Johnson Controls GCGA Series Instruction Manual

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
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Installation of Vapor Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Underground Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Heat Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Orifice Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Outdoor Unit Control Box (Single Phase) . . . . . . . . . . . . . . . . . . . . . .8
Outdoor Unit Control Box (Three Phase - GCGA36-60) . . . . . . . . . . .8
Outdoor Unit Control Box (GCGA76 With Transformer) . . . . . . . . . . .8
Typical Field Wiring (Air Handler / Electrical Heat)
(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
EVACUATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SYSTEM CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTRUCTING THE OWNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
LIST OF FIGURES
Typical Field Wiring (Air Handler / Electrical Heat)
(Three Phase - GCGA36-60) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Typical Field Wiring for 76 Models with Air Handler
(Three-Phase - GCGA76) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Thermostat Chart - Single Stage AC with PSC Furnace . . . . . . . . . 10
Thermostat Chart - Single Stage AC with PSC Air Handler . . . . . . . 11
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-A-0310