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.
Johnson Controls Unitary Products
872678-UIM-C-0213
872678-UIM-C-0213
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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Johnson Controls Unitary Products
872678-UIM-C-0213
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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872678-UIM-C-0213
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.
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Johnson Controls Unitary Products
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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
7
872678-UIM-C-0213
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
Johnson Controls Unitary Products
872678-UIM-C-0213
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
9
872678-UIM-C-0213
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
Johnson Controls Unitary Products
872678-UIM-C-0213
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
872678-UIM-C-0213
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
Johnson Controls Unitary Products
872678-UIM-C-0213
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
13
872678-UIM-C-0213
SECTION X: WIRING DIAGRAM
FIGURE 14: Wiring Diagram - Single Phase
14
Johnson Controls Unitary Products
872678-UIM-C-0213
*412217*
FIGURE 15: Wiring Diagram - Three Phase 2.5-5 Tons
Johnson Controls Unitary Products
15
872678-UIM-C-0213
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
Johnson Controls Unitary Products
872678-UIM-C-0213
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
17
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
|