Johnson Controls Unitary Products PCG4 series User manual

Johnson Controls Unitary Products 5163360-UIM-G-0616
®
SINGLE PACKAGE
AIR CONDITIONER / GAS HEAT
MODELS: PCG4 Series
3 - 5 Tons – 3 Phase – 460V
INSTALLATION MANUAL
LIST OF SECTIONS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MODEL NUMBER NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
AIRFLOW PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
TYPICAL WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
START UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
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
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Measuring External Static Pressure . . . . . . . . . . . . . . . . . . . . . . . . .17
Connection Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Ladder Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
R-410A Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
LIST OF TABLES
Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Weights and Dimensions -Three-phase models . . . . . . . . . . . . . . . . 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
High Altitude Gas Orifice Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Natural Gas Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Propane (LP) Gas Application Data . . . . . . . . . . . . . . . . . . . . . . . . .11
Airflow Performance - Side Duct Application . . . . . . . . . . . . . . . . . .12
Airflow Performance - Bottom Duct Application . . . . . . . . . . . . . . . .13
Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Ignition Control Board Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . .15
Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
SECTION I: GENERAL INFORMATION
These are electric cooling/gas heating units designed for outdoor instal-
lation. Only gas piping, electric power and duct connections are
required at the point of installation.
The gas-fired heaters have spark ignition.
The refrigerant system is fully charged with R-410A Refrigerant, and is
tested and factory sealed.
SECTION II: SAFETY
This is a safety alert symbol. When you see this symbol on
labels or in manuals, be alert to the 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 dam-
age.
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 mal-
function, 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 installa-
tion instructions and any applicable local, state, and national codes
including, but not limited to building, electrical, and mechanical
codes.
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5163360-UIM-G-0616
2 Johnson Controls Unitary Products
Due to system pressure, moving parts, and electrical components,
installation and servicing of air conditioning equipment can be hazard-
ous. Only qualified, trained service personnel should install, repair, or
service this equipment. Untrained personnel can perform basic mainte-
nance 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 includ-
ing 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
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.
4. Always install unit to operate within the unit's intended temperature-
rise 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
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 mainte-
nance 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 pres-
sures than R-22. No other refrigerant may be used in this system.
Gage sets, hoses, refrigerant containers and recovery systems must
be designed to handle R-410A. If you are unsure, consult the equip-
ment manufacturer. Failure to use R-410A compatible 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 depart-
ment.
Installation and service must be performed by a qualified installer,
service agency or the gas supplier.
!
PCG 4 A 24 050 3 X 1 A
123456789
1. Model Family
PCG - packaged A/C with gas heat,
PCE - packaged A/C with electric heat,
PHE - packaged heat pump with electric heat
PHG - packaged heat pump with gas heat.
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
2. Nominal Cooling Efficiency
4 = 14 SEER, 6 = 16 SEER, etc. 7. NOx Approval X = low-NOx, blank = not low-NOx
3. Cabinet Size
A = small 35 x 51, B = large 45 x 51 8. Generation Level 1 = first generation
4. Nominal Air Conditioning Cooling Capacity
24 = Nominal Capacity, etc. 9. Revision Level A = original release, B = second release
Examples:
PCG4B421003X1A 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, three
phase, low-NOx model (first generation, first release).
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.
!

5163360-UIM-G-0616
Johnson Controls Unitary Products 3
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 Edi-
tion
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.
FIGURE 1: Component Location
FAN MOTOR OUTDOOR FAN
COIL GUARD PANEL
OUTDOOR COIL
(Behind Panel)
CONTROL BOARD
TRANSFORMER
HIGH VOLTAGE
CONTACTOR
PRESSURE SWITCH
DRAFT INDUCER BLOWER
GAS VALVE
BURNER
ASSEMBLY
GAS HEAT
EXCHANGER
BLOWER MOTOR
TXV
INDOOR COIL
INDOOR BLOWER
COMPRESSOR
REMOVABLE
BASE RAILS
A0297-001
Table 1: Unit Limitations
Model Unit Voltage Unit Limitations Applied Voltage Outdoor DB Temp
Min Max Max (°F)
PCG4A36 460-3-60 432 504 125PCG4B48
PCG4B60

5163360-UIM-G-0616
4 Johnson Controls Unitary Products
LOCATION
Use the following guidelines to select a suitable location for these units:
1. Unit is designed for outdoor installation only.
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.
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.
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, CSA-
B149.1 (in Canada) - Latest Edition, and/or applicable provisions of the
local building codes. Refer to Table 4 for clearances required for com-
bustible construction, servicing, and proper unit operation.
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.
Units may be moved or lifted with a forklift. Slotted openings in the base
rails are provided for this purpose.
WARNING
Do not attach supply and return duct work to the bottom of the unit
base pan as the drain pan could be compromised.
WARNING
Excessive exposure of this unit to contaminated combustion air may
result in equipment damage or personal injury. Typical contaminates
include: permanent wave solution, chlorinated waxes and cleaners,
chlorine based swimming pool chemicals, water 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.
WARNING
Do not permit overhanging structures or shrubs to obstruct con-
denser air discharge outlet, combustion air inlet or vent outlets.
!
!
!
CAUTION
Before lifting, make sure the unit weight is distributed equally on the
rigging cables so it will lift evenly.
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.
FIGURE 2: Center of Gravity Location
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!
!
X
CENTER OF
GRAVITY
FRONT
OF UNIT
Y
"D"
"C"
"B"
"A"
A0295-001
COMPRESSOR
Table 2: Weights and Dimensions -Three-phase models
Model Weight (lbs.) Center of Gravity 4 Point Load Location (lbs.)
Shipping Operating X Y ABCD
36050 425 420 28
15
141 107 94 78
36075 432 427 28 135 115 103 74
36100 436 431 28 139 113 99 80
48065 520 515 28 189 116 93 117
48100 528 523 28 169 139 115 100
48125 533 528 28 164 145 124 95
60065 537 532 29 174 142 124 92
60100 541 536 28 177 140 117 102
60125 548 543 27 151 167 141 84

5163360-UIM-G-0616
Johnson Controls Unitary Products 5
FIGURE 3: Unit Dimensions
Table 3: Unit Dimensions
Model Dimensions
ABC
PCG4A36 51-1/4 35-3/4 47
PCG4B48 45-3/4 53
PCG4B60 45-3/4 55
Table 4: Unit Clearances1,2
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.
Direction Distance (in.) Direction Distance (in.)
Top3
3. Units must be installed outdoors. Over hanging structure or shrubs should not obstruct condenser air discharge outlet.
36 Power Entry (Right Side) 36
Side Opposite Ducts 36 Left Side 24
Duct Panel 0 Bottom4
4. Units may be installed on combustible floors made from class A, B or C roof covering materials only if factory base rails are left in place as shipped.
1
HIGH VOLTAGE
CONNECTION 7/8”
HIGH VOLTAGE
CONNECTION 1-3/32”
COMPRESSOR
ACCESS PANEL
CONDENSATE
DRAIN BLOWER
ACCESS
PANEL CONTROL / HEAT
ACCESS PANEL
LOW VOLTAGE CONNECTION
GAS SUPPLY
EXHAUST HOOD
COMBUSTION AIR INTAKE
HEAT EXCHANGER ACCESS PANEL
B
A
C
A0296-001
COIL GUARD

5163360-UIM-G-0616
6 Johnson Controls Unitary Products
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 preceding Step) to the rear sup-
ply and return air duct openings.
3. Seal duct covers with silicone caulk.
Duct work should be designed and sized according to the methods of
theAir Conditioning Contractors ofAmerica (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 recom-
mended to be used in the supply and return duct work to minimize the
transmission of vibration and noise.
Refer to Figures 4 and 5 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.
It is the responsibility of the installer to secure a filter in the return air
ductwork or utilize the filter rack kit shipped with all three phase models.
A filter rack kit is included with all 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.
Model A B C D E F
36 10 21.5 54.5 47.5 32
48, 60 14 13.5 3.5 42
FIGURE 4: Bottom Duct Dimensions (inches)
Model A B
36 9.6 22
48, 60 13.6 14
FIGURE 5: Rear Duct Dimensions (inches)
D16
C
A
B
A
A0298-001
SUPPLY
AIR DUCT
RETURN
AIR DUCT
F
E
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NOTICE
All units are shipped in the horizontal supply/return configuration. It is
important to reduce the possibility of any air leakage through the bot-
tom duct covers (resulting from cut, torn, or rolled gasket) due to
improper handling or shipping processes. To ensure a good tight
seal, it is recommended that silicone caulk and/or foil tape be applied
along the cover edges.
NOTICE
Be sure to note supply and return openings.

5163360-UIM-G-0616
Johnson Controls Unitary Products 7
CONDENSATE DRAIN
A condensate trap must be installed in the condensate drain. The
plumbing must conform to local codes.
Use Teflon tape or pipe thread compound if needed.
SERVICE ACCESS
Access to all serviceable components is provided at the following loca-
tions:
• 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 3 for location of these access locations and minimum
clearances in Table 4.
Refer to Figure 13 for the R-410A Quick Reference Guide.
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 proce-
dure. 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.
CAUTION
Hand tighten only.
CAUTION
This system uses R-410A Refrigerant which operates at higher pres-
sures than R-22. No other refrigerant may be used in this system.
Gage sets, hoses, refrigerant containers and recovery systems must
be designed to handle R-410A. If you are unsure, consult the equip-
ment manufacturer. Failure to use R-410A compatible 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.
!
!
!
FIGURE 6: Typical Field Control Wiring Diagram For Gas Heat - AC
Models
FIGURE 7: Typical Field Power Wiring Diagram
THERMOSTAT
NOTE:
Heat Anticipator should be set at 0.35 AMPS for all models
CONTROL
BOARD
Minimum wire size of 18 AWG wire should be used for all field
installed control wiring.
RED
GREEN
YELLOW
WHITE
BLUE
R
G
W
Y
C
A0294-001
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'$7$7$%/(6726,=(
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Table 5: Electrical Data
Model Voltage Compressor Outdoor Fan
Motor Indoor Fan Blower Motor MCA1
(Amps)
1. Minimum Circuit Ampacity.
Max Fuse2/
Breaker3Size
(Amps)
2. Maximum Over Current Protection per standard UL 1995.
3. Fuse or HACR circuit breaker size installed at factory or field installed.
RLA LRA MCC FLA FLA
36050, 36075
460-3-60
4.1 34.0 7.6 0.70 1.95 7.8 15
36100 4.1 34.0 7.6 0.70 3.15 9.0 15
48065, 48100, 48125 6.2 41.0 9.7 0.87 3.15 11.8 15
60065, 60100, 60125 7.8 52.0 12.1 0.87 3.15 13.8 20

5163360-UIM-G-0616
8 Johnson Controls Unitary Products
Table 6: Physical Data
COMPONENT MODELS
A36 B48 B60
NOMINAL TONNAGE 3.0 4.0 5.0
AHRI Cooling Performance
Gross Capacity @ AHRI A point (MBH) 37.2 47.7 55.0
AHRI net capacity (MBH) 34.6 45.5 52.5
EER 11.0 11.0 11.0
SEER 14.0 14.0 14.0
Nominal CFM 1200 1600 2000
System power (KW) 3.2 4.2 4.8
Refrigerant type R410A R410A R410A
Refrigerant charge (lb-oz) 8-3 14-4 14-2
AHRI Gas Heat Performance
Heating model 50 75 100 65 100 125 65 100 125
Heat input (K Btu) 50.0 75.0 100.0 65.0 100.0 125.0 65.0 100.0 125.0
Heat output (K Btu) 40 60 80 52 80 100 52 80 100
AFUE% 81.0 81.0 81.0
No. burners 2 34234234
No. stages 1 1 1
Temperature Rise Range (°F) 35-65 40-70 40-70 40-70 40-70
Max. Static Pressure w.c. 0.5 0.5 0.5
Max. Outlet Air Temp. (°F) 180 180 180
Gas piping connection (in.) 1/2 1/2 1/2
Dimensions (inches)
Length 51-1/4 51-1/4 51-1/4
Width 35-3/4 45-3/4 45-3/4
Height 47 53 55
Operating WT. (lbs.) 420 427 431 515 523 528 532 536 543
Compressors
Type Recip Scroll Scroll
Outdoor Coil Data
Face area (Sq. Ft.) 15.1 23.8 25.9
Rows 2 2 2
Fins per inch 22 22 22
Tube diameter 3/8 3/8 3/8
Circuitry Type Interlaced Interlaced Interlaced
Indoor Coil Data
Face area (Sq. Ft.) 4.6 6.3 6.3
Rows 3 3 3
Fins per inch 16 16 16
Tube diameter 3/8 3/8 3/8
Circuitry Type Interlaced Interlaced Interlaced
Refrigerant control TXV TXV TXV
Outdoor Fan Data
Fan diameter (Inch) 24 26 26
Type Prop Prop Prop
Drive type Direct Direct Direct
No. speeds 1 1 1
Motor HP each 1/4 1/3 1/3
RPM 850 850 850
Nominal total CFM 2400 3200 3200
Direct Drive Indoor Fan Data
Fan Size (Inch) 11 x 10 11 x 10 11 x 10
Type Centrifugal Centrifugal Centrifugal
Motor HP each 1/2 1/2 1 1 1
RPM 1200 Max 1200 Max 1200 Max
Frame size 48 48 48
Filters
Quantity - Size Field-supplied external filters must be sized so as not to exceed 300 FPM air velocity through disposable filters. All three phase models are shipped with an internal filter rack kit. Consult the instructions supplied
with that kit for replacement filter sizes. Filter sizes: A=20x20, B=20x30.

5163360-UIM-G-0616
Johnson Controls Unitary Products 9
COMPRESSORS
The compressor used in this product is specifically designed to operate
with R-410A Refrigerant and cannot be interchanged.
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 pre-
cautions to avoid exposure of the oil to the atmosphere.
POE (polyolester) compressor lubricants are known to cause long term
damage to some synthetic roofing materials.
Procedures which risk oil leakage include, but are not limited to, com-
pressor 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 factory-
adjusted and ready for operation.
PHASING
Three-phase, scroll compressors operate in only one direction. If the
scroll is drawing low amperage, has similar suction and discharge pres-
sures, or is producing a high noise level, the scroll is out of phase.
Change the incoming line connection phasing to obtain the proper rota-
tion.
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 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 sup-
plied 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.
Gas piping requirements:
1. A drip leg and a ground joint union must be installed in the gas pip-
ing.
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.
CAUTION
This system uses R-410A Refrigerant which operates at higher pres-
sures than R-22. No other refrigerant may be used in this system.
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
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.
CAUTION
Do not loosen compressor mounting bolts.
CAUTION
Scroll compressors require proper rotation to operate properly. Fail-
ure to check and correct rotation may result in property damage.
!
!
!
!
!
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.
Table 7: Natural Gas Pipe Sizing Chart1
1. Maximum capacity of pipe in cubic feet of gas per hour (based upon a pres-
sure drop of 0.3 inch water column and 0.6 specific gravity gas).
Length
In Feet Nominal Inches Iron Pipe Size
1/2” 3/4” 1” 1-1/4”
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
Table 8: Propane (LP) Gas Pipe Sizing Chart1
1. Maximum capacity of pipe in thousands of BTU per hour (based upon a
pressure drop of 0.5 inch water column).
Length
In Feet Nominal Inches Iron Pipe Size
1/2” 3/4” 1” 1-1/4”
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
CAUTION
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 cas-
ing.
!

5163360-UIM-G-0616
10 Johnson Controls Unitary Products
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.
5. The gas supply should be a separate line and installed in accor-
dance with all applicable safety codes. After the gas connections
have been completed, open the main shut-off valve admitting nor-
mal gas pressure to the gas valve. Check all joints for leaks with
soap solution or other material suitable for the purpose. NEVER
USE AN OPEN FLAME.
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).
HIGH ALITITUDE GAS CONVERSION
This furnace is constructed at the factory for natural gas-fired operation
at altitudes up to 2,000 feet above sea level. For installations located
above 2,000 feet, the gas input rate to the burners must be reduced by
4% per 1,000 feet above sea level. It may be necessary to change to
smaller orifices at high altitude. Refer to the table below for the correct
orifice size to use.
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 fas-
tened to the outside of the side gas control/electrical compartment with
the screws provided. See Figure 8.
WARNING
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 com-
pounds such as gaskoloc or stalastic, and compounds such as Rec-
torseal # 5, Clyde’s or John Crane may be used.
!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.
!
Table 9: High Altitude Gas Orifice Sizing
ELEVATION ABOVE SEA LEVEL (FEET)
GAS TYPE 0-2000 (FACTORY) 2001-3000 3001-4000 4001-5000 5001-6000 6001-7000 7001-8000 8001-9000 9001-10000
NATURAL GAS ORIFICE SIZES 36 37 38 38 39 40 41 41 42
42 42 43 43 43 44 44 45 46
LP GAS ORIFICE SIZES 51 51 52 52 52 52 53 53 53
54 54 55 55 55 55 55 56 56
WARNING
Flue hood surfaces may be hot.
!
FIGURE 8: Flue Vent Outlet Air Hood
CAUTION
The flue exhaust hood must be properly installed and within the rec-
ommended 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 HOOD
AIR INTAKE SCREEN
EXHAUST HOOD
A0284-001
!

5163360-UIM-G-0616
Johnson Controls Unitary Products 11
Table 10: Natural Gas Application Data
Available On Models Input (MBH)1
High Fire
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.
Output (MBH)
High Fire
Gas Rate2
Ft.3/Hr.
High Fire/Low Fire
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.
Number of
Burners
Temp. Rise ºF
Min. Max.
3 Tons 50 41 46 2 35 65
4, 5 Tons 65 53 60 2 40 70
3 Tons 75 61 70 3 40 70
3 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
Table 11: Propane1(LP) Gas Application Data
1. Propane applications are accomplished by field installation of a Propane ConversionAccessory, Model 1NP0701 for “A” cabinet models and Model 1NP0702 for
“B” cabinet models.
Available On Models Input (MBH) Output Capacity
(MBH)2
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.
Gas Rate3
Ft.3/Hr.
High Fire/Low Fire
3. Based on 2500 BTU/Ft.3.
Number of
Burners
Temp. Rise ºF4
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.
Min. Max.
3 Tons 50 41 20 2 35 65
4, 5 Tons 65 53 26 2 40 70
3 Tons 75 61 30 3 40 70
3 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

5163360-UIM-G-0616
12 Johnson Controls Unitary Products
SECTION V: AIRFLOW PERFORMANCE
1. Airflow tested with dry coil conditions, without air filters, at 460 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. Heating applications tested at 0.50" w.c. esp, and cooling applications tested at 0.30" w.c.esp per standards.
Table 12: Airflow Performance - Side Duct Application
Model Motor Speed External Static Pressure (Inches WC) 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 1.0
SCFM SCFM SCFM SCFM SCFM SCFM SCFM SCFM SCFM
36050
Low (1) 1003 952 904 851 790 730 674 633 551
Low/Medium (2) 1180 1133 1085 1042 995 942 889 834 724
Medium (3) 1259 1209 1166 1126 1084 1032 980 928 824
Medium/High (4) 1314 1271 1229 1186 1144 1097 1049 998 896
High (5) 1506 1471 1403 1389 1345 1305 1262 1216 1124
36075
Low (1) 1225 1174 1131 1090 1046 993 941 888 782
Low/Medium (2) 1259 1209 1166 1126 1084 1032 980 928 824
Medium (3) 1314 1271 1229 1186 1144 1097 1049 998 896
Medium/High (4) 1348 1306 1259 1222 1179 1133 1086 1036 936
High (5) 1506 1471 1403 1389 1345 1305 1262 1216 1124
36100
Low (1) 1342 1302 1260 1217 1178 1134 1082 1034 938
Low/Medium (2) 1425 1368 1332 1293 1251 1208 1163 1113 1013
Medium (3) 1554 1503 1465 1423 1386 1346 1302 1257 1167
Medium/High (4) 1658 1599 1588 1530 1495 1454 1414 1373 1291
High (5) 1966 1914 1862 1810 1757 1705 1653 1600 1496
48065
Low (1) 1046 1009 980 946 915 878 844 779 649
Low/Medium (2) 1295 1250 1213 1172 1133 1087 1045 964 802
Medium (3) 1620 1564 1517 1466 1418 1360 1308 1206 1002
Medium/High (4) 1798 1722 1669 1620 1572 1527 1480 1413 1280
High (5) 2146 2085 2025 1960 1872 1862 1798 1735 1609
48100
Low (1) 1620 1564 1517 1466 1418 1360 1308 1206 1002
Low/Medium (2) 1694 1630 1580 1530 1482 1430 1380 1292 1116
Medium (3) 1798 1722 1669 1620 1572 1527 1480 1413 1280
Medium/High (4) 1835 1758 1703 1653 1604 1558 1511 1442 1304
High (5) 2146 2085 2025 1960 1872 1862 1798 1735 1609
48125
Low (1) 1620 1564 1517 1466 1418 1360 1308 1206 1002
Low/Medium (2) 1798 1722 1669 1620 1572 1527 1480 1413 1280
Medium (3) 1922 1863 1804 1754 1724 1658 1612 1559 1453
Medium/High (4) 2001 1952 1890 1839 1820 1742 1696 1651 1561
High (5) 2146 2085 2025 1960 1872 1862 1798 1735 1609
60065
Low (1) 1073 1043 1009 988 963 941 917 892 842
Low/Medium (2) 1329 1292 1250 1223 1192 1165 1136 1105 1043
Medium (3) 2054 1998 1934 1890 1843 1801 1757 1710 1616
Medium/High (4) 2195 2144 2098 2049 2003 1955 1883 1868 1838
High (5) 2445 2388 2306 2293 2235 2178 2129 2077 1973
60100
Low (1) 1730 1682 1628 1592 1552 1517 1479 1439 1359
Low/Medium (2) 1858 1807 1749 1710 1667 1629 1589 1546 1460
Medium (3) 2054 1998 1934 1890 1843 1801 1757 1710 1616
Medium/High (4) 2195 2144 2098 2049 2003 1955 1883 1868 1838
High (5) 2445 2388 2306 2293 2235 2178 2129 2077 1973
60125
Low (1) 2063 2008 1943 1899 1851 1809 1763 1717 1625
Low/Medium (2) 2130 2084 2032 1983 1927 1951 1860 1815 1725
Medium (3) 2195 2144 2098 2049 2003 1955 1883 1868 1838
Medium/High (4) 2275 2252 2169 2154 2112 2065 1989 1976 1950
High (5) 2445 2388 2306 2293 2235 2178 2129 2077 1973

5163360-UIM-G-0616
Johnson Controls Unitary Products 13
1. Airflow tested with dry coil conditions, without air filters, at 460 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. Heating applications tested at 0.50" w.c. esp, and cooling applications tested at 0.30" w.c.esp per standards.
Table 13: Airflow Performance - Bottom Duct Application
Model Motor Speed External Static Pressure (Inches WC) 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 1.0
SCFM SCFM SCFM SCFM SCFM SCFM SCFM SCFM SCFM
36050
Low (1) 1008 962 916 861 807 757 700 650 550
Low/Medium (2) 1190 1148 1106 1055 1008 955 914 863 761
Medium (3) 1262 1223 1181 1137 1091 1044 994 952 868
Medium/High (4) 1324 1282 1245 1202 1161 1112 1067 1018 920
High (5) 1517 1475 1447 1400 1357 1318 1275 1232 1146
36075
Low (1) 1231 1186 1146 1103 1069 1030 977 912 781
Low/Medium (2) 1270 1225 1189 1140 1098 1046 1008 960 866
Medium (3) 1317 1286 1245 1198 1151 1110 1064 1024 943
Medium/High (4) 1358 1317 1275 1238 1197 1148 1105 1057 961
High (5) 1517 1475 1447 1400 1357 1318 1275 1232 1146
36100
Low (1) 1340 1299 1264 1224 1182 1182 1097 1049 953
Low/Medium (2) 1409 1368 1334 1291 1253 1201 1173 1128 1038
Medium (3) 1527 1492 1470 1419 1385 1343 1299 1250 1152
Medium/High (4) 1663 1585 1594 1601 1521 1480 1440 1400 1320
High (5) 1930 1892 1853 1805 1760 1696 1625 1553 1409
48065
Low (1) 1032 999 970 938 910 879 843 808 737
Low/Medium (2) 1272 1236 1204 1165 1129 1081 1037 968 829
Medium (3) 1611 1574 1518 1494 1439 1405 1357 1266 1083
Medium/High (4) 1892 1777 1771 1701 1639 1617 1565 1489 1336
High (5) 2131 2058 1998 1949 1892 1840 1788 1728 1608
48100
Low (1) 1598 1548 1502 1454 1410 1362 1307 1251 1139
Low/Medium (2) 1663 1612 1568 1522 1476 1422 1370 1297 1152
Medium (3) 1789 1733 1670 1650 1596 1578 1535 1483 1379
Medium/High (4) 1931 1814 1808 1736 1673 1650 1597 1519 1362
High (5) 2131 2058 1998 1949 1892 1840 1788 1728 1608
48125
Low (1) 1598 1548 1502 1454 1410 1362 1307 1251 1139
Low/Medium (2) 1766 1703 1656 1611 1566 1518 1469 1419 1319
Medium (3) 1912 1875 1805 1787 1750 1713 1672 1636 1564
Medium/High (4) 2105 2014 2006 1931 1898 1845 1793 1739 1631
High (5) 2131 2058 1998 1949 1892 1840 1788 1728 1608
60065
Low (1) 1026 999 989 950 907 907 886 862 816
Low/Medium (2) 1263 1230 1192 1165 1167 1101 1099 1071 1015
Medium (3) 1987 1933 1861 1817 1820 1715 1725 1651 1504
Medium/High (4) 2114 2050 2047 1974 1899 1889 1920 1866 1758
High (5) 2369 2308 2249 2183 2126 2088 2034 1990 1902
60100
Low (1) 1655 1612 1596 1531 1461 1462 1429 1391 1316
Low/Medium (2) 1766 1720 1667 1629 1632 1539 1537 1498 1421
Medium (3) 1987 1933 1861 1817 1820 1715 1725 1651 1504
Medium/High (4) 2114 2050 2047 1974 1899 1889 1920 1866 1758
High (5) 2369 2308 2249 2183 2126 2088 2034 1990 1902
60125
Low (1) 1973 1924 1905 1826 1743 1744 1703 1660 1574
Low/Medium (2) 2024 1983 1937 1889 1886 1843 1799 1759 1679
Medium (3) 2123 2075 2019 1970 1978 1862 1849 1804 1714
Medium/High (4) 2191 2154 2117 2075 2002 1995 2028 1974 1866
High (5) 2369 2308 2249 2183 2126 2088 2034 1990 1902

5163360-UIM-G-0616
14 Johnson Controls Unitary Products
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 (con-
nected 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 de-
energizes the inducer without post-purge and returns to standby.
If the pressure switch does not close within 5 seconds of inducer ener-
gizing, 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 sec-
ond 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 de-
energizes 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.
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 post-
purge period, and then de-energizes the inducer. If a call for heat
occurs during post-purge, the control finishes the postpurge, and imme-
diately 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 com-
plete, 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 remov-
ing 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 min-
utes or power interruption. Cooling operations are available during a
heating lockout.
Table 14: Additional Static Resistance
Size (Tons) CFM Wet Indoor Coil1
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 u.nit will deliver less CFM during full economizer operation.
Economizer Filter/Frame Kit
A36 (3.0)
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
B48 (4.0)
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
B60 (5.0)
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
NOTE: Filter pressure drop based on standard filter media tested at velocities
not to exceed 300 ft/min.

5163360-UIM-G-0616
Johnson Controls Unitary Products 15
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 oper-
ation 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 sec-
ond 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 compart-
ment 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 ener-
gized.
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.
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 replace-
ments for the R-410A pressure switches.
Circulating Fan
When the thermostat calls for FAN, the thermostat terminal G is ener-
gized 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 Y-
Speed 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.
NOTICE
The manual reset Rollout Switch (RS) must be reset before allowing
furnace operation.
Table 15: 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 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 code
11 Red Flashes Limit/Rollout switch open between 5 and 15
minutes
Wiring Related Faults
9 Red Flashes Incorrect low voltage polarity
4 Amber Flashes Y thermostat demand without a G
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 mainte-
nance 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.
!

5163360-UIM-G-0616
16 Johnson Controls Unitary Products
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 per-
formed.
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 sec-
tion 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.
Compressor Rotation
Three-phase, scroll compressors operate in only one direction. If the
scroll is drawing low amperage, has similar suction and discharge pres-
sures, or is producing a high noise level, the scroll is out of phase.
Change the incoming line connection phasing to obtain the proper rota-
tion.
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.
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 counter-
clockwise.
3. To increase the gas pressure, turn the adjusting screw clockwise.
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 calcu-
lated as follows:
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.
CAUTION
Scroll compressors require proper rotation to operate properly. Fail-
ure to check and correct rotation may result in property damage.
FIGURE 9: Gas Valve
NOTICE
The correct manifold pressure for natural gas furnaces is 3.5 IWG.
The correct manifold pressure for propane (LP) is 10.0 IWG.
!
INLET
WRENCH
BOSS
INLET
PRESSURE
PORT
ON
OFF
ON/OFF SWITCH
(Shown in ON position)
MAIN REGULATOR
ADJUSTMENT
OUTLET
OUTLET
PRESSURE
PORT
VENT PORT
A0303-001
BTUH Output
1.08 x CFM
OR
CFM= BTUH Output
Degrees F Temp Rise =
1.08 x Degrees F Temp Rise

5163360-UIM-G-0616
Johnson Controls Unitary Products 17
EXTERNAL STATIC PRESSURE SETUP
To measure external static pressure:
• Measure the supply air static pressure
• Record this positive number
• 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
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 allow-
ance being made for the permissible range of the regulator setting,
replace the orifice spuds with spuds of the proper size.
Example of Table 15 Use
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 run-
ning. Using this information, locate 38 seconds in the first column of
Table 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.
FIGURE 10: Measuring External Static Pressure
A0435-001
RETURN AIR
DUCT
SUPPLY AIR
DUCT
NOTICE
To find the BTU input, multiply the number of cubic feet of gas con-
sumed 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 16: Gas Rate Cubic Feet Per Hour
Seconds for
One Revolution Size of Test Dial
1/2 cu. ft. 1 cu. ft.
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

5163360-UIM-G-0616
18 Johnson Controls Unitary Products
SECTION VII: TYPICAL WIRING DIAGRAMS
FIGURE 11: Connection Wiring Diagram
BLU 23
RED 22
WHT 20
GRN 19
Y
R
G
C
THERMOSTAT
USE COPPER
CONDUCTORS
ONLY
RED/GRN 36
ORG 39
RED 34
YEL 31
WHT 33 GRN 4
(LOW)
(LOW/MED)
(MED)
(MED/HIGH)
(HIGH)
RED 32
RED/BLK 35
ROLLOUT
PRESSURE
LIMIT
BLOWER
DELAY
60
90
120
180
FS
L1 IND
SPARK
TRANSFORMER
C
L
G
N
1
2
3
4
5
1
2
3
4
DRAFT
MOTOR
YEL 17
HI PRESS
YEL 38
YEL 38
GRN 40
ORG 37
4
5
6
1
2
3
7
8
9
3
2
1
24V COM
Y SPD
G SPD
W SPD
R
O
Y
W
C
BRN
WHT
BLK
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
W
Y
O
R
G
C
LOW
VOLTAGE
BOX
RED 28
ORG
IGNITOR FLAME
SENSOR
GAS
VALVE
CONTROL
BOARD
CAP
PUR 26
W
(COOLING SPEED)
(HEATING SPEED)
(CONTINUOUS FAN)
BLK
YEL
BLU
BLK/WHT 12
BRN/WHT 13
BLK 6
RED 9
OD FAN
MOTOR
POWER SUPPLY
460-3-60
PUR 1
BLK 5
COM
24V SEC
75 VA
460V
COMPR
L1 T1
T2
L2
CAPACITOR
RED 7
GRN
BLU 43
GND
CONTACTOR
COIL
CONTACTOR
RED 45
BLU 42
BLU 30
PUR 2
YEL 21
BLK
YEL 18
GRN 44
LINE VOLTAGE
FIELD INSTALLED POWER
LOW VOLTAGE
FIELD INSTALLED CONTROL
5
4
3
2
6
1BLK
BRN
GRN 10
RED
Flashes
Operational Fault Codes
Fault Condition
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
Normal Operation
Standby mode
Call for furnace heat active
Control in Factory Test mode
Green Heartbeat
Amber Heartbeat
Rapid Green Flashes
Power Off or open fuse
Normal Operation
Normal Operation with call for heat
Low flame sense current
No G from thermostat with Y call
Control Failure
Flame present 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
Improper ground OR
incorrect 24V phasing
Gas valve shorted "ON"
Check blower motor/wiring
DSI Fault Codes
THREE - PHASE
COOLING UNIT WITH GAS HEAT
CONNECTION WIRING DIAGRAM
BLOWER
MOTOR
SHARED TAP
460-3-60
SEE NOTE 7
XFMR
L3 T3
CONTACTOR
460V
PRI
120V SEC
25 VA
AUX XFMR
PUR
YEL
AUX
RELAY
WHT
YEL
YEL
GRN
CAUTION - OPEN ALL DISCONNECTS
BEFORE SERVICING THIS UNIT
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 460 VOLT THREE PHASE SUPPLY POWER.
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:
THIS UNIT IS WIRED
FOR THREE-PHASE POWER.
DO NOT CONNECT TO
A SINGLE-PHASE SUPPLY.
NOTICE
T1/C
T3/R
T2/S
5155330-UWD-B-0116

5163360-UIM-G-0616
Johnson Controls Unitary Products 19
FIGURE 12: Ladder Wiring Diagram
CAUTION - OPEN ALL DISCONNECTS
BEFORE SERVICING THIS UNIT
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 460 VOLT THREE PHASE SUPPLY POWER.
NOTES:
COM
24V SEC
75 VA
460V
L1 L2
COMPR.
BLOWER
MOTOR
LN
G
BLOWER
MOTOR
5
3
C
1
HI PRESS
CONTACTOR
COIL
42
CAPACITOR
T1
L1
L2
T2
DRAFT
MOTOR
CONTROL BOARD
RELAY
CAP
BLU
RED
WHT
GRN
Y
R
G
C
THERMOSTAT
RED/GRN
ORG
RED
RED/BLK
ROLLOUT
PRESSURE
LIMIT
FS
L1 IND
SPARK
TRANSFORMER
YEL
YEL
GRN
ORG
4
5
6
1
2
3
7
8
9
3
2
1
24V COM
Y SPD
G SPD
W SPD
W
Y
O
R
G
C
RED
ORG
IGNITOR FLAME
SENSOR
GAS
VALVE
CONTROL
BOARD
W
YEL
BLU
YEL
RED
WHT
3A
FUSE
LADDER WIRING DIAGRAM
BLK BLU
RED
OD FAN
MOTOR
R
C
S
BLK/WHT
RED
BRN/WHT
PUR
BLK
BLK
PUR
BLU
RED
BLK
BLU
YEL
XFMR
L3
L3
T3
YEL
THIS UNIT IS WIRED
FOR THREE-PHASE POWER.
DO NOT CONNECT TO
A SINGLE-PHASE SUPPLY.
NOTICE
SEE NOTE 7
GND
120V
AUX RELAY
COIL
WHT
GRN
BLK
460V
AUX XFMR
25 VA
PUR
AUX RELAY
YEL
PUR
YEL YEL
Flashes
Operational Fault Codes
Fault Condition
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
Normal Operation
Standby mode
Call for furnace heat active
Control in Factory Test mode
Green Heartbeat
Amber Heartbeat
Rapid Green Flashes
Power Off or open fuse
Normal Operation
Normal Operation with call for heat
Low flame sense current
No G from thermostat with Y call
Control Failure
Flame present 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
Improper ground OR
incorrect 24V phasing
Gas valve shorted "ON"
Check blower motor/wiring
DSI Fault Codes
THREE - PHASE
COOLING UNIT WITH GAS HEAT
460-3-60
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 APPROXIMATELY 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
LINE VOLTAGE
FIELD INSTALLED POWER
LOW VOLTAGE
FIELD INSTALLED CONTROL
T1/C
T3/R
T2/S
5155330-UWD-B-0116

5163360-UIM-G-0616
20 Johnson Controls Unitary Products
FIGURE 13: R-410A Quick Reference Guide
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.