INSTALLATION MANUAL

SINGLE PACKAGE ®
AIR CONDITIONER/GAS HEAT
MODELS: PCG4 SERIES
2 TONS TO 5 TONS - 208/230 V - 1 PHASE

LIST OF SECTIONS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 AIRFLOW PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
MODEL NUMBER NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . 2 TYPICAL WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 START UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

LIST OF FIGURES
Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Flue Vent Outlet Air Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Center of Gravity Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Bottom Duct Dimensions (in.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Measuring External Static Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 18
Rear Duct Dimensions (in.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Connection Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Typical Field Control Wiring Diagram for Gas Heat - AC Models . . . 7 Ladder Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Typical Field Power Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 7 R-410A Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

LIST OF TABLES
Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 High-Altitude Gas Orifice Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Application Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Natural Gas Application Data - PCG4 . . . . . . . . . . . . . . . . . . . . . . . 10
Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Propane (LP) Gas Application Data - PCG4 . . . . . . . . . . . . . . . . . . . 11
Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Airflow Performance - Side Duct Application . . . . . . . . . . . . . . . . . . 11
Unit Clearances, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electrical Data - PCG4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Natural Gas Pipe Sizing Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Default Blower Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Propane (LP) Gas Pipe Sizing Chart . . . . . . . . . . . . . . . . . . . . . . . . . 9 Gas Rate (ft3/h) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

SECTION I: GENERAL INFORMATION

These are electric cooling/gas heating units designed for outdoor instal- ! WARNING
lation. Only gas piping, electric power, and duct connections are
Improper installation may create a condition where the operation of
required at the point of installation. the product could cause personal injury or property damage.
The gas-fired heaters have spark ignition. Improper installation, adjustment, alteration, service, or maintenance
The refrigerant system is fully charged with R-410A refrigerant, tested, can cause injury or property damage. Failure to carefully read and
and factory sealed. follow all instructions in this manual can result in furnace mal-
function, death, personal injury, and/or property damage. Only a
SECTION II: SAFETY qualified contractor, installer, or service agency should install this
product.
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,
! CAUTION
WARNING, or CAUTION. This product must be installed in strict compliance with the installa-
tion instructions and any applicable local, state, and national codes,
DANGER indicates an imminently hazardous situation, which, if not
including but not limited to building, electrical, and mechanical codes.
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.

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! WARNING ! WARNING
Before performing service or maintenance operations on unit, turn off If the information in this manual is not followed exactly, a fire or
main power switch to unit. Electrical shock could cause personal explosion may result causing property damage, personal injury, or
injury. Improper installation, adjustment, alteration, service, or main- loss of life.
tenance can cause injury or property damage. Refer to this manual. Do not store or use gasoline or other flammable vapors and liquids in
For assistance or additional information consult a qualified installer, the vicinity of this or any other appliance.
service agency, or the gas supplier. WHAT TO DO IF YOU SMELL GAS:
1. Do not try to light any appliance.

CAUTION
2. Do not touch any electrical switch; do not use any phone in
! your building.
This system uses R-410A refrigerant, which operates at higher pres- 3. Immediately call your gas supplier from a neighbor’s phone.
sures than R-22. No other refrigerant may be used in this system. Follow the gas supplier’s instructions.
Gage sets, hoses, refrigerant containers, and recovery systems must 4. If you cannot reach your gas supplier, call the fire depart-
be designed to handle R-410A. If you are unsure, consult the equip- ment.
ment manufacturer. Failure to use R-410A compatible servicing Installation and service must be performed by a qualified installer,
equipment may result in property damage or injury. service agency, or the gas supplier.

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

PCG 4 A 24 050 2 X 4 A
1 2 3 4 5 6 7 8 9
1. Model Family 5. Gas Heating Input BTU/Hr x 1000
PCG - packaged A/C with gas heat 050 = 50,000 BTU/Hr input, blank = electric heat
PHG - packaged heat pump with gas heat
6. Voltage-Phase-Frequency
PCE - packaged A/C with electric heat
2 = 208/230-1-60, 3 = 208/230-3-60, 4 = 460-3-60
PHE - packaged heat pump with electric heat
2. Nominal Cooling Efficiency 7. NOx Approval
4 = 14 SEER, 6 = 16 SEER X = Low NOx, blank = not Low NOx
3. Cabinet Size 8. Generation Level
A = small 35.75 x 51.25, B = large 45.75 x 51.25 1 = first generation 2 = second generation
4. Nominal Air Conditioning Cooling Capacity BTU/Hr x 1000 9. Revision Level
24 = 24,000 BTU/Hr, 30 = 30,000 BTU/Hr 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.

SECTION IV: INSTALLATION

INSTALLATION SAFETY INFORMATION • Install the unit to operate within the unit's intended temperature
rise range with the duct system and within the allowable external
Read these instructions before continuing the unit installation. This is an static pressure range, as specified on the unit name/rating plate
outdoor combination heating and cooling unit. Give the instructions to and in Table 7.
the homeowner, and instruct the homeowner to retain them for future • Do not use this equipment for temporary heating of buildings or
reference. structures under construction.
Adhere to the following:
• Refer to the unit rating plate for the approved type of gas for this
product.
! WARNING
FIRE OR EXPLOSION HAZARD
• Install the unit only in a location and position specified on page 4 of Failure to follow the safety warning exactly could result in serious
these instructions. injury, death, or property damage.
• Never test for gas leaks with an open flame. Use commercially Never test for gas leaks with an open flame. Use a commercially
available soap solution made specifically for the detection of leaks available soap solution made specifically for the detection of leaks to
when checking all connections, as specified on page 9 of these check all connections. A fire or explosion may result causing property
instructions. damage, personal injury, or loss of life.

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LIMITATIONS See the unit application data in this document.

These units must be installed in accordance with the following: After installation, adjust gas-fired units to obtain a temperature rise within
the range specified on the unit rating plate.
In U.S.
If it is necessary to add components to a unit to meet local codes, instal-
• National Electrical Code, ANSI/NFPA No. 70 - Latest Edition
lation is done at the dealer’s and/or customer’s expense.
• National Fuel Gas Code, ANSI Z223.1 - Latest Edition
The size of the unit for proposed installation must be based on heat
• Gas-Fired Central Furnace Standard, ANSI Z21.47a. - Latest Edi-
tion loss/heat gain calculation made according to the methods of the Air
Conditioning Contractors of America (ACCA).
• Local building codes
• Local gas utility requirements Do not use this furnace for temporary heating of buildings or structures
under construction.
In Canada
• Canadian Electrical Code, CSA C22.1
• Installation Codes, CSA - B149.1
• Local plumbing and wastewater codes
• Other applicable local codes

Table 1: Unit Limitations

Unit Limitations
Model Unit Voltage 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

Air Temperature at Outdoor Coil (°F) Air Temperature at Indoor Coil (°F)
Packaged Equipment
Minimum Maximum Minimum Maximum
Series
DB Cool DB Cool WB Cool WB Cool
14 SEER AC 55 125 57 72

FAN MOTOR OUTDOOR FAN

COIL GUARD PANEL

OUTDOOR COIL
(Behind Panel)

CONTROL BOARD
BLOWER MOTOR TRANSFORMER
HIGH VOLTAGE
CONTACTOR
TXV
PRESSURE SWITCH
INDOOR COIL
DRAFT INDUCER BLOWER
INDOOR BLOWER
GAS VALVE
COMPRESSOR GAS HEAT
EXCHANGER
REMOVABLE BURNER
BASE RAILS ASSEMBLY
A0297-001

Figure 1: Component Location

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LOCATION All units require particular clearances for proper operation and service.
Use the following guidelines to select a suitable location for these units: Make provisions for adequate combustion and ventilation air in accor-
dance with the following:
• The unit is designed for outdoor installation only.
• Section 5.3 of Air for Combustion and Ventilation of the National
• Outdoor coils must have an unlimited supply of air. Where a choice
Fuel Gas Code, ANSI Z223.1 - Latest Edition (in U.S.)
of location is available, position the unit on either the north or east
side of the building. • Sections 7.2, 7.3, or 7.4 of Gas Installation Codes, CSA-B149.1 -
Latest Edition (in Canada)
• The unit is suitable for mounting on a roof curb.
• Applicable provisions of local building codes

! WARNING See Table 5 for the clearances required for combustible construction,
servicing, and proper unit operation.
Do not attach supply and return duct work to the bottom of the unit
base pan as the drain pan could be compromised. RIGGING AND HANDLING

• 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
! CAUTION
weight of the unit. Do not tie the slab to the building foundation. All panels must be secured in place when the unit is lifted.
• Roof structures must be able to support the weight of the unit and The outdoor coils should be protected from rigging cable damage
its options/accessories. Install the unit on a solid, level roof curb or with plywood or other suitable material.
an appropriate angle iron frame.

CAUTION
• Maintain level tolerance to 1/8 in. across the entire width and
length of the unit. !

WARNING
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.
Excessive exposure of this unit to contaminated combustion air may
result in equipment damage or personal injury. Typical contaminates Exercise care when moving the unit. Do not remove any packaging until
include: permanent wave solution, chlorinated waxes and cleaners, the unit is near the place of installation. Rig the unit by attaching chain
chlorine based swimming pool chemicals, water softening chemicals, or cable slings to the lifting holes provided in the base rails.
carbon tetrachloride, Halogen type refrigerants, cleaning solvents
(for example, perchloroethylene), printing inks, paint removers, var- Note: Use spreader bars whose length exceeds the largest dimension
nishes, hydrochloric acid, cements and glues, anti-static fabric soft- across the unit across the top of the unit.
eners for clothes dryers, masonry acid washing materials.

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

Do not permit overhanging structures or shrubs to obstruct outdoor Units can be moved or lifted with a forklift. Slotted openings in the base
air discharge outlet, combustion air inlet, or vent outlets. rails are provided for this purpose.

Table 3: Weights and Dimensions

Weight (lb) Center of Gravity 4-Point Load Location (lb)
Model
Shipping Operating X Y A B C D
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

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 5844973-UIM-A-0920

"D"

CENTER OF
GRAVITY
COMPRESSOR

"A" "C"

FRONT
OF UNIT
"B" Y
X
A0295-001

Figure 2: Center of Gravity Location

Table 4: Unit Dimensions

Dimensions (in.)
Model
A B C
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

UNIT TOP PANEL

CORNER POST

INDOOR COIL
(BEHIND PANEL) OUTDOOR COIL GUARD

HIGH VOLTAGE
OPENING 7/8"
C

HIGH VOLTAGE
COMBUSTION AIR INTAKE
OPENING 1 3/32"
HEAT EXCHANGER ACCESS PANEL
COMPRESSOR
ACCESS PANEL
FLUE EXHAUST HOOD

CONDENSATE A
DRAIN B
BLOWER
ACCESS CONTROL / HEAT LOW VOLTAGE OPENING 7/8"
PANEL ACCESS PANEL GAS SUPPLY HOLE 1 5/8" WITH
GROMMET OPENING OF 7/8" A0296-004

Figure 3: Unit Dimensions

Table 5: Unit Clearances1,2

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

Top3 36 Power Entry (Right Side) 36
Side Opposite Ducts 36 Left Side 24
Duct Panel 0 Bottom4 1
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.

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5844973-UIM-A-0920

DUCT WORK
9,(:/22.,1*83
' ´

NOTICE
´
$7%277202)81,7
&
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 5(7851
improper handling or shipping processes. To ensure a good tight $ $,5'8&7
seal, it is recommended that silicone caulk and/or foil tape be applied
along the cover edges.

These units are adaptable to downflow use. To convert to downflow: +2/(´ (

1. Remove the duct covers found in the bottom return and supply air % ZLWK´JURPPHW
duct openings. RSHQLQJIRUJDVSLSH
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. +2/(´
Design and size duct work according to the methods of the Air Condi- 6833/< IRUKLJK
$ $,5'8&7 YROWDJH
tioning Contractors of America (ACCA), as outlined in their Manual D.
Use a closed return duct system. This does not preclude use of econo- +2/(´ IRU
mizers or ventilation air intake. It is best practice to use flexible joints in ORZYROWDJH
the supply and return duct work to minimize the transmission of vibra-
tion and noise.
)

NOTICE
$

Model A B C D E F
Be sure to note supply and return openings. 24, 30, 36, 42 10 21.5 5 4.5 47.5 32
48, 60 14 13.5 5 3.5 47.5 42
See Figures 4 and 5 for information concerning rear and bottom supply Figure 4: Bottom Duct Dimensions (in.)
and return air duct openings.
FILTERS 127(6HH)LJXUHWLWOHG³8QLW'LPHQVLRQV´IRUVLGHKROHVL]HVRI
Correct filter size is very important. Always consider filter size, type, and HOHFWULFDODQGJDVOLQHV
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.

6833/< 5(7851
 $,5'8&7 $,5'8&7



$ % $ 
$

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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CONDENSATE DRAIN POWER AND CONTROL WIRING

Install a condensate trap in the condensate drain. The plumbing must Field wiring to the unit must conform to provisions of the current NEC
conform to local codes. ANSI/NFPA No. 70 or CEC and/or local ordinances. The unit must be
electrically grounded in accordance with local codes or, in their
! CAUTION absence, with the NEC/CEC. Voltage tolerances that must be main-
tained at the compressor terminals during starting and running condi-
Hand tighten only. tions are indicated on the unit Rating Plate and in Table 1.
Provide the wiring entering the cabinet with mechanical strain relief.
SERVICE ACCESS
A fused disconnect switch must be field provided for the unit. If any of
Access to all serviceable components is provided at the following loca- the wire supplied with the unit needs to be replaced, replacement wire
tions: must be of the type shown on the wiring diagram.
• Coil guards Electrical service must be sized properly to carry the load. Each unit
• Unit top panel must be wired with a separate branch circuit fed directly from the main
• Corner posts distribution panel and correctly fused.
• Blower access panel See Figures 6 and 7 for typical field wiring and refer to the appropriate
• Control access panel unit wiring diagram for control circuit and power wiring information.
• Indoor coil access panel
Minimum wire size of 18 AWG wire should be used for all field
• Compressor access panel installed control wiring.
• Heat exchanger access panel
THERMOSTAT
See Figure 3 for the location of these access locations and see Table 5
for minimum clearances. R
RED

! CAUTION G
GREEN

This system uses R-410A refrigerant, which operates at higher pres-

sures than R-22. No other refrigerant may be used in this system. YELLOW CONTROL
Gage sets, hoses, refrigerant containers, and recovery systems must Y BOARD
be designed to handle R-410A. If you are unsure, consult the equip-
ment manufacturer. Failure to use R-410A compatible servicing WHITE
equipment may result in property damage or injury. W

WARNING
BLUE
! C

Wear safety glasses and gloves when handling refrigerants. Failure

to follow this warning can cause serious personal injury. NOTE:
Heat Anticipator should be set at 0.35 AMPS for all models
A0294-001
See Figure 14 for the R-410A Quick Reference Guide.
Figure 6: Typical Field Control Wiring Diagram for Gas Heat - AC
THERMOSTAT Models
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 CONTACTOR
from electrical fixtures or appliances. Use sealant behind the thermostat FIELD SUPPLIED
to prevent air infiltration. Follow the manufacturer's instructions DISCONNECT
enclosed with the thermostat for the general installation procedure. Use SINGLE
color-coded insulated wires (minimum No. 18 AWG) to connect the PHASE
thermostat to the unit. See Figure 6. Do not use power stealing thermo- POWER
GND REFER TO ELECTRICAL SUPPLY
stats.
LUG DATA TABLES TO SIZE
THE DISCONNECT A0293-001

Figure 7: Typical Field Power Wiring Diagram

Table 6: Electrical Data - PCG4

Outdoor Fan Indoor Max Fuse2/
Compressor MCA1
Model Voltage Motor Blower Motor
(Amps) Breaker3 Size
RLA LRA MCC FLA FLA (Amps)
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
1. Minimum Circuit Ampacity.
2. Maximum Overcurrent Protection per standard UL 1995.
3. Fuse or HACR circuit breaker is field installed.

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Table 7: Physical Data

MODELS
NOMINAL TONNAGE 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 2 3 4 2 3 4
Number of Stages 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Temperature Rise Range (°F) 40–70 40–70 35–65 40–70 40–70 40–70 40–70
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
Field-supplied external filters must be sized so as not to exceed 300 fpm air velocity through disposable fil-
Quantity - Size 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.

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COMPRESSORS Gas piping requirements:

The compressor used in this product is specifically designed to operate • Install a drip leg and a ground joint union in the gas piping.
with R-410A refrigerant and cannot be interchanged with a different • When required by local codes, install a manual shut-off valve out-
type of compressor. side of the unit.
• Use wrought iron or steel pipe for all gas lines. Apply pipe thread
! CAUTION sealant sparingly to male threads only.

This system uses R-410A refrigerant, which operates at higher pres- Table 8: Natural Gas Pipe Sizing Chart1
sures than R-22. No other refrigerant may be used in this system. Length Nominal Inches Iron Pipe Size
The compressor uses polyolester (POE) oil, Mobil 3MA POE. This oil is (ft) 1/2 in. 3/4 in. 1 in. 1 1/4 in.
extremely hygroscopic, meaning it absorbs water readily. POE oil can 10 132 278 520 1,050
absorb 15 times as much water as other oils designed for HCFC and 20 92 190 350 730
CFC refrigerants. If the refrigerant circuit is opened, take all necessary 30 73 152 285 590
precautions to avoid exposure of the oil to the atmosphere.
40 63 130 245 500

CAUTION
50 56 115 215 440
! 60 50 105 195 400
Do not leave the system open to the atmosphere. Unit damage could 70 46 96 180 370
occur due to moisture being absorbed by the POE oil in the system. 80 43 90 170 350
This type of oil is highly susceptible to moisture absorption.
90 40 84 160 320
POE compressor lubricants are known to cause long-term damage to 100 38 79 150 305
some synthetic roofing materials.
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).
! CAUTION Table 9: Propane (LP) Gas Pipe Sizing Chart1
Exposure to compressor oil, even if immediately cleaned up, may
Length Nominal Inches Iron Pipe Size
cause embrittlement (leading to cracking) to occur in one year or
more. When performing any service that may risk exposure of com- (ft) 1/2 in. 3/4 in. 1 in. 1 1/4 in.
pressor oil to the roof, take precautions to protect roofing. 10 275 567 1071 2,205
20 189 393 732 1496
Procedures that risk oil leakage include but are not limited to the follow-
ing: 30 152 315 590 1212
40 129 267 504 1039
• Replacing the compressor
50 114 237 448 913
• Repairing refrigerant leaks
60 103 217 409 834
• Replacing refrigerant components, for example, filter drier, pres-
sure switch, metering device, or coil 70 96 196 378 771
80 89 185 346 724
! CAUTION 90
100
83
78
173
162
322
307
677
630
Do not loosen compressor mounting bolts.
1. Maximum capacity of pipe in thousands of BTU per hour (based upon a pres-
Units are shipped with compressor mountings, which are factory- sure drop of 0.5 in. W.C.).
adjusted and ready for operation.

GAS HEAT ! CAUTION

These single-stage gas-fired heat sections have direct spark ignition. If flexible stainless steel tubing is allowed by the authority having
jurisdiction, wrought iron or steel pipe must be installed at the gas
GAS PIPING
valve and extend a minimum of 2 in. outside of the unit casing.
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
! WARNING
and 9. Natural gas may contain some propane. Propane being an excellent
solvent, will quickly dissolve white lead or most standard commercial
The BTU content of the gas may differ with locality. Check the value compounds. Therefore, a special pipe thread sealant must be
with the local gas utility. applied when wrought iron or steel pipe is used. Compounds such as

NOTICE
RectorSeal No. 5 or equivalent compounds may be used.

• Clean all piping of dirt and scale by hammering on the outside of

There may be a local gas utility requirement specifying a minimum the pipe and blowing out the loose dirt and scale. Before initial
diameter for gas piping. All units require a 1/2-in. pipe connection at start-up, ensure that all of the gas lines external to the unit have
the gas valve. been purged of air.
• The gas supply must be a separate line and installed in accor-
GAS CONNECTION dance with all applicable safety codes. After the gas connections
Route the gas supply line through the 1 5/8-in. hole located on the right have been completed, open the main shut-off valve admitting nor-
side of the unit. See Figure 3 for the location. The unit is supplied with a mal gas pressure to the gas valve. Check all joints for leaks with
rubber grommet that fits in this hole and is used to seal around the gas soap solution or other material suitable for the purpose.
pipe. Note: Never test for gas leaks with an open flame.
Note: Install the rubber grommet to prevent leakage of air and water
into the heating/controls compartment.

Johnson Controls Ducted Systems 9

5844973-UIM-A-0920

• Isolate the unit from the gas supply piping system by closing its
! WARNING individual manual shut-off valve before conducting any pressure
testing of the gas supply piping system at test pressures equal to
FIRE OR EXPLOSION HAZARD or less than 1/2 psig (3.48 kPa).
Failure to follow the safety warning exactly could result in serious
injury, death, or property damage. HIGH-ALTITUDE GAS CONVERSION
Never test for gas leaks with an open flame. Use a commercially
The furnace is constructed at the factory for natural gas-fired operation
available soap solution made specifically for the detection of leaks to
check all connections. A fire or explosion may result causing property at altitudes up to 2,000 ft above sea level. For installations located
damage, personal injury, or loss of life. 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-
• Disconnect the unit and its equipment shutoff valve from the gas fices at high altitude. See Table 10 for the correct orifice size to use.
supply system during any pressure testing of that system at test
pressures in excess of 1/2 psig (3.48 kPa).

Table 10: High-Altitude Gas Orifice Sizing

Elevation Above Sea Level (ft)
Gas Type Cabinet 0–2000 2001– 3001– 4001– 5001– 6001– 7001– 8001– 9001–
Size (Factory) 3000 4000 5000 6000 7000 8000 9000 10000
B 36 37 38 38 39 40 41 41 42
Natural Gas Orifice Sizes
A 42 42 43 43 43 44 44 45 46
B 51 51 52 52 52 52 53 53 53
LP Gas Orifice Sizes
A 54 54 55 55 55 55 55 56 56

FLUE VENT AND AIR INTAKE HOOD

! WARNING
Flue hood surfaces may be hot. AIR INTAKE HOOD

AIR INTAKE SCREEN

! CAUTION EXHAUST HOOD
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.
A0284-002

The flue vent hood and air intake hoods are shipped loose. Install these Figure 8: Flue Vent Outlet Air Hood
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.

Table 11: Natural Gas Application Data - PCG4

Temperature Rise ºF
Gas Rate2 Number of
Available on Models Input (MBH)1 Output (MBH) at Full Input3
ft3/h Burners
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
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.
2. Based on 1,075 BTU/ft3.
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.

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Table 12: Propane1 (LP) Gas Application Data - PCG4

Gas Rate3 Temperature Rise ºF Propane

Number of
Available on Models Input (MBH) 2 Output (MBH) ft3/h at Full Input4 Conversion
Burners
High Fire/Low Fire Minimum Maximum Accessory Kit
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.

SECTION V: AIRFLOW PERFORMANCE

Table 13: Airflow Performance - Side Duct Application
External Static Pressure (in. W.C.)
Model Motor Speed 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
Low (1) 560 520 480 410 370 320 270 220 120
Medium Low (2) 720 690 640 590 530 490 440 400 300
PCG4A24050 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
Low (1) 580 550 500 440 390 350 290 240 130
Medium Low (2) 800 760 720 680 630 570 530 480 400
PCG4A24075 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
Low (1) 680 640 600 550 490 440 390 350 250
Medium Low (2) 750 710 670 620 560 510 460 430 330
PCG4A30050 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
Low (1) 690 660 620 570 520 460 410 360 270
Medium Low (2) 1040 1010 980 940 910 880 840 800 700
PCG4A30075 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
Low (1) 850 790 710 660 610 560 510 450 400
Medium Low (2) 1000 950 900 840 790 730 680 640 550
PCG4A36050 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
Low (1) 850 790 710 660 610 560 510 450 400
Medium Low (2) 1130 1090 1050 1000 940 890 830 790 700
PCG4A36075 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
Low (1) 870 800 730 670 610 560 510 450 230
Medium Low (2) 1220 1170 1130 1080 1030 970 920 860 780
PCG4A36100 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

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Table 13: Airflow Performance - Side Duct Application

External Static Pressure (in. W.C.)
Model Motor Speed 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
Low (1) 960 910 840 780 720 670 610 570 420
Medium Low (2) 1150 1100 1050 1000 940 880 830 780 690
PCG4A42075 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
Low (1) 960 910 840 780 720 670 610 570 420
Medium Low (2) 1520 1480 1440 1400 1360 1320 1270 1220 1110
PCG4A42100 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
Low (1) 1090 1040 990 930 870 800 720 670 540
Medium Low (2) 1140 1090 1030 980 920 850 780 730 600
PCG4B48065 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
Low (1) 1140 1090 1030 980 920 850 780 730 600
Medium Low (2) 1520 1470 1430 1390 1340 1300 1250 1210 1090
PCG4B48100 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
Low (1) 1140 1090 1030 980 920 850 780 730 600
Medium Low (2) 1690 1650 1600 1570 1530 1490 1440 1400 1310
PCG4B48125 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
Low (1) 1090 1020 960 910 840 750 690 640 550
Medium Low (2) 1160 1100 1050 990 930 860 800 740 640
PCG4B60065 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
Low (1) 1300 1240 1200 1150 1090 1050 1000 940 820
Medium Low (2) 1510 1470 1430 1390 1340 1310 1260 1220 1130
PCG4B60100 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
Low (1) 1300 1240 1200 1150 1090 1050 1000 940 820
Medium Low (2) 1700 1670 1630 1590 1550 1520 1480 1440 1370
PCG4B60125 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
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.

12 Johnson Controls Ducted Systems

 5844973-UIM-A-0920

Table 14: Additional Static Resistance SECTION VI: OPERATION

Size (Tons) CFM Wet Indoor Coil Economizer1 Filter/Frame Kit The unit is controlled by a conventional heating/cooling thermostat. If an
500 0.01 0.00 0.01 electronic thermostat is used, make sure it has a common connection.
Note: Do not use a power stealing thermostat.
600 0.01 0.00 0.02
700 0.01 0.00 0.04 HEATING SEQUENCE OF OPERATION
800 0.02 0.01 0.06 Heating
024 (2.0)
900 0.03 0.01 0.08 The control board begins a call for heat when W is energized (con-
1000 0.04 0.01 0.10 nected to R). The control board checks if the pressure switch is open. If
1100 0.05 0.01 0.13 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
1200 0.06 0.02 0.16
to open. When the pressure switch is sensed as open, the control board
700 0.01 0.00 0.04 begins the pressure switch proving period. If the call for heat is
800 0.02 0.01 0.06 removed, the control board goes back to standby.
900 0.03 0.01 0.08 Pressure Switch Proving
030 (2.5) 1000 0.04 0.01 0.10 The control board energizes the induced draft motor and waits for the
1100 0.05 0.01 0.13 pressure switch to close. When the pressure switch closes, the control
1200 0.06 0.02 0.16 board begins the pre-purge period. If the call for heat is removed, the
1300 0.07 0.03 0.17 control board de-energizes the inducer without a post-purge period and
returns to standby.
700 0.01 0.00 0.04
If the pressure switch does not close within 5 s of the inducer energiz-
800 0.02 0.01 0.06
ing, the LED on the control board emits 3 red flashes. If the pressure
900 0.03 0.01 0.08 switch does not close within 60 s of the inducer energizing, the control
1000 0.04 0.01 0.10 board shuts off the inducer for 60 s, then energizes the inducer for
036 (3.0)
1100 0.05 0.01 0.13 another 60 s in an attempt to close the pressure switch. This cycle con-
1200 0.06 0.02 0.16 tinues indefinitely until the pressure switch is proved to be closed or the
call for heat ends.
1300 0.07 0.03 0.17
1400 0.08 0.04 0.18 Pre-Purge
1100 0.02 0.02 0.04 The control board monitors the pressure switch and ensures it remains
closed during the pre-purge period. If the pressure switch opens, the
1200 0.03 0.02 0.04
control board returns to pressure switch proving mode. The control
1300 0.04 0.02 0.05 board waits for a 15-s pre-purge period, then begins the ignition trial.
1400 0.05 0.03 0.05
Ignition Trial
1500 0.06 0.04 0.06
042 (3.5) The control board energizes the gas valve and spark outputs for a 5-s
1600 0.07 0.04 0.07
ignition trial. The control board de-energizes the spark when the flame
1700 0.07 0.04 0.08 is sensed and enters a flame stabilization period.
1800 0.08 0.04 0.09 If the flame is not established within the ignition trial, the control board
1900 0.09 0.05 0.10 de-energizes the spark and gas valve and begins an inter-purge period
2000 0.09 0.05 0.11 before attempting another ignition trial.
1100 0.02 0.02 0.04 If the call for heat is removed during an ignition trial, the control board
1200 0.03 0.02 0.04 immediately de-energizes spark and gas. The control board runs the
induced draft motor through a post-purge period before de-energizing.
1300 0.04 0.02 0.05
1400 0.05 0.03 0.05 If the pressure switch opens during an ignition trial, the control board
immediately de-energizes spark and gas. The control board begins
1500 0.06 0.04 0.06
048 (4.0) pressure switch proving before an inter-purge and reignition attempt.
1600 0.07 0.04 0.07
Heat Blower On Delay
1700 0.07 0.04 0.08
The control board waits for 30 s and then energizes the indoor blower
1800 0.08 0.04 0.09
heat speed. The blower on delay time begins at the start of the flame
1900 0.09 0.05 0.10 proving period in the ignition trial.
2000 0.09 0.05 0.11
If the thermostat demand for heat is removed, the control board de-
1100 0.02 0.02 0.04 energizes the gas valve, energizes the blower on heat speed, and initi-
1200 0.03 0.02 0.04 ates a post-purge period and heat blower off delay.
1300 0.04 0.02 0.05 Main Burner Operation
1400 0.05 0.03 0.05 The control board keeps the main gas valve and induced draft motor
1500 0.06 0.04 0.06 energized while continuously monitoring the call for heat, pressure
060 (5.0)
1600 0.07 0.04 0.07 switch, and flame status.
1700 0.07 0.04 0.08 If the call for heat (W) is removed, the control board de-energizes the
1800 0.08 0.04 0.09 gas valve, and begins the post-purge period and heat blower off delay.
1900 0.09 0.05 0.10 If the pressure switch opens, the control board de-energizes the gas
2000 0.09 0.05 0.11 valve and begins pressure switch proving mode.
If the flame is removed, the control board de-energizes the gas valve
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,
within 2.0 s and counts the flame loss. If the flame has been lost less
the unit delivers less CFM during full economizer operation. than five times, the control attempts re-ignition after a 15-s inter-purge
Note: Filter pressure drop based on standard filter media tested at velocities not period. If the flame has been lost five times within the same call for
to exceed 300 ft/min. heat, the control board locks out, and the LED on the control board
emits 8 red flashes.

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5844973-UIM-A-0920

Post-Purge Safety Controls

The control board runs the induced draft motor for a 15-s post-purge The control circuit includes the following safety controls:
period, and then de-energizes the inducer. If a call for heat occurs • High-temperature limit switch - This is located inside the blower
during the post-purge period, the control board finishes the post-purge compartment and protrudes into the heat exchanger compartment.
period, and begins the next ignition sequence immediately. The high-temperature limit switch is set to open at a temperature
Heat Blower Off Delay selected to prevent the outlet air temperature from exceeding the
maximum shown on the unit rating plate. It resets automatically.
After a heating sequence, the control board de-energizes the indoor The high-temperature limit switch operates when a high-tempera-
blower motor after a delay time as selected by a movable shunt (60 s, ture condition occurs. The high-temperature limit switch shuts
90 s, 120 s, or 180 s). The blower off timing begins when the thermostat down the ignition control, closes the main gas valve, and ener-
is satisfied and removes (W) the call for heat. The control board returns gizes the blower.
to standby when the blower off delay is complete. • Pressure switch - If the induced draft motor fails, the pressure
If a thermostat call for heat occurs before the blower off delay is com- switch prevents the ignition control and gas valve from being ener-
plete, the control board begins an ignition sequence, starting with the gized.
pre-purge period, while the blower off delay continues. • Flame sensor - The flame sensor is located on the left-most
Lockout burner. If an ignition control fails to detect a signal from the flame
sensor indicating the flame is properly ignited, the main gas valve
During a lockout, the control board keeps the main gas valve and closes.
induced draft motor de-energized. • Rollout switch - This is located on the burner assembly. In the
You can reset lockouts resulting from failed ignition or flame losses by event of a sustained main burner flame rollout, the rollout switch
removing the call for heat (W) for more than 1 s or removing power from closes the main gas valve. This is a manual reset switch.
the control board for over 0.25 s. The control board automatically resets
after 60 min. NOTICE
Lockouts resulting from the detection of internal control faults reset after The manual reset Rollout Switch (RS) must be reset before allowing
60 min or power interruption. Cooling operations are available during a furnace operation.
heating lockout.
High-Temperature Limit Switch GAS HEATING FAULT CODES
Any time the high-temperature limit switch is open for less than 5 min, The gas heating section has built-in self-diagnostic capability. A blinking
the control board runs the indoor blower motor on heat speed, runs the LED light on the control board can flash red, green, or amber to indicate
inducer, and de-energizes the gas valve, and the LED on the control various conditions. The control board continuously monitors its own
board emits 4 red flashes. When the high-temperature limit switch operation and the operation of the system. If a fault occurs, the LED
closes, the control board restarts the ignition sequence, beginning with light indicates the fault code.
the pre-purge period. 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
If the high-temperature limit switch is open for more than 5 min, the con-
turns off for 1/3 s. This pattern is repeated the number of times equal to
trol board de-energizes the inducer and continues to operate the indoor
the code. There is a 2-s pause between codes. For example, the 6 Red
blower motor on heat speed, and the LED on the control board emits 11
Flashes fault code means the LED light flashes on and off six times and
red flashes.
then remains off for 2 s. This pattern repeats as long as the fault condi-
Rollout Switch tion remains. The continuous flash codes listed below mean the LED
If the limit circuit is open for more than 15 min, the LED on the control light flashes on and off continuously with no breaks or longer pauses.
board emits 5 red flashes. The blower output is energized when the roll- Slow Green Flash: Indicates normal operation with no thermostat
out switch is open. calls. Standby mode.
If the rollout switch is reset, the control board remains locked out until Rapid Green Flashes: Indicates the control board is in factory test
power is removed or a call for heat (W) is removed. mode.
A rollout switch lockout does not reset automatically. Slow Amber Flash: Indicates normal operation with a thermostat call
for heat.
Power Interruptions
LED Steady Off: If the LED light does not flash at all, check that there
Power interruptions of any duration do not cause a lockout or any oper-
is power to the control board and check for an open fuse on the control
ation requiring manual intervention.
board. If the control board is correctly powered and the fuse is not open,
Flame Present with Gas Off the control board may need to be replaced.
If the flame is sensed for longer than 4.0 s during a period when the gas Steady on Red: Indicates a possible control board failure. Turn off the
valve should be closed, the control board enters lockout, and the LED power to the unit and turn on the power to the unit again. If the fault
on the control board emits 1 red flash. The control board energizes the code recurs, replace the control board. The control board is not field-
inducer blower while the flame is sensed. repairable.

GAS VALVE FAULT Rapid Amber Flash: Indicates the flame sense current is below 1.5
VDC. Do the following:
If the main valve output is sensed as energized for more than 1 s when
• Check and clean the flame sensor.
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 • Check for proper gas flow.
switch to de-energize the gas valve. If the main gas valve is still sensed • Verify that the current is greater than 1.5 VDC at the flame current
as energized after the inducer has been off for 10 s, the control board test pad.
re-energizes the inducer to vent the unburned gas. The control board 4 Amber Flashes: Indicates the control board is receiving a Y signal
enters a hard lockout, and the LED on the control board emits 10 red from the thermostat without a G signal. The furnace operates normally
flashes. during heating and cooling, but this fault code is displayed to alert the
The only way to recover from a hard lockout is to remove and reapply user that there is a wiring problem. Verify that the G wire from the ther-
24-VAC power to the control board. mostat is connected properly.

14 Johnson Controls Ducted Systems

 5844973-UIM-A-0920

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

Johnson Controls Ducted Systems 15

5844973-UIM-A-0920

CHARGING ADJUSTMENT OF MANIFOLD GAS PRESSURE AND

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

16 Johnson Controls Ducted Systems

 5844973-UIM-A-0920

AIRFLOW SETTINGS
NOTICE Cooling Airflow Settings
The regulated outlet pressure has been calibrated at the factory. The unit is equipped with a five-speed blower motor. Select the required
Additional pressure adjustment should not be necessary. If adjust- cooling airflow by connecting the required motor speed tap wire to the
ment is necessary, set to the following specifications. After adjust- yellow COOL speed wire coming from the control board. Select the
ment, check for gas leakage. 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-
3. See Figure 9 for the location of the pressure regulator adjustment
ished air conditioning performance, lower overall energy efficiency, and
cap and adjustment screws on the main gas valve.
higher electric utility bills. See Table 17 for default cooling blower set-
4. Turn on gas and electrical supplies and follow the operating instruc-
tings.
tions to place the unit back in operation.
5. Adjust the manifold pressure by adjusting the gas valve regulator Table 17: Default Blower Speeds
screw for the appropriate gas per Table 16.
Default Blower Speeds
Table 16: Nominal Manifold Pressure Model Number Heat Cool Continuous Fan
Nominal Manifold Pressure (White Wire) (Yellow Wire) (Red Wire)
Natural Gas 3.5 in. W.C. (0.87 kPa) PCG4A24050 Medium Low (2) High (5) Low (1)
Propane (LP) Gas 10.0 in. W.C. (2.488 kPa) PCG4A24075 Medium High (4) High (5) Low (1)
PCG4A30050 Low (1) High (5) Low (1)
OUTLET PCG4A30075 Medium Low (2) High (5) Low (1)
PRESSURE PCG4A36050 Low (1) High (5) Low (1)
PORT VENT PORT
PCG4A36075 Medium Low (2) High (5) Low (1)
PCG4A36100 Medium (3) High (5) Low (1)
INLET OUTLET
PCG4A42075 Medium Low (2) High (5) Low (1)
FF PCG4A42100 Medium Low (2) High (5) Low (1)
WRENCH O
BOSS PCG4B48065 Low (1) High (5) Low (1)
INLET N MAIN REGULATOR
O
PRESSURE ADJUSTMENT PCG4B48100 Medium Low (2) High (5) Low (1)
ON/OFF SWITCH
PORT PCG4B48125 Medium Low (2) High (5) Low (1)
(Shown in ON position) A0226-001
PCG4B60065 Low (1) High (5) Low (1)
Figure 9: Gas Valve
PCG4B60100 Medium Low (2) High (5) Low (1)
PCG4B60125 Medium Low (2) High (5) Low (1)
IMPORTANT: If gas valve regulator is turned in (clockwise), manifold
pressure increases. If the screw is turned out (counterclockwise), Continuous Fan Airflow Settings
manifold pressure decreases.
The default blower speed for continuous fan operation is Low speed. To
6. When the manifold pressure has been adjusted, re-calculate the operate the furnace in continuous fan mode, set the wall thermostat fan
furnace input to make sure you have not exceeded the specified switch to ON. To select the required continuous fan airflow, connect the
input on the rating plate. See Natural Gas in the CHECKING GAS required motor speed tap wire to the red FAN speed wire coming from
HEAT INPUT section. the control board.
7. When the correct BTU (kW) input has been established, turn the The default position is with the red (Low) blower speed wire connected
gas valve to OFF and turn the electrical supply switch to OFF.
to the red FAN speed wire coming from the control board. In certain cir-
Remove the flexible tubing from the gas valve pressure tap and
cumstances, it may be necessary to move the continuous fan speed to
tighten the pressure tap plug using the 3/32 in. (2.4 mm) hex head
wrench. a different speed tap. However, this is not best practice because it
causes higher electrical energy usage and higher electric utility bills.
8. Turn on the electrical and gas supplies, and with the burners in
operation, check for gas leakage around the gas valve pressure Gas Heating Airflow Settings
port using an approved non-corrosive gas leak detection fluid or See Table 17 for the default heating blower speed. The unit is equipped
other non-flammable leak detection methods.
with a five-speed blower motor. See Table 17 for the default heating
MANIFOLD PRESSURE U-TUBE CONNECTION blower speed for each model.
 287/(7
  In certain circumstances, it may be necessary to move the heating
35(6685(3257 blower speed to a different motor speed tap.
*$69$/9(
´78%,1* Note: Not all of the five motor speeds are appropriate for gas heating
operation.
)/$0( 0$1,)2/'
6(1625 3,3( 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.
,1
:$7(5
&2/801
*$6
*$6 35(6685(
%851(56 878%( 6+2:1
0$120(7(5
$

Figure 10: Reading Gas Pressure

Johnson Controls Ducted Systems 17

5844973-UIM-A-0920

Measurement of Temperature Rise

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

INCHES OF WATER

HI PORT

MAX. PRESSURE 15 PSIG

LO PORT
RETURN AIR
DUCT

SUPPLY AIR
DUCT

A0435-002

Figure 11: Measuring External Static Pressure

18 Johnson Controls Ducted Systems

 5844973-UIM-A-0920

CHECKING GAS HEAT INPUT Table 18: Gas Rate (ft3/h)1

Natural Gas
Seconds for Size of Test Dial
1. Turn off all other gas appliances connected to the gas meter.
One Revolution 1/2 ft3 1 ft3
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 10 180 360
12 150 300
usually has a 1/2 ft3 or a 1 ft3 test dial.
14 129 257
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 16 113 225
from Table 18. 18 100 200
If the actual input is not within 5% of the unit heating rating with allow- 20 90 180
ance being made for the permissible range of the regulator setting, 22 82 164
replace the orifice spuds with spuds of the proper size. 24 75 150
26 69 138

NOTICE 28
30
64
60
129
120
To find the BTU input, multiply the number of cubic feet of gas con- 32 56 113
sumed per hour by the BTU content of the gas in your particular 34 53 106
locality. Contact your gas company for this information since it varies 36 50 100
widely from city to city. 38 47 95
40 45 90
42 43 86
44 41 82
46 39 78
48 37 75
50 36 72
52 35 69
54 34 67
56 32 64
58 31 62
60 30 60
1. Example: By actual measurement, it takes 38 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.

Johnson Controls Ducted Systems 19

5844973-UIM-A-0920

SECTION VII: TYPICAL WIRING DIAGRAMS

CONNECTION WIRING DIAGRAM

COOLING UNIT WITH GAS HEAT
208/230-1-60
POWER SUPPLY 208/230-1-60

CAUTION - OPEN ALL DISCONNECTS USE COPPER

CONDUCTORS

BEFORE SERVICING THIS UNIT

ONLY

GND
BLK 6

208V PUR 1 L1 T1 BLK C

230V PRI COM
SINGLE POLE
CONTACTOR BRN S COMPR
XFMR

CONTACTOR 24V SEC L2 T2 RED R

40 VA

GRN 44
COIL
BLK/WHT 12
DUAL
BLU 43 CAPACITOR
FAN
HI PRESS RED 45
YEL 18 YEL 17
HERM C
1 BLK
RED 7

BLU 42
2
BRN/WHT 13 3 BRN
W 4 OD FAN
MOTOR
Y GRN 10 5 GRN
BLOWER RED
O DELAY RED 9 6
R 180
LOW
VOLTAGE C BLK 5
BOX 120
C BLU 23 C 90
R RED 22 R
60
O
PUR 2
Y YEL 21 Y CONTROL
W WHT 20 W
BOARD (CONTINUOUS FAN) (LOW) 1
G GRN 19 G RED 32

PUR 26
THERMOSTAT RED 34 RED/GRN 36 2 N
(LOW/MED) 1
ROLLOUT LIMIT (HEATING SPEED) (MED) 3 BLOWER G
WHT 33 MOTOR 2 GRN 4
3 2 1
RED/BLK 35 (COOLING SPEED) (MED/HIGH) 4 L
BLK

YEL 31 3
YEL 38 6 5 4
SHARED TAP
5 SEE NOTE 7 C
GRN 40 9 8 7 (HIGH) 4

YEL 38

ORG 37 FLAME
GAS IGNITOR SENSOR
VALVE ORG 39
PRESSURE
W SPD
SPARK
G SPD TRANSFORMER
CONTROL BOARD SETTINGS:
L1 IND FS
Y SPD COMBUSTION BLOWER POST PURGE: 60 SEC
1 2 3 ORG
24V COM INDOOR BLOWER HEAT ON DELAY: 30 SEC
INDOOR BLOWER COOL OFF DELAY: 60 SEC
RED 28 INDOOR BLOWER HEAT OFF DELAY: FIELD SELECT
BRN
DRAFT CAP
MOTOR
WHT 27 YEL LINE VOLTAGE

FIELD INSTALLED POWER

BLU 30
LOW VOLTAGE

FIELD INSTALLED CONTROL

DSI Fault Codes

Normal Operation
Green Heartbeat Standby mode NOTES:
Amber Heartbeat Call for furnace heat active
1. ALL FIELD WIRING TO BE ACCOMPLISHED FOLLOWING CITY, LOCAL AND/OR
Rapid Green Flashes Control in Factory Test mode NATIONAL CODES IN EFFECT AT THE TIME OF INSTALLATION OF THE UNIT.

Operational Fault Codes 2. CAUTION : LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING
Flashes Fault Condition CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS
OPERATION. IF ANY OF THE WIRING, AS SUPPLIED WITH THE UNIT, MUST
None Power Off or open fuse BE REMOVED, IT MUST BE REPLACED WITH TYPE 105 C. 600 VOLT
Slow Green Flashes Normal Operation WIRE OR EQUIVALENT CLEARLY RENUMBERED FOR IDENTIFICATION.
Slow Amber Flashes Normal Operation with call for heat VERIFY PROPER OPERATION AFTER SERVICING.

Rapid Amber Flashes Low flame sense current 3. FACTORY WIRED FOR 230 VOLT SUPPLY POWER. FOR 208 VOLT, MOVE
4 Amber Flashes No G from thermostat with Y call BLACK WIRES FROM THE 230 TO THE 208 VOLT TAP ON THE TRANSFORMER.
Steady on Red Control Failure 4. MOTORS ARE INHERENTLY PROTECTED.
1 Red Flash Flame present with gas off
2 Red Flashes Check pressure switch wiring 5. SEE UNIT NAMEPLATE FOR MAXIMUM FUSE AND/OR CIRCUIT BREAKER SIZE
AND MINIMUM CIRCUIT AMPACITY.
3 Red Flashes Vent OR termination problem
4 Red Flashes Airflow problem 6. SELECT INDOOR BLOWER SPEED TO REMAIN WITHIN THE TEMPERATURE
RISE RANGE ON THE NAMEPLATE IN HEATING AND TO OBTAIN APPROX.
5 Red Flashes Flame Rollout 400 CFM/TON IN COOLING.
6 Red Flashes Repeated pressure switch cycles
7 Red Flashes Failed to light burners 7. BLOWER MOTOR SPEED CONNECTIONS SHOWN ARE TYPICAL,
BUT MAY VARY BY MODEL AND APPLICATION.
8 Red Flashes Loss of flame during call for heat
9 Red Flashes Incorrect polarity OR Don't have neutral
10 Red Flashes Gas valve shorted "ON"
11 Red Flashes Check blower motor/wiring
1174285-UWD-C-0519
Refer to Installation Manual for more detailed information.

Figure 12: Connection Wiring Diagram

20 Johnson Controls Ducted Systems

 5844973-UIM-A-0920

LADDER WIRING DIAGRAM

COOLING UNIT WITH GAS HEAT
208/230-1-60

CAUTION - OPEN ALL DISCONNECTS

BEFORE SERVICING THIS UNIT
GROUND
LUG

L1 L2
NOTES:
R RED
1. ALL FIELD WIRING TO BE ACCOMPLISHED FOLLOWING CITY, LOCAL AND/OR
NATIONAL CODES IN EFFECT AT THE TIME OF INSTALLATION OF THE UNIT. L1 T1 BLK C COMPRES

2. CAUTION : LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING S

R RED
CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS
OPERATION. IF ANY OF THE WIRING, AS SUPPLIED WITH THE UNIT, MUST OD FAN
C MOTOR
BLK/WHT
BE REMOVED, IT MUST BE REPLACED WITH TYPE 105 C. 600 VOLT
WIRE OR EQUIVALENT CLEARLY RENUMBERED FOR IDENTIFICATION.

BRN
S
VERIFY PROPER OPERATION AFTER SERVICING.
T2

BRN/WHT
L2
3. FACTORY WIRED FOR 230 VOLT SUPPLY POWER. FOR 208 VOLT, MOVE DUAL
BLACK WIRES FROM THE 230 TO THE 208 VOLT TAP ON THE TRANSFORMER. CAPACITOR
H C F
4. MOTORS ARE INHERENTLY PROTECTED. RED

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. BLK L BLOWER N PUR
400 CFM/TON IN COOLING. MOTOR

G
7. BLOWER MOTOR SPEED CONNECTIONS SHOWN ARE TYPICAL,
CONTROL
BUT MAY VARY BY MODEL AND APPLICATION. BOARD
RELAY DRAFT
PUR WHT MOTOR BLK
L1 IND

CONTROL BOARD SETTINGS: LINE VOLTAGE

COMBUSTION BLOWER POST PURGE: 60 SEC FIELD INSTALLED POWER CAP
INDOOR BLOWER HEAT ON DELAY: 30 SEC
INDOOR BLOWER COOL OFF DELAY: 60 SEC LOW VOLTAGE 208V
230V PRI COM
INDOOR BLOWER HEAT OFF DELAY: FIELD SELECT FIELD INSTALLED CONTROL BLK PUR
XFMR
RED BLU
24V SEC
40 VA

DSI Fault Codes

HI PRESS
YEL YEL
Green Heartbeat Standby mode THERMOSTAT CONTACTOR
COIL
Amber Heartbeat Call for furnace heat active C BLU C
3A
Rapid Green Flashes Control in Factory Test mode R RED R FUSE
O
Operational Fault Codes Y Y
Flashes Fault Condition W WHT W
CONTROL
None Power Off or open fuse G GRN G
Slow Green Flashes Normal Operation BOARD
RED RED/GRN
Slow Amber Flashes Normal Operation with call for heat BLU
ROLLOUT LIMIT
Rapid Amber Flashes Low flame sense current
3 2 1
4 Amber Flashes No G from thermostat with Y call RED/BLK
Steady on Red Control Failure YEL 6 5 4

1 Red Flash Flame present with gas off GRN 9 8 7

2 Red Flashes Check pressure switch wiring YEL
3 Red Flashes Vent OR termination problem GAS
PRESSURE
FLAME
ORG
4 Red Flashes Airflow problem VALVE IGNITOR SENSOR
ORG
5 Red Flashes Flame Rollout
3 WHT W SPD
6 Red Flashes Repeated pressure switch cycles 4 2 SPARK
1 RED G SPD TRANSFORMER
7 Red Flashes Failed to light burners 5
BLOWER L1 IND FS
Y SPD
8 Red Flashes Loss of flame during call for heat MOTOR ORG
C BLU 24V COM 1 2 3
9 Red Flashes Incorrect polarity OR Don't have neutral
YEL
10 Red Flashes Gas valve shorted "ON" RED

11 Red Flashes Check blower motor/wiring

1174285-UWD-C-0519
Refer to Installation Manual for more detailed information.

Figure 13: Ladder Wiring Diagram

Johnson Controls Ducted Systems 21

5844973-UIM-A-0920

R-410A QUICK REFERENCE GUIDE

Refer to Installation Instructions for specific installation requirements

R-410A refrigerant operates at 50 - 70 percent higher pressures than R-22. Be sure that servicing
equipment and replacement components are designed to operate with R-410A.
R-410A refrigerant cylinders are rose colored.
Recovery cylinder service pressure rating must be 400 psig, DOT 4BA400, or DOT BW400.
Recovery equipment must be rated for R-410A.
DO NOT use R-410A service equipment on R-22 systems. All hoses, gages, recovery cylinders, charging
cylinders and recovery equipment must be dedicated for use on R-410A systems only.
Manifold sets must be at least 700 psig high side, and 180 psig low side, with 550 psig retard.
All hoses must have a service pressure rating of 800 psig.
Leak detectors must be designed to detect HFC refrigerants.
Systems must be charged with liquid refrigerant. Use a commercial type metering device
in the manifold hose.
R-410A can only be used with POE type oils.
POE type oils rapidly absorb moisture from the atmosphere.
Vacuum pumps will not remove moisture from R-410A refrigerant oils.
Do not use liquid line driers with a rated working pressure rating less than 600 psig.
Do not install suction line driers in the liquid line.
A liquid line drier is required on every unit.
Do not use a R-22 TXV. If a TXV is to be used, it must be a R-410A TXV.
Never open system to atmosphere when under a vacuum.
If system must be opened for service, evacuate system then break the vacuum with dry nitrogen
and replace all filter driers.

Figure 14: R-410A Quick Reference Guide

22 Johnson Controls Ducted Systems

 5844973-UIM-A-0920

SECTION VIII: START UP SHEET

Residential Package Unit Cooling / Gas Heat Start-Up Sheet

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

Start-Up Date Company Name Start-Up Technician

Owner Information
Name Address Daytime Phone

City State or Province Zip or Postal Code

Equipment Data
Unit Model # Unit Serial #

General Information (Check all that apply)

Residential New Construction Roof level Down flow
Commercial Retrofit Grade level Side flow
Unit Location and Connections (Check all that apply)
Unit is level and installed on: Slab Roof curb Duct connections are complete: Supply Return
Condensate drain properly connected per the installation instructions Condensate trap has been primed with water

Filters
Filters installed Number of filters Filter size Filter located inside Filter located outside

Additional Kits & Accessories Installed (Check all that apply)

Refrigerant safety kit Low ambient kit Anti-recycle timer Crank case heater Filter frame kit
Transformer kit Economizer Roof curb kit Base rail hole blockage kit
Manual fresh air damper kit Motorized fresh air damper kit

Electrical Connections & Inspection (Check all that apply)

Single phase Three phase 208 volts AC 230 volt AC 460 volts AC 575 volts AC
Inspect wires and electrical connections Transformer wired properly for primary supply voltage Ground connected
Low voltage present at control board "R & C" Measured voltage "R" and "C" outdoor unit control board

Line voltage present at disconnect Measured voltage "L1 to L2" "L2 to L3" "L1 to L3"

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

Single stage compressor Two stage compressor

Air Flow Setup / Cooling

COOL A B C D
V.S.
ECM ADJUST A B C D
Blower Type
DELAY A B C D
&
Set-Up ECM 1 2 3 4 5
PSC Low Medium Low Medium Medium High High

Supply static (inches of water column) Supply air dry bulb temperature Outside air dry bulb temperature

Return static (inches of water column) Return air dry bulb temperature Return air wet bulb temperature

Total external static pressure Temperature drop Supply air wet bulb temperature

Johnson Controls Ducted Systems 23

 Refrigerant Charge and Metering Device
R-410A R-22 Suction line temperature Discharge pressure
Data plate - lbs / Oz
TXV Fixed Orifice Suction pressure Liquid line temperature
Discharge line
TXV# / Orifice size temperature Superheat Subcooling

Gas Heat
Single Stage Two Stage Natural Gas Propane LP (Requires LP Conversion Kit)

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

Manifold Pressure at 100% Firing Rate (w.c.") Measured BTU/H (Clock Gas Meter Nat Gas) Rated BTU/H

Manifold Pressure / Low Fire Rate (w.c.") Return Air Dry Bulb Temp Supply Air Dry Bulb Temp Temp Rise
Burner Flame Inspection - Blue flames extending directly into the primary heat exchanger cells

Clean Up Job Site

Job site has been cleaned, indoor and outdoor debris removed from job site
Tools have been removed from unit
All panels have been installed

Unit Operation and Cycle Test

Operate the unit through continuous fan cycles from the thermostat, noting and correcting any problems
Operate the unit through cooling cycles from the thermostat, noting and correcting any problems

Owner Education
Provide owner with the owner's manual
Explain operation of system to equipment owner
Explain thermostat use and programming (if applicable) to owner
Explain the importance of regular filter replacement and equipment maintenance

Comments and Additional Job Details

Subject to change without notice. Published in U.S.A. 5844973-UIM-A-0920

Copyright © 2020 by Johnson Controls. All rights reserved. Supersedes: 5731233-UIM-B-0120

York International Corp.

5005 York Drive
Norman, OK 73069