Johnson Controls PCG4 Series Installation Manual Download

Page: 26 / 26

Subject to change without notice. Published in U.S.A.

5750156-UIM-B-0919

Supersedes: 5750156-UIM-A-0619

York International Corp.

5005 York Drive

Norman, OK 73069

Refrigerant Charge and Metering Device

Subcooling

R-410A

R-22

Discharge line

temperature

Superheat

Discharge pressure

Data plate - lbs / Oz

TXV# / Orifice size

Explain operation of system to equipment owner

Explain the importance of regular filter replacement and equipment maintenance

Clean Up Job Site

Owner Education

Comments and Additional Job Details

Provide owner with the owner's manual

Explain thermostat use and programming (if applicable) to owner

Unit Operation and Cycle Test

Operate the unit through continuous fan cycles from the thermostat, noting and correcting any problems

Operate the unit through cooling cycles from the thermostat, noting and correcting any problems

Job site has been cleaned, indoor and outdoor debris removed from job site

Tools have been removed from unit

All panels have been installed

TXV

Fixed Orifice

Liquid line temperature

Suction pressure

Suction line temperature

Manifold Pressure / Low Fire Rate (w.c.")

Gas Heat

Rated BTU/H

Measured BTU/H (Clock Gas Meter Nat Gas)

Supply Air Dry Bulb Temp

Temp Rise

Return Air Dry Bulb Temp

Manifold Pressure at 100% Firing Rate (w.c.")

Inlet Gas Pressure (w.c.")

LP Gas Conversion Kit #

LP Conversion Kit Installed By

Two Stage

Single Stage

Propane LP (Requires LP Conversion Kit)

Natural Gas

Burner Flame Inspection - Blue flames extending directly into the primary heat exchanger cells

Summary of Contents for PCG4 Series

Page 1: ...g 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...

Page 2: ...ormation consult a qualified installer service agency or the gas supplier CAUTION This system uses R 410A Refrigerant which operates at higher pres sures than R 22 No other refrigerant may be used in this system Gage sets hoses refrigerant containers and recovery systems must be designed to handle R 410A If you are unsure consult the equip ment manufacturer Failure to use R 410A compatible servici...

Page 3: ...must be based on heat loss heat gain calculation made according to the methods of Air Condi tioning Contractors of America ACCA This furnace is not to be used for temporary heating of buildings or structures under construction Table 1 Unit Limitations Model Unit Voltage Unit Limitations Applied Voltage Outdoor DB Temp Minimum Maximum Maximum F PCG4A24 208 230 1 60 187 252 125 PCG4A30 208 230 1 60 ...

Page 4: ...ided for this purpose WARNING Do not attach supply and return duct work to the bottom of the unit base pan as the drain pan could be compromised WARNING Excessive exposure of this unit to contaminated combustion air may result in equipment damage or personal injury Typical contaminates include permanent wave solution chlorinated waxes and cleaners chlorine based swimming pool chemicals water softe...

Page 5: ...CESS PANEL LOW VOLTAGE CONNECTION GAS SUPPLY EXHAUST HOOD COMBUSTION AIR INTAKE HEAT EXCHANGER ACCESS PANEL B A C A0296 001 COIL GUARD Table 5 Unit Clearances1 2 Direction Distance in Direction Distance in Top3 36 Power Entry Right Side 36 Side Opposite Ducts 36 Left Side 24 Duct Panel 0 Bottom4 1 1 A 1 in clearance must be provided between any combustible material and the supply air duct work 2 T...

Page 6: ...shipped without a filter or filter racks It is the responsibility of the installer to secure a filter in the return air ductwork or install a Filter Frame Kit A filter rack and high velocity filters are standard on three phase units Always use filters and keep filters clean When filters become dirt laden insufficient air is delivered by the blower decreasing your unit s effi ciency and increasing ...

Page 7: ...must be wired with a separate branch circuit fed directly from the main distribution panel and properly fused See Figures 6 and 7 for typical field wiring and refer to the appropriate unit wiring diagram for control circuit and power wiring information CAUTION Hand tighten only CAUTION This system uses R 410A Refrigerant which operates at higher pres sures than R 22 No other refrigerant may be use...

Page 8: ...Operating Weight lb 341 351 386 390 394 401 405 441 443 460 468 473 477 481 488 Compressors Type Scroll Scroll Scroll Scroll Scroll Scroll Outdoor Coil Data Face area sq ft 15 1 15 1 15 1 16 9 19 5 21 5 Rows 1 2 2 2 2 2 Fins per inch 22 22 22 22 22 22 Tube diameter 3 8 3 8 3 8 3 8 3 8 3 8 Circuitry type Interlaced Interlaced Interlaced Interlaced Interlaced Interlaced Indoor Coil Data Face area sq...

Page 9: ...t be a separate line and installed in accor dance with all applicable safety codes After the gas connections have been completed open the main shut off valve admitting nor mal gas pressure to the gas valve Check all joints for leaks with soap solution or other material suitable for the purpose NEVER USE AN OPEN FLAME CAUTION This system uses R 410A Refrigerant which operates at higher pres sures t...

Page 10: ... result causing property damage personal injury or loss of life Table 10 High Altitude Gas Orifice Sizing Elevation Above Sea Level ft Gas Type Cabinet Size 0 2000 Factory 2001 3000 3001 4000 4001 5000 5001 6000 6001 7000 7001 8000 8001 9000 9001 10000 Natural Gas Orifice Sizes B 36 37 38 38 39 40 41 41 42 A 42 42 43 43 43 44 44 45 46 LP Gas Orifice Sizes B 51 51 52 52 52 52 53 53 53 A 54 54 55 55...

Page 11: ...5 1148 1108 1071 1035 996 960 925 901 853 PCG4A24075 Low 1 887 847 802 750 705 664 613 563 463 Low Medium 2 978 941 898 850 803 759 713 667 575 Medium 3 1171 1114 1074 1039 993 949 906 864 780 Medium High 4 1349 1297 1265 1224 1185 1146 1107 1063 975 High 5 1487 1462 1392 1331 1318 1281 1241 1201 1121 PCG4A30050 Low 1 700 657 599 554 512 461 411 365 273 Low Medium 2 906 868 825 779 735 692 650 608...

Page 12: ...1620 1564 1517 1466 1418 1360 1308 1206 1002 Low Medium 2 1694 1630 1580 1530 1482 1430 1380 1292 1116 Medium 3 1798 1722 1669 1620 1572 1527 1480 1413 1280 Medium High 4 1835 1758 1703 1653 1604 1558 1511 1442 1304 High 5 2146 2085 2025 1960 1872 1862 1798 1735 1609 PCG4B48125 Low 1 1620 1564 1517 1466 1418 1360 1308 1206 1002 Low Medium 2 1798 1722 1669 1620 1572 1527 1480 1413 1280 Medium 3 192...

Page 13: ... 3 1262 1223 1181 1137 1091 1044 994 952 868 Medium High 4 1324 1282 1245 1202 1161 1112 1067 1018 920 High 5 1517 1475 1447 1400 1357 1318 1275 1232 1146 PCG4A36075 Low 1 1231 1186 1146 1103 1069 1030 977 912 781 Low Medium 2 1270 1225 1189 1140 1098 1046 1008 960 866 Medium 3 1317 1286 1245 1198 1151 1110 1064 1024 943 Medium High 4 1358 1317 1275 1238 1197 1148 1105 1057 961 High 5 1517 1475 14...

Page 14: ...713 1672 1636 1564 Medium High 4 2105 2014 2006 1931 1898 1845 1793 1739 1631 High 5 2131 2058 1998 1949 1892 1840 1788 1728 1608 PCG4B60065 Low 1 1026 999 989 950 907 907 886 862 816 Low Medium 2 1263 1230 1192 1165 1167 1101 1099 1071 1015 Medium 3 1987 1933 1861 1817 1820 1715 1725 1651 1504 Medium High 4 2114 2050 2047 1974 1899 1889 1920 1866 1758 High 5 2369 2308 2249 2183 2126 2088 2034 199...

Page 15: ... inter purge and reignition attempt Heat Blower On Delay The control board waits for 30 seconds and then energizes the indoor blower heat speed Blower on delay time begins at the start of flame proving period in the trial for ignition If the thermostat demand for heat is removed the control de energizes the gas valve energizes the blower on heat speed and initiates a post purge and heat blower off...

Page 16: ...it switch is set to open at a temperature selected to prevent the outlet air temperature from exceeding the maximum shown on the unit rating plate It resets automatically The limit switch oper ates when a high temperature condition occurs The limit switch shuts down the ignition control closes the main gas valve and energizes the blower Pressure Switch PS If the draft motor fails the pressure swit...

Page 17: ...ot start the ignition sequence until this problem is corrected 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 11 Red Flashes Indicates the limit circuit has remained open for more than 5 minutes and less than 15 minutes This con...

Page 18: ...he gas line pressure must be taken at the port marked IN P 3 Using a 3 32 in 2 4 mm hex head wrench loosen the set screw by turning it one turn counter clockwise DO NOT REMOVE THE SET SCREW FROM THE PRESSURE PORT Read the inlet gas pressure Connect the positive side of the manometer to the IN P Tap on the gas valve Do not connect any tubing to the negative side of the manometer because it referenc...

Page 19: ... speed blower motor See Table 18 for the default heating blower speed for each model In certain circumstances it may be necessary to move the heating blower speed to a different motor speed tap Not all of the five motor speeds are appropriate for gas heating operation The use of heating airflow at a speed other than the default speed causes diminished heat ing performance and may cause the furnace...

Page 20: ...ng connect the white Heat speed wire and the yellow Cool speed wire terminal to the required motor lead using a jumper wire or Y terminal DIRECT DRIVE BLOWER All units have direct drive multi speed standard ECM blower motors Connect manometer as per the EXTERNAL STATIC PRESSURE SETUP section Place the unit in cooling mode and adjust the blower speed accordingly as per Table 13 or 14 EXTERNAL STATI...

Page 21: ...e gas in your particular locality Contact your gas company for this information since it varies widely from city to city Table 19 Gas Rate Cubic Feet Per Hour1 1 EXAMPLE By actual measurement it takes 38 seconds for the hand on the 1 cubic foot dial to make a revolution with just a 100 000 BTUH furnace running Using this information locate 38 seconds in the first column of Table 19 Read across to ...

Page 22: ...Flashes 6 Red Flashes 7 Red Flashes 8 Red Flashes 9 Red Flashes 10 Red Flashes 11 Red Flashes Normal Operation Standby mode Call for furnace heat active Control in Factory Test mode Green Heartbeat Amber Heartbeat Rapid Green Flashes Power Off or open fuse Normal Operation Normal Operation with call for heat Low flame sense current No G from thermostat with Y call Control Failure Flame present wit...

Page 23: ...ontrol Failure Flame present with gas off Check pressure switch wiring Vent OR termination problem Airflow problem Flame Rollout Repeated pressure switch cycles Failed to light burners Loss of flame during call for heat Incorrect polarity OR Don t have neutral Gas valve shorted ON Check blower motor wiring DSI Fault Codes CAUTION OPEN ALL DISCONNECTS BEFORE SERVICING THIS UNIT 1 ALL FIELD WIRING T...

Page 24: ... Manifold sets must be at least 700 psig high side and 180 psig low side with 550 psig retard All hoses must have a service pressure rating of 800 psig Leak detectors must be designed to detect HFC refrigerants Systems must be charged with liquid refrigerant Use a commercial type metering device in the manifold hose R 410A can only be used with POE type oils POE type oils rapidly absorb moisture f...

Page 25: ...age L1 to L2 L2 to L3 L1 to L3 Total amperes L1 L2 L3 Compressor amperes L1 L2 L3 Measured voltage R and C outdoor unit control board Electrical Connections Inspection Check all that apply Equipment Data Additional Kits Accessories Installed Check all that apply Equipment Data Blower Type Set Up Supply air dry bulb temperature ADJUST A B C D A B C D Total external static pressure Supply static inc...

Page 26: ...n and Cycle Test Operate the unit through continuous fan cycles from the thermostat noting and correcting any problems Operate the unit through cooling cycles from the thermostat noting and correcting any problems Job site has been cleaned indoor and outdoor debris removed from job site Tools have been removed from unit All panels have been installed TXV Fixed Orifice Liquid line temperature Sucti...

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