Johnson Controls Air Conditioner 13 145 SEER TCGD User Manual

INSTALLATION MANUAL  
R-410A  
OUTDOOR SPLIT-SYSTEM  
AIR CONDITIONING  
MODELS: 13 & 14.5 SEER -  
®
TCG(D,F)/GCGD/TCJ(D,F)/YCJ(D,F) SERIES  
1.5 TO 6.3 TONS – 1 & 3 PHASE  
LIST OF SECTIONS  
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1  
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1  
UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2  
ORIFICE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5  
TXV INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5  
EVACUATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5  
SYSTEM CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
INSTRUCTING THE OWNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13  
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14  
START UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17  
LIST OF FIGURES  
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2  
Installation of Vapor Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3  
Underground Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3  
Heat Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4  
Orifice Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5  
Outdoor Unit Control Box (Single Phase) . . . . . . . . . . . . . . . . . . . . . .7  
Outdoor Unit Control Box (Three Phase) . . . . . . . . . . . . . . . . . . . . . . .7  
Typical Field Wiring (Air Handler / Electrical Heat) (Single-Phase) . . .8  
Typical Field Wiring (Air Handler / Electrical Heat) (Three-Phase) . . .8  
Thermostat Chart - Single Stage AC with PSC Air Handler . . . . . . . . 9  
Thermostat Chart - Single Stage AC with PSC Air Handler . . . . . . . 10  
Thermostat Chart - Single Stage AC with PSC Furnace . . . . . . . . . 11  
Thermostat Chart - Single Stage AC with PSC Furnace . . . . . . . . . 12  
Wiring Diagram - Single Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14  
Wiring Diagram - Three Phase 2.5-5 Tons . . . . . . . . . . . . . . . . . . . . 15  
Wiring Diagram - Three Phase 6.3 Ton . . . . . . . . . . . . . . . . . . . . . . 16  
24 VAC Connection Wiring for 2-pipe A/C, 6.3 Ton  
Condensing Unit with 7.5 Ton Air Handler . . . . . . . . . . . . . . . . . . . . 16  
LIST OF TABLES  
Application Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2  
R-410A Saturation Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
SECTION I: GENERAL  
The outdoor units are designed to be connected to a matching indoor  
coil with sweat connect lines. Sweat connect units are factory charged  
with refrigerant for a matching indoor coil plus 15 feet of field-supplied  
lines.  
R-410A systems operate at higher pressures than R-22 systems.  
Do not use R-22 service equipment or components on R-410A  
equipment. Service equipment Must Be Rated for R-410A.  
The refrigerant charge may need to be changed for some indoor-out-  
door unit combinations, elevation differences or total line lengths. Refer  
to Application Data covering “General Piping Recommendations and  
Refrigerant Line Length” (Part Number 247077).  
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 mainte-  
nance can cause injury or property damage. Refer to this manual  
for assistance or for additional information, consult a qualified con-  
tractor, installer or service agency.  
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.  
INSPECTION  
As soon as a unit is received, it should be inspected for possible dam-  
age during transit. If damage is evident, the extent of the damage  
should be noted on the carrier’s delivery receipt. A separate request for  
inspection by the carrier’s agent should be made in writing. See Local  
Distributor for more information.  
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.  
Requirements For Installing/Servicing R-410A Equipment  
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.  
Gauge sets, hoses, refrigerant containers, and recovery system  
must be designed to handle the POE type oils, and the higher  
pressures of R-410A.  
Manifold sets should be high side and low side with low side  
retard.  
All hoses must have a 700 psig service pressure rating.  
Leak detectors should be designed to detect HFC refrigerant.  
Recovery equipment (including refrigerant recovery containers)  
must be specifically designed to handle R-410A.  
Do not use an R-22 TXV.  
This product must be installed in strict compliance with the  
enclosed installation instructions and any applicable local, state,  
and national codes including, but not limited to building, electrical,  
and mechanical codes.  
A liquid-line filter drier is required on every unit.  
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GROUND INSTALLATION  
The unit should be installed on a solid base that is 2” (5.1 cm) above  
grade and will not shift or settle, causing strain on the refrigerant lines  
and possible leaks. Maintain the clearances shown in Figure 1 and  
install the unit in a level position. The base pad should not come in con-  
tact with the foundation or side of the structure because sound may be  
transmitted to the residence.  
This system uses R-410A refrigerant which operates at higher pres-  
sures than R-22. No other refrigerant may be used in this system.  
Gauge sets, hoses, refrigerant containers, and recovery system  
must be designed to handle R-410A. If you are unsure, consult the  
equipment manufacturer.  
The length of the refrigerant tubing between the outdoor unit and indoor  
coil should be as short as possible to avoid capacity and efficiency  
losses. Excessive spacing of the outdoor unit from the home can result  
in the refrigerant lines being restricted by trampling or being punctured  
by lawn mowers. Locate the outdoor unit away from bedroom windows  
or other rooms where sound might be objectionable.  
Never install a suction-line filter drier in the liquid line of an R-410A  
system. Failure to follow this warning can cause a fire, injury or  
death.  
Adverse effects of snow or sleet accumulating on the outdoor coil can  
be eliminated by placing the outdoor unit where the prevailing wind  
does not blow across the unit. Trees, shrubs, corners of buildings, and  
fences standing off from the coil can reduce capacity loss due to wind  
chill effect.  
PRECAUTIONS DURING LINE INSTALLATION  
1. Install the lines with as few bends as possible. Care must be taken  
not to damage the couplings or kink the tubing. Use clean hard  
drawn copper tubing where no appreciable amount of bending  
around obstruction is necessary. If soft copper must be used, care  
must be taken to avoid sharp bends which may cause a restriction.  
2. The lines should be installed so that they will not obstruct service  
access to the coil, air handling system, or filter.  
Provide ample clearance from shrubs to allow adequate air to pass  
across the outdoor coil without leaves or branches being pulled into the  
coil.  
ROOF INSTALLATION  
3. Care must also be taken to isolate the refrigerant lines to minimize  
noise transmission from the equipment to the structure.  
4. The vapor line must be insulated with a minimum of 1/2" foam rub-  
ber insulation (Armaflex or equivalent). Liquid lines that will be  
exposed to direct sunlight, high temperatures, or excessive humid-  
ity must also be insulated.  
When installing units on a roof, the structure must be capable of sup-  
porting the total weight of the unit, including a pad, lintels, rails, etc.,  
which should be used to minimize the transmission of sound or vibra-  
tion into the conditioned space.  
LIQUID LINE FILTER-DRIER  
The air conditioning unit’s filter/dryer is located on the liquid line.  
5. Tape and suspend the refrigerant lines as shown. DO NOT allow  
tube metal-to-metal contact. See Figure 2.  
6. Use PVC piping as a conduit for all underground installations as  
shown in Figure 3. Buried lines should be kept as short as possible  
to minimize the build up of liquid refrigerant in the vapor line during  
long periods of shutdown.  
7. Pack fiberglass insulation and a sealing material such as perma-  
gum around refrigerant lines where they penetrate a wall to reduce  
vibration and to retain some flexibility.  
NOTICE  
Replacements for the liquid line drier must be exactly the same as  
marked on the original factory drier. See Source1 for O.E.M.  
replacement driers.  
8. For systems with total line length exceeding 70 feet (21.3 m), see  
APPLICATION DATA and worksheet "General Piping Recommen-  
dations and Refrigerant Line Length" for vapor and liquid line siz-  
ing, calibration of liquid line pressure loss or gain, determination of  
vapor line velocity, elevation limitations, orifice connections, sys-  
tem charging, traps, etc.  
Failure to do so or using a substitute drier or a granular type may  
result in damage to the equipment.  
Filter-Drier  
Apply with Models  
Source 1 Part No.  
Sheet Metal Hanger  
S1-02922195000  
All  
Liquid  
Line  
PIPING CONNECTIONS  
Incorrect  
The outdoor condensing unit must be connected to the indoor evapora-  
tor coil using field supplied refrigerant grade (ACR) copper tubing that is  
internally clean and dry. Units should be installed only with the tubing  
sizes for approved system combinations as specified in tabular data  
sheet. The charge given is applicable for total tubing lengths up to 15  
feet (4.6 m). See Application Data Part Number 247077 for installing  
tubing of longer lengths and elevation differences.  
Tape  
Correct  
FIGURE 2: Installation of Vapor Line  
TO OUTDOOR UNIT  
TO INDOOR COIL  
Liquid Line  
NOTICE  
Using a larger than specified line size could result in oil return prob-  
lems. Using too small a line will result in loss of capacity and other  
problems caused by insufficient refrigerant flow. Slope horizontal  
vapor lines at least 1" (2.5 cm) every 20 feet (6.1 m) toward the out-  
door unit to facilitate proper oil return.  
Insulated  
Vapor Line  
Cap  
PVC  
Conduit  
FIGURE 3: Underground Installation  
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PRECAUTIONS DURING BRAZING OF LINES  
All outdoor unit and evaporator coil connections are copper-to-copper  
and should be brazed with a phosphorous-copper alloy material such  
as Silfos-5 or equivalent. DO NOT use soft solder. The outdoor units  
have reusable service valves on both the liquid and vapor connections.  
The total system refrigerant charge is retained within the outdoor unit  
during shipping and installation. The reusable service valves are pro-  
vided to evacuate and charge per this instruction.  
Do not install any coil in a furnace which is to be operated during  
the heating season without attaching the refrigerant lines to the coil.  
The coil is under 30 to 35 psig inert gas pressure which must be  
released to prevent excessive pressure build-up and possible coil  
damage.  
Serious service problems can be avoided by taking adequate precau-  
tions to assure an internally clean and dry system.  
4. Braze the liquid line to the evaporator liquid connection. Nitrogen  
should be flowing through the evaporator coil.  
5. Slide the grommet away from the vapor connection at the indoor  
coil. Braze the vapor line to the evaporator vapor connection. After  
the connection has cooled, slide the grommet back into original  
position.  
Dry nitrogen should always be supplied through the tubing while it  
is being brazed, because the temperature required is high enough  
to cause oxidation of the copper unless an inert atmosphere is pro-  
vided. The flow of dry nitrogen should continue until the joint has  
cooled. Always use a pressure regulator and safety valve to insure  
that only low pressure dry nitrogen is introduced into the tubing.  
Only a small flow is necessary to displace air and prevent oxidation.  
6. Protect the vapor valve with a wet rag and braze the vapor line  
connection to the outdoor unit. The nitrogen flow should be exiting  
the system from the vapor service port connection. After this con-  
nection has cooled, remove the nitrogen source from the liquid fit-  
ting service port.  
7. Replace the Schrader core in the liquid and vapor valves.  
PRECAUTIONS DURING BRAZING SERVICE VALVE  
8. Go to SECTION IV or SECTION V for orifice or TXV installation  
depending on application.  
Precautions should be taken to prevent heat damage to service valve  
by wrapping a wet rag around it as shown in Figure 4. Also, protect all  
painted surfaces, insulation, and plastic base during brazing. After braz-  
ing, cool joint with wet rag.  
9. Leak test all refrigerant piping connections including the service  
port flare caps to be sure they are leak tight. DO NOT OVER-  
TIGHTEN (between 40 and 60 inch - lbs. maximum).  
NOTICE  
Line set and indoor coil can be pressurized to 250 psig with dry  
nitrogen and leak tested with a bubble type leak detector. Then  
release the nitrogen charge.  
Do not use the system refrigerant in the outdoor unit to purge or  
leak test.  
This is not a backseating valve. The service access port has a  
valve core. Opening or closing valve does not close service access  
port.  
If the valve stem is backed out past the chamfered retaining wall,  
the O-ring can be damaged causing leakage or system pressure  
could force the valve stem out of the valve body possibly causing  
personal injury.  
10. Evacuate the vapor line, evaporator, and liquid line to 500 microns  
or less.  
11. Replace cap on service ports. Do not remove the flare caps from  
the service ports except when necessary for servicing the system.  
Valve can be opened by removing the plunger cap and fully inserting a  
hex wrench into the stem and backing out counter-clockwise until valve  
stem just touches the chamfered retaining wall.  
Connect the refrigerant lines using the following procedure:  
1. Remove the cap and Schrader core from both the liquid and vapor  
service valve service ports at the outdoor unit. Connect low pres-  
sure nitrogen to the liquid line service port.  
Do not connect manifold gauges unless trouble is suspected.  
Approximately 3/4 ounce of refrigerant will be lost each time a stan-  
dard manifold gauge is connected.  
2. Braze the liquid line to the liquid valve at the outdoor unit. Be sure  
to wrap the valve body with a wet rag. Allow the nitrogen to con-  
tinue flowing.  
12. Release the refrigerant charge into the system. Open both the liq-  
uid and vapor valves by removing the plunger cap and with an  
allen wrench back out counter-clockwise until valve stem just  
touches the chamfered retaining wall. If the service valve is a ball  
valve, use a cresent wrench to turn valve stem one-quater turn  
counterclockwise to open. Do not overturn or the valve stem may  
break or become damaged. See “PRECAUTIONS DURING  
BRAZING SERVICE VALVE”.  
3. Carefully remove the plugs from the evaporator liquid and vapor  
connections at the indoor coil.  
13. Replace plunger cap finger tight, then tighten an additional 1/12  
turn (1/2 hex flat). Cap must be replaced to prevent leaks.  
Never attempt to repair any brazed connections while the system is  
under pressure. Personal injury could result.  
See "System Charge” section for checking and recording system  
charge.  
Supplied with the outdoor unit is a Schrader Valve Core and Orifice for  
highest sales volume indoor coil. The valve core must be installed in  
equalizer fitting of the indoor coil.  
FIGURE 4: Heat Protection  
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SECTION IV: ORIFICE INSTALLATION  
Only 1TVM900 series valves are to be used on this product.  
1. Relieve the holding charge by pulling off the rubber cap plug on  
the suction manifold line of the coil.  
Failure to install Schrader Valve Core on orifice applications could  
result in total refrigerant loss of the system!  
2. After holding charge is completely discharged, loosen and remove  
the Schrader cap seal.  
Install Schrader Valve Core and Orifice as follows:  
1. Slide indoor coil out of cabinet far enough to gain access to equal-  
izer fitting on the suction line.  
3. Loosen and remove distributor cap seal.  
4. Install the thermal expansion valve to the orifice distributor assem-  
bly with supplied fittings. Hand tighten and turn an additional 1/4  
turn to seal. Do not overtighten fittings.  
2. After holding charge is completely discharged remove black plas-  
tic cap on equalizer fitting.  
3. Install Schrader Valve Core supplied with the outdoor unit into  
equalizer fitting using a valve core tool.  
5. Install the liquid line to the top of the thermal expansion valve with  
fitting supplied with the liquid line. Hand modify the liquid line to  
align with casing opening. Hand tighten the liquid line and an addi-  
tional 1/4 turn to seal.  
4. Loosen and remove the liquid line fitting from the orifice distributor  
assembly. Note that the fitting has right hand threads.  
6. Install the TXV equalizer line into the vapor line as follows:  
5. Install proper size orifice supplied with outdoor unit. Refer to sup-  
plied Tabular Data Sheet for specific orifice size and indoor coil  
match up.  
a. Hand tighten the 1/4” SAE nut to the Schrader fitting and an  
additional 1/3 turn to seal.  
6. After orifice is installed reinstall the liquid line to the top of the ori-  
fice distributor assembly. Hand tighten and turn an additional 1/8  
turn to seal. Do not over tighten fittings.  
7. Install the TXV bulb to the vapor line near the equalizer line, using  
the bulb clamp(s) furnished with the TXV assembly. Ensure the  
bulb is making maximum contact.  
7. Leak test system.  
a. Bulb should be installed on a horizontal run of the vapor line if  
possible. The bulb should be installed on top of the line.  
8. Replace black plastic cap on equalizer fitting.  
9. Slide indoor coil back into cabinet.  
b. If bulb installation is made on a vertical run, the bulb should  
be located at least 16” (40.6 cm) from any bend, and on the  
tubing sides opposite the plane of the bend. The bulb should  
be positioned with the bulb tail at the top, so that the bulb acts  
as a reservoir.  
LIQUID LINE  
SWIVEL COUPLING  
(This fitting is a right-hand thread,  
turn counter-clockwise to remove)  
c. Bulb should be insulated using thermal insulation provided to  
protect it from the effect of the surrounding ambient tempera-  
ture. Cover completely to insulate from air-stream.  
ORIFICE  
In all cases, mount the TXV bulb after vapor line is brazed and has  
had sufficient time to cool.  
DISTRIBUTOR  
Schrader valve core MUST NOT be installed with TXV installation.  
Poor system performance or system failure could result.  
SECTION VI: EVACUATION  
FIGURE 5: Orifice Installation  
It will be necessary to evacuate the system to 500 microns or less. If a  
leak is suspected, leak test with dry nitrogen to locate the leak. Repair  
the leak and test again.  
SECTION V: TXV INSTALLATION  
To verify that the system has no leaks, simply close the valve to the vac-  
uum pump suction to isolate the pump and hold the system under vac-  
uum. Watch the micron gauge for a few minutes. If the micron gauge  
indicates a steady and continuous rise, it’s an indication of a leak. If the  
gauge shows a rise, then levels off after a few minutes and remains  
fairly constant, it’s an indication that the system is leak free but still con-  
tains moisture and may require further evacuation if the reading is  
above 500 microns.  
When using a TXV, 13 SEER models 12-48 require a hard start kit.  
Models 12-48 with a “H” on the end of the model number have a  
factory installed hard start.  
The following are the basic steps for installation. For detailed instruc-  
tions, refer to the Installation Instructions accompanying the TXV kit.  
Install TXV kit as follows:  
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4. Using the charging chart located on the unit, find the intersection  
of the outdoor ambient dry bulb and the suction pressure obtained  
in step 3. This is the recommended suction tube temperature at  
the service valve.  
SECTION VII: SYSTEM CHARGE  
The factory charge in the outdoor unit includes enough charge for the  
unit, a 15 ft. (4.6 m) line set, and the smallest indoor coil match-up.  
Some indoor coil matches may require additional charge. See tabular  
data sheet provided in unit literature packet for charge requirements.  
5. Measure and record the suction tube temperature at the service  
valve and compare to the recommended temperature obtained in  
step 4.  
6. Add charge if the measured suction temperature in step 5 is above  
the recommended value. Remove / recover refrigerant if the mea-  
sured suction temperature is below the recommended value.  
Do not leave the system open to the atmosphere.  
The “TOTAL SYSTEM CHARGE” must be permanently stamped on the  
unit data plate.  
Example: The suction tube temperature listed on the table at the  
intersection of the outdoor DB and the suction pressure is 63°F.  
Temperature of the suction tube at the service valve is 68°F. It would  
be necessary to add refrigerant to drop the suction tube temperature  
to 63°F.  
Total system charge is determined as follows:  
1. Determine outdoor unit charge from tabular data sheet.  
2. Determine indoor coil adjustment from tabular data sheet.  
3. Calculate the line charge using the tabular data sheet if line length  
is greater than 15 feet (4.6 m).  
SUBCOOLING CHARGING METHOD - TXV INDOOR  
For cooling operation, unless otherwise specified, the default subcool-  
ing is 10°F.  
4. Total system charge = item 1 + item 2 + item 3.  
5. Permanently stamp the unit data plate with the total amount of  
refrigerant in the system.  
1. Set the system running in cooling mode by setting the thermostat  
at least 6°F below the room temperature and operate system for at  
least 10 – 15 minutes.  
Use the following charging method whenever additional refrigerant is  
required for the system charge.  
2. Refer to the technical guide for the recommended indoor airflow  
and verify it is correct (it should be about 400 SCFM per ton).  
3. Measure and record the indoor wet bulb (WB) and the outdoor  
ambient dry bulb (DB) temperature.  
DO NOT attempt to pump “Total System Charge” into outdoor unit  
for maintenance, service, etc. This may cause damage to the com-  
pressor and/or other components. the outdoor unit only has enough  
volume for the factory charge, not the “Total System Charge”.  
4. Using the charging chart located on the unit, find the intersection  
of the indoor wet bulb and the outdoor dry bulb. This is the recom-  
mended liquid pressure (and subcooling value).  
5. Measure and record the pressure at the liquid valve pressure port  
and compare to the value obtained in step 4.  
6. Add charge if the measured liquid pressure is lower than the rec-  
ommended value. Remove / recover charge if the measured liquid  
pressure is above the recommended value.  
Refrigerant charging should only be carried out by a qualified air  
conditioning contractor.  
Example: The liquid pressure listed at the intersection of the indoor  
WB and the outdoor DB 320 psig. Pressure at the liquid valve is 305  
psig. It would be necessary to add refrigerant to increase the liquid  
pressure to 320 psig.  
Compressor damage will occur if system is improperly charged. On  
new system installations, charge system per tabular data sheet for  
the matched coil and follow guidelines in this instruction.  
Condenser subcooling is obtained by calculating the difference of the  
saturated refrigerant temperature of the pressure measured at the liquid  
base valve and the liquid tube temperature as measured at the liquid  
base valve.  
If a calibrated charging cylinder or accurate weighing device is avail-  
able, add refrigerant accordingly. Otherwise, model-specific charging  
charts are provided on the access panel of the unit.  
Subcooling Temp. (TC) = Saturated Temp. (TS) – Liquid Temp. (T).  
SUPERHEAT CHARGING METHOD -  
PISTON INDOOR  
1. Set the system running in cooling mode by setting the thermostat  
at least 6°F below the room temperature and operate system for at  
least 10 – 15 minutes.  
IT IS UNLAWFUL TO KNOWINGLY VENT, RELEASE OR DIS-  
CHARGE REFRIGERANT INTO THE OPEN AIR DURING  
REPAIR, SERVICE, MAINTENANCE OR THE FINAL DISPOSAL  
OF THIS UNIT.  
2. Refer to the technical guide for the recommended airflow and ver-  
ify indoor airflow (it should be about 400 SCFM per ton).  
3. Measure and record the outdoor ambient (DB) temperature and  
the suction pressure at the suction service valve.  
6
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TABLE 2: R-410A Saturation Properties  
PRESSURE  
PRESSURE  
PSIG  
PRESSURE  
PSIG  
PRESSURE  
PSIG  
PRESSURE  
TEMP. °F  
TEMP. °F  
TEMP. °F  
TEMP. °F  
TEMP. °F  
PSIG  
130  
132  
135  
137  
140  
142  
145  
147  
150  
153  
156  
158  
161  
164  
167  
PSIG  
341  
345  
350  
355  
360  
365  
370  
375  
380  
385  
391  
396  
401  
407  
412  
45  
46  
47  
48  
49  
50  
51  
52  
53  
54  
55  
56  
57  
58  
59  
60  
61  
62  
63  
64  
65  
66  
67  
68  
69  
70  
71  
72  
73  
74  
170  
173  
176  
179  
182  
185  
188  
191  
194  
197  
201  
204  
207  
211  
214  
75  
76  
77  
78  
79  
80  
81  
82  
83  
84  
85  
86  
87  
88  
89  
217  
221  
224  
228  
232  
235  
239  
243  
247  
250  
254  
258  
262  
266  
270  
90  
91  
274  
278  
282  
287  
291  
295  
299  
304  
308  
313  
317  
322  
326.  
331  
336  
105  
106  
107  
108  
109  
110  
111  
112  
113  
114  
115  
116  
117  
118  
119  
92  
93  
94  
95  
96  
97  
98  
99  
100  
101  
102  
103  
104  
SECTION VIII: ELECTRICAL  
CONNECTIONS  
Contactor  
GENERAL INFORMATION & GROUNDING  
Check the electrical supply to be sure that it meets the values specified  
on the unit nameplate and wiring label.  
Power wiring, control (low voltage) wiring, disconnect switches and over  
current protection must be supplied by the installer. Wire size should be  
sized per NEC requirements.  
Ground  
Lug  
All field wiring must USE COPPER CONDUCTORS ONLY and be  
in accordance with Local, National, Fire, Safety & Electrical Codes.  
This unit must be grounded with a separate ground wire in accor-  
dance with the above codes.  
Low  
Voltage  
Box  
Dual  
Run/Fan  
Capacitor  
The complete connection diagram and schematic wiring label is located  
on the inside surface of the unit service access panel.  
“Fingered”  
Bushing  
Reversible High  
Voltage Conduit Plate  
FIELD CONNECTIONS POWER WIRING  
1. Install the proper size weatherproof disconnect switch outdoors  
and within sight of the unit.  
FIGURE 6: Outdoor Unit Control Box (Single Phase)  
2. Remove the screws at the top and sides of the corner cover. Slide  
corner cover down and remove from unit.  
Contactor  
3. Run power wiring from the disconnect switch to the unit.  
4. Route wires from disconnect through power wiring opening pro-  
vided and into the unit control box as shown in Figures 6 & 7.  
5. Install the proper size time-delay fuses or circuit breaker, and  
make the power supply connections.  
Ground  
Lug  
Low  
Voltage  
Box  
Fan  
Capacitor  
“Fingered”  
Bushing  
Reversible High  
Voltage Conduit Plate  
FIGURE 7: Outdoor Unit Control Box (Three Phase)  
Johnson Controls Unitary Products  
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5. Mount the thermostat about 5 ft. above the floor, where it will be  
exposed to normal room air circulation. Do not place it on an out-  
side wall or where it is exposed to the radiant effect from exposed  
glass or appliances, drafts from outside doors or supply air grilles.  
FIELD CONNECTIONS CONTROL WIRING  
1. Route low voltage wiring into bottom of control box as shown in  
Figure 6. Make low voltage wiring connections inside the low volt-  
age box per Figures 7 - 11.  
6. Route the 24-volt control wiring (NEC Class 2) from the outdoor  
unit to the indoor unit and thermostat.  
2. The complete connection diagram and schematic wiring label is  
located on the inside surface of the unit service access panel.  
3. Replace the corner cover removed in Step 2.  
4. All field wiring to be in accordance with national electrical codes  
(NEC) and/or local-city codes.  
NOTICE  
To eliminate erratic operation, seal the hole in the wall at the ther-  
mostat with permagum or equivalent to prevent air drafts affecting  
the operation of in the thermostat.  
NOTE: A Start Assist Kit is available and recommended for long line set  
applications or in areas of known low voltage problems.  
ALL FIELD WIRING TO BE IN ACCORDANCE WITH ELECTRIC CODE (NEC) AND/OR LOCAL CODES  
POWER WIRING  
CONTROL WIRING  
FACTORY WIRING  
POWER WIRING  
24 VOLT CONTROL WIRING  
MINIMUM 18 GA. WIRE  
(NEC CLASS 2)  
FURNACE OR AIR HANDLER TERMINAL BLOCK  
C
Y
R
G
W
*
TERMINAL W IS ONLY  
REQUIRED ON SYSTEMS  
WITH HEAT.  
CONTACTOR  
TERMINALS  
*
GND.  
LUG  
COIL  
Y
R
G
W
ROOM THERMOSTAT  
CONDENSING UNIT  
ALL OUTDOOR WIRING MUST BE WEATHERPROOF. USE COPPER CONDUCTORS ONLY.  
FIGURE 8: Typical Field Wiring (Air Handler / Electrical Heat) (Single-Phase)  
ALL FIELD WIRING TO BE IN ACCORDANCE WITH ELECTRIC CODE (NEC) AND/OR LOCAL CODES  
POWER WIRING  
CONTROL WIRING  
FACTORY WIRING  
24 VOLT CONTROL WIRING  
MINIMUM 18 GA. WIRE  
(NEC CLASS 2)  
POWER WIRING  
FURNACE OR AIR HANDLER TERMINAL BLOCK  
C
Y
R
G
W
*
TERMINAL W IS ONLY  
REQUIRED ON SYSTEMS  
WITH HEAT.  
CONTACTOR  
TERMINALS  
GND.  
LUG  
*
COIL  
Y
R
G
W
ROOM THERMOSTAT  
CONDENSING UNIT  
ALL OUTDOOR WIRING MUST BE WEATHERPROOF. USE COPPER CONDUCTORS ONLY.  
FIGURE 9: Typical Field Wiring (Air Handler / Electrical Heat) (Three-Phase)  
8
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Product Catalog Section.  
AC 1A  
Single Stage Air Conditioner – PSC Air Handler  
ID MODELS  
AHP  
SHP  
MA  
THERMOSTAT  
SINGLE STAGE  
AIR  
PSC  
AIR HANDLER  
*PP11C70224  
CONDITIONER  
PSC  
SINGLE STAGE  
AIR CONDITIONER  
1
AIR HANDLER CONTROL  
COM  
24 – Volt Common  
C
24 – Volt Common  
Y/Y2  
Y
Y
Second or Full  
Stage Compressor  
Full Stage Compressor  
CompressorContactor  
RH  
R
24 – Volt Hot  
(Heat XFMR)  
24 – Volt Hot  
G
Fan  
G
Fan  
W2  
Second Stage Heat  
RC  
Y1  
24 – Volt Hot  
(Cool XFMR)  
Single Stage Compressor  
O
Reversing Valve  
Energized in Cool  
X/L  
Malfunction Light  
W
W1  
Full Stage Heat  
First Stage Heat  
HUM  
Humidity Switch  
Open on Humidity Rise  
HUM OUT  
24VAC Humidifier  
(Optional)  
HM1  
Humidistat  
24VAC  
Electronic Air Cleaner  
(Optional)  
(24 VAC out)  
Humidifier  
EAC(24 VAC out)  
Electronic Air Cleaner  
Clipping Jumper W914 for  
electric heat on thermostat  
is not necessary  
Move HUM STAT  
jumper to “YES”  
if humidistat is to be used.  
Refer to AH documentation  
for W1 and W2 electric  
heat staging options.  
Part Numbers:
1  
SAP  
=
Legacy  
159480= 031-09156  
FIGURE 10: Thermostat Chart - Single Stage AC with PSC Air Handler  
Johnson Controls Unitary Products  
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AC 1B  
Single Stage Air Conditioner – PSC Air Handler  
ID MODELS  
AHP  
SHP  
MA  
THERMOSTAT  
THERMOSTAT  
*BP11C50124  
*BN11C01124  
*DP11C40124  
*DN11C00124  
SINGLE STAGE  
AIR  
CONDITIONER  
PSC  
AIR HANDLER  
*BN11C00124  
PSC  
SINGLE STAGE  
AIR CONDITIONER  
1
AIR HANDLER CONTROL  
C
C
COM  
24 – Volt Common  
C
24 – Volt Common  
24 – Volt Common  
24 – Volt Common  
Y/Y2  
Y
Y
Y
Second or Full  
Stage Compressor  
Full Stage Compressor  
Full Stage Compressor  
Compressor Contactor  
RH  
RH  
R
24 – Volt Hot  
(Heat XFMR)  
24 – Volt Hot  
(Heat XFMR)  
24 – Volt Hot  
G
Fan  
G
Fan  
G
Fan  
W2  
Second Stage Heat  
RC  
RC  
Y1  
24 – Volt Hot  
(Cool XFMR)  
24 – Volt Hot  
(Cool XFMR)  
Single Stage Compressor  
O
Reversing Valve  
Energized in Cool  
X/L  
Malfunction Light  
W
W
W1  
Full Stage Heat  
Full Stage Heat  
First Stage Heat  
HUM  
Humidity Switch  
Open on Humidity Rise  
HUM OUT  
External Humidistat  
(Optional)  
Open on Humidity Rise  
2
24VAC Humidifier  
(Optional)  
(24 VAC out)  
Humidifier  
24VAC  
Electronic Air Cleaner  
(Optional)  
EAC(24 VAC out)  
Electronic Air Cleaner  
Thermostat Installer Setup Selection of GAS/ELEC  
1-System Type-must be  
set to 0  
switch on thermostat  
is not necessary  
Move HUM STAT  
jumper to “YES”  
if humidistat is to be used.  
Refer to AH documentation  
for W1 and W2 electric  
heat staging options.  
Thermostat Installer Setup  
15-Compressor Protection  
must be set to 5  
Part Numbers:
Part Number:  
S1-2HU16700124  
2
1  
SAP  
=
Legacy  
159480= 031-09156  
FIGURE 11: Thermostat Chart - Single Stage AC with PSC Air Handler  
10  
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AC 5D  
Single Stage Air Conditioner – Single Stage PSC Furnace  
ID MODELS  
G*(8/9)S  
G*9F  
GF(8/9)  
LF8  
L(Y/M)8S  
G8C  
TG(8/9)S  
(G/T)GLS  
THERMOSTAT  
SINGLE STAGE  
SINGLE STAGE  
AIR  
CONDITIONER  
*PP11C70224  
PSC  
FURNACE  
SINGLE STAGE PSC  
FURNACE  
SINGLE STAGE  
1
AIR CONDITIONER  
C
C
24 – Volt Common  
24 – Volt Common  
Y
Y/Y2  
Y
Full Stage Compressor  
Full Stage Compressor  
CompressorContactor  
RH  
R
24 – Volt Hot  
(Heat XFMR)  
24 – Volt Hot  
G
Fan  
G
Fan  
W
Full Stage Heat  
RC  
24 – Volt Hot  
(Cool XFMR)  
W
Full Stage Heat  
24VAC Humidifier  
(Optional)  
HM1  
Humidistat  
Clipping Jumper W914 for  
electric heat on thermostat  
is not necessary  
Other Part Numbers:  
1
SAP  
=
Legacy  
265901 = 031-09166  
FIGURE 12: Thermostat Chart - Single Stage AC with PSC Furnace  
Johnson Controls Unitary Products  
11  
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AC 5E  
Single Stage Air Conditioner – Single Stage PSC Furnace  
ID MODELS  
G*(8/9)S  
G*9F  
GF(8/9)  
LF8  
L(Y/M)8S  
G8C  
TG(8/9)S  
(G/T)GLS  
THERMOSTAT  
THERMOSTAT  
*BP11C50124  
*BN11C01124  
*DP11C40124  
*DN11C00124  
SINGLE STAGE  
SINGLE STAGE  
AIR  
CONDITIONER  
*BN11C00124  
PSC  
FURNACE  
SINGLE STAGE PSC  
FURNACE  
SINGLE STAGE  
AIR CONDITIONER  
1
C
C
C
C
24 – Volt Common  
24 – Volt Common  
24 – Volt Common  
24 – Volt Common  
Y
Y
Y/Y2  
Y
Full Stage Compressor  
Full Stage Compressor  
Full Stage Compressor  
Compressor Contactor  
RH  
RH  
R
24 – Volt Hot  
(Heat XFMR)  
24 – Volt Hot  
(Heat XFMR)  
24 – Volt Hot  
G
Fan  
G
Fan  
G
Fan  
W
Full Stage Heat  
RC  
RC  
24 – Volt Hot  
(Cool XFMR)  
24 – Volt Hot  
(Cool XFMR)  
W
W
Full Stage Heat  
Full Stage Heat  
External Humidistat  
(Optional)  
Open on Humidity Rise  
2
24VAC Humidifier  
(Optional)  
Thermostat Installer Setup Selection of GAS/ELEC  
1-System Type-must be  
set to 0  
switch on thermostat  
is not necessary  
Thermostat Installer Setup  
15-Compressor Protection  
must be set to 5  
Other Part Numbers:  
Part Number:  
S1-2HU16700124  
2
1
SAP  
=
Legacy  
265901 = 031-09166  
FIGURE 13: Thermostat Chart - Single Stage AC with PSC Furnace  
12  
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3. If the coil needs to be cleaned, use clean water to wash dust, dirt,  
and debris from outdoor condensing coil.  
SECTION IX: INSTRUCTING THE OWNER  
Assist owner with processing warranty cards and/or online registration.  
Review Owners Guide and provide a copy to the owner and guidance  
on proper operation and maintenance. Instruct the owner or the opera-  
tor how to start, stop and adjust temperature setting.  
NOTICE  
DO NOT use coil cleaners to clean outdoor condensing coil. clean-  
ers containing HF-, hydroxides, chlorides, and sulfates can greatly  
reduce the lifetime of the aluminum condensing coil.  
When applicable, instruct the owner that the compressor is equipped  
with a crankcase heater to prevent the migration of refrigerant to the  
compressor during the OFF cycle. The heater is energized only when  
the unit is not running. If the main switch is disconnected for long peri-  
ods of shut down, do not attempt to start the unit until 8 hours after the  
switch has been connected. This will allow sufficient time for all liquid  
refrigerant to be driven out of the compressor.  
4. Refer to the furnace or air handler instructions for filter and blower  
motor maintenance.  
5. The indoor coil and drain pan should be inspected and cleaned  
regularly to prevent odors and assure proper drainage.  
The installer should also instruct the owner on proper operation and  
maintenance of all other system components.  
MAINTENANCE  
IT IS UNLAWFUL TO KNOWINGLY VENT, RELEASE OR DIS-  
CHARGE REFRIGERANT INTO THE OPEN AIR DURING  
REPAIR, SERVICE, MAINTENANCE OR THE FINAL DISPOSAL  
OF THIS UNIT.  
1. Dirt should not be allowed to accumulate on the outdoor coils or  
other parts in the air circuit. Clean as often as necessary to keep  
the unit clean. Use a brush, vacuum cleaner attachment, or other  
suitable means.  
SUBCOOLING CHARGE TABLE IS ON THE UNIT RATING  
PLATE.  
2. The outdoor fan motor is permanently lubricated and does not  
require periodic oiling.  
Johnson Controls Unitary Products  
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SECTION X: WIRING DIAGRAM  
FIGURE 14: Wiring Diagram - Single Phase  
14  
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*412217*  
FIGURE 15: Wiring Diagram - Three Phase 2.5-5 Tons  
Johnson Controls Unitary Products  
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DANGER - SHOCK HAZARD  
TURN OFF ELECTRICAL POWER BEFORE  
SERVICING TO PREVENT POSSIBLE DAMAGE  
TO THE EQUIPMENT AND POSSIBLE  
PERSONAL INJURY.  
1
2
COMPONENTS SHOWN IN DASHED LINES ARE OPTIONAL.  
RED WIRE WILL BE REMOVED IF LOW AMBIENT KIT IS  
INSTALLED.  
3
4
YELLOW WIRE WILL BE REMOVED IF PRESSURE SWITCH  
KIT IS INSTALLED.  
CAUTION  
TO PREVENT ELECTRICAL SHOCK OPEN  
REMOTE DISCONNECT SO ELECTRICAL  
SUPPLY TO AIR CONDITIONER IS SHUT OFF.  
IF ANY OF THE ORIGINAL WIRE SUPPLIED WITH THIS UNIT  
MUST BE REPLACED, IT MUST BE REPLACED WITH TYPE  
105 C, THERMOPLASTIC OR ITS EQUIVALENT.  
5
WIRING MUST CONFORM TO NATIONAL AND LOCAL CODES.  
HIGH VOLTAGE FACTORY WIRING  
LOW VOLTAGE FACTORY WIRING  
FIELD WIRING, LINE VOLTAGE  
OPTIONAL WIRING  
HPS -HIGH PRESSURE SWITCH  
LP -LOW PRESSURE SWITCH  
LAP -LOW AMBIENT PRESSURE SWITCH  
CCH -CRANKCASE HEATER  
CC -CONTACTOR COIL  
ASCT -ANTI-SHORT CYCLE TIME  
Optional Low Ambient Kit  
LAP RELAY 1  
RED  
RED  
1
A
B
7
BRN  
RED  
FAN  
S
C
MOTOR  
GND.  
LAP  
1
R
6
3
5
4
2
1
Optional Pressure Out Kit  
PLUG  
PS RELAY  
1
YEL  
7
A
B
BLK  
BLK  
COMPRESSOR  
MOTOR  
FAN  
CAPACITOR  
2
T1  
GRN  
1
RED  
HPS  
T2  
T3  
24V  
240V  
OR  
480V  
COM  
CCH  
1
208V  
1
LP  
2
YEL / PNK  
YEL / PNK  
CONTACTOR  
HPS  
CC  
3
LOW  
VOLTAGE  
BOX  
GND.  
LUG  
208/230 VAC 60 Hz 3Ph  
380/415 VAC 50 Hz 3Ph  
460 VAC 60 Hz 3Ph  
USE COPPER CONDUCTOR ONLY  
GND.  
872677-UWD-A-0712  
FIGURE 16: Wiring Diagram - Three Phase 6.3 Ton  
6.3 TON CONDENSING UNIT  
LOW VOLTAGE BOX  
7.5 TON AIR HANDLER  
24 V TERMINAL BLOCK  
BLUE  
830 /BR  
24 I/BR  
C
SI  
YELLOW  
RED  
S2  
GI  
66  
60  
2I0/Y  
A
A
BRI  
B
B
832 /BK  
833 /BL  
EHRI  
83 I/BR  
A EHR 2 B  
USED WITH ELECTRIC  
HEAT ACCESSORIES  
C
R
YI  
G
W1  
W2  
TYPICAL WALL THERMOSTAT  
FIGURE 17: 24 VAC Connection Wiring for 2-pipe A/C, 6.3 Ton Condensing Unit with 7.5 Ton Air Handler  
16  
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SECTION XI: START UP SHEET  
Air Conditioning and Heating Start-Up Sheet  
Print Form  
Reset Form  
Proper start-up is critical to customer comfort and equipment longevity  
Start-Up Date  
Technician Performing Start-Up  
Installing Contractor Name  
Owner Information  
Name  
Address  
City  
State or Province  
Downflow  
Zip or Postal Code  
Horizontal Left Horizontal Right  
Equipment Data  
Upflow  
Indoor Unit Model #  
Indoor Unit Serial #  
Indoor Coil Model #  
Indoor Coil Serial #  
Outdoor Unit Model #  
Outdoor Unit Serial #  
Filter, Thermostat, Accessories  
Filter Type  
Filter Size  
Filter Location(s)  
Thermostat Type  
Other System Equipment and Accessories  
Connections -- Per Installation Instructions and Local Codes  
Unit is level  
Supply plenum and return ducts are connected and sealed  
Refrigerant piping complete and leak tested  
Vent system is connected (if applicable)  
Condensate drain for furnace (if applicable)  
Gas piping is connected (if applicable)  
Condensate drain for indoor coil properly connected  
Electrical: Line Voltage  
Indoor unit (volts AC)  
Outdoor unit (volts AC)  
Overcurrent Protection Breaker / Fuses Amperes  
Ground wire is connected  
Polarity is correct (120vac indoor units) black is L1 (hot), white is N (neutral)  
Electrical: Low Voltage  
Thermostat wiring complete  
Heat anticipator  
recommended value  
Heat anticipator is set to the recommended value listed in the Installation Instructions  
Low voltage values: "R" and "C" at Indoor unit control board (volts AC)  
"R" and "C" Outdoor unit control board (volts AC)  
Heating Set-Up  
Heating Type  
Electric Air Handler  
Natural Gas  
LP Gas (Requires LP Conversion Kit)  
LP Gas Conversion Kit Part # Used  
Inlet Gas Pressure (in. w.c.")  
Manifold Gas Pressure (in. w.c.")  
Calculated input in btuh - clock the gas meter (Nat Gas Only)  
LP Kit Installed By  
Electric Heat Kit Part # (if applicable)  
KW installed  
Rated BTU/H (furnaces)  
Venting (if applicable)  
Venting system properly sized, within the limitations of the charts in the installation instructions.  
Intake Size  
# of 90 Degree Ells  
# of 90 Degree Ells  
# 0f 45 Degree Ells  
# 0f 45 Degree Ells  
Length  
Exhaust Size  
Length  
Continued on next Page  
Johnson Controls Unitary Products  
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Air Side: System Total External Static Pressure  
Supply static before indoor coil (in w.c.")  
Supply static after indoor coil (in w.c.")  
Return Static (in w.c.") after filter (furnace side)  
Maximum Rated ESP (in w.c.")  
Return Static (in w.c.") before filter  
Total External Static Pressure  
COOL  
A
B
C
D
ADJUST  
ECM  
A
B
C
D
Cooling  
Indoor  
Blower Set-Up  
DELAY  
A
B
C
D
X-13  
PSC  
1
2
3
4
5
Low  
Medium Low  
Medium  
Medium High  
High  
Return Air: Dry Bulb  
Wet Bulb  
Supply Air: Dry Bulb  
Temperature Drop  
Outside Air: Dry Bulb  
ECM  
A
2
B
3
C
4
D
HEAT  
1
Heating  
Indoor  
Blower Set-Up  
X-13  
5
Medium  
Low  
Medium  
High  
PSC  
Low  
Medium  
High  
Temperature Rise  
Return Air: Dry Bulb  
Wet Bulb  
Supply Air: Dry Bulb  
Refrigerant Charge and Metering Device  
Additional Lineset Length  
Adder per foot - lbs.  
Total Added - lbs.  
Oz.  
Oz.  
R-22  
R-410A  
TXV  
Fixed Orifice  
# Elbows  
# 45s  
Orifice Size  
Liquid Line Temp  
Subcooling  
High Side Pressure  
Suction Line Temp  
Superheat  
Low Side Pressure  
TXV #  
Cycle Test  
Operate the unit through continuous fan cycles from the thermostat, noting and correcting any problems  
Operate the unit through a cooling cycles, noting and correcting any problems  
Operate the unit through several heating cycles (if applicable) from the thermostat, noting and correcting any problems  
Clean Up  
Installation debris disposed of and indoor and outdoor areas cleaned up?  
Owner Education  
Provide owner with the owner's manual  
Explain operation of system to equipment owner  
Explain thermostat use and programming (if applicable) to owner  
Explain the importance of regular filter replacement and equipment maintenance  
Comments Section  
Subject to change without notice. Published in U.S.A.  
872678-UIM-C-0213  
Copyright © 2013 by Johnson Controls, Inc. All rights reserved.  
Supersedes: 872678-UIM-B-0712  
York International Corp.  
5005 York Drive  
Norman, OK 73069  
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