Johnson Controls PCG4 Series Installation Manual

INSTALLATION MANUAL
SINGLE PACKAGE
AIR CONDITIONER/GAS HEAT
MODELS: PCG4 SERIES
2 TONS 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 Control Wiring Diagram for Gas Heat - AC Models . . . 7
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
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, 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TYPICAL WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
START UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
LIST OF FIGURES
Flue Vent Outlet Air Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Measuring External Static Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 18
Connection Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Ladder Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
R-410A Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
LIST OF TABLES
High-Altitude Gas Orifice Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Natural Gas Application Data - PCG4 . . . . . . . . . . . . . . . . . . . . . . . 10
Propane (LP) Gas Application Data - PCG4 . . . . . . . . . . . . . . . . . . . 11
Airflow Performance - Side Duct Application . . . . . . . . . . . . . . . . . . 11
Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Default Blower Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Gas Rate (ft3/h) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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.
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WARNING
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CAUTION
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