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INSTALLATION MANUAL
SINGLE PACKAGE
AIR CONDITIONER / GAS HEAT
MODELS: PCG4 SERIES
2 TO 5 TONS - 208/230 V - 1 PHASE
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MODEL NUMBER NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Center of Gravity Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bottom Duct Dimensions (in.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Rear Duct Dimensions (in.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Typical Field Power Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 7
Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Application Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Unit Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical Data - PCG4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Natural Gas Pipe Sizing Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Propane (LP) Gas Pipe Sizing Chart . . . . . . . . . . . . . . . . . . . . . . . . . 9
High Altitude Gas Orifice Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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 Ducted Systems
LIST OF SECTIONS
AIRFLOW PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
TYPICAL WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
START UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
LIST OF FIGURES
Flue Vent Outlet Air Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Measuring External Static Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 20
Connection Wiring Diagram - 3.5 to 5 Ton Models . . . . . . . . . . . . . . 22
Ladder Wiring Diagram - 3.5 to 5 Ton Models . . . . . . . . . . . . . . . . . 23
R-410A Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
LIST OF TABLES
Natural Gas Application Data - PCG4 . . . . . . . . . . . . . . . . . . . . . . . 10
Propane (LP) Gas Application Data - PCG4 . . . . . . . . . . . . . . . . . . . 11
Airflow Performance - Side Duct Application . . . . . . . . . . . . . . . . . . 11
Airflow Performance - Bottom Duct Application . . . . . . . . . . . . . . . . 13
Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Default Blower Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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
!
5750156-UIM-B-0919
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Summary of Contents for Johnson Controls PCG4 Series
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Page 1: Table Of Contents
SINGLE PACKAGE ® AIR CONDITIONER / GAS HEAT MODELS: PCG4 SERIES 2 TO 5 TONS – 208/230 V - 1 PHASE LIST OF SECTIONS GENERAL INFORMATION ....... . 1 AIRFLOW PERFORMANCE . -
Page 2: Model Number Nomenclature
Page 10 of these check all connections. A fire or explosion may result causing property instructions. damage, personal injury or loss of life. Johnson Controls Ducted Systems... -
Page 3: Component Location
OUTDOOR COIL (Behind Panel) CONTROL BOARD TRANSFORMER BLOWER MOTOR HIGH VOLTAGE CONTACTOR PRESSURE SWITCH INDOOR COIL DRAFT INDUCER BLOWER INDOOR BLOWER GAS VALVE COMPRESSOR GAS HEAT EXCHANGER REMOVABLE BURNER BASE RAILS ASSEMBLY A0297-001 FIGURE 1: Component Location Johnson Controls Ducted Systems... -
Page 4: Weights And Dimensions
Table 3: Weights and Dimensions Model Weight (lb) Center of Gravity 4 Point Load Location (lb) Shipping Operating PCG4A24050 PCG4A24075 PCG4A30050 PCG4A30075 PCG4A36050 PCG4A36075 PCG4A36100 PCG4A42075 PCG4A42100 PCG4B48065 PCG4B48100 PCG4B48125 PCG4B60065 PCG4B60100 PCG4B60125 Johnson Controls Ducted Systems... -
Page 5: Center Of Gravity Location
2. The products of combustion must not be allowed to accumulate within a confined space and recirculate. 3. Units must be installed outdoors. Overhanging structures or shrubs must not obstruct outdoor air discharge outlet. 4. Units can be installed on combustible floors made from class A, B, or C roof covering materials. Johnson Controls Ducted Systems... -
Page 6: Bottom Duct Dimensions (In.)
Check filters monthly. This is especially important because the unit is used for both heating and cooling. Model 24, 30, 36, 42 48, 60 13.6 FIGURE 5: Rear Duct Dimensions (in.) Johnson Controls Ducted Systems... -
Page 7: Typical Field Control Wiring Diagram For Gas Heat - Ac Models
34.0 34.4 60065, 60100, 60125 208/230-1-60 24.4 144.2 38.0 39.2 1. Minimum Circuit Ampacity 2. Maximum Over Current Protection per standard UL 1995 3. Fuse or HACR circuit breaker size installed at factory or field installed Johnson Controls Ducted Systems... -
Page 8: Physical Data
Field-supplied external filters must be sized so as not to exceed 300 fpm air velocity through disposable fil- Quantity - size ters. For internal filter use, a filter rack kit is available. Consult the instructions supplied with that kit for replacement filter sizes. Filter sizes: A=20x20, B=20x30. Johnson Controls Ducted Systems... -
Page 9: Natural Gas Pipe Sizing Chart
Check all joints for leaks with CONTROLS COMPARTMENT. soap solution or other material suitable for the purpose. NEVER USE AN OPEN FLAME. Johnson Controls Ducted Systems... -
Page 10: High Altitude Gas Orifice Sizing
1. Heating capacity valid for elevations up to 2000 ft above sea level. For elevations above 2,000 ft, rated capacity must be reduced by 4% for each 1,000 ft above sea level. 2. Based on 1075 BTU/ft 3. The airflow must be adequate to obtain a temperature rise within the range shown. Continuous return air temperature must not be below 55°F. Johnson Controls Ducted Systems... -
Page 11: Airflow Performance
Medium (3) 1554 1503 1465 1423 1386 1346 1302 1257 1167 Medium/High (4) 1658 1599 1588 1530 1495 1454 1414 1373 1291 High (5) 1966 1914 1862 1810 1757 1705 1653 1600 1496 Continued on next page. Johnson Controls Ducted Systems... - Page 12 4. Minimal variations in airflow performance data result from operating at 208 V. Data above may be used in those cases. 5. Heating applications tested at 0.50 in. W.C. esp, and cooling applications tested at 0.30 in. W.C. esp per standards. Johnson Controls Ducted Systems...
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Page 13: Airflow Performance - Bottom Duct Application
Medium (3) 1611 1574 1518 1494 1439 1405 1357 1266 1083 Medium/High (4) 1892 1777 1771 1701 1639 1617 1565 1489 1336 High (5) 2131 2058 1998 1949 1892 1840 1788 1728 1608 Continued on next page. Johnson Controls Ducted Systems... - Page 14 4. Minimal variations in airflow performance data result from operating at 208 V. Data above may be used in those cases. 5. Heating applications tested at 0.50 in. W.C. esp, and cooling applications tested at 0.30 in. W.C. esp per standards. Johnson Controls Ducted Systems...
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Page 15: Operation
If flame has been lost more than 5 times within the same call for 2. Filter pressure drop based on standard filter media tested at velocities not heat, the control board locks out, flashing “8” on the LED. to exceed 300 ft/min. Johnson Controls Ducted Systems... - Page 16 The control confirms the pressure switch contacts are open at the beginning of each heat cycle. The control prevents the ignition sequence from continuing if the pressure switch contacts are closed when they should be open. Check for a faulty pressure switch or miswir- ing. Johnson Controls Ducted Systems...
- Page 17 10 Red Flashes: Indicates the gas valve is energized with no call for heat. The main blower and inducer blower run and no ignition sequence starts as long as this condition exists. Check the gas valve and gas valve wiring. Johnson Controls Ducted Systems...
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Page 18: Inlet Gas Pressure Range
3. Using a 3/32 in. (2.4 mm) hex head wrench, loosen the set screw Propane (LP) Gas 10.0 in. W.C. (2.488 kPa) by turning it one turn counter clockwise. DO NOT REMOVE THE SET SCREW FROM THE PRESSURE PORT. Johnson Controls Ducted Systems... -
Page 19: Gas Valve
Maximum Supply Air Temperature. Operating the blower settings. furnace above the Maximum Supply Air Temperature will cause pre- mature heat exchanger failure, high levels of Carbon Monoxide, a fire hazard, personal injury, property damage, and/or death. Johnson Controls Ducted Systems... -
Page 20: Measuring External Static Pressure
3. Treat the negative number as a positive and add the two numbers 1. Measure the supply air static pressure and record this positive num- together. This is total system static. ber. FIGURE 11: Measuring External Static Pressure Johnson Controls Ducted Systems... -
Page 21: Gas Rate Cubic Feet Per Hour
Multiply 95 x 1050 (or the BTU rating of the gas obtained from the local gas com- pany). The result is 99,750 BTUH, which is close to the 100,000 BTUH rat- ing of the unit. Johnson Controls Ducted Systems... -
Page 22: Typical Wiring Diagrams
Incorrect polarity OR Don't have neutral 10 Red Flashes Gas valve shorted "ON" 11 Red Flashes Check blower motor/wiring 1174285-UWD-C-0519 Refer to Installation Manual for more detailed information. FIGURE 12: Connection Wiring Diagram - 3.5 to 5 Ton Models Johnson Controls Ducted Systems... -
Page 23: Ladder Wiring Diagram - 3.5 To 5 Ton Models
Incorrect polarity OR Don't have neutral 10 Red Flashes Gas valve shorted "ON" 11 Red Flashes Check blower motor/wiring 1174285-UWD-C-0519 Refer to Installation Manual for more detailed information. FIGURE 13: Ladder Wiring Diagram - 3.5 to 5 Ton Models Johnson Controls Ducted Systems... -
Page 24: R-410A Quick Reference Guide
Never open system to atmosphere when under a vacuum. If system must be opened for service, evacuate system then break the vacuum with dry nitrogen and replace all filter driers. FIGURE 14: R-410A Quick Reference Guide Johnson Controls Ducted Systems... -
Page 25: Start Up Sheet
Supply air dry bulb temperature Outside air dry bulb temperature Return static (inches of water column) Return air dry bulb temperature Return air wet bulb temperature Total external static pressure Temperature drop Supply air wet bulb temperature Johnson Controls Ducted Systems... - Page 26 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. 5750156-UIM-B-0919 Copyright © 2019 by Johnson Controls. All rights reserved. Supersedes: 5750156-UIM-A-0619 York International Corp. 5005 York Drive...
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