MDL Solutions PCG SERIES Setup guide

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SK2014 SON-002-TechMnl PCG(H)-V/P-EC-001(Americas)
SUPERIOR SERIES
INSTALLATION OPERATION AND SERVICE MANUAL
(AMERICAS VERSION)
PCG(H)-V/P~AECM SERIES
V ~ 2 pipe
P ~ 4 pipe

Page 2 of 98
SK2014 SON-002-TechMnl PCG(H)-V/P-EC-001(Americas)
INVESTING IN QUALITY, RELIABILITY & PERFORMANCE.
ISO 9001 QUALITY
World Leading Design and Technology
Every product is manufactured to meet
the stringent requirements of the
internationally recognized ISO 9001
standard for quality assurance in
design, development and production.
Equipped with the latest CAD/CAM computer aided
design and manufacturing technology, our factories
in China and Thailand produce over 2,000,000 air
conditioning units each year, all conforming to the
highest international standards of quality and safety.
CE SAFETY STANDARDS
The Highest Standards of Manufacturing
All products conform to the Certificate
Europe directives (Machinery Safety,
Electromagnetic Compatibility and Low
Voltage), as required throughout the
European Community, to guarantee
correct standards of safety.
In order to guarantee the very highest standards
and performance, we manage every stage in the
manufacturing of our products. Throughout the
production process we maintain strict control,
starting with our extensive resources in research
and development through to the design and
manufacture of almost every individual component,
from molded plastics to the assembly of units and
controllers.
WEEE MARK
Quality Controlled from Start to Finish
All products conform to the “WEEE”
directive to guarantee correct standards
of environmental solutions.
Our highly trained staff and strict quality control
methods enable us to produce products with an
exceptional reputation for reliability and efficiency,
maintained over many years. As well as full CE
certification and ISO 9001, several products have
UL/ ETL / CSA (NRTL) safety approval plus ARI
Certification in the USA and Canada, in addition to
ROHS compliance for Europe, giving you the
confidence of knowing our company is the right
choice when selecting air conditioning equipment.
ALWAYS MAKE SURE THIS MANUAL REMAINS WITH THE WATER CASSETTE. READ THIS MANUAL BEFORE
PERFORMING ANY OPERATION ON THE WATER CASSETTE.

Page 3 of 98
SK2014 SON-002-TechMnl PCG(H)-V/P-EC-001(Americas)
Table of Content
A. TECHNICAL DATA................................................................................................................................ 6
A.1. GENERAL SPECIFICATION .............................................................................................................................6
A.1.1. 2-Pipe Systems..............................................................................................................................6
A.1.2. 4-Pipe Systems..............................................................................................................................8
A.2. COIL DATA ................................................................................................................................................9
A.2.1. 2-Pipe Systems..............................................................................................................................9
A.2.2. 4-Pipe Systems..............................................................................................................................9
A.3. DIMENSIONAL DRAWINGS .........................................................................................................................10
A.4. VALVE INFORMATION................................................................................................................................21
A.4.1. 2-Way Valve Body...................................................................................................................... 21
A.4.2. 3-Way Valve Body...................................................................................................................... 21
B. SAFETY PRECAUTIONS...................................................................................................................... 22
B.1. INSTALLATION..........................................................................................................................................23
B.1.1. Standard Configurations and Accessories ................................................................................. 23
B.1.2. Operating Limits ........................................................................................................................ 24
B.1.3. Before Installation ..................................................................................................................... 24
B.1.4. Installation Location .................................................................................................................. 25
B.1.5. Installation and False Ceiling Clearance .................................................................................... 26
B.1.6. Pipe Works................................................................................................................................. 27
B.1.7. Water Connections .................................................................................................................... 27
B.1.8. Valve configurations .................................................................................................................. 27
B.1.9. External Drain Pan..................................................................................................................... 29
B.1.10. Fresh Air Renewal Connection ................................................................................................... 29
B.1.11. Branch Duct Connection ............................................................................................................ 32
B.1.12. Branch Duct Installation Procedure........................................................................................... 33
B.2. SUSPENSION BOLTS LAYOUT AND FALSE CEILING OPENING..............................................................................34
B.2.1. Suspension Structure ................................................................................................................. 36
B.2.2. Installation Procedure................................................................................................................ 37
B.3. INTERCONNECTING WIRING.......................................................................................................................40
B.3.1. Wiring procedures: .................................................................................................................... 40
B.3.2. Mounting Front Panel Assembly................................................................................................ 41
B.3.3. Filter Removal............................................................................................................................ 41
B.3.4. Getting Start-Up ........................................................................................................................ 42
B.4. MAINTENANCE........................................................................................................................................43
B.4.1. For Units Out Of Use for Extended Period. ................................................................................ 43
B.4.2. Extra Maintenance .................................................................................................................... 43
B.5. AIR VENT AND WATER PURGE....................................................................................................................44
B.6. REPLACING MOTOR AND FAN BLOWER........................................................................................................44
B.7. REPLACING CONDENSATE PUMP.................................................................................................................45
B.8. REPLACING CONTROL BOX.........................................................................................................................46
B.9. INSTALL ELECTRIC HEATER .........................................................................................................................47
C. CONTROL SPECIFICATIONS: SKUSA-NCGH-001-AECM......................................................................... 48
C.1. I/O PORT DEFINITIONS .............................................................................................................................48
C.2. WIRING DIAGRAM ...................................................................................................................................50
C.3. CONFIGURATION SETTINGS........................................................................................................................52
C.4. CONTROL LOGICS FOR 2-PIPE SYSTEM.........................................................................................................53
C.4.1. With Valve Configuration .......................................................................................................... 53
C.4.2. Without Valve Configuration..................................................................................................... 56
C.5. CONTROL LOGICS FOR 4-PIPE SYSTEM.........................................................................................................59
C.6. SLEEP MODE...........................................................................................................................................61
C.7. AUTO FAN SPEED.....................................................................................................................................62
C.8. MODULATING VALVE CONTROL UNDER ENERGY SAVING MODE.......................................................................62

Page 4 of 98
SK2014 SON-002-TechMnl PCG(H)-V/P-EC-001(Americas)
C.9. SWING /LOUVER.....................................................................................................................................62
C.10. BUZZER ..................................................................................................................................................63
C.11. AUTO RESTART ........................................................................................................................................63
C.12. ON/OFF SWITCH ON THE FRONT PANEL......................................................................................................63
C.13. DRAIN PUMP ..........................................................................................................................................63
C.14. FLOAT SWITCH.........................................................................................................................................64
C.15. ELECTRIC HEATER SAFETY SWITCH ..............................................................................................................64
C.16. LED INDICATION AND ERROR DESCRIPTION ..................................................................................................65
C.17. LED INDICATION ON MASTER/SLAVE CONNECTION .......................................................................................66
D. NETWORKING SYSTEM ..................................................................................................................... 67
D.1. MASTER-SLAVE NETWORK ........................................................................................................................67
D.1.1. Master –Slave Network Setup .................................................................................................. 68
D.1.2. Master-Slave Communication Method...................................................................................... 71
D.2. OPEN MODBUS PROTOCOL........................................................................................................................72
E. CONTROL SPECIFICATIONS: SKUSA-NCGH-002/003-AECM.................................................................. 76
E.1. FEATURES ...............................................................................................................................................76
E.2. I/O PORT DEFINITIONS .............................................................................................................................76
E.3. ONBOARD CONFIGURATION .......................................................................................................................77
E.4. WIRING DIAGRAMS..................................................................................................................................78
E.4.1. SKUSA-NCGH-002-AECM ........................................................................................................... 78
E.4.2. SKUSA-NCGH-003-AECM ........................................................................................................... 79
E.4.3. Zone control wiring diagram 1 (ON/OFF thermostat) ............................................................... 80
E.4.4. Zone control wiring diagram 2 (Modulating signal thermostat)............................................... 81
E.5. CONTROL LOGIC SPECIFICATION ..................................................................................................................82
E.5.1. Unit power ON/OFF ................................................................................................................... 82
E.5.2. Alarm protection and error display ........................................................................................... 82
E.5.3. Drain-pump run management................................................................................................... 82
E.5.4. Swing and louver control ........................................................................................................... 82
E.5.5. Modulating signal input ............................................................................................................ 82
E.6. LED INDICATION AND ERROR DESCRIPTION ..................................................................................................83
F. USER INTERFACE .............................................................................................................................. 84
F.1. REMOTE HANDSET ...................................................................................................................................84
F.2. WIRED WALL PAD....................................................................................................................................85
F.2.1. Wall Pad Operation Guidelines.................................................................................................. 86
F.2.2. EC unit RPM setting ................................................................................................................... 89
G. SENSOR RESISTANCE R-T CONVERSION TABLE ................................................................................... 90
H. TROUBLESHOOTING GUIDE .............................................................................................................. 92
I. EXPLODED DIAGRAMS & SUB-ASSEMBLY DESCRIPTIONS ................................................................... 93
I.1. EXPLODED VIEW FOR SINGLE FAN MODEL....................................................................................................93
I.1.1. Spare Parts Of Single Fan Model ............................................................................................... 94
I.2. EXPLODED VIEW FOR TWIN FAN MODEL......................................................................................................95
I.2.1. Spare Parts Of Twin Fan Model ................................................................................................. 96
I.3. OPTIONAL PARTS .....................................................................................................................................96
I.4. ACCESSORIES...........................................................................................................................................97

Page 5 of 98
SK2014 SON-002-TechMnl PCG(H)-V/P-EC-001(Americas)
Model Code Nomenclature
PCG
-
04
-
V
X
-
S
-
AECM
AECM
EC motor configuration
for Americas
S
Complete function integrated
control, compatible with IR
handset controller, wired
wall-pad, serial networking for
master-slave and MODBUS BMS
functionality
W
Flexible function control for
external thermostat applications
with control of drain pump,
louvers and zone control product
operations
X
No control box pre-installed, for
on demand plug and play of Total
Control or Flex Control option
X
220V EC motor
Y
115V EC motor
P
Chilled/Hot Water, 4-Pipe
V
Chilled/Hot Water, 2-Pipe
VEH
Chilled Water, 2-Pipe with
Electric Heater
04–16
(for PCG)
Unit Sizes. See General
Specification section A for
cooling and heating capacities
12–20
(for PCH)
PCG
Hydronic Cassette G Series
PCH
Hydronic Cassette H Series

Page 6 of 98
SK2014 SON-002-TechMnl PCG(H)-V/P-EC-001(Americas)
A. Technical Data
A.1. General Specification
A.1.1. 2-Pipe Systems
Product range: PCG(H) -AECM Flexi Hydronic Cassette with EC Motor
PCG(H)-V~-AECM Hydronic Cassette 2-pipe with EC Motor (Americas Version)
PCG(H)-[Size]-V~-AECM
PCG-04R
PCG-08
PCG-08R
PCG-09
Unit Configuration
Configuration
2-pipe
Number Of Fan Blowers
Single
Twin
Power Supply
(V/Ph/Hz)
115/1/60
220/1/60
Operation Control - PCG(H)
~S: Complete function onboard PCB with integrated group control functionality, incl. 1 pc return air
sensor and 2 pcs temperature sensors.
~W: Limited function onboard PCB with drain-pump, louver and zone control functionality, incl. 1 pc coil
temperature sensor.
~X: No control box pre-installed.
Performance Data
Air
Total Air Flow
H
CFM
338
476
476
600
M
235
306
306
318
L
118
118
118
212
Cooling
Cooling Capacity
H
BTU/Hr
11348
16019
16857
20850
M
8129
11200
11742
12341
L
4721
5051
10372
8799
Sensible Cooling Capacity
H
7702
10802
11208
13999
M
5466
7486
7751
8184
L
3129
3315
6830
5791
Heating
Heating Capacity
H
BTU/Hr
17105
23840
24436
30813
M
12089
16453
16831
17898
L
6867
7204
14809
12605
Max. Electric Heater Capacity @ 115V
1700
3400
5100
Max. Electric Heater Capacity @ 202V
3400
6800
10200
Sound
Sound Pressure Level ( Outlet )
dB(A)
38/35/27
46/35/24
46/35/24
42/34/26
Sound Power Level ( Outlet )
52/45/38
60/45/35
60/45/35
50/41/37
Electrical
Fan Motor Power
H
W
30
40
40
60
M
9
18
18
24
L
8
8
8
16
Fan Motor Apparent Power @ H
60
80
80
120
Fan Motor Running Current @
115V
H
A
0.26
0.35
0.35
0.52
Fan Motor Running Current @
220V
H
0.14
0.18
0.18
0.27
Hydraulic
Cooling Water Flow Rate
H
GPM
2.262
3.188
3.36
4.15
M
1.616
2.233
2.341
2.456
L
0.941
1.005
2.068
1.752
Cooling Pressure Drop
H
Ft.wg
3.498
7.943
11.373
7.379
M
1.979
4.288
6.115
3.001
L
0.487
0.654
4.942
1.686
Heating Water Flow Rate
@H/M/L
GPM
Same as "Cooling Water Flow Rate"
Heating Pressure Drop
H
Ft.wg
2.753
6.319
8.981
5.867
M
1.537
3.362
4.762
2.347
L
0.51
0.846
3.836
1.3
Water Content
Gal
0.33
0.41
0.36
0.58
Construction and Packing
Data
Water
Connections
Type
Socket (Threaded Female)
In
in.
3/4”
Out
Condensate Drainage Connection
Dimensions
L
in.
22.6
44.9
W
22.6
22.8
H
10.0
11.4
10.0
Panel Dimensions
26.8 x 26.8 x 1.1
26.8 x 48.8 x 1.1
Net Weight
lbs
61.7
66.1
72.8
110
a. Cooling mode (2-pipe):
b. Heating mode (2-pipe):
- Return air temperature: 80F DB/ 67F WB..
- Return air temperature: 70F
- Inlet/ Outlet water temperature: 45F/55F.
- Inlet water temperature: 140F.
- Water flow-rate: same as 2-pipe cooling.

Page 7 of 98
SK2014 SON-002-TechMnl PCG(H)-V/P-EC-001(Americas)
Product range: PCG(H) -AECM Flexi Hydronic Cassette with EC Motor
PCG(H)-V~-AECM Hydronic Cassette 2-pipe with EC Motor (Americas Version)
PCG(H)-[Size]-V~-AECM
PCG-16
PCH-12
PCH-20
Unit Configuration
Configuration
2-pipe
Number Of Fan Blowers
Twin
Single
Power Supply
(V/Ph/Hz)
115/1/60
220/1/60
Operation Control - PCG(H)
~S: Complete function onboard PCB with integrated group control functionality, incl. 1
pc return air sensor and 2 pcs temperature sensors.
~W: Limited function onboard PCB with drain-pump, louver and zone control
functionality, incl. 1 pc coil temperature sensor.
~X: No control box pre-installed.
Performance Data
Air
Total Air Flow
H
CFM
853
765
1240
M
536
483
812
L
212
212
483
Cooling
Cooling Capacity
H
BTU/Hr
28882
23678
38241
M
19798
16376
29869
L
17385
8352
17164
Sensible Cooling Capacity
H
19440
16165
36426
M
13207
11081
20488
L
11562
5553
11586
Heating
Heating Capacity
H
BTU/Hr
42839
35968
59135
M
28973
24554
45725
L
25323
12196
25687
Max. Electric Heater Capacity @ 115V
5100
6800
Max. Electric Heater Capacity @ 220V
10200
13600
Sound
Sound Pressure Level ( Outlet )
dB(A)
48/37/26
50/40/28
54/45/30
Sound Power Level ( Outlet )
63/47/37
67/53/39
66/58/42
Electrical
Fan Motor Power
H
W
80
88
200
M
52
32
61
L
16
20
22
Fan Motor Apparent Power @ H
240
144
362
Fan Motor Running Current @ 115V
H
A
0.70
0.77
1.74
Fan Motor Running Current @ 220V
H
0.36
0.40
0.91
Hydraulic
Cooling Water Flow Rate
H
GPM
5.751
4.71
7.611
M
3.942
3.26
5.945
L
3.461
1.666
3.418
Cooling Pressure Drop
H
Ft.wg
8.846
7.785
7.785
M
4.604
4.13
5.077
L
3.678
1.307
1.959
Heating Water Flow Rate
@H/M/L
GPM
Same as "Cooling Water Flow Rate"
Heating Pressure Drop
H
Ft.wg
7.041
6.206
6.228
M
3.633
3.25
4.017
L
2.888
1.006
1.525
Water Content
Gal
0.73
0.47
0.63
Construction and Packing
Data
Water
Connections
Type
Socket (Threaded Female)
In
in.
3/4"
Out
Condensate Drainage Connection
Dimensions
L
in.
44.9
28.7
32.7
W
22.8
28.7
32.7
H
10.0
10.2
11.4
Panel Dimensions
26.8 x 48.8 x 1.1
32.7 x 32.7 x 1.1
38.6 x 38.6 x 1.1
Net Weight
lbs
115
79.4
110
a. Cooling mode (2-pipe):
b. Heating mode (2-pipe):
- Return air temperature: 80F DB/ 67F WB
- Return air temperature: 70F.
- Inlet/ Outlet water temperature: 45F/55F.
- Inlet water temperature: 140F.
- Water flow-rate: same as 2-pipe cooling.

Page 8 of 98
SK2014 SON-002-TechMnl PCG(H)-V/P-EC-001(Americas)
A.1.2. 4-Pipe Systems
Product range: PCG(H) -AECM Flexi Hydronic Cassette with EC Motor
PCG(H)-P~-AECM Hydronic Cassette 4-pipe with EC Motor (Americas Version)
PCG(H)-[Size]-P~-AECM
PCG-08
PCG-09
PCG-16
PCH-12
PCH-20
Unit Configuration
Configuration
4-pipe
Number Of Fan Blowers
Single
Twin
Single
Power Supply
(V/Ph/Hz)
115/1/60
220/1/60
Operation Control - PCG(H)
~S: Complete function onboard PCB with integrated group control functionality, incl. 1 pc return air sensor and 2 pcs temperature
sensors.
~W: Limited function onboard PCB with drain-pump, louver and zone control functionality, incl. 1 pc coil temperature sensor.
~X: No control box pre-installed.
Performance Data
Air
Total Air Flow
H
CFM
477
600
853
765
1240
M
306
318
536
483
812
L
118
212
212
212
483
Cooling
Cooling Capacity
H
BTU/Hr
13020
14451
21393
19707
26817
M
9720
8885
15011
13822
23060
L
8225
6498
12614
12201
18104
Sensible Cooling
Capacity
H
8997
9943
14793
13621
18777
M
6662
6047
10286
9465
16072
L
5612
4392
8666
8329
12527
Heating
Heating Capacity
H
BTU/Hr
15289
26600
30446
17993
34859
M
12895
16404
21665
17224
32083
L
11764
12030
19281
12393
27395
Max. Electric Heater Capacity @
115V
3400
5100
6800
Max. Electric Heater Capacity @
220V
6800
10200
13600
Sound
Sound PressureLevel ( Outlet )
dB(A)
46/37/24
48/34/26
48/37/26
50/40/28
54/45/30
Sound Power Level ( Outlet )
60/49/35
50/41/37
63/47/37
65/53/39
66/58/42
Electrical
Fan Motor Power
H
W
40
60
80
88
200
M
18
24
40
32
61
L
8
16
16
20
22
Fan Motor Apparent Power @ H
80
120
240
144
362
Fan Motor Running
Current @ 115V
H
A
0.35
0.52
0.70
0.77
1.74
Fan Motor Running
Current @ 220V
H
0.18
0.27
0.36
0.40
0.91
Hydraulic
Cooling Water Flow
Rate
H
GPM
2.592
2.879
4.258
3.927
5.342
M
1.939
1.766
2.987
2.75
4.595
L
1.637
1.292
2.513
2.427
3.604
Cooling Pressure
Drop
H
Ft.wg
4.152
5.551
3.949
9.297
5.168
M
2.505
2.415
2.144
5.032
3.994
L
1.891
1.417
1.487
4.062
2.64
Heating Water Flow
Rate
H
GPM
0.761
1.321
1.587
0.898
1.738
M
0.642
0.819
1.077
0.854
1.601
L
0.586
0.599
0.962
0.617
1.364
Heating Pressure
Drop
H
Ft.wg
0.361
0.616
0.781
0.465
0.878
M
0.269
0.266
0.431
0.431
0.758
L
0.23
0.157
0.352
0.244
0.575
Water Content
Chilled
Water
Gal
0.28
0.36
0.51
0.36
0.44
Hot
Water
0.13
0.23
0.23
0.11
0.2
Construction and Packing Data
Water
Connections
Type
Socket (Threaded Female)
In
in.
3/4"
Out
Condensate Drainage
Connection
Dimensions
L
in.
22.6
44.9
28.7
32.7
W
22.6
22.8
28.7
32.7
H
11.4
10.0
11.4
10.2
11.4
Panel Dimensions
26.8 x 26.8 x 1.1
26.8 x 48.8 x 1.1
32.7 x 32.7 x 1.1
38.6 x 28.6 x 1.1
Net Weight
lbs
66.1
110
115
79.4
110
:
a. Cooling mode (4-pipe):
b. Heating mode (4-pipe):
- Return air temperature: 80F DB/ 67F WB.
- Return air temperature: 70F.
- Inlet/ Outlet water temperature: 45F/55F.
- Inlet/ outlet water temperature: 180F/140F.

Page 9 of 98
SK2014 SON-002-TechMnl PCG(H)-V/P-EC-001(Americas)
A.2. Coil Data
A.2.1. 2-Pipe Systems
Model
Fin Height
(inch)
Fin Length (inch)
Fins / inch
No. of rows
No. of
circuits
Tube
Diameter
(inch)
Inner
Outer
PCG-04R-V
7.9
47.1
51.1
13
2
3
3/8”
PCG-08-V
9.8
47.1
51.1
13
2
3
3/8”
PCG-08R-V
9.8
47.1
51.1
13
3
5
0.276”
PCG-09-V
7.9
84.6
90.0
13
2
4
3/8”
PCG-16-V
9.8
84.6
90.0
13
2
5
3/8”
PCH-12-V
8.7
60.2
64.3
13
2
4
3/8”
PCH-20-V
9.8
73.8
77.9
13
2
6
3/8”
A.2.2. 4-Pipe Systems
Cooling Coil
Model
Fin Height
(inch)
Fin Length (inch)
Fins / inch
No. of rows
No. of
circuits
Tube
Diameter
(inch)
Inner
Outer
PCG-08-P
9.8
47.1
51.1
13
2
3
3/8”
PCG-09-P
7.9
84.6
90.0
13
2
3
3/8”
PCG-16-P
9.8
84.6
90.0
13
2
5
3/8”
PCH-12-P
8.9
60.2
64.3
13
2
3
3/8”
PCH-20-P
9.8
73.8
77.9
13
2
5
3/8”
Heating Coil
Model
Fin Height
(inch)
Fin Length (inch)
Fins / inch
No. of rows
No. of
circuits
Tube
Diameter
(inch)
Inner
Outer
PCG-08-P
9.8
47.1
51.1
13
1
3
3/8”
PCG-09-P
7.9
84.6
90.0
13
1
3
3/8”
PCG-16-P
9.8
84.6
90.0
13
1
3
3/8”
PCH-12-P
8.7
60.2
64.3
13
1
2
3/8”
PCH-20-P
9.8
73.8
77.9
13
1
3
3/8”

Page 10 of 98
SK2014 SON-002-TechMnl PCG(H)-V/P-EC-001(Americas)
A.3. Dimensional Drawings
Dimensional Drawings: PCG-04R-V
(All dimensions in inch.)