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
1031452-UIM-B-0513
1031452-UIM-B-0513
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
3
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).
4
Johnson Controls Unitary Products
1031452-UIM-B-0513
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.
Johnson Controls Unitary Products
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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.
6
Johnson Controls Unitary Products
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
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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
|