Johnson Controls PCG4 Series User manual

Johnson Controls Ducted Systems 5844973-UIM-A-0920
®
SINGLE PACKAGE
AIR CONDITIONER/GAS HEAT
MODELS: PCG4 SERIES
2 TONS TO 5 TONS - 208/230 V - 1 PHASE
INSTALLATION MANUAL
LIST OF SECTIONS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MODEL NUMBER NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
AIRFLOW PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TYPICAL WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
START UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
LIST OF FIGURES
Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Center of Gravity Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bottom Duct Dimensions (in.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Rear Duct Dimensions (in.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Measuring External Static Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 18
Connection Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Ladder Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
R-410A Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
LIST OF TABLES
Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Application Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Unit Clearances, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical Data - PCG4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 - PCG4 . . . . . . . . . . . . . . . . . . . . . . . 10
Propane (LP) Gas Application Data - PCG4 . . . . . . . . . . . . . . . . . . . 11
Airflow Performance - Side Duct Application . . . . . . . . . . . . . . . . . . 11
Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Default Blower Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Gas Rate (ft3/h) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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, 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.
!
!

5844973-UIM-A-0920
2 Johnson Controls Ducted Systems
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 must install, repair, or ser-
vice this equipment. Untrained personnel can perform the basic
maintenance functions of cleaning coils and filters and replacing filters.
Observe all precautions in the literature, labels, and tags accompanying
the equipment when working on air conditioning equipment. Ensure 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
SECTION IV: INSTALLATION
INSTALLATION SAFETY INFORMATION
Read these instructions before continuing the unit installation. This is an
outdoor combination heating and cooling unit. Give the instructions to
the homeowner, and instruct the homeowner to retain them for future
reference.
Adhere to the following:
• Refer to the unit rating plate for the approved type of gas for this
product.
• Install the unit only in a location and position specified on page 4 of
these instructions.
• 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 9 of these
instructions.
• Install the 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
and in Table 7.
• Do not use this equipment 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 main-
tenance 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 2 X 4 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
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
7. NOx Approval
X = Low NOx, blank = not Low NOx
3. Cabinet Size
A = small 35.75 x 51.25, B = large 45.75 x 51.25
8. Generation Level
1 = first generation 2 = second generation
4. Nominal Air Conditioning Cooling Capacity BTU/Hr x 1000
24 = 24,000 BTU/Hr, 30 = 30,000 BTU/Hr
9. Revision Level
A = original release, B = second release
Example:
PCG4A240502X4A is a packaged A/C with gas heat, 14 SEER, small cabinet, 2 ton, single-stage heat, 50,000 BTU/Hr gas heat, 208/230 V, single-
phase, Low NOx model, fourth generation, original 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.
!

5844973-UIM-A-0920
Johnson Controls Ducted Systems 3
LIMITATIONS
These units must be installed in accordance with the following:
In U.S.
• National Electrical Code, ANSI/NFPA No. 70 - Latest Edition
• National Fuel Gas Code, ANSI Z223.1 - Latest Edition
• Gas-Fired Central Furnace Standard, ANSI Z21.47a. - Latest Edi-
tion
• Local building codes
• Local gas utility requirements
In Canada
• Canadian Electrical Code, CSA C22.1
• Installation Codes, CSA - B149.1
• Local plumbing and wastewater codes
• Other applicable local codes
See the unit application data in this document.
After installation, adjust gas-fired units to obtain a temperature rise within
the range specified on the unit rating plate.
If it is necessary to add components to a unit to meet local codes, instal-
lation is done at the dealer’s and/or customer’s expense.
The size of the unit for proposed installation must be based on heat
loss/heat gain calculation made according to the methods of the Air
Conditioning Contractors of America (ACCA).
Do not use this furnace for temporary heating of buildings or structures
under construction.
Table 1: Unit Limitations
Model Unit Voltage
Unit Limitations
Applied Voltage Outdoor DB Temperature
Minimum Maximum Maximum (°F)
PCG4A24 208/230-1-60 187 252 125
PCG4A30 208/230-1-60 187 252 125
PCG4A36 208/230-1-60 187 252 125
PCG4A42 208/230-1-60 187 252 125
PCG4B48 208/230-1-60 187 252 125
PCG4B60 208/230-1-60 187 252 125
Table 2: Application Limitations
Packaged Equipment
Series
Air Temperature at Outdoor Coil (°F) Air Temperature at Indoor Coil (°F)
Minimum Maximum Minimum Maximum
DB Cool DB Cool WB Cool WB Cool
14 SEER AC 55 125 57 72
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

5844973-UIM-A-0920
4 Johnson Controls Ducted Systems
LOCATION
Use the following guidelines to select a suitable location for these units:
• The unit is designed for outdoor installation only.
• Outdoor coils must have an unlimited supply of air. Where a choice
of location is available, position the unit on either the north or east
side of the building.
• The unit is suitable for mounting on a roof curb.
• For ground level installation, use a level pad or slab. The thickness
and size of the pad or slab must meet local codes and support the
weight of the unit. Do not tie the slab to the building foundation.
• Roof structures must be able to support the weight of the unit and
its options/accessories. Install the unit on a solid, level roof curb or
an appropriate angle iron frame.
• Maintain level tolerance to 1/8 in. across the entire width and
length of the unit.
CLEARANCES
All units require particular clearances for proper operation and service.
Make provisions for adequate combustion and ventilation air in accor-
dance with the following:
• Section 5.3 of Air for Combustion and Ventilation of the National
Fuel Gas Code, ANSI Z223.1 - Latest Edition (in U.S.)
• Sections 7.2, 7.3, or 7.4 of Gas Installation Codes, CSA-B149.1 -
Latest Edition (in Canada)
• Applicable provisions of local building codes
See Table 5 for the clearances required for combustible 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.
Note: Use spreader bars whose length exceeds the largest dimension
across the unit across the top of the unit.
Units can 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
(for example, perchloroethylene), printing inks, paint removers, var-
nishes, hydrochloric acid, cements and glues, anti-static fabric soft-
eners for clothes dryers, masonry acid washing materials.
WARNING
Do not permit overhanging structures or shrubs to obstruct outdoor
air discharge outlet, combustion air inlet, or vent outlets.
!
!
!
CAUTION
All panels must be secured in place when the unit is lifted.
The outdoor coils should be protected from rigging cable damage
with plywood or other suitable material.
CAUTION
If a unit is to be installed on a roof curb other than a Ducted Systems
roof curb, gasket or sealant must be applied to all surfaces that come
in contact with the unit underside.
CAUTION
Before lifting, make sure the unit weight is distributed equally on the
rigging cables so it will lift evenly.
!
!
!
Table 3: Weights and Dimensions
Model Weight (lb) Center of Gravity 4-Point Load Location (lb)
Shipping Operating X Y ABCD
PCG4A24050 321 316 29 15 118 63 76 59
PCG4A24075 341 336 28 15 119 79 76 62
PCG4A30050 357 352 28 15 119 87 76 70
PCG4A30075 377 372 28 15 122 89 83 78
PCG4A36050 364 359 28 15 123 84 79 73
PCG4A36075 384 379 27 16 121 92 85 81
PCG4A36100 388 383 27 16 120 95 87 81
PCG4A42075 403 398 28 15 143 93 88 74
PCG4A42100 407 402 28 15 137 96 90 79
PCG4B48065 455 450 28 18 165 107 99 79
PCG4B48100 461 456 28 18 163 110 99 84
PCG4B48125 465 460 28 18 163 112 101 84
PCG4B60065 474 469 27 18 167 118 102 82
PCG4B60100 480 475 27 18 165 121 102 87
PCG4B60125 484 479 27 18 165 122 104 88

5844973-UIM-A-0920
Johnson Controls Ducted Systems 5
Figure 2: Center of Gravity Location
X
CENTER OF
GRAVITY
FRONT
OF UNIT
Y
"D"
"C"
"B"
"A"
A0295-001
COMPRESSOR
Table 4: Unit Dimensions
Model Dimensions (in.)
ABC
PCG4A24 51 1/4 35 3/4 44
PCG4A30 51 1/4 35 3/4 45
PCG4A36 51 1/4 35 3/4 47
PCG4A42 51 1/4 35 3/4 47
PCG4B48 51 1/4 45 3/4 47
PCG4B60 51 1/4 45 3/4 50
Figure 3: Unit Dimensions
HIGH VOLTAGE
OPENING 7/8"
HIGH VOLTAGE
OPENING 1 3/32"
COMPRESSOR
ACCESS PANEL
CONDENSATE
DRAIN BLOWER
ACCESS
PANEL CONTROL / HEAT
ACCESS PANEL
LOW VOLTAGE OPENING 7/8"
GAS SUPPLY HOLE 1 5/8" WITH
GROMMET OPENING OF 7/8"
FLUE EXHAUST HOOD
COMBUSTION AIR INTAKE
HEAT EXCHANGER ACCESS PANEL
B
A
C
A0296-004
OUTDOOR COIL GUARD
UNIT TOP PANEL
CORNER POST
INDOOR COIL
(BEHIND PANEL)
Table 5: Unit Clearances1,2
Direction Distance (in.) Direction Distance (in.)
Top336 Power Entry (Right Side) 36
Side Opposite Ducts 36 Left Side 24
Duct Panel 0 Bottom41
1. Provide a 1-in. clearance between any combustible material and the supply air duct work.
2. Do not allow the products of combustion to accumulate within a confined space and recirculate.
3. Install units outdoors. Make sure that overhanging structures or shrubs do not obstruct the outdoor air discharge outlet.
4. You can install units on combustible materials made from wood or class A, B, or C roof covering materials if factory base rails are left in place as shipped.

5844973-UIM-A-0920
6 Johnson Controls Ducted Systems
DUCT WORK
These units are adaptable to downflow use. To convert to downflow:
1. Remove the duct covers found in the bottom return and supply air
duct openings.
2. Install the duct covers removed in Step 1 to the rear supply and
return air duct openings.
3. Seal the duct covers with silicone caulk.
Design and size duct work according to the methods of the Air Condi-
tioning Contractors of America (ACCA), as outlined in their Manual D.
Use a closed return duct system. This does not preclude use of econo-
mizers or ventilation air intake. It is best practice to use flexible joints in
the supply and return duct work to minimize the transmission of vibra-
tion and noise.
See Figures 4 and 5 for information concerning rear and bottom supply
and return air duct openings.
FILTERS
Correct filter size is very important. Always consider filter size, type, and
pressure drop 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.
Always use filters and keep filters clean. When filters become dirt laden,
insufficient air is delivered by the blower, decreasing your unit’s effi-
ciency and increasing operating costs and wear-and-tear on the unit
and controls.
Check filters monthly. This is especially important because the unit can
be used for both heating and cooling.
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.
Model ABCDEF
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 (in.)
Model A B
24, 30, 36, 42 9.6 22
48, 60 13.6 14
Figure 5: Rear Duct Dimensions (in.)
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5844973-UIM-A-0920
Johnson Controls Ducted Systems 7
CONDENSATE DRAIN
Install a condensate trap in the condensate drain. The plumbing must
conform to local codes.
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
See Figure 3 for the location of these access locations and see Table 5
for minimum clearances.
See Figure 14 for the R-410A Quick Reference Guide.
THERMOSTAT
Locate the room thermostat on an inside wall approximately 60 in.
above the floor where it is not subject to drafts, sun exposure, or heat
from electrical fixtures or appliances. Use sealant behind the thermostat
to prevent air infiltration. Follow the manufacturer's instructions
enclosed with the thermostat for the general installation procedure. Use
color-coded insulated wires (minimum No. 18 AWG) to connect the
thermostat to the unit. See Figure 6. Do not use power stealing thermo-
stats.
POWER AND CONTROL WIRING
Field wiring to the unit must conform to provisions of the current NEC
ANSI/NFPA No. 70 or CEC and/or local ordinances. The unit must be
electrically grounded in accordance with local codes or, in their
absence, with the NEC/CEC. Voltage tolerances that must be main-
tained at the compressor terminals during starting and running condi-
tions are indicated on the unit Rating Plate and in Table 1.
Provide the wiring entering the cabinet with mechanical strain relief.
A fused disconnect switch must be field provided for the unit. If any of
the wire supplied with the unit needs to 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 correctly fused.
See Figures 6 and 7 for typical field wiring and refer 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
CONTACTOR
FIELD SUPPLIED
DISCONNECT
GND
LUG
REFER TO ELECTRICAL
DATA TABLES TO SIZE
THE DISCONNECT
SINGLE
PHASE
POWER
SUPPLY
A0293-001
Table 6: Electrical Data - PCG4
Model Voltage Compressor Outdoor Fan
Motor
Indoor
Blower Motor MCA1
(Amps)
1. Minimum Circuit Ampacity.
Max Fuse2/
Breaker3 Size
(Amps)
2. Maximum Overcurrent Protection per standard UL 1995.
3. Fuse or HACR circuit breaker is field installed.
RLA LRA MCC FLA FLA
24050 208/230-1-60 10.8 55.0 16.8 0.8 2.6 16.9 25
24075 208/230-1-60 10.8 55.0 16.8 0.8 3.8 18.1 25
30050 208/230-1-60 12.3 63.0 19.2 0.8 2.6 18.8 30
30075 208/230-1-60 12.3 63.0 19.2 0.8 3.8 20.0 30
36050, 36075 208/230-1-60 14.7 75.0 22.9 1.7 3.8 23.9 35
36100 208/230-1-60 14.7 75.0 22.9 1.7 5.4 25.5 40
42075, 42100 208/230-1-60 15.9 112.3 24.8 1.7 5.4 27.0 40
48065, 48100, 48125 208/230-1-60 18.3 108.0 28.5 1.7 5.4 30.0 45
60065, 60100, 60125 208/230-1-60 22.2 127.9 34.7 1.7 7.0 36.5 50

5844973-UIM-A-0920
8 Johnson Controls Ducted Systems
Table 7: Physical Data
NOMINAL TONNAGE
MODELS
PCG4A24 PCG4A30 PCG4A36 PCG4A42 PCG4B48 PCG4B60
2.0 2.5 3.0 3.5 4.0 5.0
Refrigerant Information
Refrigerant Type R-410A R-410A R-410A R-410A R-410A R-410A
Refrigerant Charge (lb-oz) 3-10 6-10 6-14 7-0 7-14 10-2
AHRI Gas Heat Performance
Heating Model 50 75 50 75 50 75 100 75 100 65 100 125 65 100 125
Heat Input (KBTU) 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 (KBTU) 40 60 40 60 40 60 80 60 80 52 80 100 52 80 100
AFUE (%) 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
Number of Burners 2 3 2 3 2 3 4 3 4 234234
Number of Stages 1 1 1 1 1 1 1 1 1 111111
Temperature Rise Range (°F) 40–70 40–70 35–65 40–70 40–70 40–70 40–70
Maximum Static Pressure W.C. 0.5 0.5 0.5 0.5 0.5 0.5
Maximum Outlet Air Temperature (°F) 180 180 180 180 180 180
Gas Piping Connection (in.) 1/2 1/2 1/2 1/2 1/2 1/2
Dimensions (in.)
Length 51 1/4 51 1/4 51 1/4 51 1/4 51 1/4 51 1/4
Width 35 3/4 35 3/4 35 3/4 35 3/4 45 3/4 45 3/4
Height 44 45 47 47 47 50
Operating Weight (lb) 316 336 352 372 359 379 383 398 402 450 456 460 469 475 479
Compressors
Type Scroll Scroll Scroll Scroll Scroll Scroll
Outdoor Coil Data
Face Area (sq. ft) 12.3 13.8 15.3 15.3 17.5 21.1
Rows 1 2 2 2 2 2
Fins per Inch 22 22 22 22 22 22
Tube Diameter (mm) 7 7 7 7 7 7
Circuitry Type Straight Interlaced Interlaced Interlaced Interlaced Interlaced
Indoor Coil Data
Face Area (sq. ft) 4.6 4.6 4.6 4.6 6.2 6.2
Rows 2 2 3 3 3 4
Fins per Inch 16 16 16 16 16 16
Tube Diameter (in.) 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
Outdoor Fan Data
Fan Diameter (in.) 24 24 24 24 26 26
Type Prop Prop Prop Prop Prop Prop
Drive Type Direct Direct Direct Direct Direct Direct
Number of Speeds 1 1 1 1 1 1
Motor HP each 1/8 1/8 1/3 1/3 1/3 1/3
RPM 790 790 850 850 850 850
Nominal Total CFM 2400 2400 2400 2400 3200 3200
Direct Drive Indoor Blower Data
Blower Size (in.) 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 1400 Max 1400 Max 1400 Max 1400 Max 1400 Max 1400 Max
Frame Size 48 48 48 48 48 48
Filters
Filter Size A A A A B B
Quantity - Size
Field-supplied external filters must be sized so as not to exceed 300 fpm air velocity through disposable fil-
ters. For internal filter use, a filter rack kit is available. Refer to the instructions supplied with the kit for
replacement filter sizes. Filter sizes: A = 20 in. x 20 in., B = 20 in. x 30 in.

5844973-UIM-A-0920
Johnson Controls Ducted Systems 9
COMPRESSORS
The compressor used in this product is specifically designed to operate
with R-410A refrigerant and cannot be interchanged with a different
type of compressor.
The compressor uses polyolester (POE) oil, Mobil 3MA POE. This oil is
extremely hygroscopic, meaning it absorbs water readily. POE oil can
absorb 15 times as much water as other oils designed for HCFC and
CFC refrigerants. If the refrigerant circuit is opened, take all necessary
precautions to avoid exposure of the oil to the atmosphere.
POE compressor lubricants are known to cause long-term damage to
some synthetic roofing materials.
Procedures that risk oil leakage include but are not limited to the follow-
ing:
• Replacing the compressor
• Repairing refrigerant leaks
• Replacing refrigerant components, for example, filter drier, pres-
sure switch, metering device, or coil
Units are shipped with compressor mountings, which are factory-
adjusted and ready for operation.
GAS HEAT
These single-stage gas-fired heat sections have direct spark ignition.
GAS PIPING
Correct sizing of gas piping depends on the cubic feet per hour of gas
flow required, the specific gravity of the gas, and the length of run. Fol-
low National Fuel Gas Code Z223.1 or CSA B149.1 in all cases unless
superseded by local codes or gas company requirements. See Tables 8
and 9.
The BTU content of the gas may differ with locality. Check the value
with the local gas utility.
GAS CONNECTION
Route the gas supply line through the 1 5/8-in. 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.
Note: Install the rubber grommet to prevent leakage of air and water
into the heating/controls compartment.
Gas piping requirements:
• Install a drip leg and a ground joint union in the gas piping.
• When required by local codes, install a manual shut-off valve out-
side of the unit.
• Use wrought iron or steel pipe for all gas lines. Apply pipe thread
sealant sparingly to male threads only.
• Clean all piping of dirt and scale by hammering on the outside of
the pipe and blowing out the loose dirt and scale. Before initial
start-up, ensure that all of the gas lines external to the unit have
been purged of air.
• The gas supply must 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.
Note: Never test for gas leaks with an open flame.
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 to compressor oil, 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 com-
pressor oil to the roof, take precautions to protect roofing.
CAUTION
Do not loosen compressor mounting bolts.
NOTICE
There may be a local gas utility requirement specifying a minimum
diameter for gas piping. All units require a 1/2-in. pipe connection at
the gas valve.
!
!
!
!
Table 8: Natural Gas Pipe Sizing Chart1
1. Maximum capacity of pipe in cubic feet of gas per hour (based upon a pressure
drop of 0.3 in. W.C. and 0.6 specific gravity gas).
Length
(ft)
Nominal Inches Iron Pipe Size
1/2 in. 3/4 in. 1 in. 1 1/4 in.
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 9: Propane (LP) Gas Pipe Sizing Chart1
1. Maximum capacity of pipe in thousands of BTU per hour (based upon a pres-
sure drop of 0.5 in. W.C.).
Length
(ft)
Nominal Inches Iron Pipe Size
1/2 in. 3/4 in. 1 in. 1 1/4 in.
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 2 in. outside of the unit casing.
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. Compounds such as
RectorSeal No. 5 or equivalent compounds may be used.
!
!

5844973-UIM-A-0920
10 Johnson Controls Ducted Systems
• Disconnect the unit and its equipment shutoff valve from the gas
supply system during any pressure testing of that system at test
pressures in excess of 1/2 psig (3.48 kPa).
• Isolate the unit 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-ALTITUDE GAS CONVERSION
The furnace is constructed at the factory for natural gas-fired operation
at altitudes up to 2,000 ft above sea level. For installations located
above 2,000 ft, reduce the gas input rate to the burners by 4% per
1,000 ft above sea level. It may be necessary to change to smaller ori-
fices at high altitude. See Table 10 for the correct orifice size to use.
FLUE VENT AND AIR INTAKE HOOD
The flue vent hood and air intake hoods are shipped loose. Install these
hoods to ensure proper unit operation. Fasten the hoods to the outside
of the side gas control/electrical compartment with the screws provided.
See Figure 8.
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 10: High-Altitude Gas Orifice Sizing
Gas Type
Elevation Above Sea Level (ft)
Cabinet
Size
0–2000
(Factory)
2001–
3000
3001–
4000
4001–
5000
5001–
6000
6001–
7000
7001–
8000
8001–
9000
9001–
10000
Natural Gas Orifice Sizes B 36 3738383940414142
A 42 4243434344444546
LP Gas Orifice Sizes B 51 5152525252535353
A 54 5455555555555656
WARNING
Flue hood surfaces may be hot.
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 owners 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.
!
!
Figure 8: Flue Vent Outlet Air Hood
AIR INTAKE HOOD
AIR INTAKE SCREEN
EXHAUST HOOD
A0284-002
Table 11: Natural Gas Application Data - PCG4
Available on Models Input (MBH)1
1. Heating capacity is valid for elevations up to 2,000 ft above sea level. For elevations above 2,000 ft, reduce the rated capacity by 4% for each 1,000 ft above sea level.
Output (MBH) Gas Rate2
ft3/h
2. Based on 1,075 BTU/ft3.
Number of
Burners
Temperature Rise ºF
at Full Input3
3. The airflow must be adequate to obtain a temperature rise within the range shown. The continuous return air temperature must not be below 55°F.
Minimum Maximum
2 tons, 2 1/2 tons 50 41 46 2 40 70
3 tons 50 41 46 2 35 65
4 tons, 5 tons 65 53 60 2 40 70
2 tons, 2 1/2 tons, 3 tons, 3 1/2 tons 75 61 70 3 40 70
3 tons, 3 1/2 tons 100 81 93 4 40 70
4 tons, 5 tons 100 81 93 3 40 70
4 tons, 5 tons 125 101 116 4 40 70

5844973-UIM-A-0920
Johnson Controls Ducted Systems 11
SECTION V: AIRFLOW PERFORMANCE
Table 12: Propane1 (LP) Gas Application Data - PCG4
Available on Models Input (MBH)2Output (MBH)
Gas Rate3
ft3/h
High Fire/Low Fire
Number of
Burners
Temperature Rise ºF
at Full Input4
Propane
Conversion
Accessory Kit
Minimum Maximum
2 tons, 2 1/2 tons 50 41 20 2 40 70 S1-1NP0703
3 tons 50 41 20 2 35 65 S1-1NP0703
4 tons, 5 tons 65 53 26 2 40 70 S1-1NP0704
2 tons, 2 1/2 tons, 3 tons, 3 1/2 tons 75 61 30 3 40 70 S1-1NP0703
3 tons, 3 1/2 tons 100 81 40 4 40 70 S1-1NP0703
4 tons, 5 tons 100 81 40 3 40 70 S1-1NP0704
4 tons, 5 tons 125 101 50 4 40 70 S1-1NP0704
1. Propane applications are accomplished by field installation of a propane conversion accessory kit. For more information, refer to the APPLICATIONS AND ACCESSO-
RIES section in the Technical Guide.
2. Heating capacity is valid for elevations up to 2,000 ft above sea level. For elevations above 2,000 ft, reduce the rated capacity by 4% for each 1,000 ft above sea level.
3. Based on 2,500 BTU/ft3.
4. The airflow must be adequate to obtain a temperature rise within the range shown. The continuous return air temperature must not be below 55°F.
Table 13: Airflow Performance - Side Duct Application
Model Motor Speed
External Static Pressure (in. W.C.)
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
PCG4A24050
Low (1) 560 520 480 410 370 320 270 220 120
Medium Low (2) 720 690 640 590 530 490 440 400 300
Medium (3) 810 770 730 690 630 590 540 500 420
Medium High (4) 880 840 810 770 720 670 630 590 500
High (5) 960 920 890 850 810 770 720 680 600
PCG4A24075
Low (1) 580 550 500 440 390 350 290 240 130
Medium Low (2) 800 760 720 680 630 570 530 480 400
Medium (3) 910 870 840 810 770 730 680 620 540
Medium High (4) 1120 1080 1060 1030 1000 970 930 890 820
High (5) 1180 1160 1130 1100 1070 1050 1010 980 910
PCG4A30050
Low (1) 680 640 600 550 490 440 390 350 250
Medium Low (2) 750 710 670 620 560 510 460 430 330
Medium (3) 880 840 810 770 720 670 630 590 500
Medium High (4) 1000 970 930 900 860 820 780 730 650
High (5) 1120 1090 1050 1020 990 960 920 880 800
PCG4A30075
Low (1) 690 660 620 570 520 460 410 360 270
Medium Low (2) 1040 1010 980 940 910 880 840 800 700
Medium (3) 1120 1080 1060 1030 1000 970 930 890 820
Medium High (4) 1150 1120 1090 1060 1030 1000 970 930 870
High (5) 1180 1160 1130 1100 1070 1050 1010 980 910
PCG4A36050
Low (1) 850 790 710 660 610 560 510 450 400
Medium Low (2) 1000 950 900 840 790 730 680 640 550
Medium (3) 1140 1100 1060 1010 960 900 850 800 710
Medium High (4) 1270 1230 1190 1150 1110 1060 1000 960 860
High (5) 1370 1340 1300 1260 1220 1180 1130 1070 980
PCG4A36075
Low (1) 850 790 710 660 610 560 510 450 400
Medium Low (2) 1130 1090 1050 1000 940 890 830 790 700
Medium (3) 1230 1190 1150 1110 1060 1010 960 910 820
Medium High (4) 1270 1230 1190 1150 1110 1060 1000 960 860
High (5) 1370 1340 1300 1260 1220 1180 1130 1070 980
PCG4A36100
Low (1) 870 800 730 670 610 560 510 450 230
Medium Low (2) 1220 1170 1130 1080 1030 970 920 860 780
Medium (3) 1390 1350 1310 1270 1220 1180 1130 1080 970
Medium High (4) 1520 1480 1440 1400 1360 1320 1270 1220 1110
High (5) 1600 1560 1520 1490 1440 1400 1360 1310 1200
Continued on next page

5844973-UIM-A-0920
12 Johnson Controls Ducted Systems
Notes:
Airflow is tested with dry coil conditions, without air filters, at 230 V.
Applications above 0.8 in. W.C. external static pressure are not recommended.
Brushless DC high-efficiency standard ECM blower motor is used for all indoor blower assemblies.
Minimal variations in airflow performance data result from operating at 208 V. The data in the table can be used in those cases.
Heating applications are tested at 0.50 in. W.C. external static pressure. Cooling applications are tested per AHRI Standard 210/240.
The differences between side duct airflows and bottom duct airflows are insignificant.
PCG4A42075
Low (1) 960 910 840 780 720 670 610 570 420
Medium Low (2) 1150 1100 1050 1000 940 880 830 780 690
Medium (3) 1270 1230 1190 1140 1090 1030 980 930 840
Medium High (4) 1610 1570 1540 1500 1460 1420 1370 1330 1230
High (5) 1640 1600 1570 1530 1490 1450 1410 1360 1270
PCG4A42100
Low (1) 960 910 840 780 720 670 610 570 420
Medium Low (2) 1520 1480 1440 1400 1360 1320 1270 1220 1110
Medium (3) 1580 1540 1510 1470 1430 1390 1340 1290 1180
Medium High (4) 1610 1570 1540 1500 1460 1420 1370 1330 1230
High (5) 1640 1600 1570 1530 1490 1450 1410 1360 1270
PCG4B48065
Low (1) 1090 1040 990 930 870 800 720 670 540
Medium Low (2) 1140 1090 1030 980 920 850 780 730 600
Medium (3) 1430 1380 1340 1290 1240 1200 1150 1100 980
Medium High (4) 1690 1650 1600 1570 1530 1490 1440 1400 1310
High (5) 1800 1760 1720 1680 1650 1610 1560 1520 1440
PCG4B48100
Low (1) 1140 1090 1030 980 920 850 780 730 600
Medium Low (2) 1520 1470 1430 1390 1340 1300 1250 1210 1090
Medium (3) 1600 1560 1510 1470 1430 1390 1350 1300 1200
Medium High (4) 1690 1650 1600 1570 1530 1490 1440 1400 1310
High (5) 1800 1760 1720 1680 1650 1610 1560 1520 1440
PCG4B48125
Low (1) 1140 1090 1030 980 920 850 780 730 600
Medium Low (2) 1690 1650 1600 1570 1530 1490 1440 1400 1310
Medium (3) 1800 1760 1720 1680 1650 1610 1560 1520 1440
Medium High (4) 1870 1840 1790 1760 1730 1690 1640 1600 1520
High (5) 1960 1920 1880 1840 1810 1770 1730 1690 1620
PCG4B60065
Low (1) 1090 1020 960 910 840 750 690 640 550
Medium Low (2) 1160 1100 1050 990 930 860 800 740 640
Medium (3) 1570 1530 1490 1450 1410 1370 1330 1290 1200
Medium High (4) 1870 1840 1810 1770 1730 1690 1650 1620 1540
High (5) 2000 1970 1930 1890 1860 1830 1780 1740 1670
PCG4B60100
Low (1) 1300 1240 1200 1150 1090 1050 1000 940 820
Medium Low (2) 1510 1470 1430 1390 1340 1310 1260 1220 1130
Medium (3) 1600 1560 1530 1480 1440 1410 1370 1330 1240
Medium High (4) 1870 1840 1810 1770 1730 1690 1650 1620 1540
High (5) 2000 1970 1930 1890 1860 1830 1780 1740 1670
PCG4B60125
Low (1) 1300 1240 1200 1150 1090 1050 1000 940 820
Medium Low (2) 1700 1670 1630 1590 1550 1520 1480 1440 1370
Medium (3) 1870 1840 1810 1770 1730 1690 1650 1620 1540
Medium High (4) 1950 1920 1880 1840 1800 1770 1730 1690 1620
High (5) 2000 1970 1930 1890 1860 1830 1780 1740 1670
Table 13: Airflow Performance - Side Duct Application
Model Motor Speed
External Static Pressure (in. W.C.)
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

5844973-UIM-A-0920
Johnson Controls Ducted Systems 13
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.
Note: 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 board checks if the pressure switch is open. If
the pressure switch is closed, the LED on the control board emits 2 red
flashes, and the control board waits indefinitely for the pressure switch
to open. When the pressure switch is sensed as open, the control board
begins the pressure switch proving period. If the call for heat is
removed, the control board 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
board begins the pre-purge period. If the call for heat is removed, the
control board de-energizes the inducer without a post-purge period and
returns to standby.
If the pressure switch does not close within 5 s of the inducer energiz-
ing, the LED on the control board emits 3 red flashes. If the pressure
switch does not close within 60 s of the inducer energizing, the control
board shuts off the inducer for 60 s, then energizes the inducer for
another 60 s in an attempt to close the pressure switch. This cycle con-
tinues indefinitely until the pressure switch is proved to be closed or the
call for heat ends.
Pre-Purge
The control board monitors the pressure switch and ensures it remains
closed during the pre-purge period. If the pressure switch opens, the
control board returns to pressure switch proving mode. The control
board waits for a 15-s pre-purge period, then begins the ignition trial.
Ignition Trial
The control board energizes the gas valve and spark outputs for a 5-s
ignition trial. The control board de-energizes the spark when the flame
is sensed and enters a flame stabilization period.
If the flame is not established within the ignition trial, the control board
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, the control board
immediately de-energizes spark and gas. The control board runs the
induced draft motor through a post-purge period before de-energizing.
If the pressure switch opens during an ignition trial, the control board
immediately de-energizes spark and gas. The control board begins
pressure switch proving before an inter-purge and reignition attempt.
Heat Blower On Delay
The control board waits for 30 s and then energizes the indoor blower
heat speed. The blower on delay time begins at the start of the flame
proving period in the ignition trial.
If the thermostat demand for heat is removed, the control board de-
energizes the gas valve, energizes the blower on heat speed, and initi-
ates a post-purge period 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 board de-energizes the
gas valve, and begins the post-purge period and heat blower off delay.
If the pressure switch opens, the control board de-energizes the gas
valve and begins pressure switch proving mode.
If the flame is removed, the control board de-energizes the gas valve
within 2.0 s and counts the flame loss. If the flame has been lost less
than five times, the control attempts re-ignition after a 15-s inter-purge
period. If the flame has been lost five times within the same call for
heat, the control board locks out, and the LED on the control board
emits 8 red flashes.
Table 14: Additional Static Resistance
Size (Tons) CFM Wet Indoor Coil Economizer1
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 delivers less CFM during full economizer operation.
Note: Filter pressure drop based on standard filter media tested at velocities not
to exceed 300 ft/min.
Filter/Frame Kit
024 (2.0)
500 0.01 0.00 0.01
600 0.01 0.00 0.02
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
030 (2.5)
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
036 (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
042 (3.5)
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
048 (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
060 (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

5844973-UIM-A-0920
14 Johnson Controls Ducted Systems
Post-Purge
The control board runs the induced draft motor for a 15-s post-purge
period, and then de-energizes the inducer. If a call for heat occurs
during the post-purge period, the control board finishes the post-purge
period, and begins the next ignition sequence immediately.
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 s,
90 s, 120 s, or 180 s). The blower off timing begins when the thermostat
is satisfied and removes (W) the call for heat. The control board returns
to standby when the blower off delay is complete.
If a thermostat call for heat occurs before the blower off delay is com-
plete, the control board begins an ignition sequence, starting with the
pre-purge period, while the blower off delay continues.
Lockout
During a lockout, the control board keeps the main gas valve and
induced draft motor de-energized.
You can reset lockouts resulting from failed ignition or flame losses by
removing the call for heat (W) for more than 1 s or removing power from
the control board for over 0.25 s. The control board automatically resets
after 60 min.
Lockouts resulting from the detection of internal control faults reset after
60 min or power interruption. Cooling operations are available during a
heating lockout.
High-Temperature Limit Switch
Any time the high-temperature limit switch is open for less than 5 min,
the control board runs the indoor blower motor on heat speed, runs the
inducer, and de-energizes the gas valve, and the LED on the control
board emits 4 red flashes. When the high-temperature limit switch
closes, the control board restarts the ignition sequence, beginning with
the pre-purge period.
If the high-temperature limit switch is open for more than 5 min, the con-
trol board de-energizes the inducer and continues to operate the indoor
blower motor on heat speed, and the LED on the control board emits 11
red flashes.
Rollout Switch
If the limit circuit is open for more than 15 min, the LED on the control
board emits 5 red flashes. The blower output is energized when the roll-
out switch is open.
If the rollout switch is reset, the control board remains locked out until
power is removed or a call for heat (W) is removed.
A rollout switch lockout does not reset automatically.
Power Interruptions
Power interruptions of any duration do not cause a lockout or any oper-
ation requiring manual intervention.
Flame Present with Gas Off
If the flame is sensed for longer than 4.0 s during a period when the gas
valve should be closed, the control board enters lockout, and the LED
on the control board emits 1 red flash. The control board energizes the
inducer blower while the flame is sensed.
GAS VALVE FAULT
If the main valve output is sensed as energized for more than 1 s when
commanded to be off, the control board de-energizes the induced draft
motor (if the 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 s, the control board
re-energizes the inducer to vent the unburned gas. The control board
enters a hard lockout, and the LED on the control board emits 10 red
flashes.
The only way to recover from a hard lockout is to remove and reapply
24-VAC power to the control board.
Safety Controls
The control circuit includes the following safety controls:
•High-temperature limit switch - This is located inside the blower
compartment and protrudes into the heat exchanger compartment.
The high-temperature limit switch is set to open at a temperature
selected to prevent the outlet air temperature from exceeding the
maximum shown on the unit rating plate. It resets automatically.
The high-temperature limit switch operates when a high-tempera-
ture condition occurs. The high-temperature limit switch shuts
down the ignition control, closes the main gas valve, and ener-
gizes the blower.
•Pressure switch - If the induced draft motor fails, the pressure
switch prevents the ignition control and gas valve from being ener-
gized.
•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, the main gas valve
closes.
•Rollout switch - This is located on the burner assembly. In the
event of a sustained main burner flame rollout, the rollout switch
closes the main gas valve. This is a manual reset switch.
GAS HEATING FAULT CODES
The gas heating section has built-in self-diagnostic capability. A blinking
LED light on the control board can flash red, green, or amber to indicate
various conditions. The control board continuously monitors its own
operation and the operation of the system. If a fault occurs, the LED
light indicates the fault code.
The slow flash speed is 2 s on and 2 s off. The other flash codes listed
below have the following timing: the LED light turns on for 1/3 s and
turns off for 1/3 s. This pattern is repeated the number of times equal to
the code. There is a 2-s pause between codes. For example, the 6 Red
Flashes fault code means the LED light flashes on and off six times and
then remains off for 2 s. This pattern repeats as long as the fault condi-
tion remains. The continuous flash codes listed below mean the LED
light flashes on and off continuously with no breaks or longer pauses.
Slow Green Flash: Indicates normal operation with no thermostat
calls. Standby mode.
Rapid Green Flashes: Indicates the control board is in factory test
mode.
Slow Amber Flash: Indicates normal operation with a thermostat call
for heat.
LED Steady Off: If the LED light does not flash at all, check that there
is power to the control board and check for an open fuse on the control
board. If the control board is correctly powered and the fuse is not open,
the control board may need to be replaced.
Steady on Red: Indicates a possible control board failure. Turn off the
power to the unit and turn on the power to the unit again. If the fault
code recurs, replace the control board. The control board is not field-
repairable.
Rapid Amber Flash: Indicates the flame sense current is below 1.5
VDC. Do the following:
• Check and clean the flame sensor.
• Check for proper gas flow.
• Verify that the current is greater than 1.5 VDC at the flame current
test pad.
4 Amber Flashes: Indicates the control board is receiving a Y signal
from the thermostat without a G signal. The furnace operates normally
during heating and cooling, but this fault code is displayed to alert the
user that there is a wiring problem. Verify that the G wire from the ther-
mostat is connected properly.
NOTICE
The manual reset Rollout Switch (RS) must be reset before allowing
furnace operation.

5844973-UIM-A-0920
Johnson Controls Ducted Systems 15
1 Red Flash: Indicates the flame was sensed when there was no call
for heat. The control board turns on both the induced draft motor and
supply air blower. Check for a leaking or slow-closing gas valve.
2 Red Flashes: Indicates the pressure switch is closed when it should
be open. The control board confirms the pressure switch contacts are
open at the beginning of each heat cycle. The control board prevents
the ignition sequence from continuing if the pressure switch contacts
are closed when they should be open. Check for a faulty pressure
switch or miswiring.
3 Red Flashes: Indicates the pressure switch contacts are open when
they should be closed. Check for the following:
• Faulty inducer
• Blocked vent
• Broken pressure switch hose
• Disconnected pressure switch or inducer wires
• Faulty pressure switch
4 Red Flashes: Indicates the high-temperature limit switch or rollout
switch has opened its contacts, which are normally closed. The control
board turns on the supply air blower and inducer. Check for the follow-
ing:
• Dirty filter
• Incorrectly sized duct system
• Incorrect blower speed setting
• Incorrect firing rate
• Loose high-temperature limit switch or rollout switch wiring
• Faulty blower motor
If the high-temperature limit switch does not close within 5 min, the con-
trol board operates as if the blower is not functioning. The control board
starts a hard lockout and the LED on the control board emits 11 red
flashes. If the high-temperature limit switch does not close after 15 min,
the control board operates as if a manual reset rollout switch has
opened, and the LED on the control board emits 5 red flashes. See the
5 Red Flashes and 11 Red Flashes descriptions below. If the high-tem-
perature limit switch opens five times within a call for heat, the LED on
the control board emits 4 red flashes, and the control board enters a 1-h
soft lockout.
5 Red Flashes: Indicates the limit circuit has been open for more than
15 min, usually meaning that a manual reset rollout switch has opened.
Check for the following:
• Proper combustion air
• Correct inducer operation
• Primary heat exchanger failure
• Burner problem
The control board enters a hard lockout. When the problem is cor-
rected, you must turn off the power to the unit and turn on the power to
the unit again to reset the control.
6 Red Flashes: Indicates that while the unit was operating, the pres-
sure switch opened four times during the call for heat. Check for a faulty
inducer, blocked vent, or faulty pressure switch. The furnace locks out
for 1 h and then restarts.
7 Red Flashes: Indicates the flame could not be established during
three attempts for ignition. Check that the gas valve switch is in the ON
position. Check for the following:
• Low gas pressure or no gas pressure
• Faulty gas valve
• Dirty or faulty flame sensor
• Faulty hot surface ignitor
• Loose wires
• Burner problem
The furnace locks out for 1 h and then restarts.
8 Red Flashes: Indicates the flame has been lost five times (four recy-
cles) during the heating cycle. Check for low gas pressure, a dirty or
faulty flame sensor, or a faulty gas valve. The furnace locks out for 1 h
and then restarts.
9 Red Flashes: Indicates reversed line voltage polarity, a grounding
problem, or reversed low-voltage transformer wires. Do the following:
• Check the polarity at the furnace and branch.
• Check the furnace grounding.
• Check that the flame probe is not shorted to the chassis.
The furnace does not start the ignition sequence until the problem is
corrected.
10 Red Flashes: Indicates the gas valve is energized with no call for
heat. The main blower and inducer blower run and no ignition sequence
starts as long as this condition exists. Check the gas valve and gas
valve wiring.
11 Red Flashes: Indicates the limit circuit has remained open for more
than 5 min and less than 15 min. This condition is usually caused by a
failed blower motor or blower wheel. The control board enters a hard
lockout. When the problem is corrected, you must turn off the power to
the unit and turn on the power to the unit again to reset the control
board.
Soft Lockout: The control includes a soft lockout that resets automati-
cally after 1 h. This provides protection for an unoccupied structure if a
temporary condition causes a furnace malfunction, for example, if a
temporary interruption in gas supply prevents the furnace from lighting.
The control board keeps trying to light each hour and resumes normal
operation if the gas supply is restored.
Hard Lockout: Some fault conditions cause a hard lockout, and you
must turn off the power to the unit and turn on the power to the unit
again to reset the control board. The control board does not automati-
cally restart.
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 indoor circulating blower 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 s, the indoor circulating blower is
de-energized.
Safety Controls
The control circuit includes the following safety control:
• High-pressure switch - This switch protects against excessive dis-
charge pressures due to a blocked outdoor coil or an outdoor
motor failure (opens at 650 ± 25 psig and closes at 450 ± 25 psig).
The high-pressure switch is specifically designed to operate with
R-410A systems. Do not use R-22 pressure switches as replacements
for R-410A pressure switches.
INDOOR CIRCULATING BLOWER
When the thermostat calls for FAN, the thermostat terminal G is ener-
gized, signaling the indoor circulating blower to run at the G-speed air-
flow.
If a call for COOL occurs (Y), the indoor circulating blower switches to
run at the Y-speed airflow.
If a call for HEAT occurs (W), the indoor circulating blower switches to
run at the W-speed airflow after a 30-s delay.
When the thermostat ends the call for FAN, the thermostat terminal G is
de-energized, de-energizing the indoor circulating blower.
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.
!

5844973-UIM-A-0920
16 Johnson Controls Ducted Systems
CHARGING
To check or adjust unit charge:
1. Connect a temperature probe to the compressor discharge line
approximately 6 in. away from the compressor shell.
2. Connect a high side refrigerant pressure gauge to the unit discharge
pressure port.
3. Record discharge line temperature and discharge pressure. Using an
R410A temperature pressure chart, convert gauge pressure to satu-
ration temperature.The difference between discharge saturation tem-
perature and discharge line temperature is discharge superheat.
4. Obtain an entering indoor wet bulb temperature reading.
5. Compare readings taken to the unit charging chart.
START-UP
Prestart Check List
Complete the following checks before starting the unit:
• Check the type of gas being supplied. Ensure that it is the same as
listed on the unit nameplate.
• Make sure that the vent outlet air hood and air intake hood have
been properly installed.
Operating Instructions
Note: Before you begin, stop and read the safety information on the unit
label.
1. Set the thermostat to the OFF position.
2. Turn off all electrical power to the unit.
Note: Do not try to light the burners by hand. The unit is equipped with
an ignition device that automatically lights the burners.
3. Remove the control access panel.
4. Set the gas valve switch to the OFF position.
5. Wait 5 min to clear out any gas.
If you then smell gas, STOP. Follow B in the safety information on
the unit label.
Or
If you don't smell gas, go to the next step.
6. Set the gas valve switch to the ON position.
7. Replace the control access panel.
8. Turn on all electric power to the unit.
9. Set the thermostat to the required setting.
10. If the unit does not operate, follow the instructions in the To Turn Off
Gas to Unit section 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 unit if service is to be performed.
3. Remove the control access panel.
4. Set the gas valve switch to the OFF position.
Note: Do not force the gas valve switch.
5. Replace the control access panel.
Post Start Check List
When the entire control circuit has been energized and the heating sec-
tion is operating, make the following checks:
• Check for gas leaks in the unit piping as well as the supply piping.
• Check for correct manifold gas pressures. See the CHECKING
GAS HEAT INPUT section.
• Check the supply gas pressure. It must be within the limits shown
on the rating nameplate. You must check supply pressure with all
gas appliances in the building at full fire. The standby gas line
pressure must not exceed 13.5 in. W.C. and the operating pres-
sure must not drop below 4.5 in. W.C. at any time for natural gas
units. If gas pressure is outside these limits, contact the local gas
utility for corrective action.
ADJUSTMENT OF MANIFOLD GAS PRESSURE AND
INPUT RATE
You can measure inlet gas pressure and manifold gas pressure by con-
necting the U-tube manometer to the gas valve with a piece of tubing.
Complete the steps in the Preparing to Read Gas Pressure section and
follow the steps in the Reading the Inlet Gas Pressure section or the
Reading the Manifold Gas Pressure section as required. See Figure 9
for the locations of the pressure ports on the gas valve.
Preparing to Read Gas Pressure
1. Turn off gas at the ball valve or gas cock on the gas supply line
before the gas valve, and turn off the electrical supply.
2. Find the pressure ports on the gas valve marked OUT P and IN P.
You take the manifold pressure reading at the port marked OUT P.
You take the gas line pressure reading at the port marked IN P.
3. Using a 3/32 in. (2.4 mm) hex head wrench, loosen the set screw
by turning it one turn counter clockwise.
Note: Do not remove the set screw from the pressure port.
Reading the Inlet Gas Pressure
1. Make sure that you have completed the steps in the Preparing to
Read Gas Pressure section.
2. Connect the positive side of the manometer to the IN P tap on the
gas valve. Do not connect any tubing to the negative side of the
manometer, because it references atmospheric pressure. See Fig-
ures 9 and 10 for connection details.
3. Turn on gas and electrical supplies and follow the operating instruc-
tions to place the unit back in operation.
4. When the correct inlet gas pressure has been established (see
Table 15), turn the gas valve to OFF and turn the electrical supply
switch to OFF. Remove the flexible tubing from the gas valve pres-
sure tap and tighten the pressure tap plug using the 3/32 in.
(2.4 mm) hex head wrench.
5. Turn on the electrical and gas supplies, and with the burners in
operation, check for gas leakage around the gas valve pressure
port using an approved non-corrosive gas leak detection fluid or
other non-flammable leak detection methods.
Reading the Manifold Gas Pressure
1. Make sure that you have completed the steps in the Preparing to
Read Gas Pressure section.
2. Connect the positive side of the manometer to the OUT P tap on
the gas valve. Do not connect any tubing to the negative side of the
manometer, because it references atmospheric pressure. See Fig-
ures 9 and 10 for connection details.
Table 15: Inlet Gas Pressure Range
Inlet Gas Pressure Range
Natural Gas Propane (LP)
Minimum 4.5 in. W.C. (1.12 kPa) 8.0 in. W.C. (1.99 kPa)
Maximum 10.5 in. W.C. (2.61 kPa) 13.0 in. W.C. (3.24 kPa)
IMPORTANT: The inlet gas pressure operating range table specifies
what the minimum and maximum gas line pressures must be for the
furnace to operate correctly. The gas line pressure MUST BE a mini-
mum of:
• 7 in. W.C. (1.74 kPa) for Natural Gas
• 11 in. W.C. (2.74 kPa) for Propane (LP) Gas
This is in order to obtain the BTU input specified on the rating plate
and/or the nominal manifold pressure specified in these instructions
and on the rating plate.
IMPORTANT: The cap for the pressure regulator must be removed
entirely to gain access to the adjustment screw. Loosening or tighten-
ing the cap does not adjust the flow of gas.

5844973-UIM-A-0920
Johnson Controls Ducted Systems 17
3. See Figure 9 for the location of the pressure regulator adjustment
cap and adjustment screws on the main gas valve.
4. Turn on gas and electrical supplies and follow the operating instruc-
tions to place the unit back in operation.
5. Adjust the manifold pressure by adjusting the gas valve regulator
screw for the appropriate gas per Table 16.
6. When the manifold pressure has been adjusted, re-calculate the
furnace input to make sure you have not exceeded the specified
input on the rating plate. See Natural Gas in the CHECKING GAS
HEAT INPUT section.
7. When the correct BTU (kW) input has been established, turn the
gas valve to OFF and turn the electrical supply switch to OFF.
Remove the flexible tubing from the gas valve pressure tap and
tighten the pressure tap plug using the 3/32 in. (2.4 mm) hex head
wrench.
8. Turn on the electrical and gas supplies, and with the burners in
operation, check for gas leakage around the gas valve pressure
port using an approved non-corrosive gas leak detection fluid or
other non-flammable leak detection methods.
AIRFLOW SETTINGS
Cooling Airflow Settings
The unit is equipped with a five-speed blower motor. Select the required
cooling airflow by connecting the required motor speed tap wire to the
yellow COOL speed wire coming from the control board. Select the
speed to deliver approximately 350 CFM to 400 CFM per ton of A/C
cooling capacity. Use of airflow outside of this range may cause dimin-
ished air conditioning performance, lower overall energy efficiency, and
higher electric utility bills. See Table 17 for default cooling blower set-
tings.
Continuous Fan Airflow Settings
The default blower speed for continuous fan operation is Low speed. To
operate the furnace in continuous fan mode, set the wall thermostat fan
switch to ON. To select the required continuous fan airflow, connect the
required motor speed tap wire to the red FAN speed wire coming from
the control board.
The default position is with the red (Low) blower speed wire connected
to the red FAN speed wire coming from the control board. In certain cir-
cumstances, it may be necessary to move the continuous fan speed to
a different speed tap. However, this is not best practice because it
causes higher electrical energy usage and higher electric utility bills.
Gas Heating Airflow Settings
See Table 17 for the default heating blower speed. The unit is equipped
with a five-speed blower motor. See Table 17 for the default heating
blower speed for each model.
In certain circumstances, it may be necessary to move the heating
blower speed to a different motor speed tap.
Note: Not all of the five motor speeds are appropriate for gas heating
operation.
The use of heating airflow at a speed other than the default speed
causes diminished heating performance and may cause the furnace
temperature limit controls to shut down the furnace.
NOTICE
The regulated outlet pressure has been calibrated at the factory.
Additional pressure adjustment should not be necessary. If adjust-
ment is necessary, set to the following specifications. After adjust-
ment, check for gas leakage.
Table 16: Nominal Manifold Pressure
Nominal Manifold Pressure
Natural Gas 3.5 in. W.C. (0.87 kPa)
Propane (LP) Gas 10.0 in. W.C. (2.488 kPa)
Figure 9: Gas Valve
IMPORTANT: If gas valve regulator is turned in (clockwise), manifold
pressure increases. If the screw is turned out (counterclockwise),
manifold pressure decreases.
MANIFOLD PRESSURE U-TUBE CONNECTION
Figure 10: Reading Gas Pressure
INLET
WRENCH
BOSS
INLET
PRESSURE
PORT
ON
OFF
ON/OFF SWITCH
(Shown in ON position)
MAIN REGULATOR
ADJUSTMENT
OUTLET
OUTLET
PRESSURE
PORT VENT PORT
A0226-001
287/(7
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0$1,)2/'
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6(1625
Table 17: Default Blower Speeds
Model Number
Default Blower Speeds
Heat
(White Wire)
Cool
(Yellow Wire)
Continuous Fan
(Red Wire)
PCG4A24050 Medium Low (2) High (5) Low (1)
PCG4A24075 Medium High (4) High (5) Low (1)
PCG4A30050 Low (1) High (5) Low (1)
PCG4A30075 Medium Low (2) High (5) Low (1)
PCG4A36050 Low (1) High (5) Low (1)
PCG4A36075 Medium Low (2) High (5) Low (1)
PCG4A36100 Medium (3) High (5) Low (1)
PCG4A42075 Medium Low (2) High (5) Low (1)
PCG4A42100 Medium Low (2) High (5) Low (1)
PCG4B48065 Low (1) High (5) Low (1)
PCG4B48100 Medium Low (2) High (5) Low (1)
PCG4B48125 Medium Low (2) High (5) Low (1)
PCG4B60065 Low (1) High (5) Low (1)
PCG4B60100 Medium Low (2) High (5) Low (1)
PCG4B60125 Medium Low (2) High (5) Low (1)

5844973-UIM-A-0920
18 Johnson Controls Ducted Systems
Measurement of Temperature Rise
After about 5 min of operation, determine the furnace temperature rise.
Measure the temperature of the return air and the heated air in the
ducts about 6 ft (1.83 m) from the furnace, where they are not affected
by radiant heat. Increase the blower speed to decrease the temperature
rise. Decrease the blower speed to increase the temperature rise.
The blower speed tap connections are located on the motor plug in the
blower compartment. To change the blower speed, see Table 13 and
the unit wiring diagram. To use the same speed tap for heating and
cooling, connect the white HEAT speed wire and the yellow COOL
speed wire terminal to the required motor lead using a jumper wire or Y
terminal.
DIRECT DRIVE BLOWER
All units have direct drive, multispeed standard ECM blower motors.
Connect the manometer as shown in the MEASURING EXTERNAL
STATIC PRESSURE section. Place the unit in cooling mode and adjust
the blower speed accordingly as per Table 13.
MEASURING EXTERNAL STATIC PRESSURE
1. Measure the supply air static pressure and record this positive num-
ber.
2. Measure the return air static pressure and record this negative
number.
3. Treat the negative number as a positive and add the two numbers
DANGER
The temperature rise, or temperature difference between the return
air and the supply (heated) air from the furnace, must be within the
range shown on the furnace rating plate and within the application
limitations shown in Table 7.
The supply air temperature cannot exceed the “Maximum Supply
Air Temperature” specified in these instructions and on the furnace
rating plate. Under NO circumstances can the furnace be allowed to
operate above the Maximum Supply Air Temperature. Operating the
furnace above the Maximum Supply Air Temperature will cause pre-
mature heat exchanger failure, high levels of Carbon Monoxide, a fire
hazard, personal injury, property damage, and/or death.
!
Figure 11: Measuring External Static Pressure
LO PORT
A0435-002
RETURN AIR
DUCT
SUPPLY AIR
DUCT
MAX. PRESSURE 15 PSIG
INCHES OF WATER
HI PORT

5844973-UIM-A-0920
Johnson Controls Ducted Systems 19
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 ft3 or a 1 ft3 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 18.
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.
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 18: Gas Rate (ft3/h)1
1. Example: By actual measurement, it takes 38 s for the hand on the 1 ft3 dial to
make a revolution with just a 100,000 BTUH furnace running. Using this infor-
mation, locate 38 s in the first column of Table 18. Read across to the 1 ft3 col-
umn, where you see that 95 ft3/h of gas are consumed by the furnace at that
rate. Multiply 95 x 1050 (or 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.
Seconds for
One Revolution
Size of Test Dial
1/2 ft31 ft3
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

5844973-UIM-A-0920
20 Johnson Controls Ducted Systems
SECTION VII: TYPICAL WIRING DIAGRAMS
Figure 12: Connection Wiring Diagram
Refer to Installation Manual for more detailed information.
1174285-UWD-C-0519
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
YEL
WHT 27
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
BRN
RED
BLK/WHT 12
BRN/WHT 13
BLK 6
RED 9
OD FAN
MOTOR
POWER SUPPLY 208/230-1-60
PUR 1
BLK 5
COM
PRI
24V SEC
40 VA
208V
230V
COMPR
C
S
R
L1 T1
T2L2
FAN
HERM C
DUAL
CAPACITOR
RED 7
GRN
BLU 43
GND
CONTACTOR
COIL
SINGLE POLE
CONTACTOR
RED 45
BLU 42
BLU 30
PUR 2
YEL 21
BLK
YEL 18
GRN 44
5
4
3
2
6
1BLK
BRN
GRN 10
RED
BLOWER
MOTOR
SHARED TAP
SEE NOTE 7
XFMR
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
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
Incorrect polarity OR Don't have neutral
Gas valve shorted "ON"
Check blower motor/wiring
DSI Fault Codes
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 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:
208/230-1-60
CONNECTION WIRING DIAGRAM
COOLING UNIT WITH GAS HEAT