York PCG4 Series Installation Manual
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York PCG4 Series Installation Manual

York pcg4 series single package air conditioner/gas heat
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INSTALLATION MANUAL

SINGLE PACKAGE
AIR CONDITIONER/GAS HEAT
MODELS: PCG4 Series
(2-5 Ton)
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MODEL NUMBER NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Unit Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Natural Gas Pipe Sizing Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Propane (LP) Gas Pipe Sizing Chart . . . . . . . . . . . . . . . . . . . . . . . . . 9
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 at the point of installation.
The gas-fired heaters have spark ignition.
The refrigerant system is fully charged with R-410A Refrigerant, and 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.
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.
Johnson Controls Unitary Products
LIST OF SECTIONS
AIRFLOW PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
TYPICAL WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
START UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
LIST OF FIGURES
Flue Vent Outlet Air Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Connection Wiring Diagram - 2 to 3 Ton Models . . . . . . . . . . . . . . . 19
Ladder Wiring Diagram - 2 to 3 Ton Models . . . . . . . . . . . . . . . . . . . 20
Ladder Wiring Diagram - 3.5 to 5 Ton Models . . . . . . . . . . . . . . . . . 22
R-410A Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
LIST OF TABLES
Natural Gas Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Propane (LP) Gas Application Data . . . . . . . . . . . . . . . . . . . . . . . . . 10
Airflow - Side Duct Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Airflow - Bottom Duct Application . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Ignition Control Board Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . 16
Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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.
This product must be installed in strict compliance with the installa-
tion instructions and any applicable local, state, and national codes
including, but not limited to building, electrical, and mechanical
codes.
®
WARNING
!
CAUTION
!
1183746-UIM-B-0215

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Summary of Contents for York PCG4 Series

  • Page 1: Table Of Contents

    SINGLE PACKAGE ® AIR CONDITIONER/GAS HEAT MODELS: PCG4 Series (2-5 Ton) LIST OF SECTIONS GENERAL INFORMATION ....... . 1 AIRFLOW PERFORMANCE .

  • Page 2: Installation

    1183746-UIM-B-0215 WARNING WARNING Before performing service or maintenance operations on unit, turn off If the information in this manual is not followed exactly, a fire or main power switch to unit. Electrical shock could cause personal explosion may result causing property damage, personal injury or injury.

  • Page 3: Unit Limitations

    1183746-UIM-B-0215 LIMITATIONS 4. Other applicable local codes. Refer to unit application data found in this document. These units must be installed in accordance with the following: After installation, gas fired units must be adjusted to obtain a temperature In U.S.A.: rise within the range specified on the unit rating plate.

  • Page 4: Unit 4 Point Load Weight

    1183746-UIM-B-0215 LOCATION RIGGING AND HANDLING Use the following guidelines to select a suitable location for these units: Exercise care when moving the unit. Do not remove any packaging until the unit is near the place of installation. Rig the unit by attaching chain outdoor installation 1.

  • Page 5: Unit Dimensions

    1183746-UIM-B-0215 COIL GUARD HIGH VOLTAGE CONNECTION 7/8” HIGH VOLTAGE COMBUSTION AIR INTAKE CONNECTION 1-3/32” HEAT EXCHANGER ACCESS PANEL COMPRESSOR ACCESS PANEL EXHAUST HOOD CONDENSATE DRAIN BLOWER ACCESS LOW VOLTAGE CONNECTION CONTROL ACCESS PANEL GAS SUPPLY PANEL A0296-001 FIGURE 3: Unit Dimensions Table 3: Unit Dimensions Dimensions Model...

  • Page 6: Bottom Duct Dimensions (Inches)

    1183746-UIM-B-0215 Duct work should be designed and sized according to the methods of the Air Conditioning Contractors of America (ACCA), as set forth in their Manual D. A closed return duct system shall be used. This shall not preclude use of economizers or ventilation air intake.

  • Page 7: Typical Field Power Wiring Diagram

    1183746-UIM-B-0215 THERMOSTAT Minimum wire size of 18 AWG wire should be used for all field The room thermostat should be located on an inside wall approximately installed control wiring. 60" above the floor where it will not be subject to drafts, sun exposure or THERMOSTAT heat from electrical fixtures or appliances.

  • Page 8: Physical Data

    1183746-UIM-B-0215 Table 6: Physical Data MODELS COMPONENT PCG4A24 PCG4A30 PCG4A36 PCG4A42 PCG4B48 PCG4B60 NOMINAL TONNAGE AHRI Cooling Performance Gross Capacity @ AHRI A point (MBH) 23.7 30.1 37.2 43.5 47.7 55.0 AHRI net capacity (MBH) 22.8 29.0 34.6 41.0 45.5 52.5 11.0 11.0...

  • Page 9: Natural Gas Pipe Sizing Chart

    1183746-UIM-B-0215 COMPRESSORS Gas piping requirements: 1. A drip leg and a ground joint union must be installed in the gas pip- The compressor used in this product is specifically designed to operate ing. with R-410A Refrigerant and cannot be interchanged. 2.

  • Page 10: Flue Vent Outlet Air Hood

    1183746-UIM-B-0215 5. The gas supply should be a separate line and installed in accor- WARNING dance with all applicable safety codes. After the gas connections have been completed, open the main shut-off valve admitting nor- mal gas pressure to the gas valve. Check all joints for leaks with Flue hood surfaces may be hot.

  • Page 11: Airflow Performance

    1183746-UIM-B-0215 SECTION V: AIRFLOW PERFORMANCE Table 11: Airflow - Side Duct Application External Static Pressure (Inches WC) Model Motor Speed SCFM SCFM SCFM SCFM SCFM SCFM SCFM SCFM Low (1) Low/Medium (2) 24050 Medium (3) Medium/High (4) High (5) 1148 1108 1071 1035...
  • Page 12 1183746-UIM-B-0215 Table 11: Airflow - Side Duct Application (Continued) External Static Pressure (Inches WC) Model Motor Speed SCFM SCFM SCFM SCFM SCFM SCFM SCFM SCFM Low (1) 1620 1564 1517 1466 1418 1360 1308 1206 Low/Medium (2) 1694 1630 1580 1530 1482 1430...

  • Page 13: Airflow - Bottom Duct Application

    1183746-UIM-B-0215 Table 12: Airflow - Bottom Duct Application External Static Pressure (Inches WC) Model Motor Speed SCFM SCFM SCFM SCFM SCFM SCFM SCFM SCFM Low (1) Low/Medium (2) 24050 Medium (3) Medium/High (4) 1024 High (5) 1204 1159 1121 1085 1051 1013 Low (1)
  • Page 14 1183746-UIM-B-0215 Table 12: Airflow - Bottom Duct Application (Continued) External Static Pressure (Inches WC) Model Motor Speed SCFM SCFM SCFM SCFM SCFM SCFM SCFM SCFM Low (1) 1598 1548 1502 1454 1410 1362 1307 1251 Low/Medium (2) 1663 1612 1568 1522 1476 1422...

  • Page 15: Operation

    1183746-UIM-B-0215 SECTION VI: OPERATION Table 13: Additional Static Resistance The unit is controlled by a conventional heating/cooling thermostat. If an Size (Tons) Wet Indoor Coil Economizer Filter/Frame Kit electronic thermostat is used, make sure it has a common connection. 0.01 0.00 0.01 DO NOT use a power stealing thermostat.

  • Page 16: Gas Valve

    1183746-UIM-B-0215 Main Burner Operation Flame present with Gas off The control board keeps the main gas valve and induced draft motor If flame is sensed for longer than 4.0 seconds during a period when the energized while continuously monitoring the call for heat, pressure gas valve should be closed, the control will enter lockout flashing “1”...
  • Page 17 1183746-UIM-B-0215 COOLING SEQUENCE OF OPERATIONS To Turn Off Gas To Unit 1. Set the thermostat to the OFF position. When the thermostat calls for COOL, the thermostat terminals G and Y are energized, which signals the compressor, outdoor fan and indoor 2.

  • Page 18: Gas Rate Cubic Feet Per Hour

    1183746-UIM-B-0215 Direct Drive Blower Table 15: Gas Rate Cubic Feet Per Hour All units have direct drive, multi speed standard ECM blower motors. Size of Test Dial Seconds for CHECKING GAS HEAT INPUT One Rev. 1/2 cu. ft. 1 cu. ft. Natural Gas 1.

  • Page 19: Connection Wiring Diagram - 2 To 3 Ton Models

    1183746-UIM-B-0215 SECTION VII: TYPICAL WIRING DIAGRAMS COOLING UNIT WITH GAS HEAT CAUTION - OPEN ALL DISCONNECTS WITH RECIPROCATING COMPRESSOR BEFORE SERVICING THIS UNIT 208/230-1-60 POWER SUPPLY 208/230-1-60 USE COPPER CONDUCTORS CONNECTION WIRING DIAGRAM ONLY BLK 6 PUR 1 208V 230V SINGLE POLE COMPR CONTACTOR...
  • Page 20 1183746-UIM-B-0215 GROUND COOLING UNIT WITH GAS HEAT WITH COMPRES RECIPROCATING COMPRESSOR 208/230-1-60 OD FAN BLK/WHT MOTOR LADDER WIRING DIAGRAM DUAL CAPACITOR START CAP START RELAY CAUTION BLOWER OPEN ALL DISCONNECTS MOTOR BEFORE SERVICING THIS UNIT CONTROL BOARD RELAY DRAFT MOTOR 208V 230V XFMR...

  • Page 21: Connection Wiring Diagram - 3.5 To 5 Ton Models

    1183746-UIM-B-0215 COOLING UNIT WITH GAS HEAT CAUTION - OPEN ALL DISCONNECTS WITH SCROLL COMPRESSOR BEFORE SERVICING THIS UNIT 208/230-1-60 POWER SUPPLY 208/230-1-60 USE COPPER CONDUCTORS CONNECTION WIRING DIAGRAM ONLY BLK 6 PUR 1 208V 230V SINGLE POLE COMPR CONTACTOR XFMR 24V SEC CONTACTOR 40 VA...

  • Page 22: Ladder Wiring Diagram - 2 To 3 Ton Models

    1183746-UIM-B-0215 GROUND COOLING UNIT WITH GAS HEAT WITH COMPRES SCROLL COMPRESSOR 208/230-1-60 OD FAN BLK/WHT MOTOR LADDER WIRING DIAGRAM DUAL CAPACITOR CAUTION BLOWER OPEN ALL DISCONNECTS MOTOR BEFORE SERVICING THIS UNIT CONTROL BOARD RELAY DRAFT MOTOR 208V 230V XFMR 24V SEC 40 VA HI PRESS THERMOSTAT...

  • Page 23: R-410A Quick Reference Guide

    1183746-UIM-B-0215 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 24 1183746-UIM-B-0215 NOTES Johnson Controls Unitary Products...

  • Page 25: General Information

    1183746-UIM-B-0215 SECTION VIII: START UP SHEET Residential Package Unit Cooling / Gas Heat Start-Up Sheet Print Form Reset Form 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...

  • Page 26: Gas Heat

    Explain the importance of regular filter replacement and equipment maintenance Comments and Additional Job Details Subject to change without notice. Published in U.S.A. 1183746-UIM-B-0215 Copyright © 2015 by Johnson Controls, Inc. All rights reserved. Supersedes: 1183746-UIM-A-0215 York International Corp. 5005 York Drive Norman, OK 73069...

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