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®SINGLE PACKAGE AIR CONDITIONER / GAS HEATMODELS: PCG4 SERIES2 THRU 5 TONS – 208/230V - 1 PHASE
SECTION I: GENERAL INFORMATIONThese are electric cooling/gas heating units designed for outdoor instal-lation. Only gas piping, electric power and duct connections arerequired at the point of installation.
The gas-fired heaters have spark ignition.
The refrigerant system is fully charged with R-410A Refrigerant, and istested and factory sealed.
SECTION II: SAFETYThis is a safety alert symbol. When you see this symbol onlabels or in manuals, be alert to the potential for personalinjury.
Understand and pay particular attention to the signal words DANGER,WARNING, or CAUTION.
DANGER indicates an imminently hazardous situation, which, if notavoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation, which, if notavoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation, which, if notavoided may result in minor or moderate injury. It is also used toalert against unsafe practices and hazards involving only property dam-age.
WARNINGImproper installation may create a condition where the operation ofthe product could cause personal injury or property damage.Improper installation, adjustment, alteration, service or maintenancecan cause injury or property damage. Failure to carefully read andfollow all instructions in this manual can result in furnace mal-function, death, personal injury and/or property damage. Only aqualified contractor, installer or service agency should install thisproduct.
CAUTIONThis product must be installed in strict compliance with the installa-tion instructions and any applicable local, state, and national codesincluding, but not limited to building, electrical, and mechanicalcodes.
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Due to system pressure, moving parts, and electrical components,installation and servicing of air conditioning equipment can be hazard-ous. Only qualified, trained service personnel should install, repair, orservice this equipment. Untrained personnel can perform basic mainte-nance functions of cleaning coils and filters and replacing filters.
Observe all precautions in the literature, labels, and tags accompanyingthe equipment whenever working on air conditioning equipment. Besure to follow all other applicable safety precautions and codes includ-ing ANSI Z223.1 or CSA-B149.1- latest edition.
Wear safety glasses and work gloves. Use quenching cloth and have afire extinguisher available during brazing operations.
SECTION III: MODEL NUMBER NOMENCLATURE
SECTION IV: INSTALLATIONINSTALLATION SAFETY INFORMATIONRead these instructions before continuing this appliance installation.This is an outdoor combination heating and cooling unit. The installermust assure that these instructions are made available to the consumerwith instructions to retain them for future reference.
1. Refer to the unit rating plate for the approved type of gas for thisproduct.
2. Install this unit only in a location and position as specified on Page4 of these instructions.
3. Never test for gas leaks with an open flame. Use commerciallyavailable soap solution made specifically for the detection of leakswhen checking all connections, as specified on Page 10 of theseinstructions.
4. Always install unit to operate within the unit's intended temperature-rise range with the duct system and within the allowable externalstatic pressure range, as specified on the unit name/rating plateand as specified in Table 6 of these instructions.
5. This equipment is not to be used for temporary heating of buildingsor structures under construction.
WARNINGBefore performing service or maintenance operations on unit, turn offmain power switch to unit. Electrical shock could cause personalinjury. Improper installation, adjustment, alteration, service or mainte-nance can cause injury or property damage. Refer to this manual.For assistance or additional information consult a qualified installer,service agency or the gas supplier.
CAUTIONThis system uses R-410A Refrigerant which operates at higher pres-sures than R-22. No other refrigerant may be used in this system.Gage sets, hoses, refrigerant containers and recovery systems mustbe designed to handle R-410A. If you are unsure, consult the equip-ment manufacturer. Failure to use R-410A compatible servicingequipment may result in property damage or injury.
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WARNINGIf the information in this manual is not followed exactly, a fire orexplosion may result causing property damage, personal injury orloss of life.Do not store or use gasoline or other flammable vapors and liquids inthe vicinity of this or any other appliance.WHAT TO DO IF YOU SMELL GAS:
1. Do not try to light any appliance.2. Do not touch any electrical switch; do not use any phone in
your building.3. Immediately call your gas supplier from a neighbor’s phone.
Follow the gas supplier’s instructions.4. If you cannot reach your gas supplier, call the fire depart-
ment.Installation and service must be performed by a qualified installer,service agency or the gas supplier.
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PCG 4 A 24 50 2 X 1 A1 2 3 4 5 6 7 8 9
1. Model FamilyPCG - packaged A/C with gas heat,PHG - packaged heat pump with gas heat,PCE - packaged A/C with electric heat,PHE - packaged heat pump with electric heat
5. Gas Heating Input BTU/Hr x 1000050 = 50,000 BTU/Hr. input, blank = electric heat
3. Cabinet SizeA = small 35 x 51, B = large 45 x 51
8. Generation Level1 = first generation
4. Nominal Air Conditioning Cooling Capacity BTUx100024 = 24,000 BTU, etc.
9. Revision LevelA = original release, B = second release
Examples:PCG4B421002X1A is a packaged A/C with gas heat, 14 SEER, 3-1/2 ton, large cabinet, single-stage heat, 100,000 BTU gas heat, 230 volt, single phase, low-NOx model (first generation, first release)
WARNINGFIRE OR EXPLOSION HAZARDFailure to follow the safety warning exactly could result in seriousinjury, death or property damage.Never test for gas leaks with an open flame. use a commerciallyavailable soap solution made specifically for the detection of leaks tocheck all connections. A fire or explosion may result causing propertydamage, personal injury or loss of life.
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LIMITATIONSThese units must be installed in accordance with the following:
In U.S.A.:1. National Electrical Code, ANSI/NFPA No. 70 - Latest Edition2. National Fuel Gas Code, ANSI Z223.1 - Latest Edition3. Gas-Fired Central Furnace Standard, ANSI Z21.47a. - Latest Edi-
tion4. Local building codes, and5. Local gas utility requirements
In Canada:1. Canadian Electrical Code, CSA C22.12. Installation Codes, CSA - B149.1.3. Local plumbing and waste water codes, and4. Other applicable local codes.
Refer to unit application data found in this document.
After installation, gas fired units must be adjusted to obtain a temperaturerise within the range specified on the unit rating plate.
If components are to be added to a unit to meet local codes, they are tobe installed at the dealer’s and/or customer’s expense.
Size of unit for proposed installation should be based on heat loss/heatgain calculation made according to the methods of Air ConditioningContractors of America (ACCA).
This furnace is not to be used for temporary heating of buildings orstructures under construction.
LOCATIONUse the following guidelines to select a suitable location for these units:
1. Unit is designed for outdoor installation only.
2. Condenser coils must have an unlimited supply of air. Where achoice of location is possible, position the unit on either north oreast side of building.
3. Suitable for mounting on roof curb.
4. For ground level installation, a level pad or slab should be used.The thickness and size of the pad or slab used should meet localcodes and unit weight. Do not tie the slab to the building foundation.
Table 1: Unit Limitations
Model Unit VoltageUnit Limitations
Applied Voltage Outdoor DB TempMin Max Max (°F)
24 208/230-1-60 187 252 125
30 208/230-1-60 187 252 125
36 208/230-1-60 187 252 125
42 208/230-1-60 187 252 125
48 208/230-1-60 187 252 125
60 208/230-1-60 187 252 125
FIGURE 1: Component Location
FAN MOTOR OUTDOOR FAN
COIL GUARD PANEL
OUTDOOR COIL
(Behind Panel)
CONTROL BOARD
TRANSFORMER
HIGH VOLTAGE
CONTACTOR
PRESSURE SWITCH
DRAFT INDUCER BLOWER
GAS VALVE
BURNER
ASSEMBLY
GAS HEAT
EXCHANGER
BLOWER MOTOR
TXV
INDOOR COIL
INDOOR BLOWER
COMPRESSOR
REMOVABLE
BASE RAILS
A0297-001
WARNINGDo not attach supply and return duct work to the bottom of the unitbase pan as the drain pan could be compromised.
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5. Roof structures must be able to support the weight of the unit andits options/accessories. Unit must be installed on a solid, level roofcurb or appropriate angle iron frame.
6. Maintain level tolerance to 1/8” across the entire width and length ofunit.
CLEARANCES
All units require particular clearances for proper operation and service.Installer must make provisions for adequate combustion and ventilationair in accordance with section 5.3 of Air for Combustion and Ventilationof the National Fuel Gas Code, ANSI Z223.1 – Latest Edition (inU.S.A.), or Sections 7.2, 7.3, or 7.4 of Gas Installation Codes, CSA-B149.1 (in Canada) - Latest Edition, and/or applicable provisions of thelocal building codes. Refer to Table 4 for clearances required for com-bustible construction, servicing, and proper unit operation.
RIGGING AND HANDLING
Exercise care when moving the unit. Do not remove any packaging untilthe unit is near the place of installation. Rig the unit by attaching chainor cable slings to the lifting holes provided in the base rails. Spreaderbars, whose length exceeds the largest dimension across the unit,MUST be used across the top of the unit.
Units may be moved or lifted with a forklift. Slotted openings in the baserails are provided for this purpose.
WARNINGExcessive exposure of this unit to contaminated combustion air mayresult in equipment damage or personal injury. Typical contaminatesinclude: permanent wave solution, chlorinated waxes and cleaners,chlorine based swimming pool chemicals, water softening chemicals,carbon tetrachloride, Halogen type refrigerants, cleaning solvents(e.g. perchloroethylene), printing inks, paint removers, varnishes,hydrochloric acid, cements and glues, anti-static fabric softeners forclothes dryers, masonry acid washing materials.
WARNINGDo not permit overhanging structures or shrubs to obstruct con-denser air discharge outlet, combustion air inlet or vent outlets.
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CAUTIONAll panels must be secured in place when the unit is lifted.The condenser coils should be protected from rigging cable damagewith plywood or other suitable material.
CAUTIONIf a unit is to be installed on a roof curb other than a Unitary Productsroof curb, gasket or sealant must be applied to all surfaces that comein contact with the unit underside.
CAUTIONBefore lifting, make sure the unit weight is distributed equally on therigging cables so it will lift evenly.
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Table 2: Weights and Dimensions
Model Weight (lbs.) Center of Gravity 4 Point Load Location (lbs.)Shipping Operating X Y A B C D
24050 372 367 28 15 120 95 81 71
24075 382 377 28 15 124 96 81 76
30050 417 412 28 15 139 99 90 84
30075 421 416 28 15 146 93 82 95
36050 425 420 28 15 141 107 94 78
36075 432 427 28 15 135 115 103 74
36100 436 431 28 15 139 113 99 80
42075 446 441 28 15 145 112 99 85
42100 448 443 28 15 148 110 96 89
48065 520 515 28 15 189 116 93 117
48100 528 523 28 15 169 139 115 100
48125 533 528 28 15 164 145 124 95
60065 537 532 29 15 174 142 124 92
60100 541 536 28 15 177 140 117 102
60125 548 543 27 15 151 167 141 84
FIGURE 2: Center of Gravity Location
X
CENTER OF
GRAVITY
FRONT
OF UNIT
Y
"D"
"C"
"B"
"A"
A0295-001
COMPRESSOR
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Table 3: Unit Dimensions
ModelDimensions (in inches)
A B C24 51-1/4 35-3/4 47
30 51-1/4 35-3/4 47
36 51-1/4 35-3/4 47
42 51-1/4 35-3/4 49
48 51-1/4 45-3/4 53
60 51-1/4 45-3/4 55
FIGURE 3: Unit Dimensions
HIGH VOLTAGE
CONNECTION 7/8”
HIGH VOLTAGE
CONNECTION 1-3/32”
COMPRESSOR
ACCESS PANEL
CONDENSATE
DRAINBLOWER
ACCESS
PANELCONTROL ACCESS
PANEL
LOW VOLTAGE CONNECTION
GAS SUPPLY
EXHAUST HOOD
COMBUSTION AIR INTAKE
HEAT EXCHANGER ACCESS PANEL
B
A
C
A0296-001
COIL GUARD
Table 4: Unit Clearances1,2
Direction Distance (in.) Direction Distance (in.)Top3 36 Power Entry (Right Side) 36
Side Opposite Ducts 36 Left Side 24
Duct Panel 0 Bottom4 1
1. A 1" clearance must be provided between any combustible material and the supply air duct work.2. The products of combustion must not be allowed to accumulate within a confined space and recirculate.3. Units must be installed outdoors. Over hanging structure or shrubs should not obstruct condenser air discharge outlet.4. Units may be installed on combustible floors made from class A, B or C roof covering materials.
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DUCTWORK
These units are adaptable to downflow use as well as rear supply andreturn air duct openings. To convert to downflow, use the followingsteps:
1. Remove the duct covers found in the bottom return and supply airduct openings.
2. Install the duct covers (removed in step one) to the rear supply andreturn air duct openings.
3. Seal duct covers with silicone caulk.
Duct work should be designed and sized according to the methods ofthe Air Conditioning Contractors of America (ACCA), as set forth in theirManual D.
A closed return duct system shall be used. This shall not preclude useof economizers or ventilation air intake. Flexible joints are recom-mended to be used in the supply and return duct work to minimize thetransmission of vibration and noise.
Refer to Figures 4 and 5 for information concerning rear and bottomsupply and return air duct openings.
FILTERSProper filter size is very important. Filter size, type and pressure dropshould always be considered during duct system design.
Single phase units are shipped without a filter or filter racks. It is theresponsibility of the installer to secure a filter in the return air ductworkor install a Filter/Frame Kit.
A filter rack and high velocity filters are standard on three phase units.
Filters must always be used and must be kept clean. When filtersbecome dirt laden, insufficient air will be delivered by the blower,decreasing your units efficiency and increasing operating costs andwear-and-tear on the unit and controls.
Filters should be checked monthly; this is especially important since thisunit is used for both heating and cooling.
NOTICEAll units are shipped in the horizontal supply/return configuration. It isimportant to reduce the possibility of any air leakage through the bot-tom duct covers (resulting from cut, torn, or rolled gasket) due toimproper handling or shipping processes. To ensure a good tightseal, it is recommended that silicone caulk and/or foil tape be appliedalong the cover edges.
NOTICEBe sure to note supply and return openings.
Model A B C D E F24, 30, 36, 42 10 21.5 5 4.5 47.5 32
48, 60 14 13.5 5 3.5 47.5 42
FIGURE 4: Bottom Duct Dimensions (inches)
Model A B24, 30, 36, 42 9.6 22
48, 60 13.6 14
FIGURE 5: Rear Duct Dimensions (inches)
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CONDENSATE DRAINA condensate trap must be installed in the condensate drain. Theplumbing must conform to local codes.
Use Teflon tape or pipe thread compound if needed.
SERVICE ACCESSAccess to all serviceable components is provided at the following loca-tions:
• Coil guards• Unit top panel• Corner posts• Blower access panel• Control access panel• Indoor coil access panel• Compressor access panel• Heat exchanger access panel
Refer to Figure 4 for location of these access locations and minimumclearances in Table 4.
Refer to Figure 16 for the R-410A Quick Reference Guide.
THERMOSTATThe room thermostat should be located on an inside wall approximately60" above the floor where it will not be subject to drafts, sun exposureor heat from electrical fixtures or appliances. Sealant should be usedbehind thermostat to prevent air infiltration. Follow manufacturer'sinstructions enclosed with the thermostat for general installation proce-dure. Color coded insulated wires (minimum #18 AWG) should be usedto connect thermostat to unit. See Figure 6. Do not use power stealingthermostats.
POWER AND CONTROL WIRINGField wiring to the unit must conform to provisions of the current N.E.C.ANSI/NFPA No. 70 or C.E.C. and/or local ordinances. The unit must beelectrically grounded in accordance with local codes or, in theirabsence, with the N.E.C./C.E.C. Voltage tolerances which must bemaintained at the compressor terminals during starting and runningconditions are indicated on the unit Rating Plate and Table 1.
The wiring entering the cabinet must be provided with mechanical strainrelief.
A fused disconnect switch should be field provided for the unit. If any ofthe wire supplied with the unit must be replaced, replacement wire mustbe of the type shown on the wiring diagram.
Electrical service must be sized properly to carry the load. Each unitmust be wired with a separate branch circuit fed directly from the maindistribution panel and properly fused.
Refer to Figures 6 and 7 for typical field wiring and to the appropriateunit wiring diagram for control circuit and power wiring information.
CAUTIONHand tighten only.
CAUTIONThis system uses R-410A Refrigerant which operates at higher pres-sures than R-22. No other refrigerant may be used in this system.Gage sets, hoses, refrigerant containers and recovery systems mustbe designed to handle R-410A. If you are unsure, consult the equip-ment manufacturer. Failure to use R-410A compatible servicingequipment may result in property damage or injury.
WARNINGWear safety glasses and gloves when handling refrigerants. Failureto follow this warning can cause serious personal injury.
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FIGURE 6: Typical Field Control Wiring Diagram For Gas Heat - AC Models
FIGURE 7: Typical Field Power Wiring Diagram
THERMOSTAT
NOTE:
Heat Anticipator should be set at 0.35 AMPS for all models
CONTROL
BOARD
Minimum wire size of 18 AWG wire should be used for all field
installed control wiring.
RED
GREEN
YELLOW
WHITE
BLUE
R
G
W
Y
C
A0294-001
CONTACTOR
FIELD SUPPLIED
DISCONNECT
GND
LUG
REFER TO ELECTRICAL
DATA TABLES TO SIZE
THE DISCONNECT
SINGLE
PHASE
POWER
SUPPLY
A0293-001
Table 5: Electrical Data
Model VoltageCompressor Outdoor Fan
MotorIndoor Fan
Blower Motor MCA1
(Amps)
1. Minimum Circuit Ampacity.
Max Fuse2/Breaker3 Size
(Amps)
2. Maximum Over Current Protection per standard UL 1995.3. Fuse or HACR circuit breaker size installed at factory or field installed.
Tube diameter 3/8 3/8 3/8 3/8 3/8Circuitry Type Interlaced Interlaced Interlaced Interlaced Interlaced InterlacedEvaporator Coil DataFace area (Sq. Ft.) 4.6 4.6 4.6 4.6 6.3 6,3Rows 2 3 3 3 3 3Fins per inch 16 16 16 16 16 16Tube diameter 3/8 3/8 3/8 3/8 3/8 3/8Circuitry Type Interlaced Interlaced Interlaced Interlaced Interlaced InterlacedRefrigerant control TXV TXV TXV TXV TXV TXVCondenser Fan DataFan diameter (Inch) 24 24 24 24 26 26Type Prop Prop Prop Prop Prop PropDrive type Direct Direct Direct Direct Direct DirectNo. speeds 1 1 1 1 1 1Motor HP each 1/4 1/4 1/4 1/4 1/3 1/3RPM 850
2400850 850 850 850 850
Nominal total CFM 2400 2400 2400 3200 3200Direct Drive Evaporator Fan DataFan Size (Inch) 11 x 8 11 x 8 11 x 10 11 x 10 11 x 10 11 x 10Type Centrifugal Centrifugal Centrifugal Centrifugal Centrifugal CentrifugalMotor HP each 1/3 1/2 1/3 1/2 1/2 3/4 3/4 3/4 1RPM 1200 Max 1200 Max 1200 Max 1200 Max 1200 Max 1200 MaxFrame size 48 48 48 48 48 48FiltersFilter Size A A A A B B
Quantity - SizeField-supplied external filters must be sized so as not to exceed 300 fpm air velocity through disposable fil-ters. For internal filter use, a filter rack kit is available. Consult the instructions supplied with that kit for replacement filter sizes. Filter sizes: A=20x20, B=20x30.
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COMPRESSORSThe compressor used in this product is specifically designed to operatewith R-410A Refrigerant and cannot be interchanged.
The compressor uses polyolester (POE oil), Mobile 3MA POE. This oilis extremely hydroscopic, meaning it absorbs water readily. POE oil canabsorb 15 times as much water as other oils designed for HCFC andCFC refrigerants. If refrigerant circuit is opened, take all necessary pre-cautions to avoid exposure of the oil to the atmosphere.
POE (polyolester) compressor lubricants are known to cause long termdamage to some synthetic roofing materials.
Procedures which risk oil leakage include, but are not limited to, com-pressor replacement, repairing refrigerant leaks, replacing refrigerantcomponents such as filter drier, pressure switch, metering device orcoil.
Units are shipped with compressor mountings which are factory-adjusted and ready for operation.
GAS HEATThese single stage gas-fired heat sections have direct spark ignition.
GAS PIPINGProper sizing of gas piping depends on the cubic feet per hour of gasflow required, specific gravity of the gas and the length of run. NationalFuel Gas Code Z223.1 or CSA B149.1 should be followed in all casesunless superseded by local codes or gas company requirements. Referto Tables 7 and 8.
The BTU content of the gas may differ with locality. The value should bechecked with the local gas utility.
GAS CONNECTIONThe gas supply line should be routed through the 1-5/8” hole located onthe right side of the unit. See Figure 3 for the location. The unit is sup-plied with a rubber grommet that fits in this hole and is used to sealaround the gas pipe. THIS GROMMET MUST BE INSTALLED INORDER TO PREVENT LEAKAGE OF AIR AND WATER INTO THEHEATING/CONTROLS COMPARTMENT.
Gas piping requirements:1. A drip leg and a ground joint union must be installed in the gas pip-
ing.
2. When required by local codes, a manual shut-off valve may have tobe installed outside of the unit.
3. Use wrought iron or steel pipe for all gas lines. Pipe thread sealantshould be applied sparingly to male threads only.
4. All piping should be cleaned of dirt and scale by hammering on theoutside of the pipe and blowing out the loose dirt and scale. Beforeinitial start-up, be sure that all of the gas lines external to the unithave been purged of air.
5. The gas supply should be a separate line and installed in accor-dance with all applicable safety codes. After the gas connectionshave been completed, open the main shut-off valve admitting nor-mal gas pressure to the gas valve. Check all joints for leaks withsoap solution or other material suitable for the purpose. NEVERUSE AN OPEN FLAME.
CAUTIONThis system uses R-410A Refrigerant which operates at higher pres-sures than R-22. No other refrigerant may be used in this system.
CAUTIONDo not leave the system open to the atmosphere. Unit damage couldoccur due to moisture being absorbed by the POE oil in the system.This type of oil is highly susceptible to moisture absorption
CAUTIONExposure to compressor oil, even if immediately cleaned up, maycause embrittlement (leading to cracking) to occur in one year ormore. When performing any service that may risk exposure of com-pressor oil to the roof, take precautions to protect roofing.
CAUTIONDo not loosen compressor mounting bolts.
NOTICEThere may be a local gas utility requirement specifying a minimumdiameter for gas piping. All units require a 1/2 inch pipe connection atthe gas valve.
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Table 7: Natural Gas Pipe Sizing Chart1
1. Maximum capacity of pipe in cubic feet of gas per hour (based upon a pres-sure drop of 0.3 inch water column and 0.6 specific gravity gas).
LengthIn Feet
Nominal Inches Iron Pipe Size1/2” 3/4” 1” 1-1/4”
10 132 278 520 1,050
20 92 190 350 730
30 73 152 285 590
40 63 130 245 500
50 56 115 215 440
60 50 105 195 400
70 46 96 180 370
80 43 90 170 350
90 40 84 160 320
100 38 79 150 305
Table 8: Propane (LP) Gas Pipe Sizing Chart1
1. Maximum capacity of pipe in thousands of BTU per hour (based upon a pressure drop of 0.5 inch water column).
LengthIn Feet
Nominal Inches Iron Pipe Size1/2” 3/4” 1” 1-1/4”
10 275 567 1071 2,205
20 189 393 732 1496
30 152 315 590 1212
40 129 267 504 1039
50 114 237 448 913
60 103 217 409 834
70 96 196 378 771
80 89 185 346 724
90 83 173 322 677
100 78 162 307 630
CAUTIONIf flexible stainless steel tubing is allowed by the authority havingjurisdiction, wrought iron or steel pipe must be installed at the gasvalve and extend a minimum of two (2) inches outside of the unit cas-ing.
WARNINGNatural gas may contain some propane. Propane being an excellentsolvent, will quickly dissolve white lead or most standard commercialcompounds. Therefore, a special pipe thread sealant must beapplied when wrought iron or steel pipe is used. Shellac base com-pounds such as gaskoloc or stalastic, and compounds such as Rec-torseal # 5, Clyde’s or John Crane may be used.
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6. The unit and its equipment shutoff valve must be disconnected fromthe gas supply system during any pressure testing of that system attest pressures in excess of 1/2 psi (3.48 kPa)
7. The unit must be isolated from the gas supply piping system byclosing its individual manual shut-off valve before conducting anypressure testing of the gas supply piping system at test pressuresequal to or less than 1/2 psig (3.48 kPa).
HIGH ALITITUDE GAS CONVERSIONThis furnace is constructed at the factory for natural gas-fired operationat altitudes up to 2,000 feet above sea level. For installations locatedabove 2,000 feet, the gas input rate to the burners must be reduced by4% per 1,000 feet above sea level. It may be necessary to change tosmaller orifices at high altitude. Refer to the table below for the correctorifice size to use.
FLUE VENT AND AIR INTAKE HOOD
The flue vent hood and air intake hoods are shipped loose. Thesehoods must be installed to assure proper unit operation. The hoodsmust be fastened to the outside of the side gas control/electrical com-partment with the screws provided. See Figure 8.
WARNINGFIRE OR EXPLOSION HAZARDFailure to follow the safety warning exactly could result in seriousinjury, death or property damage.Never test for gas leaks with an open flame. use a commerciallyavailable soap solution made specifically for the detection of leaks tocheck all connections. A fire or explosion may result causing propertydamage, personal injury or loss of life.
CAUTIONThe flue exhaust hood must be properly installed and within the rec-ommended clearances. Further communications and action must begiven to the home or building owner(s) to eliminate any unauthorizedhuman contact around this area during the heating cycle. Flue hoodsurfaces and the immediate area reach high temperatures during theheating cycle.
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FIGURE 8: Flue Vent Outlet Air Hood
AIR INTAKE HOOD
AIR INTAKE SCREEN
EXHAUST HOOD
A0284-001
Table 10: Natural Gas Application Data
Available On Models Input (MBH)1High Fire
1. Heating capacity valid for elevations up to 2000 feet above sea level. For elevations above 2,000 feet, rated capacity should be reduced by 4% for each 1,000 feet above sea level.
Output (MBH)High Fire
Gas Rate2
Cu. Ft./Hr.High Fire/Low Fire
2. Based on 1075 BTU/Ft.3.
Number ofBurners
Temp. Rise ºFAt Full Input3
3. The air flow must be adequate to obtain a temperature rise within the range shown. Continuous return air temperature should not be below 55°F.
Min. Max.2, 2-1/2 Tons 50 41 46 2 40 70
3 Tons 50 41 46 2 35 65
4, 5 Tons 65 53 60 2 40 70
2, 2-1/2, 3, 3-1/2 Tons 75 61 70 3 40 70
3, 3-1/2 Tons 100 81 93 4 40 70
4, 5 Tons 100 81 93 3 40 70
4, 5 Tons 125 101 116 4 40 70
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SECTION V: AIRFLOW PERFORMANCE
Table 11: Propane1 (LP) Gas Application Data
Available On ModelsInput Capacity
(MBH)2High Fire/Low Fire
Output Capacity (MBH)
High Fire/Low Fire
Gas Rate3
Cu. Ft./Hr.High Fire/Low Fire
Number of Burners
Temp. Rise ºFAt Full Input4
Min. Max.2, 2-1/2 Tons 50 41 20 2 40 70
3 Tons 50 41 20 2 35 65
4, 5 Tons 65 53 26 2 40 70
2, 2-1/2, 3, 3-1/2 Tons 75 61 30 3 40 70
3, 3-1/2 Tons 100 81 40 4 40 70
4, 5 Tons 100 81 40 3 40 70
4, 5 Tons 125 101 50 4 40 70
1. Propane applications are accomplished by field installation of a Propane Conversion Accessory Kit. For more information, see the Accessories section in the Tech-nical Guide.
2. Heating capacity valid for elevations up to 2,000 feet above sea level. For elevations above 2,000 feet, rated capacity should be reduced by 4% for each 1,000 feet above sea level.
3. Based on 2500 BTU/Ft.3. 4. The air flow must be adequate to obtain a temperature rise within the range shown. Continuous return air temperature should not be below 55°F.
Table 12: Airflow Performance - Side Duct Application
Model Motor SpeedExternal Static Pressure (Inches WC)
High (5) 1966 1914 1862 1810 1757 1705 1653 1600 1496Continued on next page.
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1. Airflow tested with dry coil conditions, without air filters, at 230 volts2. Applications above 0.8" w.c. external static pressure are not recommended.3. Brushless DC high efficiency standard ECM blower motor used for all indoor blower assemblies.4. Minimal variations in airflow performance data results from operating at 208 volts. Data above may be used in those cases.5. Heating applications tested at 0.50" w.c. esp, and cooling applications tested at 0.30" w.c.esp per standards.
1. Airflow tested with dry coil conditions, without air filters, at 230 volts2. Applications above 0.8" w.c. external static pressure are not recommended.3. Brushless DC high efficiency standard ECM blower motor used for all indoor blower assemblies.4. Minimal variations in airflow performance data results from operating at 208 volts. Data above may be used in those cases.5. Heating applications tested at 0.50" w.c. esp, and cooling applications tested at 0.30" w.c.esp per standards.
SECTION VI: OPERATIONThe unit is controlled by a conventional heating/cooling thermostat. If anelectronic thermostat is used, make sure it has a common connection.DO NOT use a power stealing thermostat.
HEATING SEQUENCE OF OPERATIONHeatingThe control board begins a call for heat when W is energized (con-nected to R).
The control checks to see if the pressure switch is open. If the pressureswitch is closed, the control board flashes “2” on the LED and waitsindefinitely for it to open. When the pressure switch is sensed as open,the control begins pressure switch proving period. If the call for heat isremoved, the control goes back to Standby.
Pressure Switch ProvingThe control board energizes the induced draft motor and waits for thepressure switch to close. When the pressure switch closes, the controlbegins Pre-purge period. If the call for heat is removed, the control de-energizes the inducer without post-purge and returns to standby.
If the pressure switch does not close within 5 seconds of inducer ener-gizing, the control board flashes “3” on the LED. If the pressure switchdoes not close within 60 seconds of inducer energizing, the controlshuts off the inducer for 60 seconds, then energizes the inducer foranother 60 seconds in an attempt to close the pressure switch. Thiscycle continues indefinitely until either the pressure switch is provedclosed, or the call for heat ends.
Pre-purgeThe control board monitors the pressure switch and ensures it remainsclosed during pre-purge. If the pressure switch opens, the control goesback to pressure switch proving mode. The control waits for a 15 sec-ond pre-purge period, then begins the ignition trial.
Ignition Trial PeriodThe control board energizes the gas valve and spark outputs for a 5second Ignition trial. The control de-energizes the spark when flame issensed and enters a flame stabilization period.
If flame is not established within the ignition trial period, the control de-energizes the spark and gas valve and begins an inter-purge periodbefore attempting another ignition trial.
If the call for heat is removed during an ignition trial period, the controlimmediately de-energizes spark and gas. The control runs the inducermotor through a post purge period before de-energizing.
If the pressure switch opens during an ignition trial period, the controlimmediately de-energizes spark and gas. The control begins pressureswitch proving before an inter-purge and reignition attempt.
Heat Blower On DelayThe control board waits for 30 seconds and then energizes the indoorblower heat speed. Blower on delay time begins at the start of flameproving period in the trial for ignition.
If the thermostat demand for heat is removed, the control de-energizesthe gas valve, energizes the blower on heat speed and initiates a postpurge and heat blower off delay.
Main Burner OperationThe control board keeps the main gas valve and induced draft motorenergized while continuously monitoring the call for heat, pressureswitch, and flame status.
If the call for heat (W) is removed, the control de-energizes the gasvalve, begins post purge and heat blower off delay.
If the pressure switch opens, the control de-energizes the gas valveand begins pressure switch proving mode.
If flame is removed, the control de-energizes the gas valve within 2.0seconds and counts the flame loss. If flame has been lost less than 5times, the control attempts re-ignition after a 15 second inter-purge
Table 14: Additional Static Resistance
Size (Tons) CFM Wet Indoor Coil Economizer1
1. The pressure drop through the economizer is greater for 100% outdoor air than for 100% return air. If the resistance of the return air duct is less than 0.25 IWG, the unit will deliver less CFM during full economizer operation. Filter pressure drop based on standard filter media tested at velocities not to exceed 300 ft/min.
Filter/Frame Kit
024 (2.0)
500 0.01 0.00 0.01
600 0.01 0.00 0.02
700 0.01 0.00 0.04
800 0.02 0.01 0.06
900 0.03 0.01 0.08
1000 0.04 0.01 0.10
1100 0.05 0.01 0.13
1200 0.06 0.02 0.16
030 (2.5)
700 0.01 0.00 0.04
800 0.02 0.01 0.06
900 0.03 0.01 0.08
1000 0.04 0.01 0.10
1100 0.05 0.01 0.13
1200 0.06 0.02 0.16
1300 0.07 0.03 0.17
036 (3.0)
700 0.01 0.00 0.04
800 0.02 0.01 0.06
900 0.03 0.01 0.08
1000 0.04 0.01 0.10
1100 0.05 0.01 0.13
1200 0.06 0.02 0.16
1300 0.07 0.03 0.17
1400 0.08 0.04 0.18
042 (3.5)
1100 0.02 0.02 0.04
1200 0.03 0.02 0.04
1300 0.04 0.02 0.05
1400 0.05 0.03 0.05
1500 0.06 0.04 0.06
1600 0.07 0.04 0.07
1700 0.07 0.04 0.08
1800 0.08 0.04 0.09
1900 0.09 0.05 0.10
2000 0.09 0.05 0.11
048 (4.0)
1100 0.02 0.02 0.04
1200 0.03 0.02 0.04
1300 0.04 0.02 0.05
1400 0.05 0.03 0.05
1500 0.06 0.04 0.06
1600 0.07 0.04 0.07
1700 0.07 0.04 0.08
1800 0.08 0.04 0.09
1900 0.09 0.05 0.10
2000 0.09 0.05 0.11
060 (5.0)
1100 0.02 0.02 0.04
1200 0.03 0.02 0.04
1300 0.04 0.02 0.05
1400 0.05 0.03 0.05
1500 0.06 0.04 0.06
1600 0.07 0.04 0.07
1700 0.07 0.04 0.08
1800 0.08 0.04 0.09
1900 0.09 0.05 0.10
2000 0.09 0.05 0.11
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period. If flame has been lost more than 5 times within the same call forheat, the control board locks out flashing “8” on the LED. Post Purge
The control board runs the induced draft motor for a 15 second post-purge period, and then de-energizes the inducer. If a call for heatoccurs during post-purge, the control finishes the postpurge, and imme-diately begins the next ignition sequence.
Heat Blower Off DelayAfter a heating sequence the control board de-energizes the indoorblower motor after a delay time as selected by a movable shunt (60, 90,120 or 180 seconds). Blower off timing begins when the thermostat issatisfied and removes (W) the call for heat. The control returns tostandby when the blower off delay is complete.
If the thermostat call for heat returns before the blower off delay is com-plete, the control begins an ignition sequence with prepurge while theblower off delay continues.
LockoutWhile in lockout, the control board keeps the main gas valve andinduced draft motor de-energized.
Lockouts due to failed ignition or flame losses may be reset by remov-ing the call for heat (W) for more than 1 second, or by removing powerfrom the control for over 0.25 seconds. The control will automaticallyreset lockout after 60 minutes.
Lockouts due to detected internal control faults will reset after 60 min-utes or power interruption. Cooling operations are available during aheating lockout.
High Temperature Limit SwitchAny time the high temperature limit switch is open less than 5 minutesthe control board will run the indoor blower motor on heat speed, runthe inducer, de-energize the gas valve, and flash “4” on the LED. Whenthe high temperature switch closes, the control will restart the ignitionsequence beginning with pre-purge.
If the limit switch has been open more than 5 minutes the control willde-energize the inducer, continue to operate the indoor blower motor onheat speed, and flash “11” on the LED
Rollout SwitchIf the limit circuit is open for more than 15 minutes, the control board willflash “5” on the LED. The blower output will be energized during anopen rollout condition.
If the rollout switch is reset, the control shall remain locked out untilpower is removed or a call for heat (W) is removed.
Rollout switch lockout shall not reset automatically.
Power InterruptionsPower interruptions of any duration shall not cause lockout or any oper-ation requiring manual intervention.
Flame present with Gas offIf flame is sensed for longer than 4.0 seconds during a period when thegas valve should be closed, the control will enter lockout flashing “1” onthe LED. The control will energize the inducer blower while the flame issensed.
GAS VALVE FAULTIf the main valve output is sensed to be energized for more than 1 sec-ond when commanded to be off, the control de-energizes the induceddraft motor (if flame is not present) to attempt to open the pressureswitch to de-energize the gas valve. If the main gas valve is still sensedas energized after the inducer has been off for 10 seconds, the controlre-energizes the inducer to vent the unburned gas. The control enters ahard lockout flashing “10” on the LED.
The only way to recover from a hard lockout is to remove and reapply24VAC power to the control board.
Safety ControlsThe control circuit includes the following safety controls:
1. Limit Switch (LS) - This control is located inside the blower compart-ment and protrudes into the heat exchanger compartment and is setto open at the temperature indicated in the Temperature ControlsTable of the unit wiring diagram. It resets automatically. The limitswitch operates when a high temperature condition occurs, thusshutting down the ignition control, closes the main gas valve andenergizes the blower.
2. Pressure Switch (PS) - If the draft motor should fail, the pressureswitch prevents the ignition control and gas valve from being ener-gized.
3. Flame Sensor - The flame sensor is located on the left-most burner.If an ignition control fails to detect a signal from the flame sensorindicating the flame is properly ignited, then the main gas valve willclose.
4. Rollout Switch (RS) - This switch is located on the burner assembly.In the event of a sustained main burner flame rollout, the control willclose the main gas valve. The is a manual reset type switch.
COOLING SEQUENCE OF OPERATIONSWhen the thermostat calls for COOL, the thermostat terminals G and Yare energized, which signals the compressor, outdoor fan and indoorblower to run.
With a call for Y, the circulating fan is energized at cooling speed.
When the thermostat is satisfied, terminals G and Y are de-energized,de-energizing the compressor and outdoor fan.
After a cool fan off delay timing of 30 seconds, the circulating fan is de-energized.
NOTICEThe manual reset Rollout Switch (RS) must be reset before allowingfurnace operation.
Table 15: Ignition Control Board Flash Codes
Flash Code DescriptionNormal Operation
Green Heartbeat Standby mode
Amber Heartbeat Call for furnace heat active
Operational FaultsSteady ON (any color) Control failure
Rapid Amber Flash Low flame current <1.5 VDC at test pad
1 Red Flash Flame sensed with gas valve off
2 Red Flashes Pressure switch closed with inducer off
3 Red Flashes Pressure switch open with inducer on
4 Red Flashes Limit switch or rollout switch open
5 Red Flashes Limit switch or rollout switch open >15 minutes
6 Red Flashes Pressure switch cycle lockout
7 Red Flashes Lockout due to failed ignition
8 Red Flashes Lockout due to too many flame dropouts
10 Red Flashes Gas valve fault
11 Red FlashesLimit/Rollout switch open between 5 and 15 minutes
Wiring Related Faults9 Red Flashes Incorrect low voltage polarity
4 Amber Flashes Y thermostat demand without a G
16 Johnson Controls Unitary Products
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Safety ControlsThe control circuit includes the following safety controls:
High Pressure Switch (HP) - This switch protects against excessive dis-charge pressures due to a blocked condenser coil or a condensermotor failure (opens at 650 ± 25 psig and closes at 450 ± 25 psig).
The above pressure switches are specifically designed to operate withR-410A systems. R-22 pressure switches must not be used as replace-ments for the R-410A pressure switches.
Circulating FanWhen the thermostat calls for FAN, the thermostat terminal G is ener-gized signaling the circulating fan to run at the G-Speed airflow.
If a call for COOL occurs (Y), the circulating fan switches to run at the Y-Speed airflow.
If a call for HEAT occurs (W), the circulating fan switches to W-Speedafter a 30 second delay.
When the thermostat ends the call for FAN, the thermostat terminal G isde-energized, de-energizing the circulating fan.
START-UPPrestart Check ListComplete the following checks before starting the unit.
1. Check the type of gas being supplied. Be sure that it is the same aslisted on the unit nameplate.
2. Make sure that the vent outlet air hood and air intake hood hasbeen properly installed.
Operating Instructions1. STOP! Read the information on the unit safety label.2. Set the thermostat to the OFF position.3. Turn off all electrical power to the unit.4. DO NOT try to light the burners by hand. This appliance is
equipped with an ignition device which automatically lights theburners.
5. Remove the access panel.6. Turn the gas valve switch to the OFF position.7. Wait five (5) minutes to clear out any gas. If you then smell gas,
STOP! Follow B in the information on the unit safety label. If youdon't smell gas, go to the next step.
8. Turn the gas valve switch to the ON position.9. Replace the control access panel.10. Turn on all electric power to the unit.11. Set the thermostat to the desired setting.12. If the unit will not operate, follow the instructions To Turn Off Gas
To Appliance and call your service technician or gas supplier.
To Turn Off Gas To Unit1. Set the thermostat to the OFF position.2. Turn off all electric power to the appliance if service is to be per-
formed.3. Remove the control access panel.4. Turn the gas valve switch to the OFF position. DO NOT FORCE.5. Replace the control access panel.
Post Start Check ListAfter the entire control circuit has been energized and the heating sec-tion is operating, make the following checks:
1. Check for gas leaks in the unit piping as well as the supply piping.2. Check for correct manifold gas pressures. See Checking Gas Input.
3. Check the supply gas pressure. It must be within the limits shownon rating nameplate. Supply pressure should be checked with allgas appliances in the building at full fire. At no time should thestandby gas line pressure exceed 13.5", nor the operating pressuredrop below 4.5" for natural gas units. If gas pressure is outsidethese limits, contact the local gas utility for corrective action.
ADJUSTMENT OF MANIFOLD GAS PRESSURE & INPUT RATEInlet and manifold gas pressure may be measured by connecting the“U” tube manometer to the gas valve with a piece of tubing. Follow theappropriate section in the instructions below. Refer to Figure 9 for thelocations of the pressure ports on the gas valve.
Turn gas off at the ball valve or gas cock on gas supply line before the gas valve. Find the pressure ports on the gas valve marked Out P and In P.1. The manifold pressure must be taken at the port marked OUT P.
2. The gas line pressure must be taken at the port marked IN P.
3. Using a 3/32” (2.4 mm) hex head wrench, loosen the set screw byturning it 1 turn counter clockwise. DO NOT REMOVE THE SETSCREW FROM THE PRESSURE PORT.
Read the inlet gas pressureConnect the positive side of the manometer to the IN P Tap on the gasvalve. Do not connect any tubing to the negative side of the manometer,as it will reference atmospheric pressure. Refer to Figures 9 and 10 forconnection details.
1. Turn gas and electrical supplies on and follow the operating instruc-tions to place the unit back in operation.
2. Once the correct gas inlet pressure has been established, seeTable 16, turn the gas valve to OFF and turn the electrical supplyswitch to OFF; then remove the flexible tubing from the gas valvepressure tap and tighten the pressure tap plug using the 3/32” (2.4mm) hex head wrench.
3. Turn the electrical and gas supplies back on, and with the burnersin operation, check for gas leakage around the gas valve pressureport for leakage using an approved non-corrosive gas leak detec-tion fluid, or other non-flammable leak detection methods.
Read the manifold gas pressureConnect the positive side of the manometer to the OUT P Tap on thegas valve. Do not connect any tubing to the negative side of themanometer, as it will reference atmospheric pressure. Refer to Figures9 and 10 for connection details.
WARNINGThe ability to properly perform maintenance on this equipmentrequires certain expertise, mechanical skills, tools and equipment. Ifyou do not possess these, do not attempt to perform any mainte-nance other than those procedures recommended in this InstallationManual. Failure to heed this warning could result in serious injuryand possible damage to this equipment.
!
Table 16: Inlet Gas Pressure Range
INLET GAS PRESSURE RANGENatural Gas Propane (LP)
Minimum 4.5” w.c. (1.12 kPa) 8.0” w.c. (1.99 kPa)
Maximum 10.5” w.c. (2.61 kPa) 13.0” w.c. (3.24 kPa).
IMPORTANTThe inlet gas pressure operating range table specifies what the mini-mum and maximum gas line pressures must be for the furnace tooperate safely. The gas line pressure MUST BE a minimum of:
• 7” w.c. (1.74 kPa) for Natural Gas• 11” w.c. (2.74 kPa) for Propane (LP) Gas
in order to obtain the BTU input specified on the rating plate and/orthe nominal manifold pressure specified in these instructions and onthe rating plate.
IMPORTANTThe cap for the pressure regulator must be removed entirely to gainaccess to the adjustment screw. Loosening or tightening the cap doesnot adjust the flow of gas.
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1. Refer to Figure 9 for location of pressure regulator adjustment capand adjustment screws on main gas valve.
2. Turn gas and electrical supplies on and follow the operating instruc-tions to place the unit back in operation.
3. Adjust manifold pressure by adjusting gas valve regulator screw forthe appropriate gas per Table 17.
4. After the manifold pressure has been adjusted, re-calculate the fur-nace input to make sure you have not exceeded the specified inputon the rating plate. Refer to “CALCULATING THE FURNACEINPUT (NATURAL GAS)”.
5. Once the correct BTU (kW) input has been established, turn thegas valve to OFF and turn the electrical supply switch to OFF; thenremove the flexible tubing from the gas valve pressure tap andtighten the pressure tap plug using the 3/32” (2.4 mm) hex headwrench.
6. Turn the electrical and gas supplies back on, and with the burnersin operation, check for gas leakage around the gas valve pressureport for leakage using an approved non-corrosive gas leak detec-tion fluid, or other non-flammable leak detection methods.
ADJUSTMENT OF TEMPERATURE RISE
After about 5 minutes of operation, determine the furnace temperaturerise. Take readings of both the return air and the heated air in the ducts,about six feet (1.8 m) from the furnace where they will not be affectedby radiant heat. Increase the blower speed to decrease the temperaturerise; decrease the blower speed to increase the rise.
DIRECT DRIVE BLOWERAll units have direct drive, multi speed standard ECM blower motors.
Connect manometer per “EXTERNAL STATIC PRESSURE SECTION”.Place unit in cooling mode and adjust blower speed accordingly perTable 12 or 13.
NOTICEThe regulated outlet pressure has been calibrated at the factory.Additional pressure adjustment should not be necessary. If adjust-ment is necessary, set to the following specifications. After adjust-ment, check for gas leakage.
Table 17: Nominal Manifold Pressure
NOMINAL MANIFOLD PRESSURENatural Gas 3.5" w.c. (0.87 kPa)
Propane (LP) Gas 10.0" w.c. (2.488 kPa)
FIGURE 9: Gas Valve
IMPORTANTIf gas valve regulator is turned in (clockwise), manifold pressure isincreased. If screw is turned out (counterclockwise), manifold pres-sure will decrease.
INLET
WRENCH
BOSS
INLET
PRESSURE
PORT
ON
OFF
ON/OFF SWITCH
(Shown in ON position)
MAIN REGULATOR
ADJUSTMENT
OUTLET
OUTLET
PRESSURE
PORTVENT PORT
A0226-001
MANIFOLD PRESSURE “U” TUBE CONNECTION
FIGURE 10: Reading Gas Pressure
DANGERThe temperature rise, or temperature difference between the returnair and the supply (heated) air from the furnace, must be within therange shown on the furnace rating plate and within the applicationlimitations shown in Table 6.The supply air temperature cannot exceed the “Maximum SupplyAir Temperature” specified in these instructions and on the furnacerating plate. Under NO circumstances can the furnace be allowed tooperate above the Maximum Supply Air Temperature. Operating thefurnace above the Maximum Supply Air Temperature will cause pre-mature heat exchanger failure, high levels of Carbon Monoxide, a firehazard, personal injury, property damage, and/or death.
• Treat the negative number as a positive and add the two numberstogether
• This is total system static
FIGURE 11: Measuring External Static Pressure
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CHECKING GAS HEAT INPUTNatural Gas1. Turn off all other gas appliances connected to the gas meter.2. With the unit turned on, measure the time needed for one revolution
of the hand on the smallest dial on the meter. A typical gas meterusually has a 1/2 or a 1 cubic foot test dial.
3. Using the number of seconds for each revolution and the size of thetest dial increment, find the cubic feet of gas consumed per hourfrom Table 18.
If the actual input is not within 5% of the unit heating rating with allow-ance being made for the permissible range of the regulator setting,replace the orifice spuds with spuds of the proper size.
NOTICETo find the BTU input, multiply the number of cubic feet of gas con-sumed per hour by the BTU content of the gas in your particularlocality. (Contact your gas company for this information since it varieswidely from city to city.)
Table 18: Gas Rate Cubic Feet Per Hour1
1. EXAMPLE: By actual measurement, it takes 38 seconds for the hand on the 1-cubic foot dial to make a revolution with just a 100,000 BTUH furnace running. Using this information, locate 38 seconds in the first column of Table 18. Read across to the column headed “1 Cubic Foot,” where you will see that 95 cubic feet of gas per hour are consumed by the furnace at that rate. Multiply 95 x 1050 (the BTU rating of the gas obtained from the local gas company). The result is 99,750 BTUH, which is close to the 100,000 BTUH rating of the unit.
FIGURE 12: Connection Wiring Diagram - 2 to 3 Ton Models
CONNECTION WIRING DIAGRAMCOOLING UNIT WITH GAS HEAT
WITH RECIPROCATING COMPRESSOR208/230-1-60 POWER SUPPLY
208/230-1-60USE COPPERCONDUCTORS ONLY
CAUTION - OPEN ALL DISCONNECTSBEFORE SERVICING THIS UNIT GND
BLK 6
PUR 1 L1 T1 BLK C230V 208V
PRI COMSINGLE POLE
XFMR CONTACTOR BRN S COMPR
CONTACTOR 24V SEC L2 T2 RED RCOIL 40 VA
BLK/WHT 12DUAL
BLU 43 CAPACITORFAN
HI PRESS RED 45
YEL 18 YEL 17HERM C
RED 7 1 BLKSTART RELAY 2
YEL 46 1 2 5BRN/WHT 13 3 BRN
W START CAP BRN 15 4 OD FANY 5 MOTOR
RED 8 GRN 10 GRNO BLOWER
DELAY RED 9 6 RED
LOW R 180VOLTAGE C
BOX 120 BLK 5
C BLU 23 C 90R RED 22 R 60
O
Y YEL 21 Y PUR 2CONTROL
W WHT 20 W BOARD (CONTINUOUS FAN) (LOW) 1G GRN 19 G RED 32
THERMOSTAT RED 34 RED/GRN 36 2 N(LOW/MED) 1
ROLLOUT LIMIT (HEATING SPEED) (MED) 3WHT 33 BLOWER G
MOTOR 2 GRN 43 2 1
RED/BLK 35 (COOLING SPEED) (MED/HIGH)4 YEL 31 4 L
5 3YEL 38 6
SHARED TAP 5 CGRN 40 9 (HIGH) SEE NOTE 7
8 7 4
YEL 38
GAS ORG 37 FLAMEIGNITOR SENSOR
VALVE ORG 39PRESSURE
W SPDSPARK
G SPD CONTROL BOARD SETTINGS:COMBUSTION BLOWER POST PURGE: 60 SECINDOOR BLOWER HEAT ON DELAY: 30 SECINDOOR BLOWER COOL OFF DELAY: 60 SECINDOOR BLOWER HEAT OFF DELAY: FIELD SELECT
TRANSFORMERL1 IND FSY SPD
24V COM 1 2 3 ORG
RED 28
BRNDRAFT CAPMOTOR LINE VOLTAGE
FIELD INSTALLED POWER
LOW VOLTAGE
FIELD INSTALLED CONTROL
WHT 27 YEL
BLU 30
DSI Fault CodesNormal Operation NOTES:
Green HeartbeatAmber HeartbeatRapid Green Flashes
Standby modeCall for furnace heat activeControl in Factory Test mode
Operational Fault CodesFlashes
NoneSlow Green FlashesSlow Amber FlashesRapid Amber Flashes4 Amber FlashesSteady on Red 1 Red Flash2 Red Flashes3 Red Flashes4 Red Flashes5 Red Flashes6 Red Flashes7 Red Flashes8 Red Flashes9 Red Flashes10 Red Flashes11 Red Flashes
Fault ConditionPower Off or open fuseNormal OperationNormal Operation with call for heatLow flame sense currentNo G from thermostat with Y callControl Failure Flame present with gas offCheck pressure switch wiringVent OR termination problemAirflow problemFlame RolloutRepeated pressure switch cyclesFailed to light burnersLoss of flame during call for heatIncorrect polarity OR Don't have neutralGas valve shorted "ON"Check blower motor/wiring
1. ALL FIELD WIRING TO BE ACCOMPLISHED FOLLOWING CITY, LOCAL AND/ORNATIONAL CODES IN EFFECT AT THE TIME OF INSTALLATION OF THE UNIT.
2. CAUTION : LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICINGCONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUSOPERATION. IF ANY OF THE WIRING, AS SUPPLIED WITH THE UNIT, MUSTBE REMOVED, IT MUST BE REPLACED WITH TYPE 105 C. 600 VOLTWIRE OR EQUIVALENT CLEARLY RENUMBERED FOR IDENTIFICATION.VERIFY PROPER OPERATION AFTER SERVICING.
3. FACTORY WIRED FOR 230 VOLT SUPPLY POWER. FOR 208 VOLT, MOVEBLACK WIRES FROM THE 230 TO THE 208 VOLT TAP ON THE TRANSFORMER.
4. MOTORS ARE INHERENTLY PROTECTED.
5. SEE UNIT NAMEPLATE FOR MAXIMUM FUSE AND/OR CIRCUIT BREAKER SIZEAND MINIMUM CIRCUIT AMPACITY.
6. SELECT INDOOR BLOWER SPEED TO REMAIN WITHIN THE TEMPERATURERISE RANGE ON THE NAMEPLATE IN HEATING AND TO OBTAIN APPROX.400 CFM/TON IN COOLING.
7. BLOWER MOTOR SPEED CONNECTIONS SHOWN ARE TYPICAL,BUT MAY VARY BY MODEL AND APPLICATION.
BLU
42
BLK
GR
N 4
4
PU
R 2
6
BLK
/WH
T 11
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FIGURE 13: Ladder Wiring Diagram - 2 to 3 Ton Models
LADDER WIRING DIAGRAMCOOLING UNIT WITH GAS HEAT
WITH RECIPROCATING COMPRESSOR208/230-1-60
CAUTION - OPEN ALL DISCONNECTSBEFORE SERVICING THIS UNIT GROUND
L1 LUG L2
NOTES: R RED
L1 T1 BLK C COMPRES
SR RED
BLK/WHT C OD FANMOTOR
ST2 L2
DUALCAPACITOR
BRN H C F
RED
5 2 1 YEL REDSTART RELAY START CAP
BLK L BLOWEMOTOR
RN PUR
GCONTROL BOARD RELAY
PUR WHT DRAFTBLK
L1 IND MOTOR
CONTROL BOARD SETTINGS:COMBUSTION BLOWER POST PURGE: 60 SECINDOOR BLOWER HEAT ON DELAY: 30 SECINDOOR BLOWER COOL OFF DELAY: 60 SECINDOOR BLOWER HEAT OFF DELAY: FIELD SELECT
LINE VOLTAGE
FIELD INSTALLED POWER
LOW VOLTAGE
FIELD INSTALLED CONTROL
CAP
208V230V PRI COM
BLK PURXFMR
RED BLU24V SEC
40 VA
DSI Fault CodesHI PRESS
Green HeartbeatAmber HeartbeatRapid Green Flashes
Standby modeCall for furnace heat activeControl in Factory Test mode
YEL YELTHERMOSTAT CONTACTOR
C BLU C COIL 3A
R RED R FUSE
Operational Fault Codes OYFlashes
NoneSlow Green FlashesSlow Amber FlashesRapid Amber Flashes4 Amber FlashesSteady on Red 1 Red Flash2 Red Flashes3 Red Flashes4 Red Flashes5 Red Flashes6 Red Flashes7 Red Flashes8 Red Flashes9 Red Flashes10 Red Flashes11 Red Flashes
Fault Condition Y
W WHT WPower Off or open fuseNormal OperationNormal Operation with call for heatLow flame sense currentNo G from thermostat with Y callControl Failure Flame present with gas offCheck pressure switch wiringVent OR termination problemAirflow problemFlame RolloutRepeated pressure switch cyclesFailed to light burnersLoss of flame during call for heatIncorrect polarity OR Don't have neutralGas valve shorted "ON"Check blower motor/wiring
CONTROLG GRN G
BOARDRED RED/GRN
ROLLOUT BLULIMIT
3 2 1RED/BLK
YEL 6 5 4
GRN 9 8 7
YELGAS PRESSURE
VALVE ORG FLAMEIGNITOR SENSOR
ORG
3 WHT W SPD4 2 SPARK
TRANSFORMERL1 IND FS
5 1 RED G SPDBLOWER MOTOR Y SPD
C 2 3 ORGBLU 24V COM 1
YEL RED
1. ALL FIELD WIRING TO BE ACCOMPLISHED FOLLOWING CITY, LOCAL AND/ORNATIONAL CODES IN EFFECT AT THE TIME OF INSTALLATION OF THE UNIT.
2. CAUTION : LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICINGCONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUSOPERATION. IF ANY OF THE WIRING, AS SUPPLIED WITH THE UNIT, MUSTBE REMOVED, IT MUST BE REPLACED WITH TYPE 105 C. 600 VOLTWIRE OR EQUIVALENT CLEARLY RENUMBERED FOR IDENTIFICATION.VERIFY PROPER OPERATION AFTER SERVICING.
3. FACTORY WIRED FOR 230 VOLT SUPPLY POWER. FOR 208 VOLT, MOVEBLACK WIRES FROM THE 230 TO THE 208 VOLT TAP ON THE TRANSFORMER.
4. MOTORS ARE INHERENTLY PROTECTED.
5. SEE UNIT NAMEPLATE FOR MAXIMUM FUSE AND/OR CIRCUIT BREAKER SIZEAND MINIMUM CIRCUIT AMPACITY.
6. SELECT INDOOR BLOWER SPEED TO REMAIN WITHIN THE TEMPERATURERISE RANGE ON THE NAMEPLATE IN HEATING AND TO OBTAIN APPROX.400 CFM/TON IN COOLING.
7. BLOWER MOTOR SPEED CONNECTIONS SHOWN ARE TYPICAL,BUT MAY VARY BY MODEL AND APPLICATION.
BLK
/WH
T
BR
N
BR
N/W
HT
22 Johnson Controls Unitary Products
1183746-UIM-J-0517
FIGURE 14: Connection Wiring Diagram - 3.5 to 5 Ton Models
BLU 23RED 22
WHT 20GRN 19
Y
R
G
C
THERMOSTAT
USE COPPERCONDUCTORS ONLY
RED/GRN 36
ORG 39
RED 34
YEL 31
WHT 33 GRN 4
(LOW)
(LOW/MED)
(MED)
(MED/HIGH)
(HIGH)
RED 32
RED/BLK 35
ROLLOUT
PRESSURE
LIMIT
BLOWER DELAY
60
90
120
180
FSL1 IND
SPARKTRANSFORMER
C
L
G
N
1
2
3
4
5
1
2
3
4
DRAFTMOTOR
YEL 17
HI PRESS
YEL 38
YEL 38
GRN 40
ORG 37
456
123
789
32124V COM
Y SPD
G SPDW SPD
R
OY
W
C
BRN
YELWHT 27
W
YO
R
G
C
LOWVOLTAGE
BOX
RED 28
ORG
IGNITORFLAME
SENSORGASVALVE
CONTROL BOARD
CAP
PU
R 2
6
W
(COOLING SPEED)
(HEATING SPEED)
(CONTINUOUS FAN)
BLK
BRN
RED
BLK/WHT 12
BRN/WHT 13
BLK 6
RED 9
OD FANMOTOR
POWER SUPPLY 208/230-1-60
PUR 1
BLK 5
COMPRI
24V SEC40 VA
208V230V
COMPR
C
S
R
L1 T1
T2L2
FAN
HERM C
DUALCAPACITOR
RED 7
GRN
BLU 43
GND
CONTACTORCOIL
SINGLE POLECONTACTOR
RED 45
BLU
42
BLU 30
PUR 2YEL 21
BLK
YEL 18
GR
N 4
4
5
4
3
2
6
1 BLK
BRN
GRN 10RED
BLOWER MOTOR
SHARED TAPSEE NOTE 7
XFMR
CONTROL BOARD SETTINGS:COMBUSTION BLOWER POST PURGE: 60 SECINDOOR BLOWER HEAT ON DELAY: 30 SECINDOOR BLOWER COOL OFF DELAY: 60 SECINDOOR BLOWER HEAT OFF DELAY: FIELD SELECT
LINE VOLTAGE FIELD INSTALLED POWER LOW VOLTAGE FIELD INSTALLED CONTROL
FlashesOperational Fault Codes
Fault ConditionNoneSlow Green FlashesSlow Amber FlashesRapid Amber Flashes4 Amber FlashesSteady on Red 1 Red Flash2 Red Flashes3 Red Flashes4 Red Flashes5 Red Flashes6 Red Flashes7 Red Flashes8 Red Flashes9 Red Flashes10 Red Flashes11 Red Flashes
Normal OperationStandby modeCall for furnace heat activeControl in Factory Test mode
Green HeartbeatAmber HeartbeatRapid Green Flashes
Power Off or open fuseNormal OperationNormal Operation with call for heatLow flame sense currentNo G from thermostat with Y callControl Failure Flame present with gas offCheck pressure switch wiringVent OR termination problemAirflow problemFlame RolloutRepeated pressure switch cyclesFailed to light burnersLoss of flame during call for heatIncorrect polarity OR Don't have neutralGas valve shorted "ON"Check blower motor/wiring
DSI Fault Codes
CAUTION - OPEN ALL DISCONNECTSBEFORE SERVICING THIS UNIT
1. ALL FIELD WIRING TO BE ACCOMPLISHED FOLLOWING CITY, LOCAL AND/OR NATIONAL CODES IN EFFECT AT THE TIME OF INSTALLATION OF THE UNIT. 2. CAUTION : LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. IF ANY OF THE WIRING, AS SUPPLIED WITH THE UNIT, MUST BE REMOVED, IT MUST BE REPLACED WITH TYPE 105 C. 600 VOLT WIRE OR EQUIVALENT CLEARLY RENUMBERED FOR IDENTIFICATION. VERIFY PROPER OPERATION AFTER SERVICING. 3. FACTORY WIRED FOR 230 VOLT SUPPLY POWER. FOR 208 VOLT, MOVE BLACK WIRES FROM THE 230 TO THE 208 VOLT TAP ON THE TRANSFORMER. 4. MOTORS ARE INHERENTLY PROTECTED. 5. SEE UNIT NAMEPLATE FOR MAXIMUM FUSE AND/OR CIRCUIT BREAKER SIZE AND MINIMUM CIRCUIT AMPACITY. 6. SELECT INDOOR BLOWER SPEED TO REMAIN WITHIN THE TEMPERATURE RISE RANGE ON THE NAMEPLATE IN HEATING AND TO OBTAIN APPROX. 400 CFM/TON IN COOLING. 7. BLOWER MOTOR SPEED CONNECTIONS SHOWN ARE TYPICAL, BUT MAY VARY BY MODEL AND APPLICATION.
NOTES:
WITH SCROLL COMPRESSOR208/230-1-60
CONNECTION WIRING DIAGRAMCOOLING UNIT WITH GAS HEAT
Johnson Controls Unitary Products 23
1183746-UIM-J-0517
FIGURE 15: Ladder Wiring Diagram - 3.5 to 5 Ton Models
COMPRI
24V SEC40 VA
208V230V
L1 L2
COMPRES
R
C
S
BLOWERMOTORL N
G
BLOWER MOTOR
5
3
C
1
HI PRESS
CONTACTOR COIL
4 2
FH C
DUALCAPACITOR
T1L1
L2T2
DRAFTMOTOR
CONTROL BOARD RELAY
CAP
BLURED
WHTGRN
Y
R
G
C
THERMOSTAT
RED/GRN
ORG
RED
RED/BLK
ROLLOUT
PRESSURE
LIMIT
FSL1 IND
SPARKTRANSFORMER
YEL
YEL
GRN
ORG
456
123
789
32124V COM
Y SPD
G SPDW SPD
WY
O
R
G
C
RED
ORG
IGNITORFLAME
SENSORGAS
VALVE
CONTROL BOARD
W
YEL
BLU
YEL
RED
WHT
3AFUSE
BLK
RED
BR
N
RED
OD FANMOTOR
R
C
S
BLK/WHT
RED
GROUND LUG
BR
N/W
HT
INDL1
PURBLK
WHT BLKPUR
PUR
BLURED
BLK
BLU
YEL
XFMR
WITH SCROLL COMPRESSOR208/230-1-60
LADDER WIRING DIAGRAMCOOLING UNIT WITH GAS HEAT
FlashesOperational Fault Codes
Fault ConditionNoneSlow Green FlashesSlow Amber FlashesRapid Amber Flashes4 Amber FlashesSteady on Red 1 Red Flash2 Red Flashes3 Red Flashes4 Red Flashes5 Red Flashes6 Red Flashes7 Red Flashes8 Red Flashes9 Red Flashes10 Red Flashes11 Red Flashes
Standby modeCall for furnace heat activeControl in Factory Test mode
Green HeartbeatAmber HeartbeatRapid Green Flashes
Power Off or open fuseNormal OperationNormal Operation with call for heatLow flame sense currentNo G from thermostat with Y callControl Failure Flame present with gas offCheck pressure switch wiringVent OR termination problemAirflow problemFlame RolloutRepeated pressure switch cyclesFailed to light burnersLoss of flame during call for heatIncorrect polarity OR Don't have neutralGas valve shorted "ON"Check blower motor/wiring
DSI Fault Codes
CAUTION - OPEN ALL DISCONNECTSBEFORE SERVICING THIS UNIT
1. ALL FIELD WIRING TO BE ACCOMPLISHED FOLLOWING CITY, LOCAL AND/OR NATIONAL CODES IN EFFECT AT THE TIME OF INSTALLATION OF THE UNIT. 2. CAUTION : LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. IF ANY OF THE WIRING, AS SUPPLIED WITH THE UNIT, MUST BE REMOVED, IT MUST BE REPLACED WITH TYPE 105 C. 600 VOLT WIRE OR EQUIVALENT CLEARLY RENUMBERED FOR IDENTIFICATION. VERIFY PROPER OPERATION AFTER SERVICING. 3. FACTORY WIRED FOR 230 VOLT SUPPLY POWER. FOR 208 VOLT, MOVE BLACK WIRES FROM THE 230 TO THE 208 VOLT TAP ON THE TRANSFORMER. 4. MOTORS ARE INHERENTLY PROTECTED. 5. SEE UNIT NAMEPLATE FOR MAXIMUM FUSE AND/OR CIRCUIT BREAKER SIZE AND MINIMUM CIRCUIT AMPACITY. 6. SELECT INDOOR BLOWER SPEED TO REMAIN WITHIN THE TEMPERATURE RISE RANGE ON THE NAMEPLATE IN HEATING AND TO OBTAIN APPROX. 400 CFM/TON IN COOLING. 7. BLOWER MOTOR SPEED CONNECTIONS SHOWN ARE TYPICAL, BUT MAY VARY BY MODEL AND APPLICATION.
NOTES:
CONTROL BOARD SETTINGS:COMBUSTION BLOWER POST PURGE: 60 SECINDOOR BLOWER HEAT ON DELAY: 30 SECINDOOR BLOWER COOL OFF DELAY: 60 SECINDOOR BLOWER HEAT OFF DELAY: FIELD SELECT
LINE VOLTAGE FIELD INSTALLED POWER LOW VOLTAGE FIELD INSTALLED CONTROL
24 Johnson Controls Unitary Products
1183746-UIM-J-0517
FIGURE 16: R-410A Quick Reference Guide
R-410A QUICK REFERENCE GUIDE
Refer to Installation Instructions for specific installation requirements
R-410A refrigerant operates at 50 - 70 percent higher pressures than R-22. Be sure that servicing
equipment and replacement components are designed to operate with R-410A.
R-410A refrigerant cylinders are rose colored.
Recovery cylinder service pressure rating must be 400 psig, DOT 4BA400, or DOT BW400.
Recovery equipment must be rated for R-410A.
DO NOT use R-410A service equipment on R-22 systems. All hoses, gages, recovery cylinders, charging
cylinders and recovery equipment must be dedicated for use on R-410A systems only.
Manifold sets must be at least 700 psig high side, and 180 psig low side, with 550 psig retard.
All hoses must have a service pressure rating of 800 psig.
Leak detectors must be designed to detect HFC refrigerants.
Systems must be charged with liquid refrigerant. Use a commercial type metering device
in the manifold hose.
R-410A can only be used with POE type oils.
POE type oils rapidly absorb moisture from the atmosphere.
Vacuum pumps will not remove moisture from R-410A refrigerant oils.
Do not use liquid line driers with a rated working pressure rating less than 600 psig.
Do not install suction line driers in the liquid line.
A liquid line drier is required on every unit.
Do not use a R-22 TXV. If a TXV is to be used, it must be a R-410A TXV.
Never open system to atmosphere when under a vacuum.
If system must be opened for service, evacuate system then break the vacuum with dry nitrogen
and replace all filter driers.
Johnson Controls Unitary Products 25
1183746-UIM-J-0517
NOTES
26 Johnson Controls Unitary Products
1183746-UIM-J-0517
SECTION VIII: START UP SHEET
Residential Package Unit Cooling / Gas Heat Start-Up Sheet Proper start-up is critical to customer comfort and equipment longevity
Slab Roof curb Supply Return
Condensate drain properly connected per the installation instructions Condensate trap has been primed with water
Duct connections are complete:
Number of filters Filter size
Unit is level and installed on:
Filters installed Filter located inside Filter located outside
Retrofit
New Construction
Grade level
Roof level
Commercial
Residential
Side flow
Down flow
Line voltage present at disconnect
Low voltage present at control board "R & C"
Ground connected
Start-Up TechnicianCompany Name
EconomizerTransformer kit Roof curb kit Base rail hole blockage kit
Filter frame kit
Three phaseSingle phase
Two stage compressorSingle stage compressor
208 volts AC 230 volt AC 460 volts AC 575 volts AC
Anti-recycle timer
Measured voltage "L1 to L2" "L2 to L3" "L1 to L3"
Total amperes "L1" "L2" "L3"Compressor amperes "L1" "L2" "L3"
Measured voltage "R" and "C" outdoor unit control board
Electrical Connections & Inspection (Check all that apply)
Equipment Data
Additional Kits & Accessories Installed (Check all that apply)
Equipment Data
Blower Type &
Set-Up
Supply air dry bulb temperature
ADJUST A B C D
A B C D
Total external static pressure
Supply static (inches of water column)
Return air dry bulb temperature
Temperature drop
1 2 3 4 5
Low Medium Low Medium Medium High High
A B C D
Outside air dry bulb temperature
Return air wet bulb temperature
Supply air wet bulb temperature
Return static (inches of water column)
V.S. ECM
ECM
PSC
COOL
DELAY
Air Flow Setup / Cooling
Page 1 of 2
Name Address
City State or Province Zip or Postal Code
Daytime Phone
Unit Model # Unit Serial #
Transformer wired properly for primary supply voltageInspect wires and electrical connections
Unit Location and Connections (Check all that apply)
General Information (Check all that apply)
Start-Up Date
Refrigerant safety kit Low ambient kit Crank case heater
Manual fresh air damper kit Motorized fresh air damper kit
Filters
Owner Information
Print Form Reset Form
Johnson Controls Unitary Products 27
Refrigerant Charge and Metering Device
Subcooling
R-410A R-22
Discharge line temperature Superheat
Discharge pressureData plate - lbs / Oz
TXV# / Orifice size
Explain operation of system to equipment owner
Explain the importance of regular filter replacement and equipment maintenance
Clean Up Job Site
Owner Education
Comments and Additional Job Details
Provide owner with the owner's manual
Explain thermostat use and programming (if applicable) to owner
Unit Operation and Cycle TestOperate the unit through continuous fan cycles from the thermostat, noting and correcting any problems
Operate the unit through cooling cycles from the thermostat, noting and correcting any problems
Job site has been cleaned, indoor and outdoor debris removed from job site
Tools have been removed from unit
All panels have been installed
TXV Fixed Orifice Liquid line temperatureSuction pressure
Suction line temperature
Manifold Pressure / Low Fire Rate (w.c.")
Gas Heat
Rated BTU/HMeasured BTU/H (Clock Gas Meter Nat Gas)
Supply Air Dry Bulb Temp Temp RiseReturn Air Dry Bulb Temp
Manifold Pressure at 100% Firing Rate (w.c.")
Inlet Gas Pressure (w.c.")LP Gas Conversion Kit # LP Conversion Kit Installed By
Two StageSingle Stage Propane LP (Requires LP Conversion Kit)Natural Gas
Burner Flame Inspection - Blue flames extending directly into the primary heat exchanger cells