Johnson Controls PCG4A30, PCG4A24, PCG4B60, PCG4B48, PCG4A42 Installation Manual

®

INSTALLATION MANUAL

SINGLE PACKAGE

AIR CONDITIONER/GAS HEAT

MODELS: PCG4 Series
(2-5 Ton)

LIST OF SECTIONS

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

MODEL NUMBER NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . 2

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

LIST OF FIGURES

Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Center of Gravity Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Bottom Duct Dimensions (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Rear Duct Dimensions (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Typical Field Control Wiring Diagram For Gas Heat - AC Models . . . 7

Typical Field Power Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 7

Flue Vent Outlet Air Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

AIRFLOW PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

TYPICAL WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

START UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Measuring External Static Pressure . . . . . . . . . . . . . . . . . . . . . . . . .18

Connection Wiring Diagram - 2 to 3 Ton Models . . . . . . . . . . . . . . .19

Ladder Wiring Diagram - 2 to 3 Ton Models . . . . . . . . . . . . . . . . . . .20

Connection Wiring Diagram - 3.5 to 5 Ton Models . . . . . . . . . . . . . .21

Ladder Wiring Diagram - 3.5 to 5 Ton Models . . . . . . . . . . . . . . . . .22

R-410A Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

LIST OF TABLES

Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Unit Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Natural Gas Pipe Sizing Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Propane (LP) Gas Pipe Sizing Chart . . . . . . . . . . . . . . . . . . . . . . . . . 9

SECTION I: GENERAL INFORMATION

These are electric cooling/gas heating units designed for outdoor instal­lation. 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 potential for personal
injury.

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 dam­age.

Natural Gas Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Propane (LP) Gas Application Data . . . . . . . . . . . . . . . . . . . . . . . . .10

Airflow - Side Duct Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Airflow - Bottom Duct Application . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Ignition Control Board Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . .16

Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

!

WARNING

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 maintenance
can cause injury or property damage. Failure to carefully read and

follow all instructions in this manual can result in furnace mal­function, death, personal injury and/or property damage. Only a

qualified contractor, installer or service agency should install this
product.

!

CAUTION

This product must be installed in strict compliance with the installa­tion instructions and any applicable local, state, and national codes
including, but not limited to building, electrical, and mechanical
codes.

Johnson Controls Unitary Products 1183746-UIM-D-1015

1183746-UIM-D-1015

!

WARNING

Before performing service or maintenance operations on unit, turn off
main power switch to unit. Electrical shock could cause personal
injury. Improper installation, adjustment, alteration, service or mainte­nance can cause injury or property damage. Refer to this manual.
For assistance or additional information consult a qualified installer,
service agency or the gas supplier.

!

CAUTION

This system uses R-410A Refrigerant which operates at higher pres­sures 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 equip­ment manufacturer. Failure to use R-410A compatible servicing
equipment may result in property damage or injury.

!

WARNING

If the information in this manual is not followed exactly, a fire or
explosion may result causing property damage, personal injury or
loss of life.
Do not store or use gasoline or other flammable vapors and liquids in
the vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS:

1. Do not try to light any appliance.

2. Do not touch any electrical switch; do not use any phone in
your building.

3. Immediately call your gas supplier from a neighbor’s phone.
Follow the gas supplier’s instructions.

4. If you cannot reach your gas supplier, call the fire depart­ment.

Installation and service must be performed by a qualified installer,
service agency or the gas supplier.

Due to system pressure, moving parts, and electrical components,
installation and servicing of air conditioning equipment can be hazard­ous. Only qualified, trained service personnel should install, repair, or
service this equipment. Untrained personnel can perform basic mainte­nance functions of cleaning coils and filters and replacing filters.

Observe all precautions in the literature, labels, and tags accompanying
the equipment whenever working on air conditioning equipment. Be
sure to follow all other applicable safety precautions and codes includ­ing ANSI Z223.1 or CSA-B149.1- latest edition.

Wear safety glasses and work gloves. Use quenching cloth and have a
fire extinguisher available during brazing operations.

SECTION III: MODEL NUMBER NOMENCLATURE

PCG 4 A 24 50 2 X 1 A

123456789

1. Model Family

PCG - packaged A/C with gas heat,
PHG - packaged heat pump with gas heat,
PCE - packaged A/C with electric heat,
PHE - packaged heat pump with electric heat

2. Nominal Cooling Efficiency
4 = 14 SEER, 6 = 16 SEER, etc.

3. Cabinet Size

A = small 35 x 51, B = large 45 x 51

4. Nominal Air Conditioning Cooling Capacity BTUx1000

24 = 24,000 BTU, etc.

Examples:

PCG4B421002X1A is a packaged A/C with gas heat, 14 SEER, 3-1/2 ton, large cabinet, single-stage heat, 100,000 BTU gas heat, 230 volt, single
phase, low-NOx model (first generation, first release)

SECTION IV: INSTALLATION

INSTALLATION SAFETY INFORMATION

Read these instructions before continuing this appliance installation.
This is an outdoor combination heating and cooling unit. The installer
must assure that these instructions are made available to the consumer
with instructions to retain them for future reference.

1. Refer to the unit rating plate for the approved type of gas for this
product.

2. Install this unit only in a location and position as specified on Page
4 of these instructions.

3. Never test for gas leaks with an open flame. Use commercially
available soap solution made specifically for the detection of leaks
when checking all connections, as specified on Page 10 of these
instructions.

5. Gas Heating Input BTU/Hr x 1000

050 = 50,000 BTU/Hr. input, blank = electric heat

6. Voltage-Phase-Frequency

2 = 208/230-1-60, 3=208/230-3-60, 4 = 460-3-60

7. NOx Approval

X = low-NOx, blank = not low-Nox

8. Generation Level

1 = first generation

9. Revision Level

A = original release, B = second release

4. Always install unit to operate within the unit's intended temperature­rise range with the duct system and within the allowable external
static pressure range, as specified on the unit name/rating plate,
specified in Table 6 of these instructions.

5. This equipment is not to be used for temporary heating of buildings
or structures under construction.

!

WARNING

FIRE OR EXPLOSION HAZARD

Failure to follow the safety warning exactly could result in serious
injury, death or property damage.
Never test for gas leaks with an open flame. use a commercially
available soap solution made specifically for the detection of leaks to
check all connections. A fire or explosion may result causing property
damage, personal injury or loss of life.

2 Johnson Controls Unitary Products

1183746-UIM-D-1015

LIMITATIONS

These units must be installed in accordance with the following:

In U.S.A.:

1. National Electrical Code, ANSI/NFPA No. 70 - Latest Edition

2. National Fuel Gas Code, ANSI Z223.1 - Latest Edition

3. Gas-Fired Central Furnace Standard, ANSI Z21.47a. - Latest Edi­tion

4. Local building codes, and

5. Local gas utility requirements

In Canada:

1. Canadian Electrical Code, CSA C22.1

2. Installation Codes, CSA - B149.1.

3. Local plumbing and waste water codes, and

4. Other applicable local codes.
Refer to unit application data found in this document.

After installation, gas fired units must be adjusted to obtain a temperature
rise within the range specified on the unit rating plate.

If components are to be added to a unit to meet local codes, they are to
be installed at the dealer’s and/or customer’s expense.

Size of unit for proposed installation should be based on heat loss/heat
gain calculation made according to the methods of Air Conditioning
Contractors of America (ACCA).

This furnace is not to be used for temporary heating of buildings or
structures under construction.

FAN MOTOR

OUTDOOR FAN

COIL GUARD PANEL

OUTDOOR COIL
(Behind Panel)

BLOWER MOTOR

TXV

INDOOR COIL

INDOOR BLOWER

COMPRESSOR

REMOVABLE
BASE RAILS

FIGURE 1: Component Location
Table 1: Unit Limitations

Model Unit Voltage

24 208/230-1-60 187 252 125
30 208/230-1-60 187 252 125
36 208/230-1-60 187 252 125
42 208/230-1-60 187 252 125
48 208/230-1-60 187 252 125
60 208/230-1-60 187 252 125

CONTROL BOARD

TRANSFORMER

HIGH VOLTAGE
CONTACTOR

PRESSURE SWITCH

DRAFT INDUCER BLOWER

GAS VALVE

GAS HEAT
EXCHANGER

BURNER
ASSEMBLY

A0297-001

Unit Limitations

Applied Voltage Outdoor DB Temp

Min Max Max (°F)

Johnson Controls Unitary Products 3

1183746-UIM-D-1015

LOCATION

Use the following guidelines to select a suitable location for these units:

1. Unit is designed for

2. Condenser coils must have an unlimited supply of air. Where a
choice of location is possible, position the unit on either north or
east side of building.

3. Suitable for mounting on roof curb.

Do not attach supply and return duct work to the bottom of the unit
base pan as the drain pan could be compromised.

4. For ground level installation, a level pad or slab should be used.
The thickness and size of the pad or slab used should meet local
codes and unit weight. Do not tie the slab to the building foundation.

5. Roof structures must be able to support the weight of the unit and
its options/accessories. Unit must be installed on a solid, level roof
curb or appropriate angle iron frame.

6. Maintain level tolerance to 1/8” across the entire width and length of
unit.

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 softening chemicals,
carbon tetrachloride, Halogen type refrigerants, cleaning solvents
(e.g. perchloroethylene), printing inks, paint removers, varnishes,
hydrochloric acid, cements and glues, anti-static fabric softeners for
clothes dryers, masonry acid washing materials.

outdoor installation only.

!

WARNING

!

WARNING

CLEARANCES

All units require particular clearances for proper operation and service.
Installer must make provisions for adequate combustion and ventilation
air in accordance with section 5.3 of Air for Combustion and Ventilation
of the National Fuel Gas Code, ANSI Z223.1 – Latest Edition (in
U.S.A.), or Sections 7.2, 7.3, or 7.4 of Gas Installation Codes, CSA­B149.1 (in Canada) - Latest Edition, and/or applicable provisions of the
local building codes. Refer to Table 4 for clearances required for com­bustible construction, servicing, and proper unit operation.

!

WARNING

Do not permit overhanging structures or shrubs to obstruct con­denser air discharge outlet, combustion air inlet or vent outlets.

RIGGING AND HANDLING

Exercise care when moving the unit. Do not remove any packaging until
the unit is near the place of installation. Rig the unit by attaching chain
or cable slings to the lifting holes provided in the base rails. Spreader
bars, whose length exceeds the largest dimension across the unit,

MUST be used across the top of the unit.

!

CAUTION

Before lifting, make sure the unit weight is distributed equally on the
rigging cables so it will lift evenly.

Units may be moved or lifted with a forklift. Slotted openings in the base
rails are provided for this purpose.

!

CAUTION

If a unit is to be installed on a roof curb other than a Unitary Products
roof curb, gasket or sealant must be applied to all surfaces that come
in contact with the unit underside.

!

CAUTION

All panels must be secured in place when the unit is lifted.
The condenser coils should be protected from rigging cable damage
with plywood or other suitable material.

"D"

CENTER OF

COMPRESSOR

"A"

FRONT
OF UNIT

X

FIGURE 2: Center of Gravity Location

"B"

GRAVITY

"C"

Y

A0295-001

Table 2: Weights and Dimensions

Model Weight (lbs.) Center of Gravity 4 Point Load Location (lbs.)

Shipping Operating X Y ABCD

24050 372 367 28 15 120 95 81 71
24075 382 377 28 15 124 96 81 76
30050 417 412 28 15 139 99 90 84
30075 421 416 28 15 146 93 82 95
36050 425 420 28 15 141 107 94 78
36075 432 427 28 15 135 115 103 74
36100 436 431 28 15 139 113 99 80
42075 446 441 28 15 145 112 99 85
42100 448 443 28 15 148 110 96 89
48065 520 515 28 15 189 116 93 117
48100 528 523 28 15 169 139 115 100
48125 533 528 28 15 164 145 124 95
60065 537 532 29 15 174 142 124 92
60100 541 536 28 15 177 140 117 102
60125 548 543 27 15 151 167 141 84

4 Johnson Controls Unitary Products

HIGH VOLTAGE
CONNECTION 7/8”

HIGH VOLTAGE
CONNECTION 1-3/32”

COMPRESSOR
ACCESS PANEL

1183746-UIM-D-1015

COIL GUARD

C

COMBUSTION AIR INTAKE

HEAT EXCHANGER ACCESS PANEL

EXHAUST HOOD

CONDENSATE
DRAIN

BLOWER
ACCESS
PANEL

CONTROL ACCESS
PANEL

A

B

LOW VOLTAGE CONNECTION

GAS SUPPLY

FIGURE 3: Unit Dimensions

Table 3: Unit Dimensions

Model

ABC

Dimensions

24 51-1/4 35-3/4 47
30 51-1/4 35-3/4 47
36 51-1/4 35-3/4 47
42 51-1/4 35-3/4 49
48 51-1/4 45-3/4 53
60 51-1/4 45-3/4 55

Table 4: Unit Clearances

1,2

Direction Distance (in.) Direction Distance (in.)

3

Top

36 Power Entry (Right Side) 36

Side Opposite Ducts 36 Left Side 24

Duct Panel 0 Bottom

1. A 1" clearance must be provided between any combustible material and the supply air duct work.

2. The products of combustion must not be allowed to accumulate within a confined space and recirculate.

3. Units must be installed outdoors. Over hanging structure or shrubs should not obstruct condenser air discharge outlet.

4. Units may be installed on combustible floors made from class A, B or C roof covering materials.

4

1

A0296-001

Johnson Controls Unitary Products 5

1183746-UIM-D-1015

D

C

A

B

A

Model A B C D E F

24, 30, 36, 42 10 21.5 5 4.5 47.5 32

48, 60 14 13.5 5 3.5 47.5 42

FIGURE 4: Bottom Duct Dimensions (inches)

16

RETURN
AIR DUCT

SUPPLY
AIR DUCT

E

F

A0298-001

Duct work should be designed and sized according to the methods of
the Air Conditioning Contractors of America (ACCA), as set forth in their
Manual D.

A closed return duct system shall be used. This shall not preclude use
of economizers or ventilation air intake. Flexible joints are recom­mended to be used in the supply and return duct work to minimize the
transmission of vibration and noise.

NOTICE

Be sure to note supply and return openings.

Refer to Figures 5 and 6 for information concerning rear and bottom
supply and return air duct openings.

FILTERS

Proper filter size is very important. Filter size, type and pressure drop
should always be considered during duct system design.

Single phase units are 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.
Filters must always be used and must be kept clean. When filters

become dirt laden, insufficient air will be delivered by the blower,
decreasing your units efficiency and increasing operating costs and
wear-and-tear on the unit and controls.

Filters should be checked monthly; this is especially important since this
unit is used for both heating and cooling.

CONDENSATE DRAIN

A condensate trap must be installed in the condensate drain. The
plumbing must conform to local codes.

DO NOT use Teflon tape or Pipe thread compound.

SUPPLY

15.6

6

A0299-001

Model A B

24, 30, 36, 42 9.6 22

48, 60 13.6 14

FIGURE 5: Rear Duct Dimensions (inches)

AIR DUCT

A

B

RETURN
AIR DUCT

A

4.3

DUCTWORK

These units are adaptable to downflow use as well as rear supply and
return air duct openings. To convert to downflow, use the following
steps:

1. Remove the duct covers found in the bottom return and supply air
duct openings.

2. Install the duct covers (removed in step one) to the rear supply and
return air duct openings.

3. Seal duct covers with silicone caulk.

!

CAUTION

Hand tighten only.

SERVICE ACCESS

Access to all serviceable components is provided at the following loca­tions:

• Coil guards

• Unit top panel

• Corner posts

• Blower access panel

• Control access panel

• Indoor coil access panel

• Compressor access panel

• Heat exchanger access panel

Refer to Figure 4 for location of these access locations and minimum
clearances in Table 4.

!

CAUTION

This system uses R-410A Refrigerant which operates at higher pres­sures 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 equip­ment manufacturer. Failure to use R-410A compatible servicing
equipment may result in property damage or injury.

!

WARNING

Wear safety glasses and gloves when handling refrigerants. Failure
to follow this warning can cause serious personal injury.

Refer to Figure 14 for the R-410A Quick Reference Guide.

6 Johnson Controls Unitary Products

1183746-UIM-D-1015

THERMOSTAT

The room thermostat should be located on an inside wall approximately
60" above the floor where it will not be subject to drafts, sun exposure or
heat from electrical fixtures or appliances. Sealant should be used
behind thermostat to prevent air infiltration. Follow manufacturer's
instructions enclosed with the thermostat for general installation proce­dure. Color coded insulated wires (minimum #18 AWG) should be used
to connect thermostat to unit. See Figure 6. Do not use power stealing
thermostats.

POWER AND CONTROL WIRING

Field wiring to the unit must conform to provisions of the current N.E.C.

ANSI/NFPA No. 70 or C.E.C. and/or local ordinances. The unit must be

electrically grounded in accordance with local codes or, in their
absence, with the N.E.C./C.E.C. Voltage tolerances which must be
maintained at the compressor terminals during starting and running
conditions are indicated on the unit Rating Plate and Table 1.

The wiring entering the cabinet must be provided with mechanical strain
relief.

A fused disconnect switch should be field provided for the unit. If any of

the wire supplied with the unit must be replaced, replacement wire must
be of the type shown on the wiring diagram.

Electrical service must be sized properly to carry the load. Each unit
must be wired with a separate branch circuit fed directly from the main
distribution panel and properly fused.

Refer to Figures 6 and 7 for typical field wiring and to the appropriate
unit wiring diagram for control circuit and power wiring information.

Minimum wire size of 18 AWG wire should be used for all field
installed control wiring.

THERMOSTAT

R

G

Y

W

C

NOTE:

Heat Anticipator should be set at 0.35 AMPS for all models

RED

GREEN

YELLOW

WHITE

BLUE

CONTROL

BOARD

A0294-001

FIGURE 6: Typical Field Control Wiring Diagram For Gas Heat - AC

Models

CONTACTOR

FIELD SUPPLIED

DISCONNECT

SINGLE
PHASE

GND

LUG

REFER TO ELECTRICAL
DATA TABLES TO SIZE
THE DISCONNECT

POWER
SUPPLY

A0293-001

FIGURE 7: Typical Field Power Wiring Diagram

Table 5: Electrical Data

Model Voltage

Compressor

Outdoor Fan

Motor

RLA LRA MCC FLA FLA

Indoor Fan

Blower Motor

MCA

(Amps)

1

Max Fuse2/

Breaker

24050 208/230-1-60 8.7 45.0 14.4 1.3 2.6 14.8 20
24075 208/230-1-60 8.7 45.0 14.4 1.3 3.8 16.0 20
30050 208/230-1-60 9.8 57.0 15.1 1.3 2.6 16.2 25
30075 208/230-1-60 9.8 57.0 15.1 1.3 3.8 17.4 25

36050, 36075 208/230-1-60 13.0 78.0 23.0 1.3 3.8 21.4 30

36100 208/230-1-60 13.0 78.0 23.0 1.3 5.4 23.0 35

42075, 42100 208/230-1-60 17.9 112.0 28.0 1.3 5.4 29.1 45
48065, 48100, 48125 208/230-1-60 21.8 117.0 34.0 1.7 5.4 34.4 50
60065, 60100, 60125 208/230-1-60 24.4 144.2 38.0 1.7 7.0 39.2 60

1. Minimum Circuit Ampacity.

2. Maximum Over Current Protection per standard UL 1995.

3. Fuse or HACR circuit breaker size installed at factory or field installed.

3

(Amps)

Size

Johnson Controls Unitary Products 7

1183746-UIM-D-1015

Table 6: Physical Data

COMPONENT

NOMINAL TONNAGE 2.0 2.5 3.0 3.5 4.0 5.0

AHRI Cooling Performance

Gross Capacity @ AHRI A point (MBH) 23.7 30.1 37.2 43.5 47.7 55.0
AHRI net capacity (MBH) 22.8 29.0 34.6 41.0 45.5 52.5
EER 11.0 11.0 11.0 11.0 11.0 11.0
SEER 14.0 14.0 14.0 14.0 14.0 14.0
Nominal CFM 800 1000 1200 1400 1600 2000
System power (KW) 2.1 2.6 3.2 3.8 4.2 4.8
Refrigerant type R410A R410A R410A R410A R410A R410A
Refrigerant charge (lb-oz) 5-4 9-2 8-3 9-4 14-4 14-2

AHRI Gas Heat Performance

Heating model 50 75 50 75 50 75 100 75 100 65 100 125 65 100 125
Heat input (K Btu) 50.0 75.0 50.0 75.0 50.0 75.0 100.0 75.0 100.0 65.0 100.0 125.0 65.0 100.0 125.0
Heat output (K Btu)
AFUE %
No. burners 2 3 2 3 2 3 4 3 4 2 3 4 2 3 4
No. stages 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Temperature Rise Range (°F) 40-70 40-70 35-65 40-70 40-70 40-70 40-70
Max. Static Pressure (in. w.c.) 0.5 0.5 0.5 0.5 0.5 0.5
Max. Outlet Air Temp. (°F) 180 180 180 180 180 180
Gas piping connection (in.) 1/2 1/2 1/2 1/2 1/2 1/2

Dimensions (inches)

Length 51-1/4
Width 35-3/4
Height 47 47 47 49 53 55

Operating WT. (lbs.) 359 366 379 386 415 422 426 442 446 495 503 508 522 530 535
Compressors

Type Recip Recip Recip Scroll Scroll Scroll

Condenser Coil Data

Face area (Sq. Ft.) 15.1 17.0 17.0 17.0 23.8 26.0
Rows 2 3 3 3 3 3
Fins per inch 16 16 16 16 16 16
Tube diameter 3/8 3/8 3/8 3/8 3/8 3/8
Circuitry Type Interlaced Interlaced Interlaced Interlaced Interlaced Interlaced

Evaporator Coil Data

Face area (Sq. Ft.) 3.4 3.4 3.4 4.4 4.4 4.4
Rows 2 3 3 3 3 3
Fins per inch 16 16 16 16 16 16
Tube diameter 3/8 3/8 3/8 3/8 3/8 3/8
Circuitry Type Interlaced Interlaced Interlaced Interlaced Interlaced Interlaced
Refrigerant control TXV TXV TXV TXV TXV TXV

Condenser Fan Data

Fan diameter (Inch) 24 24 24 24 26 26
Type Prop Prop Prop Prop Prop Prop
Drive type Direct Direct Direct Direct Direct Direct
No. speeds 1 1 1 1 1 1
Motor HP each 1/4 1/4 1/4 1/4 1/3 1/3
RPM 850 850 850 850 850 850
Nominal total CFM 2400 2400 2400 2400 3200 3200

Direct Drive Evaporator Fan Data

Fan Size (Inch) 11 x 8 11 x 8 11 x 10 11 x 10 11 x 10 11 x 10
Type Centrifugal Centrifugal Centrifugal Centrifugal Centrifugal Centrifugal
Motor HP each 1/3 1/2 1/3 1/2 1/2 3/4 3/4 3/4 1
RPM 1200 Max 1200 Max 1200 Max 1200 Max 1200 Max 1200 Max
Frame size 48 48 48 48 48 48

Filters

Quantity - Size

PCG4A24 PCG4A30 PCG4A36 PCG4A42 PCG4B48 PCG4B60

40 60 40 60 40 60 80 60 80 52 80 100 52 80 100

81.0 81.0 81.0 81.0 81.0 81.0 81.0 81.0 81.0 81.0 81.0 81.0 81.0 81.0 81.0

51-1/4
35-3/4

Field-supplied external filters must be sized so as not to exceed 300 fpm air velocity through disposable
filters. For internal filter use, a filter rack kit is available. Consult the instructions supplied with that kit for
replacement filter sizes. Filter sizes: A=20x20, B=20x30.

51-1/4 51-1/4 51-1/4 51-1/4
35-3/4 35-3/4 45-3/4 45-3/4

MODELS

8 Johnson Controls Unitary Products

1183746-UIM-D-1015

COMPRESSORS

The compressor used in this product is specifically designed to operate
with R-410A Refrigerant and cannot be interchanged.

!

CAUTION

This system uses R-410A Refrigerant which operates at higher pres­sures than R-22. No other refrigerant may be used in this system.

The compressor uses polyolester (POE oil), Mobile 3MA POE. This oil
is extremely hydroscopic, meaning it absorbs water readily. POE oil can
absorb 15 times as much water as other oils designed for HCFC and
CFC refrigerants. If refrigerant circuit is opened, take all necessary pre­cautions to avoid exposure of the oil to the atmosphere.

!

CAUTION

Do not leave the system open to the atmosphere. Unit damage could
occur due to moisture being absorbed by the POE oil in the system.
This type of oil is highly susceptible to moisture absorption

POE (polyolester) compressor lubricants are known to cause long term
damage to some synthetic roofing materials.

!

CAUTION

Exposure, even if immediately cleaned up, may cause embrittlement
(leading to cracking) to occur in one year or more. When performing
any service that may risk exposure of compressor oil to the roof, take
precautions to protect roofing.

Procedures which risk oil leakage include, but are not limited to, com­pressor replacement, repairing refrigerant leaks, replacing refrigerant
components such as filter drier, pressure switch, metering device or
coil.

Units are shipped with compressor mountings which are factory­adjusted and ready for operation.

!

CAUTION

Do not loosen compressor mounting bolts.

GAS HEAT

These single stage gas-fired heat sections have direct spark ignition.

GAS PIPING

Proper sizing of gas piping depends on the cubic feet per hour of gas
flow required, specific gravity of the gas and the length of run. National
Fuel Gas Code Z223.1 or CSA B149.1 should be followed in all cases
unless superseded by local codes or gas company requirements. Refer
to Tables 7 and 8.

The BTU content of the gas may differ with locality . The value should be
checked with the local gas utility.

Gas piping requirements:

1. A drip leg and a ground joint union must be installed in the gas pip­ing.

2. When required by local codes, a manual shut-off valve may have to
be installed outside of the unit.

3. Use wrought iron or steel pipe for all gas lines. Pipe thread sealant
should be applied sparingly to male threads only.

Table 7: Natural Gas Pipe Sizing Chart

Length
In Feet

10 132 278 520 1,050
20 92 190 350 730
30 73 152 285 590
40 63 130 245 500
50 56 115 215 440
60 50 105 195 400
70 46 96 180 370
80 43 90 170 350
90 40 84 160 320

100 38 79 150 305

1. Maximum capacity of pipe in cubic feet of gas per hour (based upon a pres­sure drop of 0.3 inch water column and 0.6 specific gravity gas).

Table 8: Propane (LP) Gas Pipe Sizing Chart

Length
In Feet

10 275 567 1071 2,205
20 189 393 732 1496
30 152 315 590 1212
40 129 267 504 1039
50 114 237 448 913
60 103 217 409 834
70 96 196 378 771
80 89 185 346 724
90 83 173 322 677

100 78 162 307 630

1. Maximum capacity of pipe in thousands of BTU per hour (based upon a
pressure drop of 0.5 inch water column).

If flexible stainless steel tubing is allowed by the authority having
jurisdiction, wrought iron or steel pipe must be installed at the gas
valve and extend a minimum of two (2) inches outside of the unit cas­ing.

Nominal Inches Iron Pipe Size

1/2” 3/4” 1” 1-1/4”

Nominal Inches Iron Pipe Size

1/2” 3/4” 1” 1-1/4”

!

CAUTION

1

1

!

NOTICE

There may be a local gas utility requirement specifying a minimum
diameter for gas piping. All units require a 1/2 inch pipe connection at
the gas valve.

GAS CONNECTION

The gas supply line should be routed through the 1-5/8" hole located on
the right side of the unit. See Figure 3 for the location. The unit is sup­plied with a rubber grommet that fits in this hole and is used to seal
around the gas pipe. THIS GROMMET MUST BE INSTALLED IN
ORDER TO PREVENT LEAKAGE OF AIR AND WATER INTO THE
HEATING/CONTROLS COMPARTMENT.

Natural gas may contain some propane. Propane being an excellent
solvent, will quickly dissolve white lead or most standard commercial
compounds. Therefore, a special pipe thread sealant must be
applied when wrought iron or steel pipe is used. Shellac base com­pounds such as gaskoloc or stalastic, and compounds such as Rec­torseal # 5, Clyde’s or John Crane may be used.

4. All piping should be cleaned of dirt and scale by hammering on the
outside of the pipe and blowing out the loose dirt and scale. Before
initial start-up, be sure that all of the gas lines external to the unit
have been purged of air.

WARNING

Johnson Controls Unitary Products 9

1183746-UIM-D-1015

5. The gas supply should be a separate line and installed in accor­dance with all applicable safety codes. After the gas connections
have been completed, open the main shut-off valve admitting nor­mal 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.

!

WARNING

FIRE OR EXPLOSION HAZARD

Failure to follow the safety warning exactly could result in serious
injury, death or property damage.
Never test for gas leaks with an open flame. use a commercially
available soap solution made specifically for the detection of leaks to
check all connections. A fire or explosion may result causing property
damage, personal injury or loss of life.

6. The unit and its equipment shutoff valve must be disconnected from
the gas supply system during and pressure testing of that system at
test pressures in excess of 1/2 psi (3.48 kPA)

7. The unit must be isolated from the gas supply piping system by
closing its individual manual shut-off valve before conducting any
pressure testing of the gas supply piping system at test pressures
equal to or less than 1/2 psig (3.48 kPA).

FLUE VENT AND AIR INTAKE HOOD

The flue vent hood and air intake hoods are shipped loose. These hoods
must be installed to assure proper unit operation. The hoods must be fas­tened to the outside of the side gas control/electrical compartment with
the screws provided. See Figure 8.

!

WARNING

Flue hood surfaces may be hot.

AIR INTAKE HOOD

New Graphic to be added later

FIGURE 8: Flue Vent Outlet Air Hood

!

CAUTION

The flue exhaust hood must be properly installed and within the rec­ommended clearances. Further communications and action must be
given to the home or building owner(s) to eliminate any unauthorized
human contact around this area during the heating cycle. Flue hood
surfaces and the immediate area reach high temperatures during the
heating cycle.

AIR INTAKE SCREEN

EXHAUST HOOD

A0284-001

Table 9: Natural Gas Application Data

Ft.3/Hr.

Ft.3/Hr.

2

Number of

Burners

3

Number of

Burners

Available On Models

2, 2-1/2 Tons 50 41 46 2 40 70

3 Tons 50 41 46 2 35 65

4, 5 Tons 65 53 60 2 40 70

2, 2-1/2, 3, 3-1/2 Tons 75 61 70 3 40 70

3, 3-1/2 Tons 100 81 93 4 40 70

4, 5 Tons 100 81 93 3 40 70
4, 5 Tons 125 101 116 4 40 70

1. Heating capacity valid for elevations up to 2000 feet above sea level. For elevations above 2,000 feet, rated capacity should be reduced by 4% for each 1,000 feet
above sea level.

2. Based on 1075 BTU/Ft.3.

3. The air flow must be adequate to obtain a temperature rise within the range shown. Continuous return air temperature should not be below 55°F.

Table 10: Propane

Available On Models

2, 2-1/2, 3, 3-1/2 Tons 75 61 30 3 40 70

1. Propane applications are accomplished by field installation of a Propane Conversion Accessory, Model 1NP0701 for 2 to 3.5 Ton units and Model 1NP0702 for 4
and 5 Ton units.

2. Heating capacity valid for elevations up to 2,000 feet above sea level. For elevations above 2,000 feet, rated capacity should be reduced by 4% for each 1,000 feet
above sea level.

3. Based on 2500 BTU/Ft.3.

4. The air flow must be adequate to obtain a temperature rise within the range shown. Continuous return air temperature should not be below 55°F.

1

(LP) Gas Application Data

2, 2-1/2 Tons 50 41 20 2 40 70

3 Tons 50 41 20 2 35 65

4, 5 Tons 65 53 26 2 40 70

3, 3-1/2 Tons 100 81 40 4 40 70

4, 5 Tons 100 81 40 3 40 70
4, 5 Tons 125 101 50 4 40 70

Input (MBH)

High Fire

Input Capacity

(MBH)

High Fire/Low Fire

1

2

Output (MBH)

High Fire

Output Capacity

(MBH)

High Fire/Low Fire

Gas Rate

High Fire/Low Fire

Gas Rate

High Fire/Low Fire

Temp. Rise ºF
At Full Input

Min. Max.

Temp. Rise ºF
At Full Input

Min. Max.

3

4

10 Johnson Controls Unitary Products

SECTION V: AIRFLOW PERFORMANCE

Table 11: Airflow - Side Duct Application

Model Motor Speed

Low/Medium (2) 818 771 723 674 628 579 530 482

24050

Medium/High (4) 994 948 906 865 823 778 739 700

Low/Medium (2) 978 941 898 850 803 759 713 667

24075

Medium/High (4) 1349 1297 1265 1224 1185 1146 1107 1063

Low/Medium (2) 906 868 825 779 735 692 650 608

30050

Medium/High (4) 1075 1032 1000 958 918 874 837 800

Low/Medium (2) 1102 1048 1010 974 934 890 850 810

30075

Medium/High (4) 1201 1225 1187 1151 1118 1080 1041 1002

Low/Medium (2) 1180 1133 1085 1042 995 942 889 834

36050

Medium/High (4) 1314 1271 1229 1186 1144 1097 1049 998

Low/Medium (2) 1259 1209 1166 1126 1084 1032 980 928

36075

Medium/High (4) 1348 1306 1259 1222 1179 1133 1086 1036

Low/Medium (2) 1425 1368 1332 1293 1251 1208 1163 1113

36100

Medium/High (4) 1658 1599 1588 1530 1495 1454 1414 1373

Low/Medium (2) 1436 1382 1342 1304 1262 1220 1179 1131

42075

Medium/High (4) 1573 1523 1484 1445 1408 1367 1327 1279

Low/Medium (2) 1544 1492 1455 1416 1376 1336 1294 1248

42100

Medium/High (4) 1681 1640 1599 1557 1517 1478 1436 1393

Low/Medium (2) 1295 1250 1213 1172 1133 1087 1045 964

48065

Medium/High (4) 1798 1722 1669 1620 1572 1527 1480 1413

Continued on next page.

Low (1) 732 667 624 567 517 470 415 369

Medium (3) 823 774 721 676 631 583 533 505

High (5) 1148 1108 1071 1035 996 960 925 901

Low (1) 887 847 802 750 705 664 613 563

Medium (3) 1171 1114 1074 1039 993 949 906 864

High (5) 1487 1462 1392 1331 1318 1281 1241 1201

Low (1) 700 657 599 554 512 461 411 365

Medium (3) 992 951 911 868 826 787 747 712

High (5) 1136 1089 1053 1018 978 941 903 869

Low (1) 1076 1020 984 943 903 859 819 779

Medium (3) 1191 1140 1112 1076 1038 1000 958 919

High (5) 1370 1329 1283 1271 1209 1176 1143 1109

Low (1) 1003 952 904 851 790 730 674 633

Medium (3) 1259 1209 1166 1126 1084 1032 980 928

High (5) 1506 1471 1403 1389 1345 1305 1262 1216

Low (1) 1225 1174 1131 1090 1046 993 941 888

Medium (3) 1314 1271 1229 1186 1144 1097 1049 998

High (5) 1506 1471 1403 1389 1345 1305 1262 1216

Low (1) 1342 1302 1260 1217 1178 1134 1082 1034

Medium (3) 1554 1503 1465 1423 1386 1346 1302 1257

High (5) 1966 1914 1862 1810 1757 1705 1653 1600

Low (1) 1315 1266 1229 1194 1156 1117 1080 1036

Medium (3) 1458 1406 1365 1327 1286 1244 1203 1155

High (5) 1966 1914 1862 1810 1757 1705 1653 1600

Low (1) 1436 1382 1342 1304 1262 1220 1179 1131

Medium (3) 1573 1523 1484 1445 1408 1367 1327 1279

High (5) 1935 1887 1834 1788 1743 1701 1651 1591

Low (1) 1046 1009 980 946 915 878 844 779

Medium (3) 1620 1564 1517 1466 1418 1360 1308 1206

High (5) 2146 2085 2025 1960 1872 1862 1798 1735

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

SCFM SCFM SCFM SCFM SCFM SCFM SCFM SCFM

1183746-UIM-D-1015

External Static Pressure (Inches WC)

Johnson Controls Unitary Products 11

1183746-UIM-D-1015

Table 11: Airflow - Side Duct Application (Continued)

External Static Pressure (Inches WC)

Model Motor Speed

Low (1) 1620 1564 1517 1466 1418 1360 1308 1206

Low/Medium (2) 1694 1630 1580 1530 1482 1430 1380 1292

48100

Medium (3) 1798 1722 1669 1620 1572 1527 1480 1413

Medium/High (4) 1835 1758 1703 1653 1604 1558 1511 1442

High (5) 2146 2085 2025 1960 1872 1862 1798 1735

Low (1) 1620 1564 1517 1466 1418 1360 1308 1206

Low/Medium (2) 1798 1722 1669 1620 1572 1527 1480 1413

48125

Medium (3) 1922 1863 1804 1754 1724 1658 1612 1559

Medium/High (4) 2001 1952 1890 1839 1820 1742 1696 1651

High (5) 2146 2085 2025 1960 1872 1862 1798 1735

Low (1) 1073 1043 1009 988 963 941 917 892

Low/Medium (2) 1329 1292 1250 1223 1192 1165 1136 1105

60065

Medium (3) 2054 1998 1934 1890 1843 1801 1757 1710

Medium/High (4) 2195 2144 2098 2049 2003 1955 1883 1868

High (5) 2445 2388 2306 2293 2235 2178 2129 2077

Low (1) 1730 1682 1628 1592 1552 1517 1479 1439

Low/Medium (2) 1858 1807 1749 1710 1667 1629 1589 1546

60100

Medium (3) 2054 1998 1934 1890 1843 1801 1757 1710

Medium/High (4) 2195 2144 2098 2049 2003 1955 1883 1868

High (5) 2445 2388 2306 2293 2235 2178 2129 2077

Low (1) 2063 2008 1943 1899 1851 1809 1763 1717

Low/Medium (2) 2130 2084 2032 1983 1927 1951 1860 1815

60125

Medium (3) 2195 2144 2098 2049 2003 1955 1883 1868

Medium/High (4) 2275 2252 2169 2154 2112 2065 1989 1976

High (5) 2445 2388 2306 2293 2235 2178 2129 2077

1. Airflow tested with dry coil conditions, without air filters, at 230 volts

2. Applications above 0.8" w.c. external static pressure are not recommended.

3. Brushless DC high efficiency standard ECM blower motor used for all indoor blower assemblies.

4. Minimal variations in airflow performance data results from operating at 208 volts. Data above may be used in those cases.

5. Heating applications tested at 0.50" w.c. esp, and cooling applications tested at 0.30" w.c.esp per standards.

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

SCFM SCFM SCFM SCFM SCFM SCFM SCFM SCFM

12 Johnson Controls Unitary Products

Table 12: Airflow - Bottom Duct Application

Model Motor Speed

Low (1) 754 710 665 611 560 491 445 391

Low/Medium (2) 867 815 773 720 677 622 559 505

24050

24075

30050

30075

36050

36075

36100

42075

42100

48065

Continued on next page.

Medium (3) 951 908 868 828 781 735 686 631

Medium/High (4) 1024 982 942 902 861 817 775 721

High (5) 1204 1159 1121 1085 1051 1013 975 938

Low (1) 899 869 827 782 734 685 630 575

Low/Medium (2) 1033 960 924 879 834 787 735 685

Medium (3) 1186 1133 1095 1056 1016 975 935 891

Medium/High (4) 1357 1322 1284 1248 1211 1174 1127 1087

High (5) 1480 1439 1404 1367 1369 1299 1264 1226

Low (1) 726 676 622 575 520 467 410 376

Low/Medium (2) 928 886 841 795 745 706 658 607

Medium (3) 1021 983 942 900 855 811 770 729

Medium/High (4) 1109 1071 1029 995 949 908 864 826

High (5) 1170 1134 1096 1061 1020 978 938 899

Low (1) 1076 1042 1009 969 930 890 849 808

Low/Medium (2) 1104 1063 1025 987 947 908 869 830

Medium (3) 1205 1170 1136 1098 1060 1025 985 943

Medium/High (4) 1285 1251 1213 1179 1141 1104 1065 1027

High (5) 1406 1375 1341 1306 1271 1236 1198 1163

Low (1) 1008 962 916 861 807 757 700 650

Low/Medium (2) 1190 1148 1106 1055 1008 955 914 863

Medium (3) 1262 1223 1181 1137 1091 1044 994 952

Medium/High (4) 1324 1282 1245 1202 1161 1112 1067 1018

High (5) 1517 1475 1447 1400 1357 1318 1275 1232

Low (1) 1231 1186 1146 1103 1069 1030 977 912

Low/Medium (2) 1270 1225 1189 1140 1098 1046 1008 960

Medium (3) 1317 1286 1245 1198 1151 1110 1064 1024

Medium/High (4) 1358 1317 1275 1238 1197 1148 1105 1057

High (5) 1517 1475 1447 1400 1357 1318 1275 1232

Low (1) 1340 1299 1264 1224 1182 1182 1097 1049

Low/Medium (2) 1409 1368 1334 1291 1253 1201 1173 1128

Medium (3) 1527 1492 1470 1419 1385 1343 1299 1250

Medium/High (4) 1663 1585 1594 1601 1521 1480 1440 1400

High (5) 1930 1892 1853 1805 1760 1696 1625 1553

Low (1) 1332 1295 1263 1222 1185 1148 1110 1063

Low/Medium (2) 1457 1419 1376 1340 1299 1253 1215 1160

Medium (3) 1451 1412 1371 1339 1296 1257 1211 1165

Medium/High (4) 1568 1524 1491 1464 1425 1383 1345 1296

High (5) 1978 1937 1891 1837 1785 1725 1656 1604

Low (1) 1455 1414 1379 1335 1294 1254 1212 1160

Low/Medium (2) 1566 1532 1492 1455 1416 1372 1333 1280

Medium (3) 1565 1530 1491 1458 1419 1381 1336 1290

Medium/High (4) 1675 1641 1606 1578 1535 1495 1455 1412

High (5) 1946 1909 1863 1815 1771 1721 1654 1595

Low (1) 1032 999 970 938 910 879 843 808

Low/Medium (2) 1272 1236 1204 1165 1129 1081 1037 968

Medium (3) 1611 1574 1518 1494 1439 1405 1357 1266

Medium/High (4) 1892 1777 1771 1701 1639 1617 1565 1489

High (5) 2131 2058 1998 1949 1892 1840 1788 1728

1183746-UIM-D-1015

External Static Pressure (Inches WC)

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

SCFM SCFM SCFM SCFM SCFM SCFM SCFM SCFM

Johnson Controls Unitary Products 13

1183746-UIM-D-1015

Table 12: Airflow - Bottom Duct Application (Continued)

External Static Pressure (Inches WC)

Model Motor Speed

Low (1) 1598 1548 1502 1454 1410 1362 1307 1251

Low/Medium (2) 1663 1612 1568 1522 1476 1422 1370 1297

48100

Medium (3) 1789 1733 1670 1650 1596 1578 1535 1483

Medium/High (4) 1931 1814 1808 1736 1673 1650 1597 1519

High (5) 2131 2058 1998 1949 1892 1840 1788 1728

Low (1) 1598 1548 1502 1454 1410 1362 1307 1251

Low/Medium (2) 1766 1703 1656 1611 1566 1518 1469 1419

48125

Medium (3) 1912 1875 1805 1787 1750 1713 1672 1636

Medium/High (4) 2105 2014 2006 1931 1898 1845 1793 1739

High (5) 2131 2058 1998 1949 1892 1840 1788 1728

Low (1) 1026 999 989 950 907 907 886 862

Low/Medium (2) 1263 1230 1192 1165 1167 1101 1099 1071

60065

Medium (3) 1987 1933 1861 1817 1820 1715 1725 1651

Medium/High (4) 2114 2050 2047 1974 1899 1889 1920 1866

High (5) 2369 2308 2249 2183 2126 2088 2034 1990

Low (1) 1655 1612 1596 1531 1461 1462 1429 1391

Low/Medium (2) 1766 1720 1667 1629 1632 1539 1537 1498

60100

Medium (3) 1987 1933 1861 1817 1820 1715 1725 1651

Medium/High (4) 2114 2050 2047 1974 1899 1889 1920 1866

High (5) 2369 2308 2249 2183 2126 2088 2034 1990

Low (1) 1973 1924 1905 1826 1743 1744 1703 1660

Low/Medium (2) 2024 1983 1937 1889 1886 1843 1799 1759

60125

Medium (3) 2123 2075 2019 1970 1978 1862 1849 1804

Medium/High (4) 2191 2154 2117 2075 2002 1995 2028 1974

High (5) 2369 2308 2249 2183 2126 2088 2034 1990

1. Airflow tested with dry coil conditions, without air filters, at 230 volts

2. Applications above 0.8" w.c. external static pressure are not recommended.

3. Brushless DC high efficiency standard ECM blower motor used for all indoor blower assemblies.

4. Minimal variations in airflow performance data results from operating at 208 volts. Data above may be used in those cases.

5. Heating applications tested at 0.50" w.c. esp, and cooling applications tested at 0.30" w.c.esp per standards.

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

SCFM SCFM SCFM SCFM SCFM SCFM SCFM SCFM

14 Johnson Controls Unitary Products

1183746-UIM-D-1015

Table 13: Additional Static Resistance

Size (Tons) CFM Wet Indoor Coil Economizer

500 0.01 0.00 0.01
600 0.01 0.00 0.02
700 0.01 0.00 0.04

024 (2.0)

030 (2.5)

036 (3.0)

042 (3.5)

048 (4.0)

060 (5.0)

1. The pressure drop through the economizer is greater for 100% outdoor air
than for 100% return air. If the resistance of the return air duct is less than

0.25 IWG, the unit will deliver less CFM during full economizer operation.

Filter pressure drop based on standard filter media tested at velocities not to

exceed 300 ft/min.

800 0.02 0.01 0.06

900 0.03 0.01 0.08
1000 0.04 0.01 0.10
1100 0.05 0.01 0.13
1200 0.06 0.02 0.16

700 0.01 0.00 0.04

800 0.02 0.01 0.06

900 0.03 0.01 0.08
1000 0.04 0.01 0.10
1100 0.05 0.01 0.13
1200 0.06 0.02 0.16
1300 0.07 0.03 0.17

700 0.01 0.00 0.04

800 0.02 0.01 0.06

900 0.03 0.01 0.08
1000 0.04 0.01 0.10
1100 0.05 0.01 0.13
1200 0.06 0.02 0.16
1300 0.07 0.03 0.17
1400 0.08 0.04 0.18
1100 0.02 0.02 0.04
1200 0.03 0.02 0.04
1300 0.04 0.02 0.05
1400 0.05 0.03 0.05
1500 0.06 0.04 0.06
1600 0.07 0.04 0.07
1700 0.07 0.04 0.08
1800 0.08 0.04 0.09
1900 0.09 0.05 0.10
2000 0.09 0.05 0.11
1100 0.02 0.02 0.04
1200 0.03 0.02 0.04
1300 0.04 0.02 0.05
1400 0.05 0.03 0.05
1500 0.06 0.04 0.06
1600 0.07 0.04 0.07
1700 0.07 0.04 0.08
1800 0.08 0.04 0.09
1900 0.09 0.05 0.10
2000 0.09 0.05 0.11
1100 0.02 0.02 0.04
1200 0.03 0.02 0.04
1300 0.04 0.02 0.05
1400 0.05 0.03 0.05
1500 0.06 0.04 0.06
1600 0.07 0.04 0.07
1700 0.07 0.04 0.08
1800 0.08 0.04 0.09
1900 0.09 0.05 0.10
2000 0.09 0.05 0.11

1

Filter/Frame Kit

SECTION VI: OPERATION

The unit is controlled by a conventional heating/cooling thermostat. If an
electronic thermostat is used, make sure it has a common connection.
DO NOT use a power stealing thermostat.

HEATING SEQUENCE OF OPERATION

Heating

The control board begins a call for heat when W is energized (con­nected to R).

The control checks to see if the pressure switch is open. If the pressure
switch is closed, the control board flashes “2” on the LED and waits
indefinitely for it to open. When the pressure switch is sensed as open,
the control begins pressure switch proving period. If the call for heat is
removed, the control goes back to Standby.

Pressure Switch Proving

The control board energizes the induced draft motor and waits for the
pressure switch to close. When the pressure switch closes, the control
begins Pre-purge period. If the call for heat is removed, the control de­energizes the inducer without post-purge and returns to standby.

If the pressure switch does not close within 5 seconds of inducer ener­gizing, the control board flashes “3” on the LED. If the pressure switch
does not close within 60 seconds of inducer energizing, the control
shuts off the inducer for 60 seconds, then energizes the inducer for
another 60 seconds in an attempt to close the pressure switch. This
cycle continues indefinitely until either the pressure switch is proved
closed, or the call for heat ends.

Pre-purge

The control board monitors the pressure switch and ensures it remains
closed during pre-purge. If the pressure switch opens, the control goes
back to pressure switch proving mode. The control waits for a 15 sec­ond pre-purge period, then begins the ignition trial.

Ignition Trial Period

The control board energizes the gas valve and spark outputs for a 5
second Ignition trial. The control de-energizes the spark when flame is
sensed and enters a flame stabilization period.

If flame is not established within the ignition trial period, the control de­energizes the spark and gas valve and begins an inter-purge period
before attempting another ignition trial.

If the call for heat is removed during an ignition trial period, the control
immediately de-energizes spark and gas. The control runs the inducer
motor through a post purge period before de-energizing.

If the pressure switch opens during an ignition trial period, the control
immediately de-energizes spark and gas. The control begins pressure
switch proving before an 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 delay.

Johnson Controls Unitary Products 15

1183746-UIM-D-1015

Main Burner Operation

The control board keeps the main gas valve and induced draft motor
energized while continuously monitoring the call for heat, pressure
switch, and flame status.

If the call for heat (W) is removed, the control de-energizes the gas
valve, begins post purge and heat blower off delay.

If the pressure switch opens, the control de-energizes the gas valve
and begins pressure switch proving mode.

If flame is removed, the control de-energizes the gas valve within 2.0
seconds and counts the flame loss. If flame has been lost less than 5
times, the control attempts re-ignition after a 15 second inter-purge
period. If flame has been lost more than 5 times within the same call for
heat, the control board locks out flashing “8” on the LED. Post Purge

The control board runs the induced draft motor for a 15 second post­purge period, and then de-energizes the inducer. If a call for heat
occurs during post-purge, the control finishes the postpurge, and imme­diately begins the next ignition sequence.

Heat Blower Off Delay

After a heating sequence the control board de-energizes the indoor
blower motor after a delay time as selected by a movable shunt (60, 90,
120 or 180 seconds). Blower off timing begins when the thermostat is
satisfied and removes (W) the call for heat. The control returns to
standby when the blower off delay is complete.

If the thermostat call for heat returns before the blower off delay is com­plete, the control begins an ignition sequence with prepurge while the
blower off delay continues.

Lockout

While in lockout, the control board keeps the main gas valve and
induced draft motor de-energized.

Lockouts due to failed ignition or flame losses may be reset by remov­ing the call for heat (W) for more than 1 second, or by removing power
from the control for over 0.25 seconds. The control will automatically
reset lockout after 60 minutes.

Lockouts due to detected internal control faults will reset after 60 min­utes or power interruption. Cooling operations are available during a
heating lockout.

High Temperature Limit Switch

Any time the high temperature limit switch is open less than 5 minutes
the control board will run the indoor blower motor on heat speed, run
the inducer, de-energize the gas valve, and flash “4” on the LED. When
the high temperature switch closes, the control will restart the ignition
sequence beginning with pre-purge.

If the limit switch has been open more than 5 minutes the control will
de-energize the inducer, continue to operate the indoor blower motor on
heat speed, and flash “11” on the LED

Rollout Switch

If the limit circuit is open for more than 15 minutes, the control board will
flash “5” on the LED. The blower output will be energized during an
open rollout condition.

If the rollout switch is reset, the control shall remain locked out until
power is removed or a call for heat (W) is removed.

Rollout switch lockout shall not reset automatically.

Power Interruptions

Power interruptions of any duration shall not cause lockout or any oper­ation requiring manual intervention.

Flame present with Gas off

If flame is sensed for longer than 4.0 seconds during a period when the
gas valve should be closed, the control will enter lockout flashing “1” on
the LED. The control will energize the inducer blower while the flame is
sensed.

GAS VALVE FAULT

If the main valve output is sensed to be energized for more than 1 sec­ond when commanded to be off, the control de-energizes the induced
draft motor (if flame is not present) to attempt to open the pressure
switch to de-energize the gas valve. If the main gas valve is still sensed
as energized after the inducer has been off for 10 seconds, the control
re-energizes the inducer to vent the unburned gas. The control enters a
hard lockout flashing "10" on the LED.

The only way to recover from a hard lockout is to remove and reapply
24VAC power to the control board.

Safety Controls

The control circuit includes the following safety controls:

1. Limit Switch (LS) - This control is located inside the blower compart­ment and protrudes into the heat exchanger compartment and is set
to open at the temperature indicated in the Temperature Controls
Table of the unit wiring diagram. It resets automatically. The limit
switch operates when a high temperature condition occurs, thus
shutting down the ignition control, closes the main gas valve and
energizes the blower.

2. Pressure Switch (PS) - If the draft motor should fail, the pressure
switch prevents the ignition control and gas valve from being ener­gized.

3. Flame Sensor - The flame sensor is located on the left-most burner .
If an ignition control fails to detect a signal from the flame sensor
indicating the flame is properly ignited, then the main gas valve will
close.

4. Rollout Switch (RS) - This switch is located on the burner assembly.
In the event of a sustained main burner flame rollout, the control will
close the main gas valve. The is a manual reset type switch.

NOTICE

The manual reset Rollout Switch (RS) must be reset before allowing
furnace operation.

Table 14: Ignition Control Board Flash Codes

Flash Code Description

Normal Operation

Green Heartbeat Standby mode

Amber Heartbeat Call for furnace heat active

Operational Faults

Steady ON (any color) Control failure
Rapid Amber Flash Low flame current <1.5 VDC at test pad
1 Red Flash Flame sensed with gas valve off
2 Red Flashes Pressure switch closed with inducer off
3 Red Flashes Pressure switch open with inducer on
4 Red Flashes Limit switch or rollout switch open
5 Red Flashes Limit switch or rollout switch open >15 minutes
6 Red Flashes Pressure switch cycle lockout
7 Red Flashes Lockout due to failed ignition
8 Red Flashes Lockout due to too many flame dropouts
10 Red Flashes Gas valve fault

11 Red Flashes

9 Red Flashes Incorrect low voltage polarity
4 Amber Flashes Y thermostat demand without a G

Limit/Rollout switch open between 5 and 15
minutes

Wiring Related Faults

16 Johnson Controls Unitary Products

1183746-UIM-D-1015

ON

OFF

COOLING SEQUENCE OF OPERATIONS

When the thermostat calls for COOL, the thermostat terminals G and Y
are energized, which signals the compressor, outdoor fan and indoor
blower to run.

With a call for Y, the circulating fan is energized at cooling speed.
When the thermostat is satisfied, terminals G and Y are de-energized,

de-energizing the compressor and outdoor fan.

After a cool fan off delay timing of 30 seconds, the circulating fan is de-

energized.

Safety Controls

The control circuit includes the following safety controls:
High Pressure Switch (HP) - This switch protects against excessive dis-

charge pressures due to a blocked condenser coil or a condenser
motor failure (opens at 650 ± 25 psig and closes at 450 ± 25 psig).

The above pressure switches are specifically designed to operate with
R-410A systems. R-22 pressure switches must not be used as replace­ments for the R-410A pressure switches.

!

WARNING

The ability to properly perform maintenance on this equipment
requires certain expertise, mechanical skills, tools and equipment. If
you do not possess these, do not attempt to perform any mainte­nance other than those procedures recommended in this Installation
Manual. Failure to heed this warning could result in serious injury
and possible damage to this equipment.

Circulating Fan

When the thermostat calls for FAN, the thermostat terminal G is ener­gized signaling the circulating fan to run at the G-Speed airflow.

If a call for COOL occurs (Y), the circulating fan switches to run at the Y­Speed airflow.

If a call for HEAT occurs (W), the circulating fan switches to W-Speed
after a 30 second delay.

When the thermostat ends the call for FAN, the thermostat terminal G is
de-energized, de-energizing the circulating fan.

START-UP

Prestart Check List

Complete the following checks before starting the unit.

1. Check the type of gas being supplied. Be sure that it is the same as
listed on the unit nameplate.

2. Make sure that the vent outlet air hood and air intake hood has
been properly installed.

Operating Instructions

1. STOP! Read the information on the unit safety label.

2. Set the thermostat to the OFF position.

3. Turn off all electrical power to the unit.

4. DO NOT try to light the burners by hand. This appliance is
equipped with an ignition device which automatically lights the
burners.

5. Remove the access panel.

6. Turn the gas valve switch to the OFF position.

7. Wait five (5) minutes to clear out any gas. If you then smell gas,
STOP! Follow B in the information on the unit safety label. If you
don't smell gas, go to the next step.

8. Turn the gas valve switch to the ON position.

9. Replace the control access panel.

10. Turn on all electric power to the unit.

11. Set the thermostat to the desired setting.

12. If the unit will not operate, follow the instructions To Turn Off Gas To

Appliance and call your service technician or gas supplier.

To Turn Off Gas To Unit

1. Set the thermostat to the OFF position.

2. Turn off all electric power to the appliance if service is to be per­formed.

3. Remove the control access panel.

4. Turn the gas valve switch to the OFF position. DO NOT FORCE.

5. Replace the control access panel.

Post Start Check List

After the entire control circuit has been energized and the heating sec­tion is operating, make the following checks:

1. Check for gas leaks in the unit piping as well as the supply piping.

2. Check for correct manifold gas pressures. See Checking Gas Input.

3. Check the supply gas pressure. It must be within the limits shown
on rating nameplate. Supply pressure should be checked with all
gas appliances in the building at full fire. At no time should the
standby gas line pressure exceed 13.5", nor the operating pressure
drop below 4.5" for natural gas units. If gas pressure is outside
these limits, contact the local gas utility for corrective action.

Manifold Gas Pressure Adjustment

Small adjustments to the gas flow may be made by turning the pressure
regulator adjusting screw on the automatic gas valve.
Refer to Figure 9.

OUTLET
PRESSURE
PORT

INLET

WRENCH
BOSS

INLET
PRESSURE
PORT

FIGURE 9: Gas Valve
Adjust as follows:

1. Remove the cap from the valve body. See Figure 9 for location.

2. To decrease the gas pressure, turn the adjusting screw counter­clockwise.

3. To increase the gas pressure, turn the adjusting screw clockwise.

ON/OFF SWITCH
(Shown in ON position)

VENT PORT

OUTLET

MAIN REGULATOR
ADJUSTMENT

A0303-001

NOTICE

The correct manifold pressure for natural gas furnaces is 3.5 IWG.
The correct manifold pressure for propane (LP) is 10.0 IWG.

Adjustment of Temperature Rise

After about 20 minutes of operation, determine the heating temperature
rise. Take readings of both the return air and the heated air in the ducts
about six feet from the unit where they will not be affected by radiant
heat.

The temperature rise (or temperature difference between the return air
and the heated air from the unit) must lie within the range shown on the
rating plate and the data in Table 6.

After the temperature rise has been determined, the CFM can be calcu­lated as follows:

Degrees F Temp Rise =

CFM=

1.08 x Degrees F Temp Rise

Direct Drive Blower

All units have direct drive, multi speed standard ECM blower motors.
Connect manometer per “EXTERNAL STATIC PRESSURE SECTION”.

Place unit in cooling mode and adjust blower speed accordingly per
Table 11 or 12.

BTUH Output

1.08 x CFM

OR

BTUH Output

Johnson Controls Unitary Products 17

1183746-UIM-D-1015

EXTERNAL STATIC PRESSURE SETUP

To measure external static pressure:

• Measure the supply air static pressure

• Record this positive number

FIGURE 10: Measuring External Static Pressure

• Measure the return air static pressure

• Record this negative number

• Treat the negative number as a positive and add the two numbers
together

• This is total system static

RETURN AIR

DUCT

SUPPLY AIR

DUCT

A0435-001

CHECKING GAS HEAT INPUT
Natural Gas

1. Turn off all other gas appliances connected to the gas meter.

2. With the unit turned on, measure the time needed for one revolution
of the hand on the smallest dial on the meter. A typical gas meter
usually has a 1/2 or a 1 cubic foot test dial.

3. Using the number of seconds for each revolution and the size of the
test dial increment, find the cubic feet of gas consumed per hour
from Table 15.

If the actual input is not within 5% of the unit heating rating with allow­ance being made for the permissible range of the regulator setting,
replace the orifice spuds with spuds of the proper size.

NOTICE

To find the BTU input, multiply the number of cubic feet of gas con­sumed per hour by the BTU content of the gas in your particular
locality. (Contact your gas company for this information since it varies
widely from city to city.)

Table 15: Gas Rate Cubic Feet Per Hour

Seconds for

One Rev.

1/2 cu. ft. 1 cu. ft.

1

Size of Test Dial

10 180 360
12 150 300
14 129 257
16 113 225
18 100 200
20 90 180
22 82 164
24 75 150
26 69 138
28 64 129
30 60 120
32 56 113
34 53 106
36 50 100
38 47 95
40 45 90
42 43 86
44 41 82
46 39 78
48 37 75
50 36 72
52 35 69
54 34 67
56 32 64
58 31 62
60 30 60

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
T able 15. Read across to the column headed “1 Cubic Foot,” where you will
see that 95 cubic feet of gas per hour are consumed by the furnace at that
rate. Multiply 95 x 1050 (the BTU rating of the gas obtained from the local
gas company). The result is 99,750 BTUH, which is close to the 100,000
BTUH rating of the unit.

18 Johnson Controls Unitary Products

SECTION VII: TYPICAL WIRING DIAGRAMS

CONNECTION WIRING DIAGRAM

COOLING UNIT WITH GAS HEAT

WITH RECIPROCATING COMPRESSOR

CAUTION - OPEN ALL DISCONNECTS

BEFORE SERVICING THIS UNIT

HI PRESS

C

R

Y

W

G

THERMOSTAT

GAS

VALVE

LOW

VOLTAGE

BOX

ROLLOUT

YEL 18

RED 34

RED/BLK 35

PRESSURE

LIMIT

WHT 20

GRN 19

YEL 17

BLU 23

RED 22

YEL 21 Y

RED/GRN 36

YEL 38

GRN 40

YEL 38

ORG 37

W

Y

O

R

C

C

R

O

W

G

3

6

9

W SPD

G SPD

Y SPD

24V COM

CONTROL

BOARD

1

2

4

5

8

7

ORG 39

L1

1

IND

2

CONTACTOR

BLOWER

DELAY

180

120

90

60

SPARK

TRANSFORMER

FS

3

WHT 27

COIL

BLU 43

RED 28

208/230-1-60

230V

XFMR

RED 45

BLU 42

FLAME

IGNITOR

SENSOR

ORG

BLU 30

208V

24V SEC

40 VA

START CAP

BLK

1183746-UIM-D-1015

POWER SUPPLY
208/230-1-60
USE COPPER
CONDUCTORS
ONLY

BLK 6

PUR 1

COM

PRI

L2 T2 RED R

GRN 44

START RELAY

125

YEL 46

RED 8

(CONTINUOUS FAN)

PUR 26

(HEATING SPEED)

(COOLING SPEED)

BRN
DRAFT
MOTOR

CAP

YEL

SINGLE POLE
CONTACTOR

SHARED TAP

L1 T1

RED 32

YEL 31

GND

C

BLK

BRN S

COMPR

BLK/WHT 12
DUAL
CAPACITOR

FAN

BLK/WHT 11

HERM

C

RED 7

BRN 15

RED 9

BLK 5

PUR 2

1

(LOW)

2N

(LOW/MED)

(MED)

3

WHT 33

(MED/HIGH)

(HIGH)

CONTROL BOARD SETTINGS:
COMBUSTION BLOWER POST PURGE: 60 SEC
INDOOR BLOWER HEAT ON DELAY: 30 SEC
INDOOR BLOWER COOL OFF DELAY: 60 SEC
INDOOR BLOWER HEAT OFF DELAY: FIELD SELECT

BLOWER
MOTOR

4L

5C

SEE NOTE 7

BRN/WHT 13

GRN 10

1

BLK

2

3

BRN

4

5

GRN

RED

6

1

G

GRN 4

2

3

4

LINE VOLTAGE

FIELD INSTALLED POWER

LOW VOLTAGE

FIELD INSTALLED CONTROL

OD FAN
MOTOR

DSI Fault Codes

Green Heartbeat

Normal Operation

Amber Heartbeat
Rapid Green Flashes

Operational Fault Codes

Flashes

None
Slow Green Flashes
Slow Amber Flashes
Rapid Amber Flashes
4 Amber Flashes
Steady on Red
1 Red Flash
2 Red Flashes
3 Red Flashes
4 Red Flashes
5 Red Flashes
6 Red Flashes
7 Red Flashes
8 Red Flashes
9 Red Flashes
10 Red Flashes
11 Red Flashes

Standby mode

Call for furnace heat active

Control in Factory Test mode

Fault Condition

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 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

1. ALL FIELD WIRING TO BE ACCOMPLISHED FOLLOWING CITY, LOCAL AND/OR
NATIONAL CODES IN EFFECT AT THE TIME OF INSTALLATION OF THE UNIT.

2. CAUTION : LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING
CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS
OPERATION. IF ANY OF THE WIRING, AS SUPPLIED WITH THE UNIT, MUST
BE REMOVED, IT MUST BE REPLACED WITH TYPE 105 C. 600 VOLT
WIRE OR EQUIVALENT CLEARLY RENUMBERED FOR IDENTIFICATION.
VERIFY PROPER OPERATION AFTER SERVICING.

3. FACTORY WIRED FOR 230 VOLT SUPPLY POWER. FOR 208 VOLT, MOVE
BLACK WIRES FROM THE 230 TO THE 208 VOLT TAP ON THE TRANSFORMER.

4. MOTORS ARE INHERENTLY PROTECTED.

5. SEE UNIT NAMEPLATE FOR MAXIMUM FUSE AND/OR CIRCUIT BREAKER SIZE
AND MINIMUM CIRCUIT AMPACITY.

6. SELECT INDOOR BLOWER SPEED TO REMAIN WITHIN THE TEMPERATURE
RISE RANGE ON THE NAMEPLATE IN HEATING AND TO OBTAIN APPROX.
400 CFM/TON IN COOLING.

7. BLOWER MOTOR SPEED CONNECTIONS SHOWN ARE TYPICAL,
BUT MAY VARY BY MODEL AND APPLICATION.

NOTES:

FIGURE 11: Connection Wiring Diagram - 2 to 3 Ton Models

Johnson Controls Unitary Products 19

1183746-UIM-D-1015

LADDER WIRING DIAGRAM

COOLING UNIT WITH GAS HEAT

WITH RECIPROCATING COMPRESSOR

208/230-1-60

CAUTION - OPEN ALL DISCONNECTS

BEFORE SERVICING THIS UNIT

NOTES:

1. ALL FIELD WIRING TO BE ACCOMPLISHED FOLLOWING CITY, LOCAL AND/OR
NATIONAL CODES IN EFFECT AT THE TIME OF INSTALLATION OF THE UNIT.

2. CAUTION : LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING
CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS
OPERATION. IF ANY OF THE WIRING, AS SUPPLIED WITH THE UNIT, MUST
BE REMOVED, IT MUST BE REPLACED WITH TYPE 105 C. 600 VOLT
WIRE OR EQUIVALENT CLEARLY RENUMBERED FOR IDENTIFICATION.
VERIFY PROPER OPERATION AFTER SERVICING.

3. FACTORY WIRED FOR 230 VOLT SUPPLY POWER. FOR 208 VOLT, MOVE
BLACK WIRES FROM THE 230 TO THE 208 VOLT TAP ON THE TRANSFORMER.

4. MOTORS ARE INHERENTLY PROTECTED.

5. SEE UNIT NAMEPLATE FOR MAXIMUM FUSE AND/OR CIRCUIT BREAKER SIZE
AND MINIMUM CIRCUIT AMPACITY.

6. SELECT INDOOR BLOWER SPEED TO REMAIN WITHIN THE TEMPERATURE
RISE RANGE ON THE NAMEPLATE IN HEATING AND TO OBTAIN APPROX.
400 CFM/TON IN COOLING.

7. BLOWER MOTOR SPEED CONNECTIONS SHOWN ARE TYPICAL,
BUT MAY VARY BY MODEL AND APPLICATION.

CONTROL BOARD SETTINGS:
COMBUSTION BLOWER POST PURGE: 60 SEC
INDOOR BLOWER HEAT ON DELAY: 30 SEC
INDOOR BLOWER COOL OFF DELAY: 60 SEC
INDOOR BLOWER HEAT OFF DELAY: FIELD SELECT

DSI Fault Codes

Green Heartbeat
Amber Heartbeat
Rapid Green Flashes

Operational Fault Codes

Flashes

None
Slow Green Flashes
Slow Amber Flashes
Rapid Amber Flashes
4 Amber Flashes
Steady on Red
1 Red Flash
2 Red Flashes
3 Red Flashes
4 Red Flashes
5 Red Flashes
6 Red Flashes
7 Red Flashes
8 Red Flashes
9 Red Flashes
10 Red Flashes
11 Red Flashes

FIGURE 12: Ladder Wiring Diagram - 2 to 3 Ton Models

Standby mode
Call for furnace heat active
Control in Factory Test mode

Fault Condition

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 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

THERMOSTAT

LINE VOLTAGE

FIELD INSTALLED POWER

LOW VOLTAGE

FIELD INSTALLED CONTROL

C

R

Y

W

G

ROLLOUT

GAS

VALVE

5

3

4

BLOWER
MOTOR

RED

RED/BLK

PRESSURE

2

1

C

LIMIT

WHT

RED

BLU

YEL

YEL

BLU

RED

WHT

GRN

GRN

L1

L1

Y

RED/GRN

YEL

YEL

T1

BLK/WHT

52

CONTROL
BOARD
RELAY

PUR

L1

BLK

C

R

O

W

G

3

6

9

ORG

W SPD

G SPD

Y SPD

24V COM

BLK

C

BLK/WHT

BRN

START RELAY

BLK

WHT

IND

RED

3A

FUSE

1

2

4

5

8

7

ORG

L1

1

COMPRES

1

L

230V

CONTROL

BOARD

TRANSFORMER

IND

2

R

S

H

BLOWE
MOTOR

DRAFT
MOTOR

24V SEC

FS

3

GROUND
LUG

RED

RED

R

OD FAN

C

MOTOR

C

START CAP

N

XFMR

RED

S

BRN/WHT

F

RED

COM

HI PRESS

IGNITOR

ORG

PUR

BLK

BLU

BRN

DUAL
CAPACITOR

YEL RED

R

G

CAP

208V

PRI

40 VA

SPARK

T2

PUR

BLU

YEL

CONTACTOR
COIL

SENSOR

L2

L2

FLAME

20 Johnson Controls Unitary Products

CONNECTION WIRING DIAGRAM

COOLING UNIT WITH GAS HEAT

CAUTION - OPEN ALL DISCONNECTS

BEFORE SERVICING THIS UNIT

HI PRESS

C

R

Y

W

G

THERMOSTAT

GAS

VALVE

LOW

VOLTAGE

BOX

ROLLOUT

YEL 18

RED 34

RED/BLK 35

PRESSURE

LIMIT

WHT 20

GRN 19

BLU 23

RED 22

YEL 21

GRN 40

YEL 17

RED/GRN 36

YEL 38

YEL 38

ORG 37

W

Y

O

R

C

C

R

O

Y

W

G

3

6

9

W SPD

G SPD

Y SPD

24V COM

CONTROL

BOARD

1

2

4

5

8

7

ORG 39

L1

1

IND

2

TRANSFORMER

FS

3

WITH SCROLL COMPRESSOR

208/230-1-60

BLK 6

208V

CONTACTOR

BLOWER

DELAY

180

120

90

60

SPARK

WHT 27

COIL

RED 28

BLU 43

BLU 42

IGNITOR

ORG

BLU 30

230V

RED 45

FLAME

SENSOR

XFMR

24V SEC

40 VA

BLK

COM

PRI

GRN 44

BRN
DRAFT
MOTOR

YEL

PUR 1

CAP

POWER SUPPLY 208/230-1-60

USE COPPER
CONDUCTORS
ONLY

SINGLE POLE
CONTACTOR

(CONTINUOUS FAN)

PUR 26

(HEATING SPEED)

(COOLING SPEED)

1183746-UIM-D-1015

GND

L1 T1

T2L2

RED 7

(LOW)

RED 32

(LOW/MED)

(MED)

WHT 33

(MED/HIGH)

YEL 31

SHARED TAP

(HIGH)

CONTROL BOARD SETTINGS:
COMBUSTION BLOWER POST PURGE: 60 SEC
INDOOR BLOWER HEAT ON DELAY: 30 SEC
INDOOR BLOWER COOL OFF DELAY: 60 SEC
INDOOR BLOWER HEAT OFF DELAY: FIELD SELECT

HERM

BLK 5

PUR 2

DUAL
CAPACITOR

FAN

RED 9

1

2

3

4

5

SEE NOTE 7

BLK

BRN

RED

C

BLOWER
MOTOR

BLK/WHT 12

BRN/WHT 13

LINE VOLTAGE

FIELD INSTALLED POWER

LOW VOLTAGE

FIELD INSTALLED CONTROL

S

GRN 10

N

G

L

C

C

COMPR

R

BLK

1

2

3

BRN

4

OD FAN
MOTOR

5

GRN

RED

6

1

GRN 4

2

3

4

DSI Fault Codes

Green Heartbeat

Normal Operation

Amber Heartbeat
Rapid Green Flashes

Operational Fault Codes

Flashes

None
Slow Green Flashes
Slow Amber Flashes
Rapid Amber Flashes
4 Amber Flashes
Steady on Red
1 Red Flash
2 Red Flashes
3 Red Flashes
4 Red Flashes
5 Red Flashes
6 Red Flashes
7 Red Flashes
8 Red Flashes
9 Red Flashes
10 Red Flashes
11 Red Flashes

Standby mode
Call for furnace heat active

Control in Factory Test mode

Fault Condition

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 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

1. ALL FIELD WIRING TO BE ACCOMPLISHED FOLLOWING CITY, LOCAL AND/OR
NATIONAL CODES IN EFFECT AT THE TIME OF INSTALLATION OF THE UNIT.

2. CAUTION : LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING
CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS
OPERATION. IF ANY OF THE WIRING, AS SUPPLIED WITH THE UNIT, MUST
BE REMOVED, IT MUST BE REPLACED WITH TYPE 105 C. 600 VOLT
WIRE OR EQUIVALENT CLEARLY RENUMBERED FOR IDENTIFICATION.
VERIFY PROPER OPERATION AFTER SERVICING.

3. FACTORY WIRED FOR 230 VOLT SUPPLY POWER. FOR 208 VOLT, MOVE
BLACK WIRES FROM THE 230 TO THE 208 VOLT TAP ON THE TRANSFORMER.

4. MOTORS ARE INHERENTLY PROTECTED.

5. SEE UNIT NAMEPLATE FOR MAXIMUM FUSE AND/OR CIRCUIT BREAKER SIZE
AND MINIMUM CIRCUIT AMPACITY.

6. SELECT INDOOR BLOWER SPEED TO REMAIN WITHIN THE TEMPERATURE
RISE RANGE ON THE NAMEPLATE IN HEATING AND TO OBTAIN APPROX.
400 CFM/TON IN COOLING.

7. BLOWER MOTOR SPEED CONNECTIONS SHOWN ARE TYPICAL,
BUT MAY VARY BY MODEL AND APPLICATION.

NOTES:

FIGURE 13: Connection Wiring Diagram - 3.5 to 5 Ton Models

Johnson Controls Unitary Products 21

1183746-UIM-D-1015

LADDER WIRING DIAGRAM

COOLING UNIT WITH GAS HEAT

WITH SCROLL COMPRESSOR

CAUTION - OPEN ALL DISCONNECTS

BEFORE SERVICING THIS UNIT

NOTES:

1. ALL FIELD WIRING TO BE ACCOMPLISHED FOLLOWING CITY, LOCAL AND/OR
NATIONAL CODES IN EFFECT AT THE TIME OF INSTALLATION OF THE UNIT.

2. CAUTION : LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING
CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS
OPERATION. IF ANY OF THE WIRING, AS SUPPLIED WITH THE UNIT, MUST
BE REMOVED, IT MUST BE REPLACED WITH TYPE 105 C. 600 VOLT
WIRE OR EQUIVALENT CLEARLY RENUMBERED FOR IDENTIFICATION.
VERIFY PROPER OPERATION AFTER SERVICING.

3. FACTORY WIRED FOR 230 VOLT SUPPLY POWER. FOR 208 VOLT, MOVE
BLACK WIRES FROM THE 230 TO THE 208 VOLT TAP ON THE TRANSFORMER.

4. MOTORS ARE INHERENTLY PROTECTED.

5. SEE UNIT NAMEPLATE FOR MAXIMUM FUSE AND/OR CIRCUIT BREAKER SIZE
AND MINIMUM CIRCUIT AMPACITY.

6. SELECT INDOOR BLOWER SPEED TO REMAIN WITHIN THE TEMPERATURE
RISE RANGE ON THE NAMEPLATE IN HEATING AND TO OBTAIN APPROX.
400 CFM/TON IN COOLING.

7. BLOWER MOTOR SPEED CONNECTIONS SHOWN ARE TYPICAL,
BUT MAY VARY BY MODEL AND APPLICATION.

CONTROL BOARD SETTINGS:
COMBUSTION BLOWER POST PURGE: 60 SEC
INDOOR BLOWER HEAT ON DELAY: 30 SEC
INDOOR BLOWER COOL OFF DELAY: 60 SEC
INDOOR BLOWER HEAT OFF DELAY: FIELD SELECT

DSI Fault Codes

Green Heartbeat
Amber Heartbeat
Rapid Green Flashes

Operational Fault Codes

Flashes

None
Slow Green Flashes
Slow Amber Flashes
Rapid Amber Flashes
4 Amber Flashes
Steady on Red
1 Red Flash
2 Red Flashes
3 Red Flashes
4 Red Flashes
5 Red Flashes
6 Red Flashes
7 Red Flashes
8 Red Flashes
9 Red Flashes
10 Red Flashes
11 Red Flashes

FIGURE 14: Ladder Wiring Diagram - 3.5 to 5 Ton Models

Standby mode
Call for furnace heat active
Control in Factory Test mode

Fault Condition

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 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

THERMOSTAT

208/230-1-60

LINE VOLTAGE

FIELD INSTALLED POWER

LOW VOLTAGE

FIELD INSTALLED CONTROL

C

R

Y

W

G

ROLLOUT

GAS

VALVE

4

5

BLOWER
MOTOR

RED

RED/BLK

PRESSURE

3

2

GROUND
LUG

L1

C

N

OD FAN
MOTOR

RED

RED

R

S

F

RED

COM

XFMR

HI PRESS

ORG

RED

BRN/WHT

PUR

BLK

CONTACTOR
COIL

BLU

IGNITOR

YEL

R

L1

T1

BLK

CONTROL
BOARD
RELAY

PUR

L1

BLK

YEL

Y

RED/GRN

YEL

YEL

C

R

O

W

G

3

6

9

ORG

W SPD

G SPD

Y SPD

24V COM

BLU

RED

WHT

GRN

LIMIT

GRN

WHT

RED

1

C

BLU

YEL

BLK

2

5

8

ORG

BLK/WHT

IND

3A

FUSE

L1

C

WHT

230V

RED

1

4

7

1

COMPRES

S

BRN

H

BLOWER

L

MOTOR

G

DRAFT
MOTOR

CAP

24V SEC

40 VA

CONTROL

BOARD

SPARK

TRANSFORMER

IND

FS

2

3

DUAL
CAPACITOR

C

208V

PRI

PUR

BLU

T2

L2

L2

FLAME

SENSOR

22 Johnson Controls Unitary Products

1183746-UIM-D-1015

R-410A QUICK REFERENCE GUIDE

Refer to Installation Instructions for specific installation requirements

R-410A refrigerant operates at 50 - 70 percent higher pressures than R-22. Be sure that servicing
equipment and replacement components are designed to operate with R-410A.
R-410A refrigerant cylinders are rose colored.
Recovery cylinder service pressure rating must be 400 psig, DOT 4BA400, or DOT BW400.
Recovery equipment must be rated for R-410A.
DO NOT use R-410A service equipment on R-22 systems. All hoses, gages, recovery cylinders, charging
cylinders and recovery equipment must be dedicated for use on R-410A systems only.
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 from the atmosphere.
Vacuum pumps will not remove moisture from R-410A refrigerant oils.
Do not use liquid line driers with a rated working pressure rating less than 600 psig.
Do not install suction line driers in the liquid line.
A liquid line drier is required on every unit.
Do not use a R-22 TXV. If a TXV is to be used, it must be a R-410A TXV.
Never open system to atmosphere when under a vacuum.
If system must be opened for service, evacuate system then break the vacuum with dry nitrogen
and replace all lter driers.

FIGURE 15: R-410A Quick Reference Guide

Johnson Controls Unitary Products 23

1183746-UIM-D-1015

NOTES

24 Johnson Controls Unitary Products

SECTION VIII: START UP SHEET

Residential Package Unit Cooling / Gas Heat Start-Up Sheet

Print Form Reset Form

Proper start-up is critical to customer comfort and equipment longevity

Start-Up Date

Owner Information

Name Address

City State or Province Zip or Postal Code

Equipment Data

Equipment Data

Unit Model # Unit Serial #

General Information (Check all that apply)

Residential

Commercial

Unit Location and Connections (Check all that apply)

Unit is level and installed on:

Condensate drain properly connected per the installation instructions Condensate trap has been primed with water

New Construction

Retrofit

Slab Roof curb Supply Return

Duct connections are complete:

Start-Up TechnicianCompany Name

Roof level

Grade level

Daytime Phone

Down flow

Side flow

1183746-UIM-D-1015

Filters

Filters installed Filter located inside Filter located outside

Additional Kits & Accessories Installed

Refrigerant safety kit Low ambient kit

Manual fresh air damper kit Motorized fresh air damper kit

Number of filters Filter size

(Check all that apply)

Anti-recycle timer

EconomizerTransformer kit Roof curb kit

Crank case heater

Base rail hole blockage kit

Filter frame kit

Electrical Connections & Inspection (Check all that apply)

Three phaseSingle phase

Low voltage present at control board "R & C"

Line voltage present at disconnect

208 volts AC 230 volt AC 460 volts AC 575 volts AC

Transformer wired properly for primary supply voltageInspect wires and electrical connections

Measured voltage "R" and "C" outdoor unit control board

Measured voltage "L1 to L2" "L2 to L3" "L1 to L3"

Total amperes "L1" "L2" "L3"Compressor amperes "L1" "L2" "L3"

Two stage compressorSingle stage compressor

Ground connected

Air Flow Setup / Cooling

Blower Type

&

Set-Up

V.S.
ECM

ECM

PSC

COOL

ADJUST

DELAY

1 2 3 4 5

Low Medium Low Medium Medium High High

A B C D

A B C D

A

B

C D

Supply static (inches of water column)

Return static (inches of water column)

Total external static pressure

Johnson Controls Unitary Products 25

Supply air dry bulb temperature

Return air dry bulb temperature

Temperature drop

Outside air dry bulb temperature

Return air wet bulb temperature

Supply air wet bulb temperature

Page 1 of 2

Refrigerant Charge and Metering Device

R-410A R-22

TXV Fixed Orifice

TXV# / Orifice size

Data plate - lbs / Oz

Discharge line

temperature

Suction line temperature

Suction pressure

Superheat

Gas Heat

Two StageSingle Stage Propane LP (Requires LP Conversion Kit)Natural Gas

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

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

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

Measured BTU/H (Clock Gas Meter Nat Gas)

Supply Air Dry Bulb Temp Temp RiseReturn Air Dry Bulb Temp

Clean Up Job Site

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

Tools have been removed from unit

All panels have been installed

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

Owner Education

Provide owner with the owner's manual

Explain operation of system to equipment owner

Explain thermostat use and programming (if applicable) to owner

Explain the importance of regular filter replacement and equipment maintenance

Discharge pressure

Liquid line temperature

Subcooling

Inlet Gas Pressure (w.c.")LP Gas Conversion Kit # LP Conversion Kit Installed By

Rated BTU/H

Comments and Additional Job Details

Subject to change without notice. Published in U.S.A. 1183746-UIM-D-1015
Copyright © 2015 by Johnson Controls, Inc. All rights reserved. Supersedes: 1183746-UIM-C-0715

York International Corp.

5005 Y ork Drive

Norman, OK 73069