Due to continuous product improvement, specifications
are subject to change without notice.
Visit us on the web at
www.upgnet.com and www.colemanac.com
Additional rating information can be found at:
www.ahridirectory.org
WARRANTY SUMMARY*
Standard 1-Year limited parts warranty.
Standard 5-Years limited compressor warranty.
Lifetime gas heat exchanger warranty with registration.
See limited warranty certificate in User’s Information Manual for details.
5564041-CTG-A-1018
DESCRIPTION
These packaged cooling/heating air conditioners are designed
for outdoor installation. Only utility and duct connections are
required at the point of installation.
FEATURES
• Operating Efficiency - All PCG4 model gas units provide a
minimum AFUE of 81.0% in heating and 14.0 SEER, 11.0
EER rating for cooling operation. All models meet California
Low-Nox requirements of 40 ng/joule emission level for Air
Quality Management Districts.
• On Site Flexibility - All model sizes use a compact design
cabinet in one of two footprints. This provides installer flexibility for placing the proper capacity unit on curbs or pads
with the smallest footprint after the internal load has been
determined. Field convertible duct connections from side
shot to down shot allows the installer to have greater flexibility with less inventory.
• Lower Installation Cost - Installation time and costs are
reduced by easy power and control wiring connections. The
small base dimension means less space is required on the
ground or roof. All units are completely wired, charged with
R-410A and tested prior to shipment. Test stations using a
state-of-the-art computerized process system are used to
insure product quality. Refrigerant charge and component
part numbers are verified via computers during assembly.
Vital run test statistics such as system pressure, motor currents, air velocity and temperature, unit vibration, and gas
system safeties are monitored and recorded by the system to
insure unit performance. Equal size side supply and return
duct connections allow easy connection of ducts to match
low crawl spaces without transition pieces.
• Utility Connections Made Easy - Gas and electric utility
access provided through the bottom or the side of the unit.
Utility connections can be made quickly and with a minimum
amount of field labor. A field supplied and field installed electrical disconnect switch must be installed.
• Convertible Airflow Design - The bottom duct openings are
covered when they leave the factory, ready to be used for a
side supply/side return application. If a bottom supply/bottom
return application is desired, simply remove the two panels
from the bottom of the unit and place them in the side supply/
side return duct openings. No panel cutting is required and
no accessory panel is necessary. Convertible airflow design
allows maximum field flexibility and minimum inventory.
• Condensate Pan - A corrosion-resistant, long-lasting, watertight pan is positioned below the evaporator coil to collect
and drain all condensate, preventing build-up of stagnant
condensate. The condensate pan conforms to ASHRAE 6289 standards (Ventilation for Acceptable Indoor Air Quality).
• Condensate Drain - The 3/4 inch NPT female connection is
rigidly mounted to assure proper fit and leak tight seal.
• Durable Finish - The cabinet is made of G90 galvanized
steel with a powder paint coating for appearance and protection. The pre-treated galvanized steel provides a better paintto-steel bond, which resists corrosion and rust creep. Powder paint finish insure less fading when exposed to sunlight,
and provides superior corrosion resistance (1000 hour salt
spray tested).
Continued on next page.
FOR DISTRIBUTION USE ONLY - NOT TO BE USED AT POINT OF RETAIL SALE
5564041-CTG-A-1018
• Outdoor Coil Grille - All models utilize a stamped slotted
design which provides superior impact protection against
small objects during transit and after installation.
• Full Perimeter Base Rails - The easily removable base rails
provide a solid foundation for the entire unit and protects the
unit during shipment. The rails provide fork lift access from
all sides, and rigging holes are also provided so that an overhead crane can be used to place the units on a roof. On
applications where the unit is placed on a pad, the base will
keep the unit off the pad to deter corrosion. On applications
where height is limited, the base rails may be removed by
removing 2 screws in each corner.
• More Attractive Appearance - A single-piece top cover
containing a top-discharge outdoor fan arrangement requires
less square footage on installation and provides a wider variety of installations. The one-piece design adds greater water
integrity. Rounded corners with water drip edges add to the
attractive appearance.
• Top Discharge - The top-discharge outdoor fan does not
disrupt neighboring areas or dry out vegetation surrounding
the unit. The warm air from the top mounted fan is blown up
and away from the structure and any landscaping. This
allows compact location on multi-unit applications.
• Low Operating Sound Level - The upward air flow carries
the normal operating noise up and away from the living area.
The rigid top panel effectively isolates noise. Isolator
mounted compressor and the rippled fins of the outdoor coil
muffle the normal fan motor and compressor operating
sounds. The unique formed base pan also aids in sound
attenuation with its structural design. This design strategically places embossments in the pan for optimum strength
and rigidity.
• Fan System - All models operate over a wide range of
design conditions with a standard ECM indoor fan motor.
These units easily match all types of applications and provide greater on-site flexibility to match comfort requirements.
The cooling speed is factory-set and can be field-adjusted to
a second speed. The heating speed is factory set to maintain
mid point rise at the units heating input, but can be field
adjusted. This allows maximum comfort conditions.
• Simple Control Circuit - A low voltage gas heat printed circuit board contains a status/diagnostic indicator light. Field
thermostat wiring connects to color coded leads using twist
on wire connections. Cooling controls use contactor and
relays for simple application and troubleshooting. Mate-nlock plug connectors are used. The electrical control box is
not located in the compressor compartment. The controls are
mounted to allow the separate access panel to be removed
for trouble shooting and maintenance without affecting the
normal system operating pressures. All wiring internal to the
unit is color/number coded.
• Protected Compressor - The compressor is internally protected against high pressure and temperature. This is
accomplished by the simultaneous operation of high pressure relief valve and a temperature sensor which protect the
compressor if undesirable operating conditions occur.
• Pressure Switches - A high pressure switch is standard in
all units. When abnormal conditions are sensed through the
pressure switch, the unit will lock out preventing any further
operation until reset or problem is corrected.
• Exclusive Coil Design - Grooved copper tubes and
enhanced aluminum fin construction improves heat transfer
for maximum efficiency and durability for long-lasting durability and efficient operation. Indoor coils use tin-coated copper
tubing with aluminum fins for effective heat transfer.
• Heat Exchangers - Gas heat exchangers use corrosionresistant, stainless-steel tubular construction to provide longlife, trouble-free operation. Gas heat exchangers are offered
with lifetime warranties as standard with registration.
• Post Purge Induced Draft Combustion - Exhausts combustion products from the heat exchanger upon completion
of the heating cycle to prolong the heat exchanger life.
• Spark To Burner Ignition - No pilot assembly required,
which provides more consistent ignition in gas heating mode.
This ignition is highly reliable, durable and eliminates nuisance lockouts.
• Multi Port In-shot Burners - No field adjustment is required
to mix the air and gas for natural gas or propane use. These
burners are constructed of high-grade corrosion-resistant,
aluminized steel.
• Low Maintenance - Long life, permanently lubricated outdoor and evaporator fan motor bearings need no annual
maintenance, adding greater reliability to the unit. Slide-out
blower assembly can be easily removed for cleaning.
• Easy Service Access - Individual access panels covering
the electrical and gas controls makes servicing easy. Removing this panel will allow easy removal of the blower assembly
for maintenance and ease of troubleshooting.
• Replacement Parts - The installer requires no special train-
ing to replace any of the components of these units and the
number of new components have been reduced to minimize
the inventory of unique parts.
• Filter Frame Kit - All 3 phase units include a filter frame kit,
which is shipped inside the unit from production. Field installation is required.
• Filters - All 3 phase units include an applicable number of 1"
washable filters, which are shipped inside the unit from production. Field installation is required. Two filters are required
for A base units. Three filters are required for B base units.
2Johnson Controls Unitary Products
5564041-CTG-A-1018
NOMENCLATURE
PCG4A240503X1A
123456789
1. Model Family
PCG - packaged A/C with gas heat,
PCE - packaged A/C with electric heat,
PHE - packaged heat pump with electric heat
PCG4B421002X1A is a packaged A/C with gas heat, 14 SEER, 3-1/2 ton, large cabinet, three-stage heat, 100,000 BTU gas heat, 230 volt, three
phase, low-NOx model (first generation, first release)
• Propane Conversion Kit (S1-1NP0703, S1-1NP0704) - Kit
includes burner orifices, gas valve conversion and installation instructions necessary to field convert unit from natural
gas to propane.
• Economizer for Downflow Applications (S1-2EE04710024, S1-2EE04710124) - Modulating integrated economizer provides simultaneous operation
between the mechanical cooling and economizer operation.
Independent blade design insures proper control and less
than 1% leak rate. Includes hood and mesh bird screen filter
integrated into the hood, dry bulb sensor, and barometric
relief damper. Separate field accessories of single enthalpy
and dual enthalpy are also available.
• Economizer for Horizontal Applications (S1-2EE04710224, S1-2EE04710324) - Modulating integrated economizer provides simultaneous operation
between the mechanical cooling and economizer operation.
Independent blade design insures proper control and less
than 1% leak rate. Includes hood and mesh bird screen filter
integrated into the hood and dry bulb sensor. Separate field
accessories of single enthalpy and dual enthalpy are also
available.
• Barometric Relief Hood (S1-1RD0501) - Used in conjunc-
tion with a horizontal economizer, the Barometric Relief
Hood helps to equalize the building pressure that is caused
by the fresh air that is introduced through the economizer
fresh air hood.
• Single/Dual Enthalpy Sensor (S1-HE-6863-0N00WS) -
Sensor replaces dry bulb sensor standard in economizer kit.
Provides improved economizer operation by sensing the dry
bulb temperature from outdoors plus the enthalpy content of
the outdoor air.
• Duct/Unit Mount CO2 Kit (S1-2AQ04700924) - Sensor kit
detects CO2 levels automatically and overrides the economizer when CO2 levels rise above the preset limits.
• Wall Mount CO2 Kit (S1-2AQ04701024) - Sensor kit
detects CO2 levels automatically and overrides the economizer when CO2 levels rise above the preset limits.
• Supply Air Temperature Sensor Kit (S1-TE-63616E-2D) -
Outdoor supply air temperature sensor kit used with economizers.
• Filter/Frame Kit (Kit provided)(S1-1FF0602, S1-1FF0601) - Kit contains the necessary
hardware to field install return air filters into the base unit.
The filter rack is suitable for either 1" or 2" filters.
• Filter (S1-02647812000) - Washable 1” filter. Two filters are
required for A base units. Three filters are required for B
base units. Washable filters are included inside shipped units
for field installation.
• Motorized Fresh Air Damper (S1-2MD04705224, S1-2MD04705124) - Designed for duct
mounted side supply/return and unit mounted down supply/
return applications. Damper capable of providing 0% through
50% of outdoor air (field supplied). Closes on power loss,
includes hood and screen assembly.
• Loss of Charge Switch (S1-2LC00024) - Kit provides Loss
of Charge sensor and wiring to provide safe shutdown of
compressor.
• Rectangle to Round (Horizontal) Adapter (S1-1AK0110, S1-1AK0111) - Kit includes one supply and
one return air rectangle to round duct adapter. Adapters are
preformed and designed to fit over current horizontal duct
openings on the base unit. Transition is from rectangle to 12"
round for the 1AK0110 kit and from rectangle to 14" round for
the 1AK0111 kit.
• Rectangle to Round (Downflow) Adapter (S1-1AK0108, S1-1AK0109) - Kit includes one supply and
one return air rectangle to round duct adapter. Adapters are
preformed and designed to fit into current downflow duct
openings on the roof curb. Transition is from rectangle to 16"
round for the 1AK0108 kit and from rectangle to 18" round for
the 1AK0109 kit.
• Roof Curbs (S1-1RC0503, S1-1RC0501) - NRCA approved
curbs provide proper fit to base unit for rooftop installations.
Curbs are designed to be assembled through hinge pins in
each corner. Kit also provides seal strip to assure an air tight
seal. These are 8 inch high roof curbs.
• Roof Curbs (S1-1RC0504, S1-1RC0502) - NRCA approved
curbs provide proper fit to base unit for rooftop installations.
Curbs are designed to be assembled through hinge pins in
each corner. Kit also provides seal strip to assure an air tight
seal. These are 14 inch high roof curbs.
• Transition Curb Kits (S1-1TC01*) - Adapter kits to allow
field use of pre-existing installed roof curbs to match PCG4
footprint to Affinity roof curbs, Carrier, Trane, or Goodman
curb footprints. Curb adapters are optional for current generation Carrier replacements but are recommended for previous generation applications. Refer to the PCG4 price pages
for more details.
• Manual Outdoor Damper (S1-1FA0502, S1-1FA0501) -
Provides 0% through 50% outdoor air capability (field adjustable). Designed for duct mounted side supply/return applications. Includes hood and screen assembly.
• Thermostat - Compatible thermostat controls are available
through accessory sourcing. For optimum performance,
these outdoor units are fully compatible with the Coleman
Hx™ Touchscreen Thermostat available through Source1.
For more information, see the thermostat section of the Product Equipment Catalog.
• Wall Thermostat - The units are designed to operate with
standard, 24-volt electronic and electro-mechanical thermostats. All units can operate with single stage heat/single
stage cool thermostats - with or without the economizer.
• Low Ambient Kit (S1-2LA04701024) - Kit provides necessary hardware to convert unit to operate in cooling cycle
down to 0º F. Standard unit operation 45º F.
• Base Rail Hole Cover Kit (S1-1HC0101) - Kit provides necessary hardware to close off openings in base rails to block
off openings, i.e. prevent animal entrance.
4Johnson Controls Unitary Products
5564041-CTG-A-1018
GUIDE SPECIFICATIONS
GENERAL
Units shall be manufactured by Unitary Products in an ISO
9001 certified facility. Package units give you the flexibility and
choices you need in today’s market. These packaged cooling/
heating air conditioners are designed for outdoor installation.
Only utility and duct connections are required at the point of
installation. The single-stage gas fired heaters have stainless
steel tubular heat exchangers and spark to burner ignition.
They are available in natural gas with field conversion to
propane.
DESCRIPTION
Units shall be factory-assembled, single packaged, Electric
Cooling/Gas Heating units, designed for outdoor installation.
For SEER ratings, refer to technical literature. They shall have
built in, equal size, field convertible duct connections for supply/
return or horizontal supply/return. The units shall be factory
wired, piped, charged with R-410A Refrigerant and factory
tested prior to shipment. All unit wiring shall be both numbered
and color coded. All models shall be rated in accordance with
DOE and AHRI test procedures for both heating and cooling
operation. Units shall be CSA listed and classified to ANSI
Z21.47/CAN/ CSA 2.3 standards and UL 1995/CAN/CSA No.
236-M90 standards.
UNIT CABINET
Unit cabinet shall be constructed of G-90 galvanized, powderpainted steel, certified at 1000 hours salt spray test per ASTMB117 standards. The unit top shall be a single piece design,
with drip edges and no-seam corners to provide optimum water
integrity. Unit shall have a rigidly mounted outdoor coil guard to
provide protection from objects and personnel after installation.
Indoor blower section shall be insulated with foil-faced or foam
insulation, fastened to prevent insulation from entering the air
stream. Cabinet panels shall be separate, easily removable for
servicing and maintenance. Unit shall be built on a formed,
design base pan, with embossments at critical points to add
strength and rigidity and to aid in minimizing sound. Full
perimeter base rails shall be provided to assure reliable transit
of equipment, overhead rigging, for truck access and proper
sealing on roof curb applications. Base rails shall be easily
removable, when required to lower unit height. Filters shall be
field installed, furnished and be accessible through a removable
access door, sealed airtight. Units vertical discharge and return
duct configuration shall be designed to fit between standard 24”
O.C. beams without modification to building structure, duct work
and base unit. Condensate pan shall be internally sloped and
conform to ASHRAE 62-89 self-draining standards, with 3/4”
NPT female ridged mount connection.
Indoor Blower Assembly - Fan shall be direct drive design.
Fan wheel shall be double-inlet type with forward-curved
blades, dynamically balanced to operate smoothly throughout
the entire range of operation. Airflow design shall be constant
air volume. Bearings shall be sealed and permanently
lubricated for longer life and no maintenance. Fan assembly
shall be a slide-out design for easy removal and cleaning.
Indoor blower motors shall be equipped with a standard high
efficiency brushless DC motor (constant torque) also known as
a standard ECM motor.
Outdoor Fan Assembly - The outdoor fan shall be of the
direct-driven propeller type, discharge air vertically, have
aluminum blades riveted to corrosion resistant steel spider
bracket and shall be statically balanced for smooth operation.
The outdoor fan motor shall be totally enclosed with
permanently lubricated bearings and internally protected
against overload conditions.
REFRIGERANT COMPONENTS
Compressors:
a. Shall be fully hermetic type, direct drive, internally pro-
tected with internal high-pressure relief and over temperature protection. The hermetic motor shall be suction gas
cooled and have a voltage range of +/- 10% of the unit
nameplate voltage.
b. Shall have internal isolation and sound muffling to mini-
mize vibration and noise, and be externally isolated on a
dedicated, independent mounting.
Coils:
a. Indoor coils shall have aluminum plate fins mechanically
bonded to seamless internally enhanced tin-coated copper tubes with all joints brazed.
b. Indoor coil shall be of the direct expansion, draw through
design.
c. Outdoor coils shall have aluminum plate fins mechanically
bonded to seamless internally enhanced copper tubes
with all joints brazed.
d. Outdoor coil shall be draw through design.
Refrigerant Circuit and Refrigerant Safety Components shall
include:
a. Thermal expansion devices (TXV's) shall be factory
mounted and provided.
b. Filter/strainer to eliminate any foreign matter.
GAS HEATING SECTION
Heat exchanger and exhaust system shall be constructed of
corrosion-resistant materials and shall be designed with
induced draft combustion with post purge logic and redundant
main gas valve. The heat exchanger shall be of the tubular
type, constructed of stainless steel for corrosion resistance and
allowing minimum mixed air entering temperature of 40ºF.
Burners shall be of the in-shot type, constructed of
aluminumized steel. All gas piping shall enter the unit cabinet at
a single location through either the side or bottom, without any
field modifications. An integrated control board shall provide
timed control of indoor fan functioning and burner ignition.
Heating section shall be provided with the following minimum
protection:
a. Primary high-temperature limit switch.
b. Induced draft pressure switch.
c. Flame roll out switch(s) (manual reset).
d. Flame proving controls.
All gas heat models will meet the California requirement for
emissions of less than 40 nanograms per Joule.
Johnson Controls Unitary Products5
5564041-CTG-A-1018
PHYSICAL DATA
COMPONENT
NOMINAL TONNAGE3.03.54.05.0
AHRI Cooling Performance
Gross Capacity @ AHRI A point (MBH)37.243.547.755.0
AHRI net capacity (MBH)34.641.045.552.5
EER11.011.011.011.0
SEER14.014.014.014.0
Nominal CFM1200140016002000
System power (KW)3.23.84.24.8
Refrigerant typeR410AR410AR410AR410A
Refrigerant charge (lb-oz)8-89-411-312-0
AHRI Gas Heat Performance
Heating model5075100751006510012565100125
Heat input (K Btu)50.075.0100.075.0100.065.0100.0125.065.0100.0125.0
Heat output (K Btu)406080608052801005280100
AFUE%81.081.081.081.081.081.081.081.081.081.081.0
No. burners23434234234
No. stages11111111111
Temperature Rise Range (°F)35-6540-7040-7040-7040-70
Max. Static Pressure w.c.0.50.50.50.5
Max. Outlet Air Temp. (°F)180180180180
Gas piping connection (in.)1/21/21/21/2
Face area (Sq. Ft.)15.116.919.521.5
Rows2222
Fins per inch22222222
Tube diameter 3/8 3/8 3/8 3/8
Circuitry TypeInterlacedInterlacedInterlacedInterlaced
Indoor Coil Data
Face area (Sq. Ft.)4.64.66.36.3
Rows3333
Fins per inch16161616
Tube diameter 3/8 3/8 3/8 3/8
Circuitry TypeInterlacedInterlacedInterlacedInterlaced
Refrigerant controlTXVTXVTXVTXV
Outdoor Fan Data
Fan diameter (Inch)24242626
TypePropPropPropProp
Drive typeDirectDirectDirectDirect
No. speeds1111
Motor HP each 1/4 1/4 1/3 1/3
RPM850850850850
Nominal total CFM2400240032003200
Direct Drive Indoor Fan Data
Fan Size (Inch)11 x 1011 x 1011 x 1011 x 10
TypeCentrifugalCentrifugalCentrifugalCentrifugal
Motor HP each 1/23/4 3/4 3/41
RPM1200 Max1200 Max1200 Max1200 Max
Frame size48484848
Filter
Filter SizeAABB
Field-supplied external filters must be sized so as not to exceed 300 fpm air velocity through disposable fil-
Quantity - Size
ters. For internal filter use, a filter rack kit is included with all three phase models. Consult the instructions
supplied with that kit for replacement filter sizes. Filter sizes: A=20x20, B=20x30.
PCG4A36PCG4A42PCG4B48PCG4B60
MODELS
6Johnson Controls Unitary Products
Loading...
+ 12 hidden pages
You need points to download manuals.
1 point = 1 manual.
You can buy points or you can get point for every manual you upload.