Johnson Controls Air Conditioner 13 SEER GCGD User Manual

INSTALLATION MANUAL  
R-22 OUTDOOR SPLIT-SYSTEM  
AIR CONDITIONING SHIPPED WITH  
NITROGEN CHARGE ONLY  
MODELS: 13 SEER - GCGD  
®
1.5 TO 5 TONS  
LIST OF SECTIONS  
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1  
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1  
UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2  
ORIFICE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4  
TXV INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5  
EVACUATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5  
SYSTEM CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  
ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
INSTRUCTING THE OWNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12  
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13  
START UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15  
LIST OF FIGURES  
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2  
Installation of Vapor Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3  
Underground Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3  
Heat Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4  
Orifice Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5  
Outdoor Unit Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7  
Typical Field Wiring (Air Handler / Electrical Heat) . . . . . . . . . . . . . . . 7  
Thermostat Chart - Single Stage AC with PSC Air Handler . . . . . . . . 8  
Thermostat Chart - Single Stage AC with PSC Air Handler . . . . . . . . 9  
Thermostat Chart - Single Stage AC with PSC Furnace . . . . . . . . . 10  
Thermostat Chart - Single Stage AC with PSC Furnace . . . . . . . . . 11  
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13  
LIST OF TABLES  
Application Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2  
R-22 Saturated Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
WARNING indicates a potentially hazardous situation, which, if not  
avoided, could result in death or serious injury.  
SECTION I: GENERAL  
The outdoor units are designed to be connected to a matching indoor  
coil with sweat connect lines. Sweat connect units have been shipped  
from the factory with a nitrogen holding charge.  
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.  
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). This unit has a com-  
pressor containing POE oil.  
Improper installation may create a condition where the operation of  
the product could cause personal injury or property damage.  
Improper installation, adjustment, alteration, service or maintenance  
can cause injury or property damage. Refer to this manual for assis-  
tance or for additional information, consult a qualified contractor,  
installer or service agency.  
This unit does not contain any refrigerant. It contains a nitrogen hold-  
ing charge. Operating this unit with the nitrogen holding charge will  
damage the compressor.  
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.  
Before operating this unit, vent the nitrogen and evacuate the entire  
system below 500 microns. Weigh in the refrigerant using the Tabular  
Data Sheet and Installation Manual.  
SECTION II: SAFETY  
INSPECTION  
This is a safety alert symbol. When you see this symbol on  
labels or in manuals, be alert to the potential for personal  
injury.  
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.  
Understand and pay particular attention to the signal words DANGER,  
WARNING, or CAUTION.  
DANGER indicates an imminently hazardous situation, which, if not  
avoided, will result in death or serious injury.  
Johnson Controls Unitary Products  
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LIQUID LINE FILTER-DRIER  
The air conditioning unit’s copper spun filter/dryer is located on the liq-  
Sheet Metal Hanger  
uid line.  
Liquid  
Line  
Incorrect  
NOTICE  
Replacements for the liquid line drier must be exactly the same as  
marked on the original factory drier. See Source 1 for O.E.M. replace-  
ment driers.  
Tape  
Correct  
Insulated Vapor Line  
Failure to do so or using a substitute drier or a granular type may  
result in damage to the equipment.  
FIGURE 2: Installation of Vapor Line  
TO OUTDOOR UNIT  
TO INDOOR COIL  
Apply with Models  
Filter-Drier  
Source 1 Part No.  
Liquid Line  
Insulated  
Vapor Line  
13 SEER  
Cap  
S1-02922156000  
S1-02922157000  
1.5 to 3 Tons  
3.5 to 5 Tons  
PVC  
Conduit  
PIPING CONNECTIONS  
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. See Application Data Part Number 247077 for installing tubing of  
longer lengths and elevation differences.  
FIGURE 3: Underground Installation  
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.  
Units are shipped from factory with a nitrogen holding charge. Refer to  
Tabular Data Sheet for refrigerant charge quantities. Reusable service  
valves are provided to evacuate and charge per this instruction.  
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" every 20 feet toward the outdoor unit to facili-  
tate proper oil return.  
Serious service problems can be avoided by taking adequate precau-  
tions to assure an internally clean and dry system.  
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.  
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 provided.  
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.  
2. The lines should be installed so that they will not obstruct service  
access to the coil, air handling system, or filter.  
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.  
PRECAUTIONS DURING BRAZING SERVICE VALVE  
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.  
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  
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.  
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.  
8. For systems with total line length exceeding 50 feet, see APPLI-  
CATION DATA and worksheet "General Piping Recommendations  
and Refrigerant Line Length" for vapor and liquid line sizing, cali-  
bration of liquid line pressure loss or gain, determination of vapor  
line velocity, elevation limitations, orifice connections, system  
charging, traps, etc.  
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.  
Johnson Controls Unitary Products  
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1031452-UIM-B-0513  
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.  
NOTICE  
Line set and indoor coil can be pressurized to 250 psig with dry nitro-  
gen and leak tested with a bubble type leak detector. Then release  
the nitrogen charge.  
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.  
11. Evacuate the vapor line, evaporator, and liquid line to 500 microns  
or less.  
3. Carefully remove the plugs from the evaporator liquid and vapor  
connections at the indoor coil.  
12. Replace cap on service ports. Do not remove the flare caps from  
the service ports except when necessary for servicing the system.  
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.  
13. Release the refrigerant charge into the system since these units  
have been shipped from the factory with a nitrogen holding  
charge.  
14. 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.  
FIGURE 4: Heat Protection  
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.  
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.  
SECTION IV: ORIFICE INSTALLATION  
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.  
Failure to install Schrader Valve Core on orifice applications could  
result in total refrigerant loss of the system!  
Install Schrader Valve Core as follows:  
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.  
1. Slide indoor coil out of cabinet far enough to gain access to equal-  
izer fitting on the suction line.  
2. After holding charge is completely discharged remove black plas-  
tic cap on equalizer fitting.  
7. Vent the nitrogen holding charge in the outdoor unit by opening  
both service valves slowly and waiting for the pressure to dissi-  
pate. Open both the liquid 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 crescent wrench to turn valve  
stem one-quarter turn counterclockwise to open. Do not overturn  
or the valve stem may break or become damaged. See “PRECAU-  
TIONS DURING BRAZING SERVICE VALVE”.  
3. Install Schrader Valve Core supplied with the outdoor unit into  
equalizer fitting using a valve core tool.  
4. Loosen and remove the liquid line fitting from the orifice distributor  
assembly. Note that the fitting has right hand threads.  
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.  
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.  
8. Replace the Schrader core in the liquid and vapor valves.  
9. Go to “SECTION V” or “SECTION IV” for orifice or TXV installation  
depending on application.  
7. Leak test system.  
8. Replace black plastic cap on equalizer fitting.  
9. Slide indoor coil back into cabinet.  
10. 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).  
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SECTION VI: EVACUATION  
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.  
LIQUID LINE  
SWIVEL COUPLING  
(This fitting is a right-hand thread,  
turn counter-clockwise to remove)  
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.  
ORIFICE  
DISTRIBUTOR  
SECTION VII: SYSTEM CHARGE  
See tabular data sheet provided in unit literature packet for charge  
requirements. Each unit has been shipped from the factory with a nitro-  
gen holding charge and POE oil in the compressor.  
FIGURE 5: Orifice Installation  
SECTION V: TXV INSTALLATIONS  
This unit does not contain any refrigerant. It contains a nitrogen hold-  
ing charge. Operating this unit with the nitrogen holding charge will  
damage the compressor.  
When using a TXV, models 18-48 require a hard start kit.  
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:  
Do not leave the system open to the atmosphere.  
The “TOTAL SYSTEM CHARGE” must be permanently stamped on the  
unit data plate.  
1. Relieve the holding charge by pulling off the rubber cap plug on  
the suction manifold line of the coil.  
Total system charge is determined as follows:  
2. After holding charge is completely discharged, loosen and remove  
the schraeder cap seal.  
1. Determine initial unit charge from tabular data sheet.  
2. Calculate the line charge using the tabular data sheet if line length  
is greater than 15 feet.  
3. Total system charge = item 1 + item 2.  
4. Permanently stamp the unit data plate with the total amount of  
refrigerant in the system.  
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.  
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.  
Use the following charging method whenever additional refrigerant is  
required for the system charge.  
6. Install the TXV equalizer line into the vapor line as follows:  
a. Hand tighten the 1/4” SAE nut to the schraeder fitting and an  
additional 1/3 turn to seal.  
DO NOT attempt to pump “Total System Charge” into outdoor unit for  
maintenance, service, etc. This may cause damage to the compres-  
sor and/or other components. the outdoor unit only has enough vol-  
ume for the factory charge, not the “Total System Charge”.  
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.  
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.  
b. If bulb installation is made on a vertical run, the bulb should  
be located at least 16 inches from any bend, and on the tub-  
ing 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.  
Refrigerant charging should only be carried out by a qualified air con-  
ditioning contractor.  
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.  
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.  
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.  
In all cases, mount the TXV bulb after vapor line is brazed and has  
had sufficient time to cool.  
Schrader valve core MUST NOT be installed with TXV installation.  
Poor system performance or system failure could result.  
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1031452-UIM-B-0513  
SUPERHEAT CHARGING METHOD -  
PISTON INDOOR  
1. Operate system until temperatures and pressures stabilize (mini-  
mum of 10 minutes).  
SUBCOOLING CHARGING METHOD - TXV INDOOR  
The recommended subcooling is 10°F  
1. Set the system running in the cooling mode by setting the thermo-  
stat at least 6°F below the room temperature.  
2. Measure and record indoor wet bulb (WB) temperature using a  
sling psychrometer and the outdoor dry bulb (DB) temperature  
using a thermometer.  
3. Measure and record the suction pressure at the suction service  
valve port.  
4. Using charts located on the unit, note the superheat value corre-  
sponding to the intersection of the indoor wet bulb and the outdoor  
dry bulb.  
5. With the superheat value obtained in step 4 and the suction pres-  
sure value from step 3, find the intersection of the values on the  
chart. This is the required suction tube temperature at the suction  
service valve.  
2. Operate the system for a minimum of 15-20 minutes.  
3. Refer to the tabular data sheet for the recommended airflow and  
verify this indoor airflow (it should be about 400 SCFM per ton).  
4. Measure the liquid refrigerant pressure P and temperature T at the  
service valve.  
5. Calculate the saturated liquid temperature ST from Table 2.  
6. Subcooling temperature TC = Saturated Temperature (ST) - Liquid  
Temp (T).  
Example: The pressure P and temperature T measured at the liq-  
uid service port is 196 psig and 90°F, respectively. From Table 2,  
the saturated temperature for 196 psig is 100°F. The subcooling  
temperature TC = 100°-90°=10°F  
6. To bring the tube temperature in line with the required value from  
chart, add refrigerant to the service port to cause the tube temper-  
ature to fall and reclaim refrigerant to cause the temperature to  
rise.  
Add charge if the calculated subcooling temperature TC in Step 6 is  
lower than the recommended level. Remove and recover the refrigerant  
if the subcooling TC is higher than the recommended level. See Table  
2.  
Check flare caps on service ports to be sure they are leak tight. DO  
NOT OVERTIGHTEN (between 40 and 60 inch - lbs. maximum).  
TABLE 2: R-22 Saturated Properties  
Pressure  
PSIG  
Pressure  
PSIG  
Pressure  
PSIG  
Pressure  
PSIG  
Pressure  
PSIG  
Pressure  
PSIG  
Temp °F  
Temp °F  
Temp °F  
Temp °F  
Temp °F  
Temp °F  
80  
82  
48  
49  
50  
51  
52  
54  
55  
56  
57  
58  
59  
60  
61  
62  
63  
110  
112  
114  
116  
118  
120  
122  
124  
126  
128  
130  
132  
134  
136  
138  
64  
65  
66  
67  
68  
69  
70  
71  
72  
73  
74  
75  
76  
77  
78  
140  
142  
144  
146  
148  
150  
152  
154  
156  
158  
160  
162  
164  
166  
168  
78  
79  
80  
81  
82  
83  
84  
84  
85  
86  
87  
88  
88  
89  
90  
170  
172  
174  
176  
178  
180  
182  
184  
186  
188  
190  
192  
194  
196  
198  
91  
91  
92  
93  
94  
94  
95  
96  
97  
97  
98  
99  
99  
100  
101  
200  
202  
204  
206  
208  
210  
212  
214  
216  
218  
220  
222  
224  
226  
228  
101  
102  
103  
103  
104  
105  
105  
106  
107  
107  
108  
109  
109  
110  
111  
230  
232  
234  
236  
238  
240  
242  
244  
246  
248  
250  
252  
254  
256  
258  
111  
112  
112  
113  
114  
114  
115  
115  
116  
117  
117  
118  
118  
119  
119  
84  
86  
88  
90  
92  
94  
96  
98  
100  
102  
104  
106  
108  
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.  
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 accordance  
with the above codes.  
WHEN THE SYSTEM IS FUNCTIONING PROPERLY AND THE  
OWNER HAS BEEN FULLY INSTRUCTED, SECURE THE  
OWNER’S APPROVAL.  
The complete connection diagram and schematic wiring label is located  
on the inside surface of the unit service access panel.  
FIELD CONNECTIONS POWER WIRING  
1. Install the proper size weatherproof disconnect switch outdoors  
and within sight of the unit.  
SECTION VIII: ELECTRICAL  
CONNECTIONS  
2. Remove the screws at the top and sides of the corner cover. Slide  
corner cover down and remove from unit.  
GENERAL INFORMATION & GROUNDING  
Check the electrical supply to be sure that it meets the values specified  
on the unit nameplate and wiring label.  
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 Figure 6.  
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.  
5. Install the proper size time-delay fuses or circuit breaker, and  
make the power supply connections.  
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1031452-UIM-B-0513  
FIELD CONNECTIONS CONTROL WIRING  
CONTACTOR  
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.  
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  
A Start Assist Kit is available and recommended for long line set  
applications or in areas of known low voltage problems.  
GROUND  
LUG  
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.  
LOW  
VOLTAGE  
BOX  
DUAL  
RUN/FAN  
CAPACITOR  
“FINGERED”  
BUSHING  
REVERSIBLE HIGH  
VOLTAGE CONDUIT PLATE  
6. Route the 24-volt control wiring (NEC Class 2) from the outdoor  
unit to the indoor unit and thermostat.  
FIGURE 6: Outdoor Unit Control Box  
NOTICE  
To eliminate erratic operation, seal the hole in the wall at the thermo-  
stat with permagum or equivalent to prevent air drafts affecting the  
operation of in the thermostat.  
ALL FIELD WIRING TO BE IN ACCORDANCE WITH ELECTRIC CODE (NEC) AND/OR LOCAL CODES  
POWER WIRING  
POWER WIRING  
208/230-1-60  
CONTROL WIRING  
FACTORY 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.  
GND.  
LUG  
CONTACTOR  
TERMINALS  
*
COIL  
Y
R
G
W
ROOM THERMOSTAT  
CONDENSING UNIT  
ALL OUTDOOR WIRING MUST BE WEATHERPROOF. USE COPPER CONDUCTORS ONLY.  
FIGURE 7: Typical Field Wiring (Air Handler / Electrical Heat)  
Johnson Controls Unitary Products  
7
 
1031452-UIM-B-0513  
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  
1
AIR HANDLER CONTROL  
AIR CONDITIONER  
COM  
C
24 – Volt Common  
24 – Volt Common  
Y/Y2  
Second or Full  
Stage Compressor  
Y
Y
Full Stage Compressor  
CompressorContactor  
RH  
R
24 – Volt Hot  
(Heat XFMR)  
24 – Volt Hot  
G
G
Fan  
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 8: Thermostat Chart - Single Stage AC with PSC Air Handler  
8
Johnson Controls Unitary Products  
 
1031452-UIM-B-0513  
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  
1
AIR HANDLER CONTROL  
AIR CONDITIONER  
C
C
COM  
C
24 – Volt Common  
24 – Volt Common  
24 – Volt Common  
24 – Volt Common  
Y/Y2  
Second or Full  
Stage Compressor  
Y
Y
Y
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
G
G
Fan  
Fan  
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 9: Thermostat Chart - Single Stage AC with PSC Air Handler  
Johnson Controls Unitary Products  
9
 
1031452-UIM-B-0513  
AC 5A  
Single Stage Air Conditioner – Single Stage PSC Furnace  
ID MODELS  
PS(8/9)  
F*(8/9)S  
G*(8/9)S  
G*9F  
L*8S  
G8C  
GF(8/9)  
THERMOSTAT  
SINGLE STAGE  
PSC  
FURNACE  
SINGLE STAGE  
AIR  
*PP11C70224  
CONDITIONER  
SINGLE STAGE PSC  
FURNACE  
SINGLE STAGE  
AIR CONDITIONER  
1
C
C
24 – Volt Common  
24 – Volt Common  
Y
Y1  
Y
Full Stage Compressor  
Single Stage Compressor  
CompressorContactor  
RH  
R
24 – Volt Hot  
(Heat XFMR)  
24 – Volt Hot  
G
G
Fan  
Fan  
W
Full Stage Heat  
RC  
Y / Y2  
24 – Volt Hot  
(Cool XFMR)  
Second or Full  
Stage Compressor  
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  
265902 = 031-09167  
FIGURE 10: Thermostat Chart - Single Stage AC with PSC Furnace  
10  
Johnson Controls Unitary Products  
 
1031452-UIM-B-0513  
AC 5B  
Single Stage Air Conditioner – Single Stage PSC Furnace  
ID MODELS  
PS(8/9)  
F*(8/9)S  
G*(8/9)S  
G*9F  
L*8S  
G8C  
GF(8/9)  
THERMOSTAT  
THERMOSTAT  
*BP11C50124  
*BN11C01124  
*DP11C40124  
*DN11C00124  
SINGLE STAGE  
PSC  
FURNACE  
SINGLE STAGE  
AIR  
CONDITIONER  
*BN11C00124  
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
Y1  
Y
Full Stage Compressor  
Full Stage Compressor  
Single Stage Compressor  
Compressor Contactor  
RH  
RH  
R
24 – Volt Hot  
(Heat XFMR)  
24 – Volt Hot  
(Heat XFMR)  
24 – Volt Hot  
G
G
G
Fan  
Fan  
Fan  
W
Full Stage Heat  
RC  
RC  
Y / Y2  
24 – Volt Hot  
(Cool XFMR)  
24 – Volt Hot  
(Cool XFMR)  
Second or Full  
Stage Compressor  
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  
265902 = 031-09167  
FIGURE 11: Thermostat Chart - Single Stage AC with PSC Furnace  
Johnson Controls Unitary Products  
11  
 
1031452-UIM-B-0513  
2. The outdoor fan motor is permanently lubricated and does not  
require periodic oiling.  
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.  
3. If the coil needs to be cleaned, use clean water to wash dust, dirt,  
and debris from outdoor 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.  
NOTICE  
DO NOT use coil cleaners to clean outdoor condensing coil. cleaners  
containing HF-, hydroxides, chlorides, and sulfates can greatly  
reduce the lifetime of the aluminum condensing coil.  
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 reg-  
ularly 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  
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.  
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.  
WHEN THE SYSTEM IS FUNCTIONING PROPERLY AND THE  
OWNER HAS BEEN FULLY INSTRUCTED, SECURE THE  
OWNER’S APPROVAL.  
12  
Johnson Controls Unitary Products  
 
1031452-UIM-B-0513  
SECTION X: WIRING DIAGRAM  
FIGURE 12: Wiring Diagram  
Johnson Controls Unitary Products  
13  
 
1031452-UIM-B-0513  
NOTES  
14  
Johnson Controls Unitary Products  
 
1031452-UIM-B-0513  
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  
15  
 
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.  
1031452-UIM-B-0513  
Copyright © 2013 by Johnson Controls, Inc. All rights reserved.  
Supersedes: 1031452-UIM-A-0413  
York International Corp.  
5005 York Drive  
Norman, OK 73069  
 

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