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INSTALLATION MANUAL
SINGLE PACKAGE
AIR CONDITIONER / GAS HEAT
MODELS: PCG6 SERIES
3 THRU 5 TONS - 208/230V - 3 PHASE
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MODEL NUMBER NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
AIRFLOW PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Center of Gravity Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bottom Duct Dimensions (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Rear Duct Dimensions (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Typical Field Control Wiring Diagram For Gas Heat - AC Models . . . 7
Typical Field Power Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 7
Flue Vent Outlet Air Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Unit Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Natural Gas Pipe Sizing Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Propane (LP) Gas Pipe Sizing Chart . . . . . . . . . . . . . . . . . . . . . . . . 10
Natural Gas Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SECTION I: GENERAL INFORMATION
These are electric cooling/gas heating units designed for outdoor instal-
lation. Only gas piping, electric power and duct connections are
required for installation.
The gas-fired heaters have spark ignition.
The refrigerant system is fully charged with R-410A Refrigerant. The
system is tested and factory sealed.
SECTION II: SAFETY
This is a safety alert symbol. When you see this symbol on
labels or in manuals, be alert to the potential for personal
injury.
Understand and pay particular attention to the signal words DANGER,
WARNING, or CAUTION.
DANGER indicates an imminently hazardous situation, which, if not
avoided, will result in death or serious injury.
Johnson Controls Unitary Products
LIST OF SECTIONS
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TYPICAL WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
START UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
LIST OF FIGURES
Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Gas Valve 19
Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Measuring External Static Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 21
Connection Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Ladder Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
R-410A Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
LIST OF TABLES
Propane,4 (LP) Gas Application Data . . . . . . . . . . . . . . . . . . . . . . . . 11
Airflow Performance - Side Duct Application . . . . . . . . . . . . . . . . . . 11
Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Ignition Control Board Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . 17
Delay Profile Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
WARNING indicates a potentially hazardous situation, which, if not
avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation, which, if not
avoided may result in minor or moderate injury. It is also used to
alert against unsafe practices and hazards involving only property dam-
age.
Improper installation may create a condition where the operation of
the product could cause personal injury or property damage.
Improper installation, adjustment, alteration, service or maintenance
can cause injury or property damage. Failure to carefully read and
follow all instructions in this manual can result in furnace mal-
function, death, personal injury and/or property damage. Only a
qualified contractor, installer or service agency should install this
product.
® ®
WARNING
!
5285473-UIM-E-1217
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Table of Contents
Related Manuals for York PCG6B42
Summary of Contents for York PCG6B42
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Page 1: Table Of Contents
INSTALLATION MANUAL SINGLE PACKAGE ® ® AIR CONDITIONER / GAS HEAT MODELS: PCG6 SERIES 3 THRU 5 TONS – 208/230V - 3 PHASE LIST OF SECTIONS GENERAL INFORMATION ....... . 1 OPERATION . -
Page 2: Installation
5285473-UIM-E-1217 WARNING CAUTION Before performing service or maintenance operations on unit, turn off This system uses R-410A Refrigerant which operates at higher pres- main power switch to unit. Electrical shock could cause personal sures than R-22. No other refrigerant may be used in this system. injury. -
Page 3: Unit Limitations
5285473-UIM-E-1217 LIMITATIONS Refer to unit application data found in this document. After installation, gas fired units must be adjusted to obtain a temperature These units must be installed in accordance with the following: rise within the range specified on the unit rating plate. In U.S.A.: If components are to be added to a unit to meet local codes, they are to 1. -
Page 4: Center Of Gravity Location
5285473-UIM-E-1217 RIGGING AND HANDLING 5. Roof structures must be able to support the weight of the unit and its options/accessories. Unit must be installed on a solid, level roof CAUTION curb or appropriate angle iron frame. 6. Maintain level tolerance to 1/8” across the entire width and length of unit. -
Page 5: Unit Dimensions
5285473-UIM-E-1217 Table 3: Unit Dimensions Dimensions Model 51-1/4 45-3/4 51-1/4 45-3/4 51-1/4 45-3/4 51-1/4 45-3/4 FIGURE 3: Unit Dimensions Table 4: Unit Clearances Direction Distance (in.) Direction Distance (in.) Power Entry (Right Side) Side Opposite Ducts Left Side Duct Panel Bottom NOTES: 1. - Page 6 5285473-UIM-E-1217 DUCTWORK NOTICE All units are shipped in the horizontal supply/return configuration. It is important to reduce the possibility of any air leakage through the bot- tom duct covers (resulting from cut, torn, or rolled gasket) due to improper handling or shipping processes. To ensure a good tight seal, it is recommended that silicone caulk and/or foil tape be applied along the cover edges.
- Page 7 5285473-UIM-E-1217 SERVICE ACCESS The wiring entering the cabinet must be provided with mechanical strain relief. A fused disconnect switch should be field provided for the unit. If Access to all serviceable components is provided at the following loca- any of the wire supplied with the unit must be replaced, replacement tions: wire must be of the type shown on the wiring diagram.
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Page 8: Physical Data
5285473-UIM-E-1217 Table 6: Physical Data MODELS: PCG6B36 PCG6B42 PCG6B48 PCG6B60 NOMINAL TONNAGE: AHRI Cooling Performance Gross Capacity @ AHRI A point (MBH) 36.5 43.3 49.1 60.0 AHRI net capacity (MBH) 36.0 42.5 45.5 58.0 12.5 12.5 12.0 12.0 SEER 16.0 16.0... -
Page 9: Gas Piping
5285473-UIM-E-1217 Table 6: Physical Data (Continued) MODELS: PCG6B36 PCG6B42 PCG6B48 PCG6B60 NOMINAL TONNAGE: Direct Drive Indoor Fan Data Fan Size (Inch) 11 x 10 11 x 10 11 x 10 11 x 10 Type Centrifugal Centrifugal Centrifugal Centrifugal Motor HP each... - Page 10 5285473-UIM-E-1217 GAS CONNECTION 4. Clean all piping of dirt and scale by hammering on the outside of the pipe and blowing out the loose dirt and scale. Before initial start- The gas supply line should be routed through the 1-5/8” hole located on up, be sure that all of the gas lines external to the unit have been the right side of the unit.
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Page 11: Airflow Performance
5285473-UIM-E-1217 Table 9: Natural Gas Application Data Gas Rate Output (MBH) Number of Input (MBH) Available On Models Cu. Ft. Per Hr. High Fire / Low Fire Burners High Fire / Low Fire High Fire / Low Fire 3, 3-1/2, 4, 5 Tons 65/43 52/34 60.5/40... -
Page 12: Johnson Controls Unitary Products
5285473-UIM-E-1217 Table 11: Airflow Performance - Side Duct Application (Continued) External Static Pressure (Inches WC) Model Jumper Position SCFM SCFM SCFM SCFM SCFM SCFM SCFM SCFM SCFM SCFM 1555 1518 1494 1459 1414 1360 1318 1261 1220 1162 1473 1435 1406 1368 1320... -
Page 13: Johnson Controls Unitary Products
5285473-UIM-E-1217 Table 11: Airflow Performance - Side Duct Application (Continued) External Static Pressure (Inches WC) Model Jumper Position SCFM SCFM SCFM SCFM SCFM SCFM SCFM SCFM SCFM SCFM 1851 1809 1781 1746 1707 1656 1609 1552 1518 1460 1689 1652 1630 1597 1556... -
Page 14: Johnson Controls Unitary Products
5285473-UIM-E-1217 Table 11: Airflow Performance - Side Duct Application (Continued) External Static Pressure (Inches WC) Model Jumper Position SCFM SCFM SCFM SCFM SCFM SCFM SCFM SCFM SCFM SCFM 2149 2114 2077 2030 1989 1948 1905 1859 1816 1768 2013 1977 1941 1898 1860... -
Page 15: Operation
5285473-UIM-E-1217 HEATING SEQUENCE OF OPERATION Table 12: Additional Static Resistance Heating Size (Tons) Wet Indoor Coil Economizer Filter/Frame Kit 0.01 0.00 0.04 The control board begins a call for heat when W1 is energized (con- 0.02 0.01 0.06 nected to R). 0.03 0.01 0.08... - Page 16 5285473-UIM-E-1217 Heat Blower On Delay High Temperature Limit Switch The control board waits for 30 seconds and then energizes the indoor Any time the high temperature limit switch is open less than 5 minutes, blower heat speed. The indoor blower heat speed is based on the the control board runs the indoor blower motor on high heat speed, runs HEAT airflow selection jumper, and the low heating (W1) or the high the inducer, de-energizes the gas valve, and flashes a sequence of “4”...
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Page 17: Ignition Control Board Flash Codes
5285473-UIM-E-1217 The control circuit includes the following safety controls: Table 13: Ignition Control Board Flash Codes High Pressure Switch (HP) - This switch protects against excessive Flash Code Description discharge pressures due to a blocked condenser coil or a condenser Normal Operation motor failure (switch opens at 650 ±... - Page 18 5285473-UIM-E-1217 START-UP Prestart Check List Complete the following checks before starting the unit. Phasing 1. Check the type of gas being supplied. Be sure that it is the same as CAUTION listed on the unit nameplate. 2. Make sure that the vent outlet air hood and air intake hood has been properly installed.
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Page 19: Inlet Gas Pressure Range
5285473-UIM-E-1217 ADJUSTMENT OF MANIFOLD GAS PRESSURE & NOTICE INPUT RATE Inlet and manifold gas pressure may be measured by connecting the The regulated outlet pressure has been calibrated at the factory. “U” tube manometer to the gas valve with a piece of tubing. Follow the Additional pressure adjustment should not be necessary. - Page 20 5285473-UIM-E-1217 CHECKING GAS HEAT INPUT 5. Once the correct BTU (kW) input has been established, turn the gas valve to OFF, and turn the electrical supply switch to OFF. Then Natural Gas remove the flexible tubing from the gas valve pressure port, and 1.
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Page 21: Maintenance
5285473-UIM-E-1217 EXTERNAL STATIC PRESSURE SETUP • Measure the return air static pressure • Record this negative number To measure external static pressure: • Treat the negative number as a positive and add the two numbers • Measure the supply air static pressure together •... -
Page 22: Control Board
5285473-UIM-E-1217 SECTION VIII: TYPICAL WIRING DIAGRAMS 2 STAGE COOLING UNIT WITH GAS HEAT 208/230-3-60 CONNECTION WIRING DIAGRAM USE COPPER ROLLOUT LIMIT CONDUCTORS SWITCH SWITCH ONLY RED 16 RED/GRN 17 POWER SUPPLY CRANKCASE TEMPERATURE HIGH PRESSURE LOSS OF CHARGE 208/230-3-60 RED/BLK 37 HEATER SWITCH 208/230V LINE VOLTAGE... -
Page 23: Ladder Wiring Diagram
5285473-UIM-E-1217 2 STAGE COOLING UNIT WITH GAS HEAT 208/230-3-60 LADDER WIRING DIAGRAM DSI FAULT CODES GROUND NORMAL OPERATION CRANKCASE TEMP. HEATER SWITCH GREEN HEARTBEAT Normal Operation / Standby mode BLK/WHT AMBER HEARTBEAT Call for furnace heat active RAPID GREEN FLASHES Control in Factory Test mode OPERATIONAL FAULT CODES COMPRESSOR... -
Page 24: R-410A Quick Reference Guide
5285473-UIM-E-1217 R-410A QUICK REFERENCE GUIDE Refer to Installation Instructions for specific installation requirements R-410A refrigerant operates at 50 - 70 percent 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 25: General Information
5285473-UIM-E-1217 SECTION IX: START UP SHEET Residential Package Unit Cooling / Gas Heat Start-Up Sheet Proper start-up is critical to customer comfort and equipment longevity Start-Up Date Company Name Start-Up Technician Owner Information Name Address Daytime Phone City State or Province Zip or Postal Code Equipment Data Equipment Data... -
Page 26: Gas Heat
Comments and Additional Job Details Page 2 of 2 (7/7/16) Subject to change without notice. Published in U.S.A. 5285473-UIM-E-1217 Copyright © 2017 by Johnson Controls, Inc. All rights reserved. Supersedes: 5285473-UIM-D-0517 York International Corp. 5005 York Drive Norman, OK 73069...