Johnson Controls PCG4 Series Installation Manual
Johnson Controls PCG4 Series Installation Manual

Johnson Controls PCG4 Series Installation Manual

Single package air conditioner/gas heat 2 tons to 5 tons - 208/230 v - 1 phase
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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 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.
®
WARNING
!
CAUTION
!
5844973-UIM-A-0920

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Summary of Contents for Johnson Controls PCG4 Series

  • Page 1: Table Of Contents

    SINGLE PACKAGE ® AIR CONDITIONER/GAS HEAT MODELS: PCG4 SERIES 2 TONS TO 5 TONS - 208/230 V - 1 PHASE LIST OF SECTIONS GENERAL INFORMATION ....... . 1 AIRFLOW PERFORMANCE .
  • Page 2: Model Number Nomenclature

    9 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 Weight (lb) Center of Gravity 4-Point Load Location (lb) Model 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

    3. Install units outdoors. Make sure that overhanging structures or shrubs do not obstruct the outdoor air discharge outlet. 4. You can install units on combustible materials made from wood or class A, B, or C roof covering materials if factory base rails are left in place as shipped. Johnson Controls Ducted Systems...
  • Page 6: Bottom Duct Dimensions (In.)

    Check filters monthly. This is especially important because the unit can be 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

    48065, 48100, 48125 208/230-1-60 18.3 108.0 28.5 30.0 60065, 60100, 60125 208/230-1-60 22.2 127.9 34.7 36.5 1. Minimum Circuit Ampacity. 2. Maximum Overcurrent Protection per standard UL 1995. 3. Fuse or HACR circuit breaker is field installed. Johnson Controls Ducted Systems...
  • Page 8: Physical Data

    For internal filter use, a filter rack kit is available. Refer to the instructions supplied with the kit for replacement filter sizes. Filter sizes: A = 20 in. x 20 in., B = 20 in. x 30 in. Johnson Controls Ducted Systems...
  • Page 9: Natural Gas Pipe Sizing Chart

    Note: Never test for gas leaks with an open flame. Note: Install the rubber grommet to prevent leakage of air and water into the heating/controls compartment. Johnson Controls Ducted Systems...
  • Page 10: Flue Vent Outlet Air Hood

    1. Heating capacity is valid for elevations up to 2,000 ft above sea level. For elevations above 2,000 ft, reduce the rated capacity by 4% for each 1,000 ft above sea level. 2. Based on 1,075 BTU/ft 3. The airflow must be adequate to obtain a temperature rise within the range shown. The continuous return air temperature must not be below 55°F. Johnson Controls Ducted Systems...
  • Page 11: Airflow Performance

    Medium (3) 1390 1350 1310 1270 1220 1180 1130 1080 Medium High (4) 1520 1480 1440 1400 1360 1320 1270 1220 1110 High (5) 1600 1560 1520 1490 1440 1400 1360 1310 1200 Continued on next page Johnson Controls Ducted Systems...
  • Page 12 Minimal variations in airflow performance data result from operating at 208 V. The data in the table can be used in those cases. Heating applications are tested at 0.50 in. W.C. external static pressure. Cooling applications are tested per AHRI Standard 210/240. The differences between side duct airflows and bottom duct airflows are insignificant. Johnson Controls Ducted Systems...
  • Page 13: Operation

    If the flame has been lost five times within the same call for Note: Filter pressure drop based on standard filter media tested at velocities not heat, the control board locks out, and the LED on the control board to exceed 300 ft/min. emits 8 red flashes. Johnson Controls Ducted Systems...
  • Page 14 Verify that the G wire from the ther- The only way to recover from a hard lockout is to remove and reapply mostat is connected properly. 24-VAC power to the control board. Johnson Controls Ducted Systems...
  • Page 15 When the thermostat ends the call for FAN, the thermostat terminal G is faulty flame sensor, or a faulty gas valve. The furnace locks out for 1 h de-energized, de-energizing the indoor circulating blower. and then restarts. Johnson Controls Ducted Systems...
  • Page 16: Inlet Gas Pressure Range

    Loosening or tighten- units. If gas pressure is outside these limits, contact the local gas ing the cap does not adjust the flow of gas. utility for corrective action. Johnson Controls Ducted Systems...
  • Page 17: Gas Valve

    The use of heating airflow at a speed other than the default speed causes diminished heating performance and may cause the furnace temperature limit controls to shut down the furnace. Figure 10: Reading Gas Pressure Johnson Controls Ducted Systems...
  • Page 18: Measuring External Static Pressure

    3. Treat the negative number as a positive and add the two numbers rise. Decrease the blower speed to increase the temperature rise. INCHES OF WATER HI PORT MAX. PRESSURE 15 PSIG LO PORT RETURN AIR DUCT SUPPLY AIR DUCT A0435-002 Figure 11: Measuring External Static Pressure Johnson Controls Ducted Systems...
  • Page 19: Gas Rate (Ft3/H)

    /h of gas are consumed by the furnace at that rate. Multiply 95 x 1050 (or the BTU rating of the gas obtained from the local gas company). The result is 99,750 BTUH, which is close to the 100,000 BTUH rating of the unit. Johnson Controls Ducted Systems...
  • Page 20: Typical Wiring Diagrams

    9 Red Flashes 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 Johnson Controls Ducted Systems...
  • Page 21: Ladder Wiring Diagram

    9 Red Flashes 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 Johnson Controls Ducted Systems...
  • Page 22: 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 23: 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 24 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. 5844973-UIM-A-0920 Copyright © 2020 by Johnson Controls. All rights reserved. Supersedes: 5731233-UIM-B-0120 York International Corp. 5005 York Drive...

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