York GCGA SERIES Installation Manual
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York GCGA SERIES Installation Manual

York GCGA SERIES Installation Manual

R-22/r-407c outdoor split-system air conditioning 1.5 to 6.3 tons-1 & 3 phase
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INSTALLATION MANUAL

R-22/R-407C
OUTDOOR SPLIT-SYSTEM

AIR CONDITIONING

MODELS: GCGA SERIES
1.5 TO 6.3 TONS - 1 & 3 PHASE
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
ORIFICE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
TXV INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
EVACUATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Installation of Vapor Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Underground Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Heat Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Orifice Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Outdoor Unit Control Box (Single Phase) . . . . . . . . . . . . . . . . . . . . . .8
(Single-Phase) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Application Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
R-22 Saturation Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
SECTION I: GENERAL
The outdoor units are designed to be connected to a matching indoor
coil with sweat connect lines. Since these units are designed to operate
on either R-22 or R-407C, they have been shipped from the factory with
a nitrogen holding charge.
This unit does not contain any refrigerant. It contains a nitrogen
holding charge. Operating this unit with the nitrogen holding charge
will damage the compressor.
Before operating this unit, vent the nitrogen and evacuate the entire
system below 500 microns. Weigh in the refrigerant using the Tabu-
lar Data Sheet and Installation Manual.
The refrigerant charge may need to be changed for some indoor-out-
door unit combinations, elevation differences or total line lengths. Refer
to Application Data covering "General Piping Recommendations and
Refrigerant Line Length" (Part Number 247077).
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.
Johnson Controls Unitary Products
LIST OF SECTIONS
SYSTEM CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTRUCTING THE OWNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
START UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
LIST OF FIGURE
(Three Phase - GCGA36-60) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
(Three-Phase - GCGA76) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Wiring Diagram - Single Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Wiring Diagram - Three Phase - GCGA36-60 . . . . . . . . . . . . . . . . . 14
Wiring Diagram - Three Phase - GCGA76 . . . . . . . . . . . . . . . . . . . . 15
LIST OF TABLES
R-407C Saturation Properties (Superheat Only) . . . . . . . . . . . . . . . . 7
R-407C Saturation Properties (Subcooling Only) . . . . . . . . . . . . . . . . 7
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.
This product must be installed in strict compliance with the
enclosed installation instructions and any applicable local, state,
and national codes including, but not limited to building, electrical,
and mechanical codes.
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 mainte-
nance can cause injury or property damage. Refer to this manual
for assistance or for additional information, consult a qualified con-
tractor, installer or service agency.
548086-XIM-C-0814

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Summary of Contents for York GCGA SERIES

  • Page 1: Table Of Contents

    R-22/R-407C OUTDOOR SPLIT-SYSTEM AIR CONDITIONING MODELS: GCGA SERIES 1.5 TO 6.3 TONS – 1 & 3 PHASE LIST OF SECTIONS GENERAL ..........1 SYSTEM CHARGE .

  • Page 2: Unit Installation

    548086-XIM-C-0814 INSPECTION TABLE 1: Application Limitations As soon as a unit is received, it should be inspected for possible dam- Ambient Air Temperature Air Temperature on age during transit. If damage is evident, the extent of the damage on Outdoor Coil Indoor Coil should be noted on the carrier’s delivery receipt.

  • Page 3: Installation Of Vapor Line

    548086-XIM-C-0814 GROUND INSTALLATION internally clean and dry. Units should be installed only with the tubing sizes for approved system combinations as specified in tabular data The unit should be installed on a solid base that is 2” (5.1 cm) above sheet.

  • Page 4: Heat Protection

    548086-XIM-C-0814 PRECAUTIONS DURING BRAZING OF LINES All outdoor unit and evaporator coil connections are copper-to-copper and should be brazed with a phosphorous-copper alloy material such Do not install any coil in a furnace which is to be operated during as Silfos-5 or equivalent. DO NOT use soft solder. The outdoor units the heating season without attaching the refrigerant lines to the coil.

  • Page 5: Orifice Installation

    548086-XIM-C-0814 SECTION IV: ORIFICE INSTALLATION If bulb installation is made on a vertical run, the bulb should be located at least 16” (40.6 cm) from any bend, and on the Install Orifice as follows: tubing sides opposite the plane of the bend. The bulb should Loosen and remove the liquid line fitting from the orifice distributor be positioned with the bulb tail at the top, so that the bulb acts assembly.

  • Page 6: Saturation Properties

    548086-XIM-C-0814 SUBCOOLING CHARGING METHOD - TXV INDOOR Set the system running in cooling mode by setting the thermostat at least 6°F below the room temperature and operate system for at Compressor damage will occur if system is improperly charged. On least 10 –...

  • Page 7: Electrical Connections

    548086-XIM-C-0814 TABLE 3: R-407C Saturation Properties (Superheat Only) Press Temp Press Temp Press Temp Press Temp Press Temp Press Temp Press Temp psig °F psig °F psig °F psig °F psig °F psig °F psig °F TABLE 4: R-407C Saturation Properties (Subcooling Only) Press Temp Press...

  • Page 8: Outdoor Unit Control Box (Single Phase)

    548086-XIM-C-0814 Contactor Contactor Ground Capacitor Voltage Voltage Ground Lug Dual “Fingered” Reversible High Run/Fan “Fingered” Bushing Reversible High Voltage Conduit Plate Capacitor Bushing A0157-001 Voltage Conduit Plate A0155-001 FIGURE 8: Outdoor Unit Control Box (GCGA76 With Transformer) FIGURE 6: Outdoor Unit Control Box (Single Phase) FIELD CONNECTIONS CONTROL WIRING Route low voltage wiring into bottom of control box as shown in Contactor...

  • Page 9: Typical Field Wiring (Air Handler / Electrical Heat) (Single-Phase)

    548086-XIM-C-0814 ALL FIELD WIRING TO BE IN ACCORDANCE WITH ELECTRIC CODE (NEC) AND/OR LOCAL CODES POWER WIRING CONTROL WIRING POWER WIRING 24 VOLT CONTROL WIRING FACTORY WIRING MINIMUM 18 GA. WIRE (NEC CLASS 2) FURNACE OR AIR HANDLER TERMINAL BLOCK TERMINAL W IS ONLY REQUIRED ON SYSTEMS WITH HEAT.

  • Page 10: Thermostat Chart - Single Stage Ac With Psc Furnace

    548086-XIM-C-0814 For additional connection diagrams for all UPG equipment refer to “Low Voltage System Wiring” document available online at www.upgnet.com in the Product Catalog Section. Single Stage Air Conditioner - Single Stage PSC Furnace YG8S SINGLE STAGE SINGLE STAGE *PP32U70124 CONDITIONER FURNACE SINGLE STAGE...

  • Page 11: Thermostat Chart - Single Stage Ac With Psc Air Handler

    548086-XIM-C-0814 Single Stage Air Conditioner - PSC Air Handler F*RP SINGLE STAGE *PP32U70124 CONDITIONER SINGLE STAGE 10160 Air Handler Control AIR CONDITIONER 24 - Volt Common 24 - Volt Common 24 - Volt Common First Stage Second or Full Compressor Contactor Compressor Contactor Compressor Stage Compressor...

  • Page 12: Instructing The Owner

    548086-XIM-C-0814 SECTION IX: INSTRUCTING THE OWNER 3. If the coil needs to be cleaned, use clean water to wash dust, dirt, and debris from outdoor condensing coil. Assist owner with processing warranty cards and/or online registration. Review Owners Guide and provide a copy to the owner and guidance NOTICE on proper operation and maintenance.

  • Page 13: Wiring Diagram

    548086-XIM-C-0814 SECTION X: WIRING DIAGRAM DANGER - SHOCK HAZARD TURN OFF ELECTRICAL POWER BEFORE MOTOR SERVICING TOPREVENT POSSIBLE DAMAGE TO THE EQUIPMENT AND POSSIBLE PERSONAL INJURY. CAUTION TO PREVENT ELECTRICAL SHOCK OPEN REMOTE DISCONNECT SO ELECTRICAL SUPPLY TO AIR CONDITIONER IS SHUT OFF. COMPONENTS SHOWN IN DASHED COMPRESSOR LINES ARE OPTIONAL.

  • Page 14: Wiring Diagram - Three Phase - Gcga36-60

    548086-XIM-C-0814 LEGEND DANGER - SHOCK HAZARD COLOR CODE TURN OFF ELECTRICAL POWER BEFORE CAP - CAPACITOR SERVICING TOPREVENT POSSIBLE DAMAGE CC - CONTACTOR COIL BLK - BLACK TO THE EQUIPMENT AND POSSIBLE CCH - CRANKCASE HEATER BLU - BLUE PERSONAL INJURY. CTRL - CONTROL BRN - BROWN HPS - HIGH PRESS SWITCH...

  • Page 15: Wiring Diagram - Three Phase - Gcga76

    548086-XIM-C-0814 DANGER - SHOCK HAZARD COMPONENTS SHOWN IN DASHED LINES ARE OPTIONAL. TURN OFF ELECTRICAL POWER BEFORE RED WIRE WILL BE REMOVED IF LOW AMBIENT KIT IS SERVICING TO PREVENT POSSIBLE DAMAGE INSTALLED. TO THE EQUIPMENT AND POSSIBLE PERSONAL INJURY. YELLOW WIRE WILL BE REMOVED IF PRESSURE SWITCH KIT IS INSTALLED.
  • Page 16 548086-XIM-C-0814 NOTES Johnson Controls Unitary Products...

  • Page 17: Start Up Sheet

    548086-XIM-C-0814 SECTION XI: START UP SHEET Air Conditioning and Heating Start-Up Sheet Print Form Reset Form Proper start-up is critical to customer comfort and equipment longevity Start-Up Date Technician Performing Start-Up Installing Contractor Name Owner Information Name Address City State or Province Zip or Postal Code Equipment Data Upflow...
  • Page 18 Explain the importance of regular filter replacement and equipment maintenance Comments Section Subject to change without notice. Published in U.S.A. 548086-XIM-C-0814 Copyright © 2014 by Johnson Controls, Inc. All rights reserved. Supersedes: 548086-XIM-B-0413 York International Corp. 5005 York Drive Norman, OK 73069...

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