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ManualsBrandsHeat Controller ManualsAir ConditionerInc. Air Conditioner 10

INSTALLATION INSTRUCTIONS

PACKAGE AIR CONDITIONERS FEATURING EARTH-FRIENDLY

R410A REFRIGERANT

PCG SERIES 6, 7.5, 8.5, 10 & 12.5 TON [21.1, 26.4, 29.9, 35.2 & 44 kW]

60 HZ MODELS

92-21916-45-00

[ ] Designates Metric Conversions

THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALI-

FIED, LICENSED SERVICE PERSONNEL FOR PROPER INSTALLA-

TION, ADJUSTMENT AND OPERATION OF THIS UNIT. READ

THESE INSTRUCTIONS THOROUGHLY BEFORE ATTEMPTING

INSTALLATION OR OPERATION. FAILURE TO FOLLOW THESE

INSTRUCTIONS MAY RESULT IN IMPROPER INSTALLATION,

ADJUSTMENT, SERVICE OR MAINTENANCE POSSIBLY RESULT-

ING IN FIRE, ELECTRICAL SHOCK, PROPERTY DAMAGE, PER-

SONAL INJURY OR DEATH.

WARNING

DO NOT DESTROY

PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE

FOR FUTURE REFERENCE.

Recognize this symbol as an indication of Important Safety Information!

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HEAT CONTROLLER

Summary of content (40 pages)

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HEAT CONTROLLER INSTALLATION INSTRUCTIONS PACKAGE AIR CONDITIONERS FEATURING EARTH-FRIENDLY R410A REFRIGERANT PCG SERIES 6, 7.5, 8.5, 10 & 12.5 TON [21.1, 26.4, 29.9, 35.2 & 44 kW] 60 HZ MODELS t i nd y earth friendly refrigerant ! Recognize this symbol as an indication of Important Safety Information! DO NOT DESTROY PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.
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I. TABLE OF CONTENTS I. II. III. IV. V. VI. VII. VIII. VIX. X. XI. XII. XIII. XIV. XV. XVI. XVII. XVIII. XIX. XX. XXI. XXII. Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Checking Product Received . . . . . . . . . . . . . . . . . . . . . 2 Equipment Protection . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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The units are weatherized for mounting outside of the building. • R-410A refrigerant cylinders are pink. The information on the rating plate is in compliance with the FTC and DOE rating for single phase units. The following information is for three phase units which are not covered under the DOE certification program. • R-410A, as with other HFC’s is only compatible with POE oils. 1.
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FIGURE 1 UNIT DIMENSIONS 403⁄16” [1020.7 mm] 65⁄8” [168.3 mm] 41⁄8” [104.8 mm] POWER ENTRY 13⁄4” [44.5 mm] DIA. 313⁄16” [96.8 mm] 1111⁄16” [296.9 mm] CONTROL ENTRY [22.2 mm] DIA. COMPRESSOR ACCESS 613⁄16” [173 mm] 7⁄8” SUPPLY COVER 9311⁄16” [2379.6 mm] 5” [127 mm] 583⁄4” [1492.2 mm] RETURN COVER ST-A1112-02-00 FIGURE 2 UNIT DIMENSIONS 23” [584.2 mm] 2” [50.8 mm] 14” [355.6 mm] 2” [50.8 mm] RE TU RN * 34” [863.6 mm] 25” [635 mm] * LY PP SU 151⁄8” [384.2 mm] 47⁄16” [112.
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FIGURE 3 UNIT DIMENSIONS 58.75” [1487.7 mm] 93.688” [2379.7 mm] 44” [1117.6 mm] GAUGE PORT CONNECTIONS COMPRESSOR ACCESS (BOTH SIDE SOME MODELS) BLOWER ACCESS ELECTRIC HEAT ACCESS CONTROL ENTRY POWER ENTRY 7.020” [178.3 mm] CONDENSATE DRAIN 1” [25.4 mm] FNPT 27.268” [692.6 mm] CONTROL/FILTER ACCESS 33.715” [805.5 mm] 5.625” [142.9 mm] A0737-03 FIGURE 4 BOTTOM VIEW SUPPLY RETURN DIMENSIONS FOR DOWNFLOW APPLICATIONS 9311/ ” [2379.4 mm] 16 25" [635 mm] 14" [355.6 mm] 151/ ” [384.
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FIGURE 5 REAR VIEW SUPPLY AND RETURN DIMENSIONS FOR HORIZONTAL APPLICATION SUPPLY DUCT MAY EXTEND UP TO THIS LEVEL 44" [1117.6 mm] *26" [660.4 mm] 34" [863.6 mm] 12" [304.8 mm] 77/ ” [183.3 mm] 32 28" [711.2 mm] 9311/ ” [2379.6 mm] 135/ ” [346 mm] 8 14" [355.6 mm] 47/ ” [112.
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GENERAL DATA - PCG NOM. SIZES 6-121⁄2 TONS [21.1-43.9 kW] Model PCG- Series 072A-3L Cooling Performance1 Gross Cooling Capacity Btu [kW] 76,000 [22.27] EER/SEER2 11.5/NA Nominal CFM/ARI Rated CFM [L/s] 2400/2375 [1133/1121] ARI Net Cooling Capacity Btu [kW] 73,000 [21.39] Net Sensible Capacity Btu [kW] 53,900 [15.79] Net Latent Capacity Btu [kW] 19,100 [5.6] Integrated Part Load Value3 N/A Net System Power kW 6.31 Compressor No.
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GENERAL DATA - PCG NOM. SIZES 6-121⁄2 TONS [21.1-43.9 kW] Model PCG- Series 090A-3L Cooling Performance1 Gross Cooling Capacity Btu [kW] 93,000 [27.25] EER/SEER2 11.2/NA Nominal CFM/ARI Rated CFM [L/s] 3000/2775 [1416/1310] ARI Net Cooling Capacity Btu [kW] 90,000 [26.37] Net Sensible Capacity Btu [kW] 63,100 [18.49] Net Latent Capacity Btu [kW] 26,900 [7.88] Integrated Part Load Value3 13 Net System Power kW 7.99 Compressor No.
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GENERAL DATA - PCG NOM. SIZES 6-121⁄2 TONS [21.1-43.9 kW] Model PCG- Series 120A-4L Cooling Performance1 Gross Cooling Capacity Btu [kW] 123,000 [36.04] EER/SEER2 11.2/NA Nominal CFM/ARI Rated CFM [L/s] 4000/3750 [1888/1770] ARI Net Cooling Capacity Btu [kW] 118,000 [34.57] Net Sensible Capacity Btu [kW] 88,800 [26.02] Net Latent Capacity Btu [kW] 29,200 [8.56] Integrated Part Load Value3 12.9 Net System Power kW 10.49 Compressor No.
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ELECTRICAL DATA - PCG Evaporator Fan Condenser Motor Compressor Motor Unit Information ELECTRICAL DATA - PCG SERIES 10 072A-3L 072A-4L 085A-3L 085A-4L 090A-3L 090A-4L 102A-3L 102A-4L 120A-3L Unit Operating Voltage Range 187-253 414-506 187-253 414-506 187-253 414-506 187-253 414-506 187-253 Volts 208/230 460 208/230 460 208/230 460 208/230 460 208/230 Minimum Circuit Ampacity 37/37 18 42/42 21 43/43 21 54/54 26 54/54 Minimum Overcurrent Protection Device Size 4
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ELECTRICAL DATA - PCG Evaporator Fan Condenser Motor Compressor Motor Unit Information ELECTRICAL DATA - PCG SERIES 120A-4L 150A-3L 150A-4L Unit Operating Voltage Range 414-506 187-253 414-506 Volts 460 208/230 460 Minimum Circuit Ampacity 28 71/71 36 Minimum Overcurrent Protection Device Size 30 75/75 40 Maximum Overcurrent Protection Device Size 35 90/90 45 No.
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VI. INSTALLATION A. GENERAL 1. PRE-INSTALLATION CHECK-POINTS FIGURE 6 OUTSIDE SLAB INSTALLATION, BASEMENT OR CRAWL SPACE DISTRIBUTION SYSTEM Before attempting any installation, the following points should be carefully considered: Recommended Clearance 48” [1219.2 mm] 18” [457.2 mm] 18” [457.2 mm] 18”* [457.2 mm] 60” [1524 mm] a. Structural strength of supporting members. (rooftop installation) b. Clearances and provision for servicing. c. Power supply and wiring. d. Air duct connections.
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D. ROOFTOP INSTALLATION 1. Before locating the unit on the roof, make sure that the strength of the roof and beams is adequate at that point to support the weight involved. This is very important and user’s responsibility. 2. For rigging and roofcurb details, see Figures 8 and 9. Use field-furnished spreaders. FIGURE 8 RIGGING FOR LIFTING CORNER WEIGHTS BY PERCENTAGE A B C D 33% 27% 17% 23% 3. For roofcurb assembly, see Roofcurb Installation Instructions. 4.
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Balancing dampers should be provided for each branch duct in the supply system. Ductwork should be properly supported from the structure. FIGURE 10 FLAT ROOFTOP INSTALLATION, ATTIC OR DROP CEILING DISTRIBUTION SYSTEM. MOUNTED ON ROOFCURB. CURB MUST BE LEVEL When installing ductwork, consider the following items: 1. Noncombustible flexible connectors should be used between ductwork and unit to reduce noise and vibration transmission into the ductwork. 2.
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X. CONDENSATE DRAIN FIGURE 13 The condensate drain connection of the evaporator is 1" [25.4 mm] nominal female pipe thread. IMPORTANT: Install a condensate trap to ensure proper condensate drainage. See Figure 12. BRANCH CIRCUIT DISCONNECT LOCATION FIGURE 12 CONDENSATE DRAIN 3” [76 mm] 3” [76 mm] e. Re-install the power entry panel & run conduit and the proper size field wiring through the opening in the panel. f. Connect field wiring to the power terminal block located on the electric heater kit.
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FIGURE 14 GROUNDING MAY ALSO BE ACCOMPLISHED BY GROUNDING THE POWER LINE CONDUIT TO THE UNIT. MAKE SURE THE CONDUIT NUT LOCKING TEETH HAVE PIERCED THE INSULATING PAINT FILM OF THE SIDE PANEL. E. THERMOSTAT The thermostat should be mounted on an inside wall about five feet above the floor in a location where it will not be affected by unconditioned air, sun, or drafts from open doors or other sources.
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FIGURE 15 THERMOSTAT CONNECTIONS DIAGRAM A0823-01 XV. STARTUP 1. Turn thermostat to “OFF,” turn “on” power supply at disconnect switch. 2. Turn temperature setting as high as it will go. 3. Turn fan switch to “ON.” 4. Indoor blower should run. Be sure it is running in the right direction. 5. Turn fan switch to “AUTO.” Turn system switch to “COOL” and turn temperature setting below room temperature. Unit should run in cooling mode. 6. Is outdoor fan operating correctly in the right direction? 7.
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XVI. OPERATION XVII. MISCELLANEOUS COOLING MODE REPLACEMENT PARTS With thermostat in the cool mode, fan auto and the room temperature higher than the thermostat setting: . A. Indoor blower contactor is energized through thermostat contact (G). B. Compressor contactors are energized through thermostat contacts (Y1) & (Y2) and high pressure controls. C. Economizer enthalpy control (if installed) controls operation of first-stage cooling and positions fresh air damper to maintain mixed air temperature.
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Model 6 Ton — — — — — 706 764 826 890 958 1029 — — — — — 802 826 852 877 904 931 — — — — — — — 805 831 858 886 — — — — — — — 751 813 878 947 0.2 [.05] RPM W 0.1 [.02] RPM W — — — 803 826 849 872 897 922 947 973 — — — 663 718 775 836 900 967 1037 1110 0.3 [.07] RPM W Voltage 208/230, 460, 575 — 3 phase — 808 828 850 871 894 916 940 964 989 1014 1 1072 2 1019 3 967 915 0.94 0.99 0.91 0.
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546 741 854 869 560 804 598 940 576 876 612 1011 592 954 628 1096 607 1030 643 1180 622 1112 658 1271 638 1202 672 1361 617 632 646 660 673 689 704 931 1010 1089 1168 1247 1344 1440 650 664 678 692 710 719 728 1024 1107 1189 1274 1306 1366 1426 612 624 635 648 660 673 685 713 722 731 739 748 757 729 791 853 923 993 1069 1144 1187 1247 1307 1368 1428 1488 645 656 667 680 708 725 734 743 751 760 769 777 786 812 878 945 1017 1069 1129 1189 1249 1309 1369 1430 1490 1550 711 720 729 737 746 755 763
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672 686 699 713 726 1361 1443 1526 1609 1692 700 713 727 740 754 1435 1518 1601 1683 1766 727 741 754 768 781 1510 1592 1675 1758 1841 755 768 782 795 809 1584 1667 1750 1832 1915 705 713 722 731 739 748 757 782 796 809 823 836 56 1 860 2 824 L 2.0 [1491.
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— — — — — 1361 1443 1526 1609 1692 1774 1857 1940 2023 2105 2188 2271 — — — — — 672 686 699 713 726 740 753 767 780 794 807 821 673 686 700 713 727 740 754 767 781 794 808 821 835 848 1270 1352 1435 1518 1601 1683 1766 1849 1932 2014 2097 2180 2263 2345 700 714 727 741 754 768 781 795 808 822 835 840 862 876 1344 1427 1510 1592 1675 1758 1841 1923 2006 2089 2172 2254 2337 2420 728 741 755 768 782 795 809 822 836 849 863 876 906 914 1419 1501 1584 1667 1750 1832 1915 1998 2081 2163 2248 2329 246
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Capacity [443 kW] Voltage 208/230,12.5 460, Ton 575 — phase 1.5[.37] [.37] 1.6 1.6[.40] [.40] 1.7 1.7[.42] [.42] 1.8 1.8[.45] [.45] 1.9 1.9[.47] [.47] 2.0 2.0[.50] [.50] 1.5 RPM RPM RPM W RPM RPM WW RPM RPM WW RPM RPM WW RPM RPM WW RPM RPM WW RPM RPM WW RPM RPM WW RPM RPM WW RPM RPM WW RPM RPM WW RPM RPM WW RPM RPM WW RPM RPM WW RPM RPM WW RPM RPM WW RPM RPM WW RPM RPM WW RPM WW RPM WWTon RPM Capacity 12.5 [44 W kW] 6 6894 813 6 58 58 [ ] Designates Metric Conversions NOTES: 1.
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XIX. HEATER KIT CHARACTERISTICS TABLE A AUXILIARY HEATER KITS CHARACTERISTICS AND APPLICATION (PCG MODELS) 208/240V – 3 PHASE 24 HEATER KIT FLA UNIT MIN. CKT. AMPACITY MAX. FUSE OR CKT. BKR. SIZE (CKT. BKR. MUST BE HACR TYPE FOR USA) — 7.2/9.6 10.8/14.4 14.4/19.2 21.6/28.8 — 20.0/23.1 30.0/34.6 40.0/46.2 60.0/69.3 37/37 37/37 45/51 57/65 82/94 50/50 50/50 50/60 60/70 90/100 NONE CC10C CC15C CC20C CC30C CC40C — 7.2/9.6 10.8/14.4 14.4/19.2 21.6/28.8 28.8/38.4 — 20.0/23.1 30.0/34.6 40.0/46.2 60.
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HEATER KIT CHARACTERISTICS (continued) TABLE B AUXILIARY HEATER KITS CHARACTERISTICS AND APPLICATION (PCG MODELS) 208/240V – 3 PHASE HEATER KIT FLA UNIT MIN. CKT. AMPACITY MAX. FUSE OR CKT. BKR. SIZE (CKT. BKR. MUST BE HACR TYPE FOR USA) — 7.2/9.6 10.8/14.4 14.4/19.2 21.6/28.8 28.8/38.4 36.1/48.0 — 20.0/23.1 30.0/34.6 40.0/46.2 60.0/69.3 80.1/92.4 100.1/115.5 54/54 54/54 54/60 67/74 92/103 117/132 142/161 60/60 60/60 60/60 70/80 100/110 125/150 150/175 NONE CC10C CC15C CC20C CC30C CC40C CC50C — 7.
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HEATER KIT CHARACTERISTICS (continued) TABLE C AUXILIARY HEATER KITS CHARACTERISTICS AND APPLICATION (PCG MODELS) 480V – 3 PHASE 26 HEATER KIT FLA UNIT MIN. CKT. AMPACITY MAX. FUSE OR CKT. BKR. SIZE (CKT. BKR. MUST BE HACR TYPE FOR USA) — 9.6 14.4 19.2 28.8 38.4 — 11.5 17.3 23.1 34.6 46.2 21 21 27 34 49 63 25 25 30 35 50 70 NONE CC10C CC15D CC20D CC30D CC40D — 9.6 14.4 19.2 28.8 38.4 — 11.5 17.3 23.1 34.6 46.
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XX. TROUBLE SHOOTING CHART ! WARNING DISCONNECT ALL POWER TO UNIT BEFORE SERVICING. CONTACTOR MAY BREAK ONLY ONE SIDE. FAILURE TO SHUT OFF POWER CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH.
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XXI. WIRING DIAGRAMS WIRING DIAGRAM 072/085 208-230/460/575V 3 PH, 60 HZ.
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WIRING SCHEMATIC 072/085 PACKAGED A/C 208-230, 3PH, 60HZ./460, 3PH, 60HZ. 575V, 3PH, 60HZ.
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WIRING DIAGRAM 090/102/120/150 208-230/460/575V 3 PH, 60 HZ.
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WIRING SCHEMATIC 090/102/120/150 PACKAGED A/C 208-230, 3PH, 60HZ./460, 3PH, 60HZ. 575V, 3PH, 60HZ.
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XXII.
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PCG SYSTEM CHARGE CHARTS FIGURE 17 SYSTEMCHARGE CHARGE CHART CHART -- REFRIGERANT REFRIGERANT 410A SYSTEM 410A -B085, -085,CIRCUIT CIRCUIT11 525 115 500 475 105 450 425 95 400 375 85 350 75 325 300 65 275 55 250 225 200 175 100 105 110 115 120 125 130 135 140 145 150 155 160 165 92-102259-07-00 33
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PCG SYSTEM CHARGE CHARTS FIGURE 18 SYSTEMCHARGE CHARGE CHART CHART -- REFRIGERANT REFRIGERANT 410A SYSTEM -B090, CIRCUITS 11 & & 22 -090, CIRCUITS BOTH COMPRESSORS MUST BE OPERATING BEFORE CHECKING REFRIGERANT CHARGE.
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PCG SYSTEM CHARGE CHARTS FIGURE 19 SYSTEMCHARGE CHARGE CHART CHART -- REFRIGERANT SYSTEM REFRIGERANT410A 410A CIRCUITS -102, -B102, CIRCUITS11&&2 2 BOTH COMPRESSORS MUST BE OPERATING BEFORE CHECKING REFRIGERANT CHARGE.
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PCG SYSTEM CHARGE CHARTS FIGURE 20 SYSTEMCHARGE CHARGE CHART CHART -- REFRIGERANT SYSTEM REFRIGERANT410A 410A CIRCUITS -120, -B120, CIRCUITS11&&22 BOTH COMPRESSORS MUST BE OPERATING BEFORE CHECKING REFRIGERANT CHARGE.
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PCG SYSTEM CHARGE CHARTS FIGURE 21 SYSTEM CHARGE CHARGE CHART CHART -- REFRIGERANT SYSTEM REFRIGERANT 410A 410A CIRCUITS -150, -B150, CIRCUITS11&&22 BOTH COMPRESSORS MUST BE OPERATING BEFORE CHECKING REFRIGERANT CHARGE.
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CM 1108