for an additional 90 seconds before turning off
(field-selectable).
Cooling Cycle - When operating in the cooling cycle, your
air conditioner will run until the indoor temperature is
lowered to the level you have selected. On extremely hot
days, your air conditioner will run for longer periods at a time
and have shorter "off" periods than on moderate days.
The following are typical conditions that add extra heat
and/or humidity to your home. Your air conditioner will work
longer to keep your home comfortable under these
conditions:
• Entrance doors are frequently opened and closed
• Laundry appliances are being operated
• A shower is running
• More than the usual number of people are present in the
home
• More than the normal number of electric lights are in use
• Drapes are open on the sunny side of the home
GAS HEATING START-UP PROCEDURE
1. Temporarily set balance point warm enough to lock out
heat pump. Adjust thermostat setting above room
temperature and set thermostat selector to HEAT. The
combustion air blower will energize on high speed.
2. The combustion air blower will run on high speed for 15
seconds to purge the combustion chamber.
3. After the 15 second purge, the combustion air blower
will remain on. The sparker will turn on to ignite the gas
at the same time the gas valve is energized on low
stage. Make sure the gas valve is in the "ON" position
(Refer to Figure 14 and the instruction label located on
the inside of the burner access panel.
4. The sparker will remain energized for 7 seconds or until
a flame is detected by the flame sensor. It may take
several ignition attempts to purge the air out of the gas
line at the initial start-up of the unit.
5. Once flame isproven, the ignition control will switch the
combustion air blower to low speed. The unit will run in
low stage gas heat for 10 minute or until the thermostat
is satisfied, whichever is shorter. Ifthe thermostat isnot
satisfied after 10 minutes, the unit will go to second
stage gas heat and run until the thermostat is satisfied.
6.30 seconds after the burners light, the circulating air
blower will begin to run.
7. After checking start up, return balance point
temperature to desired setting.
NOTE: Regardless of whether the thermostat is calling for
low stage gas heat or high stage gas heat, the unit will
always start with the high inducer speed and low stage gas
valve operation.
The gas heating system has 2 stages of heating and will
automatically pick the correct heating stage based on the
difference between the actual indoor temperature and the
set point temperature on the thermostat. For maximum
efficiency, avoid frequent changes to the set point
temperature.
7. When the heating setpoint has been satisfied:
a. The gas valve will turn immediately off.
b. The combustion air blower will run for an additional
15 seconds to purge exhaust gas.
c. The circulating air motor will continue to run an
additional 60, 100, 140, or 180 seconds
(field-selectable) before turning offto extract additional
heat from the heat exchanger.
FIRE AND/OR EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
Do NOT attempt to light the pilot or burner with a match
or flame of any kind.
ROUTINE MAINTENANCE
All routine maintenance should be handled by skilled,
experienced personnel. Your dealer can help you establish
a standard procedure.
For your safety, keep the unit area clear and free of
combustible materials, gasoline, and other flammable
liquids and vapors.
To assure proper functioning of the unit, flow of combustion
and ventilating air must not be obstructed from reaching the
unit. Clearance of at least 30 in. is required on all sides
except the duct side.
MAINTENANCE AND CARE FOR THE
EQUIPMENT OWNER
Before proceeding with those things you might want to
maintain yourself, please carefully consider the following:
• TURN OFF GAS SUPPLY AND ELECTRICAL
POWER TO YOUR UNIT BEFORE SERVICING OR
PERFORMING MAINTENANCE.
• Do not turn off electrical power to this unit without first
turning off the gas supply.
When removing access panels or performing
maintenance functions inside your unit, be aware of
sharp sheet metal parts and screws. Although special
care is taken to reduce sharp edges to a minimum, be
extremely careful when handling parts or reaching
into the unit.
AIR FILTERS - Air filter(s) should be checked at least every
3 or 4 weeks and changed or cleaned whenever it becomes
dirty. Dirty filters produce excessive stress on the blower
motor and can cause the motor to overheat and shut down.
Table 1 indicates the correct filter size for your unit.
When installing the new filter(s), note the direction of the
airflow arrows on the filter frame.
141

originally by the installer. NEVER OPERATE THE UNIT
WITHOUT FILTERS IN PLACE. FAILURE TO OPERATE
WITHOUT FILTERS COULD RESULT IN DAMAGE TO
THE BLOWER MOTOR AND/OR COMPRESSOR,
If you have difficulty in locating your air filter(s), or if you
have questions concerning proper filter maintenance,
contact your dealer for instructions. When replacing filters,
always use the same size and type offilter that was supplied
TABLE1 I FilterData I
Disposable Filters Washable Filters'
Minimum Nominal Size Minimum
Nominal Size Area (sq. (wxd) Area (sq.
Model (qty x w x d) inches) (inches) inches)
PDX424040 1 x 20" x 20" 384 1 x 10" x 20" 192
PDX430060 1 x 20" x 24" 480 1 x 12" x 20" 240
PDX436080 2x 15" x 20" 576 1 x 15" x 20" 288
PDX442080 2 x 18" x 20" 672 1 x 18" x 20" 336
PDX448100 2 x 20" x 20" 768 1 x 20" x 20" 384
PDX460100 2 x 20" x 24" 960 1 x 20" x 24" 480
Washable filter size is based on an allowable face velocity of 600ft/min. Refer to
filter manufacturer's specifications for allowable face velocity and required filter area.
HEAT EXCHANGER - To ensure dependable and efficient
heating operation, the heat exchanger should be checked
by a qualified maintenance person before each heating
season, and cleaned when necessary. This checkout
should not be attempted by anyone not having the required
expertise and equipment to properly do the job. Checking
and/or cleaning the heat exchanger involves removing the
gas controls assembly and the flue collector box cover and,
when completed, reinstalling the gas controls assembly for
proper operation. Also, the flue collector box cover must be
replaced correctly so that a proper seal is maintained.
Contact your dealer for the required periodic maintenance.
FANS AND FAN MOTOR - Periodically check the condition
of fan wheels and housings and fan-motor shaft bearings.
No lubrication of condenser- or evaporator-fan bearings or
motors is required or recommended.
EVAPORATOR AND CONDENSER COILS - Cleaning of
the coils should only be done byqualified service personnel.
Contact your dealer for the required annual maintenance.
CONDENSATE DRAIN - The drain pan and condensate
drain line should be checked and cleaned at the same time
the cooling coils are checked by your dealer.
COMPRESSOR - All compressors are factory-shipped
with a normal charge of the correct type refrigeration grade
oil in them and should rarely require additional oil. The
service person must be certain the proper oil level is
maintained in the compressor when it is installed and
running.
CONDENSER FAN -The fan must be kept free of all
obstructions to ensure proper cooling. Contact your dealer
for any required service.
ELECTRICAL CONTROLS and WIRING - Electrical
controls are difficult to check without proper
instrumentation; therefore, if there are any discrepancies in
the operating cycle, contact your dealer and request
service.
REFRIGERATION CIRCUIT - The refrigerant circuit is
difficult to check for leaks without the proper equipment;
therefore, if inadequate cooling is suspected, contact your
local dealer for service.
COMBUSTION AREA and VENT SYSTEM - The
combustion area and vent system should be inspected
visually before each heating season. The normal
accumulation of dirt, soot, rust, and scale can result in loss
of efficiency and improper performance if allowed to build.
UNIT PANELS - After performing any maintenance or
service on the unit, be sure all panels are fastened securely
in place to prevent rain from entering unit cabinet and to
prevent disruption of the correct unit airflow pattern.
REGULAR DEALER MAINTENANCE
In addition to the type of routine maintenance you might be
willing to perform, your unit should be inspected regularly by
a properly trained service technician. An inspection
(preferably each year, but at least every other year) should
include the following:
1. Inspection of all flue product passages - including the
burners, heat exchanger, and flue collector box.
2. Inspection of all combustion- and ventilation-air
passages and openings.
3. Close inspection of all gas pipes leading to and inside of
your unit.
4. Inspection and, if required, cleaning of the condenser
and evaporator coils.
5. Inspection and, if required, cleaning of the evaporator
drain pan.
6. Inspection and cleaning of blower wheel housing and
motor.
7. Inspection of all supply-air and return-air ducts for
leaks, obstructions, and insulation integrity. Any
problems found should be resolved at this time.
8. Inspection of the unit base to ensure that no cracks,
gaps, etc., exist which may cause a hazardous
condition.
9. Inspection of the unit casing for signs of deterioration.
10. Inspection of all electrical wiring and components to
assure proper connection.
151

11. Inspection for leaks in the refrigerant circuit.
Pressure-check to determine appropriate refrigerant
charge.
12. Inspection of compressor oil level.
13. Operational check of the unit to determine working
conditions. Repair or adjustment should be made at
this time.
Your servicing dealer may offer an economical service
contract that covers seasonal inspections. Ask for further
details.
Complete service instructions can be found in the unit
Installation, Start-Up and Service Instructions.
BEFORE YOU CALL FOR SERVICE, CHECK FOR
THESE EASILY SOLVED PROBLEMS
Check the indoor and outdoor disconnect switches. Verify
that circuit breakers are ON.
Check for sufficient airflow. Check the air filter(s) for any
accumulations of dirt. Check for blocked return-air or
supply-air grilles. Be sure grilles are open and
unobstructed.
Check the settings on your indoor thermostat. If you desire
cooling, see that the temperature control selector is set
below room temperature and the SYSTEM switch is on the
COOL or AUTO position. If you require warmth, be sure the
temperature control selector is set above room temperature
and the SYSTEM switch is at HEAT or AUTO. The FAN
switch should be set at ON for continuous blower operation
or AUTO ifyou wish the blower to function only while the unit
is operating.
If your comfort system still fails to operate, contact your
servicing dealer for troubleshooting and repairs. Specify
your apparent problem, and state the model and serial
numbers of your equipment. (You should have them
recorded on page 4 of this booklet.) With this information,
your dealer may be able to offer helpful suggestions over
the phone, or save valuable time through knowledgeable
preparation for the service call.
INSTALLATION DATA
Date Installed
Dealer Name
Address
City
State
Telephone
Product No.
Model No.
UNIT DATA
Zip
Serial No.