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Johnson Controls GG8S*MP User's Manual

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1. VVALL THERMOSTAT FIGURE 20 Single Wire Twinning Wiring Diagram STAGING This control can also be used along with a two stage wall thermostat to stage two twinned furnaces making them operate like a single two stage furnace This allows only one furnace to supply heat during times when the heat output from one furnace is sufficient to satisfy the demand When one duct system is used for two furnaces it is neces sary that the two blowers operate in unison The twinning function of this board ensures that both blowers turn on and off simultaneously and operate on the same blower speed Even when only one furnace is supplying heat both furnace blowers must run Single Wire Staging The single wire twinning feature of this board can also be used for stag ing of two furnaces With this feature a single wire is connected between the TWIN terminal on one furnace board to the TWIN terminal on the second furnace board The board then communicates the blower status from one furnace to the other along this wire This communica tion makes the second furnace blower come on at the same time and on the same speed as the first furnace blower To ensure stable com munication the common terminal of each control must be connected Single Wire Staging Instructions Connect the control wiring as shown in Figure 22 1 Connect the low voltage wiring from the wall thermostat to the ter minal strip on the control boa
2. RESIDENTIAL GAS FURNACE MODELS TG8S MP TGLS MP GG8S MP GGLS MP Single Stage Multi position Low NOx a 7 eC ll p 6 ion 1 mr THE R EP R x K A T l l H E Whee A E aA e KEES 0 4 d 4 1 lt E i lat aa Ov E 1 ERA GUS 2 9 Mi x 7 a ba H Ey E 08 ee H 212 T eet ee oa H 3 Ey A O O H 2 JIH 4 H O_o H H nu N 2 H H 4 H A E M A i 4 I 21 EY A B RA o CD 9 HE 9 9 DCO H H H J EC B Ha R 9 B ee Oe eC N 1 N H l A A U a MA ee 1001008 40502 B 2 A 9 na MH H A E 2 E i i a KC eee E H a I 2 21 H 9 8 1 22 21 21 45 6 2 2 1 I E 2120 E 2 mme 2 I B 2202 22 21 A mme 299 2 B Ra me as CE MH 1 A 02 7 A 7 9 H B E A 99 EE Lre CERTIFIED www ahridirectory org LA O XS Resid IF qi 9 7 40 000 REGISGRS ISO 9001 Certified Quality Management System LIST OF SECTIONS SAFELY i2ditecnecanindaneeven ee tant adbaad 1 VENT SYSTEM kora al E al eee nana 16 DUCTWORK sua er 5 START UP AND 5 19 ALTERS ua xu REEE 9 SAF
3. n ze nw wo S Jnayoedey dvd nbin l nil DVI 0155 ap Sd awe ap unaydes S4 JnayowW npul q NaI u w jnou ap in enululo2 SOY 181504 19 5 LOW ap unajyejnwwoy sq 4QN3931 JWASLL ERA b wid 18 034 soy uoljeoijdde pue japow Aq Asean Aew nq jed 1dA ae UMOUS 5401129 4 p ds JOJOW 8 Z oS01 4 TZZ 3SP 16 JO Sues iniel d l e SulAey 1 SUL M YUM Da7 6109 aq ysnW 11 padejda aq ysn adeUINJ JY YUM paljddns se asim 64181 y Aue 111 Jaueayd se 21401129 3 DVI BDELINS OH ISH NNJN A PA 580 AD JEJSOW JAY LSL 101196067 dv Josuas awe S4 YDUMS 55 Sd s li piwny INH JOJOW s npui WAI YOUMS NO OY SOY yoyms yun ST JOJOW LOW ydUMs 100q SA QN4931 IHAVd34 2 410N 335 HOLIMS LNOTION INO AINO 5 DYNAN 1 INANI 000 07 3 1 MO1 099 Jde S a SUIS 9608 Wieiselg SULTAN Wiring Diagram FIGURE 28 29 Johnson Controls Unitary Products NOTES Subject to change without notice Published in U S A 356485 UIM G 121 1 Copyright 2011 by Johnson Controls Inc All rights reserved Supersedes 356485 UIM F 0910 Johnson Controls Unitary Products 5005 York Drive Norman OK 73069
4. 1zss 1 ear no nas T0sT 1027 927 R os Hein High s z 1004 1008 si ro sir s s 77s Lovv 655 654 647 629 620 594 560 524 6 399 aros eun ar 1812 1288 1288 1260 1205 143 1091 1029 965 t v f re f nee Has ooe ios j oee si n mas a arcs mas Heun nat 1010 1004 1003 s s ese oss oia e57 798 721 ee 5 2 614 0 8 m m ore eee T r f oaa m s n 1s eae ear j nro f nes j torr f ooe Ton ee n lv ns r reso rave e reas ras eos ms G 396 NOTES 1 Airflow expressed in standard cubic feet per minute CFM 2 Motor voltage at 115 V O gt O ms Z gt gt iN oO C O iN 00 N O O iN NO 24 Johnson Controls Unitary Products 356485 UIM G 1211 Table 14 Blower Performance CFM Any Position without filter Left Side Return Left Side Airflow Data SCFM Speed Ext Static Pressure in H2O 60 nn T s r on f oe e T es r 7 ar RA NA oaos 824 s z 777 7a ors 480 so r ma Medium tow T r 3 s s eo e 4 s Na NA NA 707 684 en 604 465 397 282 NA NA NA o Yodun Figh Tas Tan ise Tose Tora ees 508 NANA tow asa j ee ee T are asa at soars Hagun
5. It is acceptable to use the primary heat exchanger tubes as a lifting point provided that the tubes are lifted at the front of the heat exchang ers where attached to the vestibule panel Do not use the top return bend of the heat exchangers as lifting points as the tubes may shift out of position or their location brackets baffles Johnson Controls Unitary Products 356485 UIM G 1211 Vent Connection Outlet RIGHT SIDE Electrical Entry Electrical 773 Entry Outlet Gas Pipe Gas Pipe Entry Thermostat Thermostat Wiring 4 Diameter Vent Connection Outlet Ba 29 i 24 25 SUPPLY END RETURN END FIGURE 12 Dimensions Table 3 Cabinet and Duct Dimensions BTUH kW Nomina i i Approximate kW inal Cabinet Cabinet Dimensions Inches i l i i Input FM m mi Size Operating Weights 5 l cm B com O C C cm cm Conn soz mz sss s 60076 1000683 A 17 262 94 60076 oeo A 352 5 5 sa es l ss ns m l 9 C 21 80 23 4 1200 34 0 80 23 4 1600 45 3 28 3 34 0 34 0 45 3 80284 2200 62 3 2 T 10612031 1200640 8 wie daq 1638 qis ns 108 100 29 3 1800 4533 2 ns 56 6 45 3 56 6 2 122 120 351 1600 1453 2 723 2000 656 c a s s ss sr Boen 2000 555 0 am e2 am s4 is uq
6. l o SECTION Ill FILTERS Table 4 Recommended Filter Sizes High Velocity 600 FPM FILTER INSTALLATION CFM Cabinet Side Bottom m m3 min Size in in All applications require the use of a field installed filter All filters and A mounting provision must be field supplied 7 Filters must be installed external to the furnace cabinet DO NOT 1000 28 3 16x 25 14x25 attempt to install filters inside the furnace 1200 34 0 A 16 x 25 14x25 1200 540 e 16x26 16x25 7 NOTICE 1600 45 3 B x exa 100 29 3 2000 56 6 xos 2 22 65 1 Air velocity through throwaway type filters may not exceed 300 feet per min ute 91 4 m min All velocities over this require the use of high velocity fil ters 2 Do not exceed 1800 CFM using a single side return and a 16x25 filter For CFM greater than 1800 you may use two side returns or one side and the bottom or one return with a transition to allow use of a 20x25 filter Single side return above 1800 CFM is approved as long as the filter velocity does not exceed filter manufacturer s recommendation x xe l x x Sx l a Johnson Controls Unitary Products 9 356485 UIM G 1211 SIDE RETURN Locate the L shaped corner locators These indicate the size of the cut out to be made in the furnace side panel Refer to Figure 13 F 7 TN A N L FIGURE 13 Side Return Cutout Mar
7. venting consists of vertically venting one or more appliances in B vent or masonry chimney as allowed using single wall metal pipe or B vent connectors Type B vent system extends in a general vertical direction and does not contain offsets exceeding 45 A vent system having not more than one 60 offset is permitted VENTING INTO AN EXISTING CHIMNEY For Category installations the furnace shall be connected to a factory built chimney or vent complying with a recognized standard or a masonry or concrete chimney lined with a material acceptable to the authority having jurisdiction Venting into an unlined masonry chimney or concrete chimney is prohibited Where use of an existing chimney is unavoidable the following rules must be followed 1 The masonry chimney must be built and installed in accordance with nationally recognized building codes or standards and must be lined with approved fire clay tile flue liners or other approved liner material that will resist corrosion softening or cracking from flue gases THIS FURNACE IS NOT TO BE VENTED INTO AN UNLINED MASONRY CHIMNEY 2 This furnace must be vented into a fire clay tile lined masonry chimney only if a source of dilution air is provided such as by com mon venting with a draft hood equipped water heater If no source of dilution air is available Type B vent must be used or masonry chimney vent kit 1CK0603 or 1 0604 must be used Refer to the instructions with the kit
8. Improper installation may create a condition where the operation of the product could cause personal injury or property damage Improper installation adjustment alteration service or mainte nance can cause injury or property damage Failure to carefully read and follow all instructions in this manual can result in fur nace malfunction death personal injury and or property dam age Only a qualified contractor installer or service agency should install this product 356485 UIM G 1211 356485 UIM G 1211 SPECIFIC SAFETY RULES AND PRECAUTIONS 1 2 Only Natural gas or Propane LP gas are approved for use with this furnace Install this furnace only in a location and position as specified in these instructions A gas fired furnace for installation in a residential garage must be installed as specified in these instructions Provide adequate combustion and ventilation air to the furnace space as specified in these instructions Combustion products must be discharged outdoors Connect this furnace to an approved vent system only as specified in SEC TION VII of these instructions Test for gas leaks as specified in these instructions AWARNING FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in serious injury death or property damage Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for detection of leaks to check a
9. Refer to Table 6 or the furnace rating plate for the correct rise range and static pressures If the ducts are undersized the result will be high duct static pres sures and or high temperature rises which can result in a heat exchanger OVERHEATING CONDITION This condition can result in premature heat exchanger failure which can result in personal injury property damage or death If a matching cooling coil is used it may be placed directly on the fur nace outlet and sealed to prevent leakage If thermoplastic evaporator A coil drain pans are to be installed in the upflow horizontal configura tion then extra 2 minimum spacing may be needed to ensure against drain pan distortion Johnson Controls Unitary Products 356485 UIM G 1211 On all installations without a coil a removable access panel is recom mended in the outlet duct such that smoke or reflected light would be observable inside the casing to indicate the presence of leaks in the heat exchanger This access cover shall be attached in such a manner as to prevent leaks DUCT FLANGES Four flanges are provided to attach ductwork to the furnace These flanges are rotated down for shipment In order to use the flanges remove the screw holding an individual flange rotate the flange so it is in the upward position and reinstall the screw then repeat this for all 4 flanges If the flanges are not used they must remain in the rotated down posi tion as shippe
10. To use the same speed tap for heating and cooling the heat terminal and cool terminal must be connected using a jumper wire and connected to the desired motor lead Place all unused motor leads on park terminals Two park terminals are provided ACAUTION Do not energize more than one motor speed at a time or damage to the motor will result ADJUSTMENT OF FAN CONTROL SETTINGS This furnace is equipped with a time on time off heating fan control The fan on delay is fixed at 30 seconds The fan off delay has 4 settings 60 90 120 and 180 seconds The fan off delay is factory set to 120 sec onds The fan off setting must be long enough to adequately cool the furnace but not so long that cold air is blown into the heated space The fan off timing may be adjusted by positioning the jumper on two of the four pins as shown in Figure 27 PARK PARK STVYLNAN 23 356485 UIM G 1211 Table 13 Blower Performance CFM Any Position without filter Bottom Return i Ext Static Pressure in H20 207 77 0 95 ee High ss zs ea giz ss sis t r NA NA 040406 u ununu umuuu nu uu muluu mum 545 N 9 ae 73v uu am m O ass rar ase R rea no ra Toes oe ors Wem o uza s s are sn ri v s tow T s 7r 7es 73 7 57 e22 584 s s T z 4307
11. rise and venting according to the manufacturer s instructions 10 When installed in a Non HUD Approved Modular Home or building constructed on site combustion air shall not be supplied from occupied spaces The size of the unit should be based on an acceptable heat loss calculation for the structure ACCA Manual J or other approved methods may be used 12 When moving or handling this furnace prior to installation it is rec ommended to leave the doors on the furnace to provide support and to prevent damage or warping of the cabinet When lifting the furnace by the cabinet support the ends of the furnace rather than lifting by the cabinet flanges at the return air openings bottom or sides or supply air opening 13 When lifting the furnace it is acceptable to use the primary heat exchanger tubes as a lifting point provided that the tubes are lifted at the front of the heat exchangers where attached to the vestibule panel Do not use the top return bend of the heat exchangers as lifting points as the tubes may shift out of position or their location brackets baffles IMPORTANT During installation doors should remain on the furnace when moving or lifting SAFETY REQUIREMENTS ACAUTION This product must be installed in strict compliance with the installa tion instructions and any applicable local state and national codes including but not limited to building electrical and mechanical codes e Refer to the
12. Installation Code latest editions If the vent system must be resized follow the appropriate tables in Appendix G of the above codes or for this appliance SECTION VIII START UP AND ADJUSTMENTS The initial start up of the furnace requires the following additional procedures IMPORTANT All electrical connections made in the field and in the factory should be checked for proper tightness When the gas supply is initially connected to the furnace the gas piping may be full of air In order to purge this air it is recommended that the ground union be loosened until the odor of gas is detected When gas is detected immediately retighten the union and check for leaks Allow five minutes for any gas to dissipate before continuing with the start up procedure Be sure proper ventilation is available to dilute and carry away any vented gas Johnson Controls Unitary Products NOx SCREEN REMOVAL Lo NOx Models Only If the furnace is equipped with NOx screens and is to be used with LP propane gas the screens must be removed prior to start up 1 Make sure that the electrical power to the unit is turned off and that the gas supply is turned off at the shut off valve 2 Remove the blower compartment and burner compartment access doors 3 Disconnect the gas supply piping at the union to permit removal of the entire burner and gas control assembly from the vestibule panel Use the wrench boss on the gas valve when removing o
13. PUMP DEMAND DEFROST T CONTROL C 24 Volt Common Y Compressor R 24 Volt Hot W1 66 out Heat O Reversing Valve Energized in Cool X L Malfunction Light W Auxiliary Heat Part Numbers 7 SAP Legacy 67297 031 01975 Johnson Controls Unitary Products ACCESSORY CONNECTIONS The furnace control will allow power switching control of various acces sories ELECTRONIC AIR CLEANER CONNECTION Two 1 4 0 64 cm spade terminals EAC and NEUTRAL for electronic air cleaner connections are located on the control board The terminals provide 115 VAC 1 0 amp maximum during circulating blower opera tion HUMIDIFIER CONNECTION Two 1 4 0 64 cm spade terminals HUM and NEUTRAL for humidi fier connections are located on the control board The terminals provide 115 VAC 1 0 amp maximum during heating system operation A mounting hole is provided on the control panel next to the furnace control board for mounting a humidifier transformer if required SECTION VI TWINNING AND STAGING In applications where more heating capacity or more airflow capacity is needed than what one furnace can deliver twinning can be used to make two furnaces operate in tandem When two furnaces are installed using the same duct system it is very important that the two furnace cir culating air blowers operate in unison If one blower starts before the second blowe
14. RED FLASHES This indicates the pressure switch contacts are open when they should be closed Check for faulty inducer blocked vent pipe broken pressure switch hose disconnected pressure switch or inducer wires or faulty pressure switch 4 RED FLASHES This indicates that the main limit switch has opened its normally closed contacts The control will operate the supply air blower and inducer while the open limit condition exists Check for a dirty filter improperly sized duct system incorrect blower speed setting incorrect firing rate loose limit switch wiring or faulty blower motor If the limit switch has not closed within five minutes the control will assume that the blower is not functioning will start a hard lockout and will begin to flash the 11 Red Flashes error code Power will have to be cycled off and on to reset the control after the problem has been cor rected See 11Red Flashes description below If the main limit switch opens five times within a single call for heat the control will also indicate 4 Red Flashes and will enter a one hour soft lockout Johnson Controls Unitary Products 356485 UIM G 1211 5 RED FLASHES This fault is indicated if the normally closed rollout switch opens The rollout control is manually reset Check for proper combustion air proper inducer operation and primary heat exchanger failure or burner problem The control will enter a hard lockout and power will have to be cycled off and
15. Space Installation 8 Casing to the Burner Compartment 17 Dimensions 9 Outside and Ambient Combustion Air 18 Side Return Cutout Markings 10 Gas Valve LLL LLL HR eee tte 22 10 Reading Gas Pressure 22 Gas Piping 10 Furnace Control Board 23 Wining Lla falll ez 4 oS eee eae Gabe ob eG we oe 29 LIST OF TABLES Unit Clearances to Combustibles 4 5002 of Hal sea ute s ba as sin 18 Coil Projection Dimensions PC Series Coils 7 Gas Rate CU PIAA 21 Cabinet and Duct Dimensions 9 Inlet Gas Pressure Range 22 Recommended Filter Sizes High Velocity 600 FPM 9 Nominal Manifold Pressure 22 Nominal Manifold Pressure 11 Blower Performance CFM Any Position Ratings amp Physical Electrical Data 12 without filter Bottom Return 0 K E eee eee eee ll 24 Estimated Free Area 17 Blower Performance CFM Any Position Unconfined Space Minimum Area 18 vvi
16. be operated without the blower panel in place This unit is equipped with an electrical interlock switch mounted in the burner compartment This switch interrupts all power at the unit when the panel covering the blower compartment is removed Electrical supply to this unit is dependent upon the panel that covers the blower compartment being in place and properly positioned ROLLOUT SWITCH CONTROLS These controls are mounted on the burner assembly If the temperature in the area surrounding the burner exceeds its set point the gas valve is de energized The operation of this control indicates a malfunction in the combustion air blower heat exchanger or a blocked vent pipe con nection Corrective action is required These are manual reset controls that must be reset before operation can continue PRESSURE SWITCHES This furnace is supplied with a pressure switch which monitors the flow through the combustion air vent piping system This switch de ener gizes the gas valve if any of the following conditions are present 1 Blockage of vent piping or terminal 2 Failure of combustion air blower motor LIMIT CONTROLS There is a high temperature limit control located on the furnace vesti bule panel near the gas valve This is an automatic reset control that provides over temperature protection due to reduced airflow This may be caused by 1 A dirty filter 2 Ifthe indoor fan motor should fail 3 Too many supply or return reg
17. dential air in the gas line or until gas manifold pressure is adjusted The ignition control will make 3 attempts to light before locking out 20 With furnace in operation check all of the pipe joints gas valve connec tions and manual valve connections for leakage using an approved gas detector a non corrosive leak detection fluid or other leak detection methods Take appropriate steps to stop any leak If a leak persists replace the component CALCULATING THE FURNACE INPUT NATURAL GAS NOTICE Burner orifices are sized to provide proper input rate using natural gas with a heating value of 1030 BTU Ft 38 4 MJ m If the heat ing value of your gas is significantly different it may be necessary to replace the orifices NOTICE If orifice hole appears damaged or it is suspected to have been redrilled check orifice hole with a numbered drill bit of correct size Never redrill an orifice A burr free and sqaurely aligned orifice hole is essential for proper flame characteristics ACAUTION DO NOT bottom out gas valve regulator adjusting screw This can result in unregulated manifold pressure and result in excess over fire and heat exchanger failures NOTICE DO NOT set manifold pressure less than 3 2 in wc or more than 3 8 in we for natural gas at sea level If manifold pressure is outside this range change main burner orifices Verify natural gas input rate by clocking meter 1 Turn off all other gas applia
18. for downflow or horizontal left installations FIGURE 3 Coil Flange FURNACE ASSEMBLY MC SERIES COILS ONLY MC coils are supplied ready to be installed in a horizontal position A horizontal pan is factory installed MC coils should be installed in all hor izontal applications with the horizontal drain pan side down Se Furnace I ls re FIGURE 4 Horizontal Right Application For horizontal left hand applications no conversion is required to an MC coil when used with a downflow horizontal furnace A mounting plate supplied with every coil should always be installed on the side desig nated as top side See Figures 4 amp 5 Mounting Plate FIGURE 5 Horizontal Left Application FURNACE ASSEMBLY PC SERIES COILS These upflow coils are designed for installation on top of upflow fur naces only If the coil is used with a furnace of a different size use a 45 transition to allow proper air distribution through the coil 1 Position the coil casing over the furnace opening as shown in Fig ure 6 2 Place the ductwork over the coil casing flange and secure 3 Check for air leakage between the furnace and coil casing and seal appropriately Do not drill any holes or drive any screws into the front duct flange on the coil in order to prevent damaging coil tubing See Figure 6 Flexible Duct Collar Field Fabricated 1 Ductvvork O Do not dri
19. latest edition and or all local code or utility requirements TWINNING In applications where more heating capacity or more airflow capacity is needed than what one furnace can deliver twinning can be used to make two furnaces operate in tandem using one duct system and one room thermostat When one duct system is used for two furnaces it is necessary that the two blowers operate in unison The twinning function of the board in this furnace ensures that both blowers turn on and off simultaneously and operate on the same blower speed Single Wire Twinning The control in the furnace has the single wire twinning feature With this feature a single wire is connected between the TWIN terminal on one furnace board to the TWIN terminal on the second furnace board The board then communicates the blower status from one furnace to the other along this wire This communication makes the second furnace blower come on at the same time and on the same speed as the first furnace blower To ensure stable communication the common terminal of each control must be connected Single Wire Twinning Instructions Connect the control wiring as shown in Figure 21 1 Connect the low voltage wiring from the wall thermostat to the ter minal strip on the control board of Furnace 1 2 Connect a wire from the TWIN terminal of Furnace 1 to the TWIN terminal of Furnace 2 3 Install a separate 24V relay as shown in the diagram below Use of this relay is r
20. microamps DC ua Low flame signal warning starts at 1 5 microamps Low flame signal control lockout point is 0 1 microamps DC 27 356485 UIM G 1211 DIAGNOSTIC FAULT CODE STORAGE AND RETRIEVAL The control in this furnace is equipped with memory that will store up to five error codes to allow a service technician to diagnose problems more easily This memory will be retained even if power to the furnace is lost This feature should only be used by a qualified service tech nician _ lf more than five error codes have occurred since the last reset only the five most recent will be retained The furnace control board has a but ton labeled LAST ERROR that is used to retrieve error codes This function will only work if there are no active thermostat signals So any call for heating cooling or continuous fan must be terminated before attempting to retrieve error codes SECTION X REPLACEMENT PARTS LIST SENSOR FLAME SWITCH PRESSURE SWITCH DOOR RAIL BLOWER 2 Req d REPLACEMENT PART CONTACT INFORMATION To retrieve the error codes push the LAST ERROR button The LED on the control will then flash the error codes that are in memory starting with the most recent There will be a two second pause between each flash code After the error codes have all been displayed the LED will resume the normal slow green flash after a five second pause To repeat the series of error codes push the button again If there
21. to properly apply these masonry chimney kits 3 The chimney must extend at least 3 ft 0 91 m above the highest point where it passes through a roof of a building and at least two feet higher than any portion of the building with a horizontal dis tance of ten feet 4 The chimney must extend at least 5 ft 1 5 m above the highest equipment draft hood or flue collar FAN ASSISTED COMBUSTION SYSTEM This appliance is equipped with an integral mechanical means to either draw products of combustion through the heat exchanger Ambient Combustion Air Supply This type installation will draw the air required for combustion from within the space surrounding the appliance and from areas or rooms adjacent to the space surrounding the appliance This may be from within the space in a non confined location or it may be brought into the furnace area from outdoors through permanent openings or ducts A single properly sized pipe from the furnace vent connector to the out doors must be provided Combustion air is brought into the furnace through the unit top panel opening Johnson Controls Unitary Products 356485 UIM G 1211 Combustion Air FIGURE 23 Combustion Airflow Path Through The Furnace Casing to the Burner Compartment AWARNING This type of installation requires that the supply air to the appli ance s be of a sufficient amount to support all of the appliance s in the area Operation of a mechanical exhaust such as an
22. ATIONS Bottom return applications normally pull return air through a base plat form or return air plenum Be sure the return platform structure or return air plenum is suitable to support the weight of the furnace The internal bottom panel must be removed for this application Attic installations must meet all minimum clearances to combustibles and have floor support with required service accessibility DOWNFLOW APPLICATION For downflow applications the furnace must be turned upside down so that the circulating air enters at the top and exits the furnace at the bot tom The combustion air inducer must be rotated 90 as shown in Fig ure 22 DO NOT BLOCK COMBUSTION AIR INLET OPENINGS HORIZONTAL APPLICATION This furnace may be installed in a horizontal position on either side as shown above It must not be installed on its back ATTIC INSTALLATION Line contact only permissible between lines formed by the intersection of furnace top and two sides and building joists studs or framing Vent Maintain required clearances to combustibles Filter rack must be a minimum distance of 18 45 7 cm Sheet metal in front of furnace t combustion air Openings is from the furnace Recommended 30 MIN San Work Area x Return Air Sediment Trap FIGURE 10 Typical Attic Installation 356485 UIM G 1211 This appliance is certified for line contact when the furnace is installed in the horiz
23. ETY CONTROLS 26 GAS PIPING 6 A E ay raraq eee ee bin 10 REPLACEMENT PARTS LIST 28 ELECTRICAL POWER ad teeta R awe wes 12 REPLACEMENT PART CONTACT INFORMATION 28 TWINNING AND STAGING 15 WIRING DIAGRAM 29 LIST OF FIGURES Duct Attachment 0s eae ees 5 Electrical WIKIO a 0455 abet sar d oS Sees 12 Vertical Applications 6 Thermostat Chart Single Stage AC with Coil Flange 6 Single Stage PSC Furnaces 2 2222 13 Horizontal Right Application 6 Thermostat Chart Single Stage HP with Horizontal Left Application 6 Single Stage PSC Furnaces L rnnr 14 PC Series Upflow Coil Installation 7 Typical Twinned Furnace Application 15 Horizontal Left or Right application Right Shown 7 Single Wire Twinning Wiring Diagram 16 Combustible Floor Base Accessory 7 Single Wire Staging Wiring Diagram 16 Horizontal Application sa n do s x SoN dese et bs x b 7 Combustion Air Inducer 16 Typical Attic Installation 8 Combustion Airflow Path Through The Furnace Typical Suspended Furnace Crawl
24. Fin m29 Ti26 1107 1094 1076 1047 1010 965 Wena T n E 884 584 en 1324 1426 1zss 485 1 1207 1049 979 330 sosi edim 975 974 oe 960 sas 679 Low ee Modun 1294 1287 1 teri reas 1er teo 10s tos r T si n ms 109s 1046 1027 957 929 840 72 1950 ee 100812 667 427 tow n ms 1406 1049 1027 996 957 929 742 Vedum 2 6 roso Tos 1010 1007 eee f omi z NOTES 1 Airflow expressed in standard cubic feet per minute CFM 2 Return air is through side opposite motor left side 3 Motor voltage at 115 V 4 Airflow through across motor side right side may be slightly less than the data shown above Johnson Controls Unitary Products 25 356485 UIM G 1211 SECTION IX SAFETY CONTROLS CONTROL CIRCUIT FUSE A 3 amp fuse is provided on the control circuit board to protect the 24 volt transformer from overload caused by control circuit wiring errors This is an ATO 3 automotive type fuse and is located on the control board BLOWER DOOR SAFETY SWITCH ACAUTION Main power to the unit must still be interrupted at the main power disconnect switch before any service or repair work is to be done to the unit Do not rely upon the interlock switch as a main power dis connect Blower and burner must never
25. NDUCER 90 Mounting Screw Remove Pressure Switch Tube Routing Flue Transition Do Not Remove Pressure Switch Mounting Screw Remove FIGURE 22 Combustion Air Inducer Johnson Controls Unitary Products CATEGORY 1 450 F MAX VENT TEMP The venting system must be installed in accordance with Section 5 3 Air for Combustion and Ventilation of the National Fuel Gas Code Z223 1 NFPA 54 latest edition or Sections 7 2 7 3 or 7 4 of CSA B149 1 National Gas and Propane Codes latest edition or applicable provisions of the local building code and these instructions The furnace shall be connected to any type of B BW or L vent connec tor and shall be connected to a factory built or masonry chimney The furnace shall not be connected to a chimney flue serving a sepa rate appliance designed to burn solid fuel It is recommended that the appliance is installed in a location where the space temperature is 32 F 0 C or higher If the appliance is installed in a location where the ambient temperature is below 32 F 0 C the combustion byproducts could condense causing damage to the appli ance heat exchanger This appliance may be common vented with another gas appliance for residential installations as allowed by the codes and standards listed in these instructions Non HUD approved Modular Homes must be vented with an approved roof jack and may not be common vented with other appliances VENTING Category
26. Pressure Altitude feet 3 5 3 5 3 5 3 5 1000 3 2 1050 2 9 1100 2 enn s TRR 950 Gas Heating Value BTU cu ft 356485 UIM G 1211 GAS ORIFICE CONVERSION FOR PROPANE LP This furnace is constructed at the factory for natural gas fired operation but may be converted to operate on propane LP gas by using a fac tory supplied LP conversion kit Follow the instructions supplied with the LP kit AWARNING LoNOx furnaces requiring propane LP gas must have the LoNOx screens removed prior to installation and operation See propane instructions HIGH ALTITUDE GAS ORIFICE CONVERSION This furnace is constructed at the factory for natural gas fired operation at 0 5 000 feet 0 m 1 524 m above sea level The manifold pressure must be changed in order to maintain proper and safe operation when the furnace is installed in a location where the altitude is greater than 5 000 feet 1 524 m above sea level Refer to Table 5 for proper manifold pressure settings HIGH ALTITUDE PRESSURE SWITCH CONVERSION For installation where the altitude is less than 5 000 feet 1 524m it is not required that the pressure switch be changed unless you are in an area subject to low pressure inversions Manifold Pressures kpa Altitude m 0 2437 2438 2742 2743 3048 ez Gas Heating Value ADANGER PROPANE AND HIGH ALTITUDE CONVERSION KITS t is very important to choose the correct kit and or gas orifices for the alt
27. Start the system by setting the thermostat above the room temperature Observe the system s response Then use the troubleshooting section in this manual to check the system s operation AWARNING Never bypass any safety control to allow furnace operation To do so will allow furnace to operate under potentially hazardous condi tions Do not try to repair controls Replace defective controls with UPG Source 7 Parts Never adjust pressure switch to allow furnace operation Johnson Controls Unitary Products FURNACE CONTROL DIAGNOSTICS The furnace has built in self diagnostic capability A blinking LED light on the control board can flash red green or amber to indicate various conditions The control continuously monitors its own operation and the operation of the system If a failure occurs the LED light will indicate the failure code The SLOW flash speed is two seconds on and two seconds off The other flash codes listed below have the following timing LED light will turn on for 1 3 second and off for 1 3 second This pattern will be repeated the number of times equal to the code There will be a two second pause between codes For example the six red flash code will flash the LED light on and off six times then will be off for two seconds This pattern will repeat as long as the fault condition remains The con tinuous flash codes listed below will flash the LED light on and off con tinuously with no breaks or long
28. USTMENT OF TEMPERATURE RISE ADANGER The temperature rise or temperature difference between the return air and the supply heated air from the furnace must be within the range shown on the furnace rating plate and within the application limitations shown in SECTION 6 The supply air temperature cannot exceed the Maximum Supply Air Temperature specified in these instructions and on the fur nace rating plate Under NO circumstances can the furnace be allowed to operate above the Maximum Supply Air Temperature Operating the furnace above the Maximum Supply Air Temperature will cause premature heat exchanger failure high levels of Carbon Monoxide a fire hazard personal injury property damage and or death Blower Off Delay Timer In seconds DOQQ OOOC Doo FIGURE 27 Furnace Control Board Johnson Controls Unitary Products ol LJ OCON 356485 UIM G 1211 After about 5 minutes of operation determine the furnace temperature rise Take readings of both the return air and the heated air in the ducts about six feet 1 83 m from the furnace where they will not be affected by radiant heat Increase the blower speed to decrease the temperature rise decrease the blower speed to increase the rise All direct drive blowers have multi speed motors The blower motor speed taps are located on the furnace control board in the blower com partment Refer to Figure 27 and the unit wiring label to change the blower speed
29. air conditioning coil cabinet to the duct connector and then position the furnace on top of the coil cabinet The connection to the fur nace air conditioning coil cabinet duct connector and supply air duct must be sealed to prevent air leakage COIL INSTALLATION IMPORTANT On all installations without a coil a removable access panel is rec ommended in the outlet duct such that smoke or reflected light would be observable inside the casing to indicate the presence of leaks in the heat exchanger This access cover shall be attached in such a manner as to prevent leaks 356485 UIM G 1211 COIL FURNACE ASSEMBLY MC FC PC SERIES COILS DOWNFLOW UPFLOW FIGURE 2 Vertical Applications FURNACE ASSEMBLY MC amp FC SERIES COILS These coils are factory shipped for installation in either upflow or down flow applications with no conversion Position the coil casing over or under the furnace opening as shown in Figure 2 after configuring coil flanges as required see Coil Flange sec tion below COIL FLANGE INSTALLATION The coils include removable flanges to allow proper fit up with furnaces having various inlet and outlet flange configurations The two flanges are attached to the top of the coil in the factory during production For proper configuration of flanges refer to Figure 3 FACTORY 4 FLANGE LOCATION Used for upflow or horizontal right installations ALTERNATE FLANGE LOCATION Used
30. anufacturer s instructions Dampers Louvers and Grilles Canada Only 1 free area of a supply air opening shall be calculated by sub tracting the blockage area of all fixed louvers grilles or screens from the gross area of the opening 2 Apertures in a fixed louver a grille or screen shall have no dimen sion smaller than 0 25 0 64 cm 3 A manually operated damper or manually adjustable louvers are not permitted for use 4 A automatically operated damper or automatically adjustable lou vers shall be interlocked so that the main burner cannot operate unless either the damper or the louver is in the fully open position Wood 20 2596 Metal 60 70 1 4 0 635 cm mesh or larger 100 17 356485 UIM G 1211 AWARNING When a Category 1 furnace is removed or replaced the original venting system may no longer be correctly sized to properly vent the attached appliances An improperly sized vent system can cause CARBON MONOXIDE to spill into the living space causing personal injury and or death Table 8 Unconfined Space Minimum Area 2 130 in 838 cm 130 000 Gable nsulation Vent ent 2 Ventilated Ventilated Attic i Optional 7 Inlet a SS E E ra xl 2 Il Gas Water Heater Ventilated Crawl Space FIGURE 24 Outside and Ambient Combustion Air Air Supply Openings and Ducts 1 An opening may be used in lieu of a duct to provide t
31. are no error codes in memory the LED will flash two green flashes To clear the memory push the LAST ERROR button and hold it for more than five seconds The LED will flash three green flashes when the memory has been cleared then will resume the normal slow green flash after a five second pause GASKET FOAM Door 1 5 ft req d This is a generic parts list To request a complete parts list refer to the contact information below e Visit our website at vvvvvv source 1parts com for the following information 1 Search for a part or browse the catalog 2 Find a dealer or distributor 3 Customer Service contact information a Click on the Brand Links button b Click on the Customer Service button e You can contact us by mail Just send a written request to Johnson Controls Unitary Products Consumer Relations 5005 York Drive Norman OK 73069 28 Johnson Controls Unitary Products 356485 UIM G 1211 WIRING DIAGRAM SECTION XI 0L80 C GQMN ZL88re Uonp lqdde ued ajapow l uoj s S LA 1 An d slew s nbid4 1405 s nbipul in elnu A Np in oul Np assail SUOIXBUUOD Sd Z DSOT 4122 sulow ne p un juede Ili l Jade 29e dWad 317 POP 3173 HOP noy D9Ae JUNO DUIZINO P SI SAP UN IS T pneu 5 ap uous ISH JNaWIOJsUueIL An p lilpiumH WAH 768 ap adednos JWI
32. creens must be given consideration in calculating free area If the free area of a specific louver or grille is not known Refer to Table 7 to estimate free area Ventilated Combustion Air The ventilated attic space or a crawl space from which the combustion air is taken must comply with the requirements specified in AIR SOURCE FROM OUTDOORS in this instruction or in Section 5 3 Air for Combustion and Ventilation of the National Fuel Gas Code ANSI 2223 1 latest edition This type installation requires two properly sized pipes One brings combustion air from a properly ventilated attic space or crawl space and a second pipe that extends from the furnace vent connection top right of unit to the exterior of the building Vent and Supply Outside Air Safety Check Procedure For Category furnaces vent installations shall be in accordance with Parts 7 and 11 of the National Fuel Gas Code ANSI 2223 1 NFPA 54 and or Section 7 and Appendix B of the CSA B149 1 Natural Gas and Propane Installation Codes the local building codes furnace and vent manufacture s instructions Johnson Controls Unitary Products Multi story or common venting systems are permitted and must be installed in accordance with the National Fuel Gas Code ANSI 2223 1 NFPA 54 and or the CSA B149 1 Natural Gas and Propane Installa tion Codes local codes and the manufacture s instructions Vent connectors serving Category furnaces shall not be connected i
33. d Factory installed For duct attachment if needed FIGURE 1 Duct Attachment DUCTWORK INSTALLATION AND SUPPLY PLENUM CONNECTION UPFLOW HORIZONTAL Attach the supply plenum to the furnace outlet The use of an approved flexible duct connector is recommended on all installations This connection should be sealed to prevent air leakage The sheet metal should be crosshatched to eliminate any popping of the sheet metal when the indoor fan is energized FLOOR BASE AND DUCTWORK INSTALLATION DOWNFLOW Installations on combustible material or directly on any floors must use a combustible floor base shown in Figure 8 Follow the instructions supplied with the combustible floor base accessory This combustible floor base can be replaced with a matching cooling coil properly sealed to prevent leaks Follow the instructions supplied with the cooling coil cabinet for installing the cabinet to the duct con nector Plug intake and vent pipe holes in bottom panel and move grommet to desired vent side exit Downflow Air Conditioning Coil Cabinet The furnace should be installed with coil cabinet part number specifi cally intended for downflow application If a matching cooling coil is used it may be placed directly on the furnace outlet and sealed to pre vent leakage For details of the coil cabinet dimensions and installation requirements refer to the installation instructions supplied with the coil cabinet Attach the
34. des NSCNGPIC STEP 2 General Installation e US Current edition of the NFGC and NFPA 90B For copies con tact the National Fire Protection Association Inc Batterymarch Park Quincy MA 02269 or for only the NFGC contact the American Gas Association 400 N Capital N W Washington DC 20001 or www NFPA org e CANADA NSCNGPIC For a copy contact Standard Sales CSA International 178 Rexdale Boulevard Etobicoke Toronto Ontario Canada M9W 1RS STEP 3 Combustion and Ventilation Air e US Section 5 3 of the NFGC air for Combustion and Ventilation e CANADA Part 7 of NSCNGPIC Venting Systems and Air Supply for Appliances STEP 4 Duct Systems e US and CANADA Air Conditioning Contractors Association ACCA Manual D Sheet Metal and Air Conditioning Contractors Association National Association SMACNA or American Soci ety of Heating Refrigeration and Air Conditioning Engineers ASHRAE 1997 Fundamentals Handbook Chapter 32 STEP 5 Acoustical Lining and Fibrous Glass Duct US and CANADA Current edition of SMACNA and NFPA 90B as tested by UL Standard 181 for Class I Rigid Air Ducts STEP 6 Gas Piping and Gas Pipe Pressure Testing e US NFGC chapters 2 3 4 amp 9 and National Plumbing Codes e CANADA NSCNGPIC Part 5 STEP 7 Electrical Connections e US National Electrical Code NEC ANSI NFPA 70 e CANADA Canadian Electrical Code CSA C22 1 These instructions cover minimum requirements and conform to exist ing national standar
35. ds and safety codes In some instances these instructions exceed certain local codes and ordinances especially those who have not kept up with changing residential and non HUD modular home construction practices These instructions are required as a minimum for a safe installation 356485 UIM G 1211 FOR FURNACES INSTALLED IN THE COMMON WEALTH OF MASSACHUSETTS ONLY For all side wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for resi dential purposes including those owned or operated by the Com monwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following require ments shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or structure served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the pro
36. e a normal start cycle If the problem has not been corrected the furnace will again lockout after three retries A momentary loss of gas supply flame blowout or a faulty flame probe circuit will result in a disruption in the flame and be sensed within 1 0 seconds The gas valve will de energize and the control will begin a recycle operation A normal ignition sequence will begin after a 15 sec ond inter purge If during the five recycles the gas supply does not return or the fault condition is not corrected the ignition control will lock out for 60 minutes During burner operation a momentary loss of power for 50 milliseconds or longer will de energize the gas valve When the power is restored the gas valve will remain de energized and the ignition sequence will immediately restart Hot Surface Ignition System AWARNING HOT SURFACE IGNITION SYSTEM Do not attempt to light this furnace by hand with a match or any other means There may be a potential shock hazard from the components of the hot surface ignition system The furnace can only be lit automatically by its hot surface ignition system TROUBLESHOOTING The following visual checks should be made before troubleshooting 1 Check to see that the power to the furnace and the ignition control module is ON 2 manual shut off valves in the gas line to the furnace must be open 3 Make sure all wiring connections are secure 4 Review the sequence of operation
37. e lighting instructions Place the appliance being inspected in operation Adjust thermostat so the appliance shall operate contin uously Test each appliance such as a water heater equipped with a draft hood for spillage down draft or no draft at the draft hood relief opening after 5 minutes of main burner operation Appliances that do not have draft hoods need to be checked at the vent pipe as close to the appliance as possible Use a combustion analyzer to check the CO2 and CO levels of each appliance Use a draft gauge to check for a downdraft or inadequate draft condition After it has been determined that each appliance properly vents when tested as outlined above return doors windows exhaust fans fire place dampers and any other gas burning appliance to their normal condition If improper venting is observed during any of the above tests a problem exists with either the venting system or the appliance does not have enough combustion air Supply Air from outside to complete combustion This condition must be corrected before the appliance can function safely NOTE An unsafe condition exists when the CO reading exceeds 40 ppm and the draft reading is not in excess of 0 1 in W C 25 kPa with all of the appliance s operating at the same time 8 Any corrections to the venting system and or to the supply outside air system must be in accordance with the National Fuel Gas Code 2223 1 or CAN CGA B149 1 Natural Gas and Propane
38. equired as it ensures that the transformers of the two furnaces are isolated thus preventing the possibility of any safety devices being bypassed 4 Connect the common wires of furnace 1 to the common terminal of furnace 2 15 356485 UIM G 1211 Single Wire Twinning Operation Heating On a call for heat W signal from the wall thermostat both furnaces will start the ignition sequence and the burners on both fur naces will light About thirty seconds after the burners light the blowers on both furnaces will come on in heating speed When the thermostat is satisfied the burners will all shut off and after the selected blower off delay time both blowers will shut off at the same time The twinning control ensures that both blowers come on and shut off at the same time Cooling On a call for cooling Y signal from the wall thermostat both furnace blowers will come on at the same time in cooling speed When the thermostat is satisfied both blowers will stay on for 60 seconds then will shut off at the same time Continuous Fan On a thermostat call for continuous fan G signal both furnace blowers will come on at the same time in cooling speed and will stay on until the G signal is removed FURNACE 1 CONTROL BOARD FURNACE 2 CONTROL BOARD Ow Ow OG Osc OR TWIN TOY TWIN ISOLATION OY RELAY
39. er pauses SLOW GREEN FLASH Normal operation no thermostat calls SLOW AMBER FLASH Normal operation with call for heat LED STEADY OFF If the LED light does not flash at all check for power to the board and check for a blown fuse on the board If the board is properly powered and the fuse is not blown the control board may need to be replaced STEADY ON ANY COLOR Control failure Turn power to the furnace off and back on If the fault code returns the control board must be replaced The control board is not field repairable CONTINUOUS GREEN FLASH Twinning error incorrect 24V phasing or no power to twinned unit Check twinning wiring Confirm that both twinned units have power CONTINUOUS AMBER FLASH Flame sense current is below 1 5 microamps Check and clean flame sensor Check for proper gas flow Verify that current is greater than 1 5 microamps at flame current test pad 1 RED FLASH This indicates that flame was sensed when there was not a call for heat The control will turn on both the inducer motor and supply air blower Check for a leaking or slow closing gas valve 2 RED FLASHES This indicates that the pressure switch is closed when it should be open The control confirms that the pressure switch contacts are open at the beginning of each heat cycle and will not let the ignition sequence continue if the pressure switch contacts are closed when they should be open Check for a faulty pressure switch or miswiring 3
40. exhaust fan kitchen ventilation system clothes dryer or fireplace may cre ate conditions requiring special attention to avoid unsatisfactory operation of gas appliances A venting problem or a lack of supply air will result in a hazardous condition which can cause the appli ance to soot and generate dangerous levels of CARBON MONOX IDE which can lead to serious injury property damage and or death An unconfined space is not less than 50 cu ft 1 42 m5 per 1 000 Btu hr 0 2928 kW input rating for all of the appliances installed in that area Rooms communicating directly with the space containing the appli ances are considered part of the unconfined space if doors are fur nished with openings or louvers A confined space is an area with less than 50 cu ft 1 42 m3 per 1 000 Btu hr 0 2928 kVV input rating for all of the appliances installed in that area The following must be considered to obtain proper air for combus tion and ventilation in confined spaces Combustion Air Source From Outdoors The blocking effects of louvers grilles and screens must be given con sideration in calculating free area If the free area of a specific louver or grille is not knovvn refer to Table 7 to estimate free area Table 7 Estimated Free Area VVood or Metal Louvers or Grilles Screens Do not use less than 1 4 0 635 cm mesh Free area of louvers and grille varies widely the installer should follow louver or grille m
41. gular duct under the floor and sealed Refer to the instructions supplied with the duct con nector for proper installation Refer to the separate accessory parts list at the end of these instructions for the approved accessory duct con nectors A FURNACE WARM AIR PLENUM WITH 1 FLANGES FIBERGLASS INSULATION FIBERGLASS TAPE UNDER FLANGE 22 COMBUSTIBLE FLOOR BASE ACCESSORY FIGURE 8 Combustible Floor Base Accessory Johnson Controls Unitary Products 356485 UIM G 1211 RESIDENTIAL AND MODULAR HOME UPFLOW RETURN PLENUM CONNECTION Return air may enter the furnace through the side s or bottom depend ing on the type of application Return air may not be connected into the rear panel of the unit SIDE RETURN APPLICATION Side return applications pull return air through an opening cut in the side of the furnace casing This furnace is supplied with a bottom block off panel that should be left in place if a side return is to be used If the furnace is to be installed on a flat solid surface this bottom panel will provide an adequate seal to prevent air leakage through the unused bottom opening However if the furnace is to be installed on a surface that is uneven or if it is to be installed on blocks or otherwise raised off the floor it will be necessary to seal the edges of the bottom panel to the casing using tape or other appropriate gasket material to prevent air leakage BOTTOM RETURN AND ATTIC INSTALL
42. he furnace to avoid condensa tion in the primary heat exchanger When a parallel flow arrangement is used dampers or other means used to control airflow must be ade quate to prevent chilled air from entering the furnace If manually oper ated the damper must be equipped with means to prevent the furnace or the air conditioner from operating unless the damper is in full heat or cool position When replacing an existing furnace if the existing plenum is not the same size as the new furnace then the existing plenum must be removed and a new plenum installed that is the proper size for the new furnace If the plenum is shorter than 12 30 5 cm the turbulent air flow may cause the limit controls not to operate as designed or the limit con trols may not operate at all The duct system is a very important part of the installation If the duct system is improperly sized the furnace will not operate properly The ducts attached to the furnace plenum should be of sufficient size so that the furnace operates at the specified external static pressure and within the air temperature rise specified on the nameplate IMPORTANT The minimum plenum height is 12 30 5 cm The furnace will not operate properly on a shorter plenum height The minimum recom mended rectangular duct height is 4 inches 10 cm attached to the AWARNING The duct system must be properly sized to obtain the correct airflow for the furnace size that is being installed
43. he outside air supply to an appliance unless otherwise permitted by the authority having jurisdiction The opening shall be located within 12 30 5 cm horizontally from the burner level of the appliance Refer to COMBUSTION AIR SOURCE FROM OUTDOORS and VENT AND SUPPLY AIR SAFETY CHECK in these instructions for additional information and safety check procedure 2 The duct shall be either metal or a material meeting the class 1 requirements of CAN4 S110 Standard for Air Ducts 3 duct shall be least the same cross sectional area as the free area of the air supply inlet opening to which it connects 4 The duct shall terminate within 12 in 30 5 cm above and within 24 in 61 cm horizontally from the burner level of the appliance having the largest input 5 A Square or rectangular shaped duct shall only be used when the required free area of the supply opening is 9 in 58 06 cm or larger VVhen a square or rectangular duct is used its small dimen sion shall not be less than 3 in 7 6 cm 6 An air inlet supply from outdoors shall be equipped with a means to prevent the direct entry of rain and vvind Such means shall not reduce the required free area of the air supply opening 7 An air supply inlet opening from the outdoors shall be located not less than 12 30 5 cm above the outside grade level Combustion Air Source from Outdoors 1 Two permanent openings one within 12 in 30 5 mm of the top and one wi
44. hen working on heating equipment observe precau tions in the manuals and on the labels attached to the unit and other safety precautions that may apply Johnson Controls Unitary Products COMBUSTION AIR QUALITY LIST OF CONTAMINANTS The furnace requires OUTDOOR AIR for combustion when the furnace is located in any of the following environments e Restricted Environments e Commercial buildings e Buildings with indoor pools e Furnaces installed in laundry rooms e Furnaces installed in hobby or craft rooms e Furnaces installed near chemical storage areas e Chemical exposure The furnace requires OUTDOOR AIR for combustion when the furnace is located in an area where the furnace is being exposed to the follow ing substances and or chemicals e Permanent wave solutions e Chlorinated waxes and cleaners e Chlorine based swimming pool chemicals e Water softening chemicals e De icing salts or chemicals e Carbon tetrachloride e Halogen type refrigerants e Cleaning solvents such as perchloroethylene e Printing inks paint removers varnishes etc e Hydrochloric acid e Cements and glues e Antistatic fabric softeners for clothes dryers e Masonry acid washing materials When outdoor air is used for combustion the combustion air intake duct system termination must be located external to the building and in an area where there will be no exposure to the substances listed above The furnace area must not be used as a broom c
45. ill shut off at the same time Continuous Fan On a thermostat call for continuous fan G signal both furnace blowers will come on at the same time in cooling speed and will stay on until the G signal is removed FURNACE 1 CONTROL BOARD FURNACE 2 CONTROL BOARD Ow Ow 09 CYC ee OR TWIN TWIN ISOLATION s RELAY VT G R Y W2 WALL THERMOSTAT FIGURE 21 Single Wire Staging Wiring Diagram SECTION VII VENT SYSTEM VENT CONNECTIONS All models are provided with a flue transition that is sized for 4 diame ter vent connections f a larger size vent connector is required that connection must be installed external to the furnace Figure 22 shows the furnace as it is shipped from the factory To convert to a horizontal or downflow position remove the four screws that secure the inducer assembly and rotate 90 being careful not to damage the gasket Rein stall screws Remove cap from appropriate vent outlet location on the cabinet cut insulation in cabinet to same size as the hole provided and reinstall cap in the hole in the top panel IMPORTANT In dovvnflovv applications do not block the combustion air inlet The furnace must be installed on a coil cabinet or subbase to allow com bustion air to enter the burner compartment COMBUSTION AIR I
46. ion and check for gas leaks Allow five minutes for any gas to dissipate before continuing with the start up procedure Be sure that proper ventilation is available to dilute and carry away any vented gas With furnace in operation check all of the pipe joints gas valve connec tions and manual valve connections for leakage using an approved gas detector a non corrosive leak detection fluid or other leak detection methods Take appropriate action to stop any leak If a leak persists replace the faulty component The furnace and its equipment shut off valve must be disconnected from the gas supply during any pressure testing of that system at test pressures in excess of 1 2 PSI 3 45 kPa The furnace must be isolated from the gas supply piping system by closing the equipment shut off valve during any pressure testing of the gas supply system IGNITION SYSTEM SEQUENCE 1 Turn the gas supply ON at external valve and main gas valve 2 Set the thermostat above room temperature to call for heat 3 System start up will occur as follows a The induced draft blower motor will start and come up to speed Shortly after inducer start up the hot surface igniter will glow for about 17 seconds b After this warm up the ignition module will energize open the main gas valve c After flame is established the supply air blower will start in about 30 seconds IMPORTANT Burner ignition may not be satisfactory on first startup due to resi
47. isters closed or blocked off The control module will lockout if the limit trips 5 consecutive times If this occurs control will reset amp try ignition again after 1 hour SEQUENCE OF OPERATION The following describes the sequence of operation of the furnace Refer to Owners Manual for component location Continuous Blower Cooling heating thermostats have a fan switch that has an ON and AUTO position In the ON position the thermostat circuit is completed between terminals R and G The motor will operate continuously on the speed tap wire that is connected to the HI COOL cooling terminal on the control board To obtain a constant air circulation at lower flow rate change the high speed wire to either the medium speed wire or the low speed wire Intermittent Blower Cooling Cooling heating thermostats have a fan switch that has an ON and AUTO position In the AUTO position the thermostat circuit is completed between terminals R and G when there is a call for cooling The motor will operate on the speed tap wire that is connected to the HI COOL cooling terminal on the control board The fan off setting is fixed at 60 seconds to improve cooling efficiency 26 Heating Cycle When the thermostat switch is set on HEAT and the fan is set on AUTO and there is a call for heat a circuit is completed between terminals R and W of the thermostat When the proper amount of combustion air is being provided the pressure swi
48. itude and the type of gas for which the furnace is being installed Only use natural gas in furnaces designed for natural gas Only use propane LP gas for furnaces that have been properly converted to use pro pane LP gas Do not use this furnace with butane gas Incorrect gas orifices or a furnace that has been improperly converted will create an extremely dangerous condition resulting in premature heat exchanger failure excessive sooting high levels of carbon monoxide personal injury property damage a fire hazard and or death High altitude and propane LP conversions are required in order for the appliance to satisfactory meet the application An authorized distributor or dealer must make all gas conversions In Canada a certified conversion station or other qualified agency using factory specified and or approved parts must perform the conversion The installer must take every precaution to insure that the furnace has been converted to the proper gas orifice size when the furnace is installed Do not attempt to drill out any orifices to obtain the proper orifice size Drilling out a gas orifice will cause misalignment of the burner flames causing premature heat exchanger burnout high levels of carbon monoxide excessive sooting a fire hazard personal injury property damage and or death Johnson Controls Unitary Products 11 356485 UIM G 1211 SECTION V ELECTRICAL POWER ELECTRICAL POWER CONNECTIONS Field wiring
49. ix cycles per hour Follow the thermo stat manufacturer s instructions The 24 volt 40 VA transformer is sized for the furnace components only and should not be connected to power auxiliary devices such as humidifiers air cleaners etc The transformer may provide power for an air conditioning unit contactor Johnson Controls Unitary Products 356485 UIM G 1211 For additional connection diagrams for all UPG equipment refer to Low Voltage System Wiring document available online at www upgnet com in the Product Catalog Section AC 5D Single Stage Air Conditioner Single Stage PSC Furnace ID MODELS G 8 9 S GF 8 9 G 9F LF8 L Y M 8S G T G 8 9 S THERMOSTAT G8C G T GLS SINGLE STAGE SINGLE STAGE PP11C70224 PSC AIR FURNACE CONDITIONER SINGLE STAGE PSC 1 SINGLE STAGE FURNACE AIR CONDITIONER C C 24 Volt Common 24 Volt Common Y Y Y2 Y Full Stage Compressor Full Stage Compressor Compressor Contactor RH R 24 Volt Hot Heat XFMR 24 Volt Hot G G Fan Fan W Full Stage Heat RC 24 Volt Hot Cool XFMR W Full Stage Heat HM1 24VAC Humidifier Humidistat Optional Clipping Jumper W914 for electric heat on thermostat is not necessary Other Part Numbers SAP Legacy 265901 031 09166 FIGURE 17 Thermostat Chart Si
50. kings l 4 Furnace Side of Furnace Markings Install the side filter rack following the instructions provided with that accessory If a filter s is provided at another location in the return air system the ductwork may be directly attached to the furnace side panel IMPORTANT Some accessories such as electronic air cleaners and pleated media may require a larger side opening Follow the instructions supplied with that accessory for side opening requirements Do not cut the opening larger than the dimensions shown in Figure 12 HORIZONTAL APPLICATION Horizontal Filters All filters and mounting provision must be field supplied All installa tions must have a filter installed Any branch duct rectangular or round duct attached to the plenum must attach to the vertical plenum before the filter The use of straps and or supports is required to support the weight of the external filter box Downflow Filters Downflow furnaces typically are installed with the filters located above the furnace extending into the return air plenum or duct Any branch duct rectangular or round duct attached to the plenum must attach to the vertical plenum above the filter height Filter s may be located in the duct system external to the furnace using an external duct filter box attached to the furnace plenum or at the end of the duct in a return filter grille s The use of straps and or supports is required to support the weigh
51. led so that the electrical components are protected from water SUPPLY VOLTAGE CONNECTIONS Junction Box Connect ground lead to screw Electrical Entry L1 Hot BLK Neutral WHT FIGURE 16 Electrical Wiring 1 Provide a power supply separate from all other circuits Install overcurrent protection and disconnect switch per local national electrical codes The switch should be close to the unit for conve nience in servicing With the disconnect or fused switch in the OFF position check all wiring against the unit wiring label Refer to the wiring diagram in this instruction 2 Remove the screws retaining the wiring box cover Route the power wiring through the opening in the unit into the junction box with a conduit connector or other proper connection In the junc tion box there will be 3 wires a Black Wire a White Wire Connect the power supply as shown on the unit wiring label on the inside of the blower compartment door or the wiring schematic in this sec tion The black furnace lead must be connected to the L1 hot wire from the power supply The white furnace screw must be con nected to neutral Connect the power supply ground to the green screw equipment ground An alternate wiring method is to use a field provided 2 5 1 cm x 4 10 2 cm box and cover on the out side of the furnace Route the furnace leads into the box using a protective bushing where the wires pass through the furnace panel After making the wiri
52. ll or Screvv Upflovv this flange Coil 5T s Upflov YT T Alternate Secondary Drain Location Drain FIGURE 6 PC Series Upflow Coil Installation Table 2 Coil Projection Dimensions PC Series Coils COIL SIZE DIMENSION C INCH Tf Dimension C should be at least 2 3 of dimension D See Figure 6 dohnson Controls Unitary Products CRITICAL COIL PROJECTION The coil assembly must be located in the duct such that a minimum dis tance is maintained between the top of the coil and the top of the duct Refer to Table 2 COIL FURNACE ASSEMBLY HC SERIES COILS These coils are supplied ready to be installed in a right hand position or a left hand position When used in conjunction with a horizontal furnace blow through application the coil should be oriented with the opening of the A coil closest to the furnace See Figure 7 NOTICE Each coil is shipped with an external tie plate that should be used to secure the coil to the furnace It should be installed on the back side of the coil using the dimpled pilot holes See Figure 7 Use tie plate supplied with coil Gas Furnace FIGURE 7 Horizontal Left or Right application Right Shown DOWNFLOW DUCT CONNECTORS All downflow installations must use a suitable duct connector approved by the furnace manufacturer for use with this furnace The duct connec tors are designed to be connected to the rectan
53. ll connections A fire or explosion may result causing prop erty damage personal injury or loss of life Always install the furnace to operate within the furnace s intended temperature rise range Only connect the furnace to a duct system which has an external static pressure within the allowable range as specified on the furnace rating plate When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace the return air shall also be handled by duct s sealed to the fur nace casing and terminating outside the space containing the fur nace It is permitted to use the furnace for heating of buildings or struc tures under construction where the application and use must com ply with all manufacturer s installation instructions including e Proper vent installation e Furnace operating under thermostatic control e Return air duct sealed to the furnace e Air filters in place e Set furnace input rate and temperature rise per rating plate marking e Means for providing outdoor air required for combustion e Return air temperature maintained between 55 F 13 C and 80 F 27 C e The air filter must be replaced upon substantial completion of the construction process e Clean furnace duct work and components upon substantial completion of the construction process and verify furnace operating conditions including ignition input rate temperature
54. loset or for any other storage purposes as a fire hazard may be created Never store items such as the following on near or in contact with the fur nace 1 Spray or aerosol cans rags brooms dust mops vacuum cleaners or other cleaning tools Soap powders bleaches waxes or other cleaning com pounds plastic items or containers gasoline kerosene ciga rette lighter fluid dry cleaning fluids or other volatile fluid Paint thinners and other painting compounds Paper bags boxes or other paper products Never operate the furnace with the blower door removed To do so could result in serious personal injury and or equipment damage Johnson Controls Unitary Products 356485 UIM G 1211 CODES AND STANDARDS Follow all national local codes and standards in addition to this installa tion manual The installation must comply with regulations of the serv ing gas supplier local building heating plumbing and other codes In absence of local codes the installation must comply with the national codes listed below and all authorities having jurisdiction In the United States and Canada follow all codes and standards for the following using the latest edition available STEP 1 Safety e US National Fuel Gas Code NFGC NFPA 54 ANSI 2223 1 and the Installation Standards Warm Air Heating and Air Conditioning Systems ANSI NFPA 90B e CANADA CAN CGA B149 1 National Standard of Canada Natu ral Gas and Propane Installation Co
55. nces and pilots 2 Run furnace for a minimum of 3 minutes in heating operation 3 Measure time in sec for gas meter to complete 1 revolution and note reading The 2 cubic feet dial provides a more accurate mea surement of gas flow 4 Refer to Table 10 for cubic feet of gas per hour 5 Multiply cubic feet per hour by heating valve BTU cu ft to obtain input If clocked rate does not match the input rate from the unit nameplate follow steps in next section to adjust the manifold pressure Repeat steps 2 5 until correct input is achieved ACAUTION Be sure to relight any gas appliances that were turned off at the start of this input check dohnson Controls Unitary Products 356485 UIM G 1211 Table 10 Gas Rate CU FT HR Seconds For Size of Test Dial Seconds For Size of Test Dial 1 Revolution 1 Revolution i o m w T T S r T sss 1 ms 257 a 120 300 109 273 Johnson Controls Unitary Products 21 356485 UIM G 1211 ADJUSTMENT OF MANIFOLD GAS PRESSURE amp INPUT RATE Inlet and manifold gas pressure may be measured by connecting the U tube manometer to the gas valve with a piece of tubing Follow the appropriate section in the instructions below Refer to Figure 25 for a drawing of the locations 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 Ou
56. ndition exists Check gas valve and gas valve wiring 11 RED FLASHES This indicates that the main limit switch has opened its normally closed contacts and has remained open for more than five minutes This condition is usually caused by a failed blower motor or blower wheel The control will enter a hard lockout and power will have to be cycled off and on to reset the control after the problem has been corrected 4 AMBER FLASHES The control is receiving a Y signal from the thermostat without a G signal The furnace will operate normally in both heating and cooling but this fault code will be displayed in order to alert the user that there is a wiring problem Verify that the G wire from the thermostat is connected properly SOFT LOCKOUT This control includes a soft lockout that will reset automatically after one hour This provides protection to an unoccupied structure if a temporary condition exists causing a furnace malfunction An example of this is a temporary interruption in gas supply that would prevent the furnace from lighting The control will keep trying to light each hour and will resume normal operation if the gas supply is restored HARD LOCKOUT Some fault conditions result in a hard lockout which requires power to the control to be turned off and then back on to reset the control The control will not automatically restart IGNITION CONTROL FLAME SENSE LEVELS Normal flame sense current is approximately 3 7
57. ng connections replace the wiring box cover and screws Refer to Figure 16 12 3 furnace s control system requires correct polarity of the power supply and a proper ground connection Refer to Figure 16 IMPORTANT The power connection leads and wiring box may be relocated to the left side of the furnace Remove the screws and cut wire tie holding excess wiring Reposition on the left side of the furnace and fasten using holes provided LOW VOLTAGE CONTROL WIRING CONNECTIONS Install the field supplied thermostat by following the instructions that come with the thermostat With the thermostat set in the OFF position and the main electrical source disconnected connect the thermostat wiring from the wiring connections on the thermostat to the terminal board on the ignition module as shown in Figures 17 or 18 Electronic thermostats may require the common wire to be connected Apply strain relief to thermostat wires passing through cabinet If air condition ing equipment is installed use thermostat wiring to connect the Y and C terminals on the furnace control board to the proper wires on the con densing unit unit outside IMPORTANT Set the heat anticipator in the room thermostat to 0 4 amps Setting it lower will cause short cycles Setting it higher will cause the room temperature to exceed the set points IMPORTANT Some electronic thermostats do not have adjustable heat anticipa tors They should be set to s
58. ngle Stage AC with Single Stage PSC Furnaces Johnson Controls Unitary Products 13 356485 UIM G 1211 HP 2C Single Stage Heat Pump Single Stage PSC Furnace ID MODELS OD MODELS G 8 9 S GF 8 9 E R RHS G 9F LF8 E ZD HP L Y M 8S G T G 8 9 S E B HGD G8C G T GLS THERMOSTAT THERMOSTAT THERMOSTAT BP21H50124 DN22U00124 BN21H00124 DP32H70124 DP21H40124 DN21H00124 Cc 24 Volt Common Y1 First Stage Compressor R 24 Volt Hot G Fan E Emergency Heat N A N A Third Stage Heat O Reversing Valve Energized in Cool L Malfunction Light Y2 Second Stage Compressor VV1 Second Stage Aux Heat 3 External Humidistat Optional Open on Humidity Rise 24VAC Humidifier Optional Step 1 of Thermostat nstaller Configuration Menu must be set to Heat Pump 1 Step 9 of Thermostat Installer Configuration Menu must be set to Pump OFF Q Part Number 1 2HU16700124 SINGLE STAGE PSC FURNACE SINGLE STAGE PSC FURNACE 24 Volt Common Y NY2 Full Stage Compressor R 24 Volt Hot G Fan W Full Stage Heat Other Part Numbers SAP Legacy 265901 031 09166 FIGURE 18 Thermostat Chart Single Stage HP with Single Stage PSC Furnaces 14 SINGLE STAGE HEAT
59. nto any portion of mechanical draft systems operating under positive pressure 356485 UIM G 1211 Horizontal portions of the venting system shall be supported to prevent sagging using hangers or perforated straps and must slope upwards not less than 1 4 per foot 0 635 cm m from the furnace to the vent ter minal It is recommended that you follow the venting safety procedure below This procedure is designed to detect an inadequate ventilation system that can cause the appliances in the area to operate improperly causing unsafe levels of Carbon Monoxide or an unsafe condition to occur AWARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monxide poisoning or death The following steps shall be followed for each appliance connected to the venting system being placed into operation while all other appliances connected to the venting system are not in operation Inspect the venting system for proper size and horizontal pitch Determine that there is no blockage restriction leakage corrosion or other deficiencies which could cause an unsafe condition Close all building doors and windows Turn on clothes dryers and TURN ON any exhaust fans such as range hoods and bathroom exhausts so they shall operate at maximum speed Open the fireplace dampers Do not operate a summer exhaust fan Follow th
60. ollowing Table 12 Nominal Manifold Pressure NOMINAL MANIFOLD PRESSURE Natural Gas 3 5 w c 0 87 kPa Propane LP Gas 10 0 w c 2 488 kPa OUTLET PRESSURE PORT MAIN REGULATOF PRESSURE ADJUSTMENT PORT ON OFF SWITCH Shown in ON position FIGURE 25 Gas Valve IMPORTANT If gas valve regulator is turned in clockwise manifold pressure is increased If screw is turned out counter clockwise manifold pres sure will decrease 4 After the manifold pressure has been adjusted re calculate the furnace input to make sure you have not exceeded the specified input on the rating plate Refer to CALCULATING THE FURNACE INPUT NATURAL GAS 5 Once the correct BTU kW input has been established turn the gas valve to OFF and turn the electrical supply switch to OFF then remove the flexible tubing from the gas valve pressure tap and tighten the pressure tap plug using the 3 32 2 4 mm Allen wrench 6 Turn the electrical and gas supplies back on and with the burners in operation check for gas leakage around the gas valve pressure port for leakage using an approved non corrosive gas leak detec tion fluid or other non flammable leak detection methods Johnson Controls Unitary Products MANIFOLD PRESSURE U TUBE CONNECTION OUTLET PRESSURE TAP GAS VALVE 1 4 TUBING MAINIFOLD FLAME Gq PIPE SENSOR 3 5 IN WATER COLUMN GAS PRESSURE SHOWN FIGURE 26 Reading Gas Pressure ADJ
61. on combustible floor 2 Line contact only permitted between lines formed by the intersection of the rear panel and side panel top in horizontal position of the furnace jacket and building joists studs or framing Johnson Controls Unitary Products SECTION II DUCTWORK DUCTWORK GENERAL INFORMATION The duct system s design and installation must 1 Handle an air volume appropriate for the served space and within the operating parameters of the furnace specifications 2 Be installed in accordance of National Fire Protection Association as outlined in NFPA standard 90B latest editions or applicable national provincial state and local fire and safety codes 3 Create a closed duct system For residential and Non HUD Modu lar Home installations when a furnace is installed so that the sup ply ducts carry air circulated by the furnace to areas outside the space containing the furnace the return air shall also be handled by a duct s sealed to the furnace casing and terminating outside the space containing the furnace 4 Complete a path for heated or cooled air to circulate through the air conditioning and heating equipment and to and from the condi tioned space ACAUTION The cooling coil must be installed in the supply air duct down stream of the furnace Cooled air may not be passed over the heat exchanger When the furnace is used with a cooling coil the coil must be installed parallel with or in the supply air side of t
62. on to reset the control after the problem has been corrected 6 RED FLASHES This indicates that while the unit was operating the pressure switch opened four times during the call for heat Check for faulty inducer blocked vent pipe or faulty pressure switch The furnace will lock out for one hour and then restart 7 RED FLASHES This fault code indicates that the flame could not be established during three trials for ignition Check that the gas valve switch is in the ON position Check for low or no gas pressure faulty gas valve dirty or faulty flame sensor faulty hot surface ignitor loose wires or a burner problem The furnace will lock out for one hour and then restart 8 RED FLASHES This fault is indicated if the flame is lost five times four recycles during the heating cycle Check for low gas pressure dirty or faulty flame sensor or faulty gas valve The furnace will lock out for one hour and then restart 9 RED FLASHES Indicates reversed line voltage polarity grounding problem or reversed low voltage transformer wires Both heating and cooling operations will be affected Check polarity at furnace and branch Check furnace grounding Check that flame probe is not shorted to chassis The furnace will not start the ignition sequence until this problem is corrected 10 RED FLASHES Gas valve energized with no call for heat The main blower and inducer blower will run and no ignition sequence will be started as long as this co
63. ontal left or right position The line contact is only permissible between lines that are formed by the intersection of the top and two sides of the furnace and the building joists studs or framing This line may be in contact with combustible material Refer to Figure 10 AWARNING When a furnace is installed in an attic or other insulated space keep all insulating materials at least 12 inches 30 5 cm away from furnace and burner combustion air openings IMPORTANT During installation doors should remain on the furnace when moving or lifting When moving or handling this furnace prior to installation always leave the doors on the furnace to provide support and to prevent damage or warping of the cabinet When lifting the furnace support the ends of the furnace rather than lifting by the cabinet flanges at the return air open ings bottom or sides or supply air opening It is acceptable to use the primary heat exchanger tubes as a lifting point provided that the tubes are lifted at the front of the heat exchang ers where attached to the vestibule panel Do not use the top return bend of the heat exchangers as lifting points as the tubes may shift out of position or their location brackets baffles SUSPENDED FURNACE CRAWL SPACE INSTALLATION The furnace can be hung from floor joists or installed on suitable blocks or pads Blocks or pad installations shall provide adequate height to ensure that the unit will not be subject to wa
64. ove the flexible tubing from the gas valve pressure tap and tighten the pressure tap plug using the 3 32 2 4 mm allen wrench 3 Tur the electrical and gas supplies back on and with the burners in operation check for gas leakage around the gas valve pressure port for leakage using an approved non corrosive gas leak detec tion fluid or other non flammable leak detection methods Read the manifold gas pressure Connect the positive side of the manometer to the adapter previously installed in the OUT P Tap on the gas valve Do not connect any tubing to the negative side of the manometer as it will reference atmospheric pressure Refer to Figure 26 for connection details 22 IMPORTANT The cap for the pressure regulator must be removed to gain access to the adjustment screw Loosening or tightening the cap does not adjust the flow of gas NOTICE The regulated outlet pressures both low and high have been cali brated at the factory Additional pressure adjustment should not be necessary If adjustment is necessary set to the following specifica tions After adjustment check for gas leakage 1 Refer to Figure 25 for location of pressure regulator adjustment cap and adjustment screws on main gas valve 2 Turn gas and electrical supplies on and follow the operating instructions to place the unit back in operation 3 Adjust manifold pressure by adjusting gas valve regulator screw for the appropriate gas per the f
65. perty owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level In the event that the requirements of this subdivision can not be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided however that during said thirty 80 day period a battery operated carbon mon oxide detector with an alarm shall be installed APPROVED CARBON MONOXIDE DETECTORS Each car bon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and IAS certified SIGNAGE A metal or plastic identification plate shall be perma nently mounted to the exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUC TIONS INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installa
66. r installing the piping 4 Unplug the igniter from the wire harness Disconnect the flame sensor wires located on top of the air shield Unplug the gas valve from the wiring harness 5 Remove the screws holding the burner assembly to the vestibule panel 6 Remove the burner assembly It should be possible to swing the burner assembly out of the way without disconnecting the remain ing wires 7 With the burner assembly out of the way simply slide the NOx screens out of the heat exchanger tubes and discard the screens 8 Replace all components in reverse order Reconnect all wiring 19 356485 UIM G 1211 GAS PIPING LEAK CHECK AWARNING FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in serious injury death or property damage Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections A fire or explosion may result causing property damage personal injury or loss of life IMPORTANT Burner ignition may not be satisfactory on first startup due to resid ual air in the gas line or until gas manifold pressure is adjusted The ignition control will make three attempts to light before locking out It is recommended that when the gas supply is first connected to the furnace the ground union be loosened until the odor of gas is detected When gas is detected immediately tighten the un
67. r the duct system will become pressurized and the blower on the second furnace will turn backwards causing the second furnace to overheat resulting in damage to the furnace Twinning is used to make two furnaces operate in tandem using one duct system one room thermostat and causing both furnaces to turn on and off simulta AWARNING Before installing the relay and wiring disconnect electrical power to both furnaces Failure to cut power could result in electrical shock or equipment damage ACAUTION The relay must not be installed in any location where it could be exposed to water If the relay has been exposed to water in any way it must not be used TWINNING DUCT SYSTEM Twinned furnaces must only be applied on a common duct system A single air supply plenum must be used for both furnaces and coil s Separate plenums and supply ducts systems cannot be utilized A sin gle return air plenum common to both furnaces must be used It is sug gested that a return platform be utilized with bottom air entrance into each furnace If a side entrance returns system is used the common return duct must be divided equally so as to supply each furnace with an equal amount of return air Both furnaces must be identical models in both heating capacity and CFM capacity Both furnaces must be operated on the same motor speed tap See typical application Figure 19 If furnace staging is desired with two single stage furnaces on a com mon duc
68. rd of Furnace 1 For staging applica tions the wire from thermostat W1 is connected to the W connection on the board on Furnace 1 The wire from thermostat W2 is connected to Furnace 2 through a separate relay as described below 2 Connect a wire from the TWIN terminal of Furnace 1 to the TWIN terminal of Furnace 2 3 Install a separate 24V relay as shown in the diagram below Use of this relay is required as it ensures that the transformers of the two furnaces are isolated thus preventing the possibility of any safety devices being bypassed 4 Connect the common between furnace 1 and furnace 2 16 Single Wire Staging Operation Heating On a call for first stage heat W1 signal from the wall thermo stat Furnace 1 will start the ignition sequence and the burners will light About thirty seconds after the burners light the blowers on both furnaces will come on in heating speed When the thermostat is satis fied the burners will shut off and after the selected blower off delay time both blowers will shut off at the same time On a call for second stage of heat the burners of Furnace 2 will also light and both blowers will run The twinning control ensures that both blowers come on and shut off at the same time Cooling On a call for cooling Y signal from the wall thermostat both furnace blowers will come on at the same time When the thermostat is satisfied both blowers will stay on for 60 seconds then w
69. rn air temperature to be below 55 F 13 C for extended periods To do so may cause condensation to occur in the main heat exchanger leading to premature heat exchanger failure Clearances for access service Ample clearances should be provided to permit easy access to the unit The following minimum clearances are recommended 1 Twenty four 24 inches 61 cm between the front of the furnace and an adjacent wall or another appliance when access is required for servicing and cleaning 2 Eighteen 18 inches 46 cm at the side where access is required for passage to the front when servicing or for inspection or replacement of flue vent connections In all cases accessibility clearances shall take precedence over clear ances for combustible materials where accessibility clearances are greater Installation in a residential garage A gas fired furnace for installation in a residential garage must be installed so the burner s and the ignition source are located not less than 18 inches 46 cm above the floor and the furnace must be located or protected to avoid physical damage by vehicles Table 1 Unit Clearances to Combustibles All Dimensions in Inches and All Surfaces Identified with the Unit in an Upflow Configuration Are E em l n un alcove Combustible No 0 Pomin res 1125 1010 oD RR 0 U 0 0 0 0 0 0 1 Special floor base or air conditioning coil required for use
70. s section specify the type of gas approved for this furnace only use those approved gases The instal lation of a drip leg and ground union is required Refer to Figure 15 NOTE Ground Union maybe installed inside or outside unit To Gas To Gas External Ground Manual Shut off Valve To Gas Supply External Supply Manual External Manual Shut off Valve eni Union Dovvnflovv Configuration Configuration Configuration Drip Leg FIGURE 15 Gas Piping 10 dohnson Controls Unitary Products IMPORTANT An accessible manual shutoff valve must be installed upstream of the furnace gas controls and within 6 feet 1 8 m of the furnace The furnace must be isolated from the gas supply piping system by closing its individual external manual shutoff valve during any pressure testing of the gas supply piping system at pressures equal to or less than 1 2 psig 3 5 kPa ACAUTION The gas valve body is a very thin casting that cannot take any external pressure Never apply a pipe wrench to the body of the gas valve when installing piping A wrench must be placed on the octa gon hub located on the gas inlet side of the valve Placing a wrench to the body of the gas valve will damage the valve causing improper operation and or the valve to leak Gas piping may be connected from either side of the furnace using any of the gas pipe entry on both sides of the furnace Refer to Figure 12 Table 5 Nominal Manifold
71. t where the gas burner on the first furnace operates on W1 and the gas burner on the second furnace operates on W2 then the use of an air mixing device in the plenum to mix the air from both fur naces is strongly recommended The mixing device must be installed before any ducts that supply air to occupied spaces Twinning causes both indoor fans to operate simultaneously If a mixing device is not used any ducts that are connected down stream from the furnace that operates on W2 will be supplying cold air in the Heating mode to the occupied spaces unless W2 is energized Johnson Controls Unitary Products 356485 UIM G 1211 Vent Pipe Gas Supply Both sides Electrical 1 Coil for Each Furnace FIGURE 19 Typical Twinned Furnace Application IMPORTANT When two furnaces are twinned typical system total airflow will be approximately 85 of additive individual furnaces i e two 2000 CFM units will yield a total 3400 CFM ACAUTION If a return duct is connected to only one furnace with a connection between the two furnaces an imbalance in the airflow will occur and the furnace furthest from the return plenum will overheat GAS PIPING Furnace gas supplies must be provided as specified with these instruc tions Since the furnaces are side by side with no space between gas supplies must enter on the right and left respectively All gas piping must be in accordance with the national fuel gas code ANSI 2223 1
72. t 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 Allen wrench loosen the set screw by turn ing it 1 turn counter clockwise DO NOT REMOVE THE SET SCREW FROM THE PRESSURE PORT Read the inlet gas pressure Connect the positive side of the manometer to the IN P Tap on the gas valve Do not connect any tubing to the negative side of the manometer as it will reference atmospheric pressure Refer to Figure 26 for connec tion details 1 Turn gas and electrical supplies on and follow the operating instructions to place the unit back in operation Table 11 Inlet Gas Pressure Range INLET GAS PRESSURE RANGE Natural Gas Propane LP 4 5 W C 1 12 kPa 8 0 W C 1 99 kPa 10 5 W C 2 61 kPa 13 0 3 24 kPa W C IMPORTANT The inlet gas pressure operating range table specifies what the minimum and maximum gas line pressures must be for the furnace to operate safely The gas line pressure MUST BE a minimum of e 7 w c 1 74 KPA for Natural Gas e 11 w c 2 74 KPA for Propane LP Gas in order to obtain the BTU input specified on the rating plate and or the nominal manifold pressure specified in these instructions and on the rating plate 2 Once the correct gas inlet pressure has been established see Table 11 turn the gas valve to OFF and turn the electrical supply switch to OFF then rem
73. t of the external filter box SECTION IV GAS PIPING GAS SAFETY ADANGER An overpressure protection device such as a pressure regulator must be installed in the gas piping system upstream of the furnace and must act to limit the downstream pressure to the gas valve so it does not exceed 0 5 PSI 14 w c 3 48 kPa Pressures exceeding 0 5 PSI 14 w c 3 48 kPa at the gas valve will cause damage to the gas valve resulting in a fire or explosion or cause damage to the furnace or some of its components that will result in property damage and loss of life Outlet Pressure Port Inlet gt Wrench Boss Inlet 2 Fressure On Off Switch Adjustment Port a Shown in ON position FIGURE 14 Gas Valve IMPORTANT Plan your gas supply before determining the correct gas pipe entry Use 90 degree service elbow s or short nipples and conventional 90 degree elbow s to enter through the cabinet access holes GAS PIPING INSTALLATION Properly sized wrought iron approved flexible or steel pipe must be used when making gas connections to the unit If local codes allow the use of a flexible gas appliance connection always use a new listed con nector Do not use a connector that has previously serviced another gas appliance Some utility companies or local codes require pipe sizes larger than the minimum sizes listed in these instructions and in the codes The furnace rating plate and the instructions in thi
74. tch will close the ignition control pro vides a 17 second ignitor warm up period the gas valve then opens the gas starts to flow ignition occurs and the flame sensor begins its sensing function The blower motor will energize 30 seconds after the gas valve opens if a flame is detected Normal furnace operation will continue until the thermostat circuit between R and W is opened which causes the ignition system and gas valve to de energize and the burner flames to be extinguished The vent motor will operate for 15 seconds and the blower motor will operate for the amount of time set by the fan off delay jumper located on the control board See Figure 27 The heat ing cycle is now complete and ready for the start of the next heating cycle If the flame is not detected within 7 seconds of the gas valve opening the gas valve is shut off and a retry operation begins Also if the flame is lost for 2 seconds during the 10 second stabilization period the gas valve is shut off and a retry operation begins During a retry operation the vent motor starts a 15 second inter purge and the ignitor warm up time is extended to 27 seconds If the flame is established for more than 10 seconds after ignition during a retry the control will clear the ignition attempt retry counter If three retries occur during a call for heat the furnace will shut down for one hour If at the end of the one hour shut down there is a call for heat the furnace will initiat
75. ter damage Units may also be suspended from rafters or floor joists using rods pipe angle supports or straps In all cases the furnace should be supported with rods straps or angle supports at three locations to properly sup port the furnace Place one support at the supply end of the furnace one support located approximately in the center of the furnace near the blower shelf and the third support should be at the return end of the fur nace Maintain a 6 15 2 cm minimum clearance between the front of the furnace and the support rods or straps All six suspension points must be level to ensure proper and quiet fur nace operation When suspending the furnace use a secure platform constructed of plywood or other building materials secured to the floor or ceiling joists Refer to Figure 11 for details and additional information Support Angle x3 guli Maintain 6 minimum clearance between support rods and front of furnace FIGURE 11 Typical Suspended Furnace Crawl Space Installation IMPORTANT During installation doors should remain on the furnace when moving or lifting When moving or handling this furnace prior to installation it is recom mended to leave the doors on the furnace to provide support and to prevent damage or warping of the cabinet When lifting the furnace support the ends of the furnace rather than lifting by the cabinet flanges at the return air openings bottom or sides or supply air opening
76. thin 12 in 30 5 mm of bottom of the confined space Two permanent openings shall communicate directly or by means of ducts with the outdoors crawl spaces or attic spaces 18 Table 9 Free Area Minimum Free Area Required for Each Opening Horizontal Duct Round Duct 2 000 BTUH 4 000 BTUH 4 000 BTUH TR 77 40 in 258 cm 20 in 129 cm 5 13 cm 50 in 322 cm2 25 in 161 cm 6 15 cm EXAMPLE Determining Free Area Appliance 1 Appliance 2 Total nput 100 000 30 000 130 000 4 000 32 5 Sq In Vertical Appliance 1 Appliance 2 Total Input 100 000 30 000 130 000 2 000 65 Sq In Horizontal BTUH Input Rating Outlet 1 Outlet Air b i Gas Water Heater 2 One permanent openings commencing within 12 in 30 5 mm of the top of the enclosure shall be permitted where the equipment has clearances of at least 1 in 2 54 cm from the sides and back and 6 in 15 24 cm from the front of the appliance The opening shall communicate directly with the outdoors and shall have a min imum free area of a 1 square in per 3000 Btu per hour 6 45 cm3 per 0 879 kW of the total input rating of all equipment located in the enclosure b Not less than the sum of all vent connectors in the confined space 3 The duct shall be least the same cross sectional area as the free area of the air supply inlet opening to which it connects 4 blocking effects of louvers grilles and s
77. thout filter Left Side Return 25 These high efficiency compact units employ induced combustion reli able hot surface ignition and high heat transfer aluminized tubular heat exchangers The units are factory shipped for installation in upflow or horizontal applications and may be converted for downflow applica tions These furnaces are designed for residential installation in a basement closet alcove attic recreation room or garage and are also ideal for commercial applications All units are factory assembled wired and tested to assure safe dependable and economical installation and oper ation These units are Category listed and may be common vented with another gas appliance as allowed by the National Fuel Gas Code SECTION 1 SAFETY This is a safety alert symbol When you see this symbol on labels or in manuals be alert to the potential for personal injury Understand and pay particular attention to the signal words DANGER WARNING or CAUTION DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury 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 AWARNING
78. tion unless upon inspection the inspector observes car bon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5 08 2 a 1 through 4 INSPECTION As soon as a unit is received it should be inspected for possible dam age during transit If damage is evident the extent of the damage should be noted on the carrier s freight bill A separate request for inspection by the carrier s agent should be made in writing Also before installation the unit should be checked for screws or bolts which may have loosened in transit There are no shipping or spacer brackets which need to be removed from the interior of this unit FURNACE LOCATION AND CLEARANCES The furnace shall be located using the following guidelines 1 Where a minimum amount of air intake vent piping and elbows will be required 2 As centralized with the air distribution as possible 3 Where adequate combustion air will be available particularly when the appliance is not using outdoor combustion air 4 Where it will not interfere with proper air circulation in the confined space Installation in freezing temperatures 1 Furnace shall be installed in an area where ventilation facilities provide for safe limits of ambient temperature under normal oper ating conditions AWARNING Improper installation in an ambient below 32 F 0 0 C could create a hazard resulting in damage injury or death 2 Do not allow retu
79. to the unit must be grounded Electric wires that are field installed shall conform to the temperature limitation for 63 F 35 C rise wire when installed in accordance with instructions Refer to Table 6 in these instructions for specific furnace electrical data Table 6 Ratings amp Physical Electrical Data Nominal Air Temp vax Airflow Rise Outlet Blower BI Max Air Temp ower Over Current Amp Size MS 2 155 68 3 9x8 z 14 HE tae 40 1117 ee 227 80 0 25 55 14 31 ACAUTION Use copper conductors only Min wire Size awg 75 ft Protect one way rao reas E rest ies ees Te xs ae Mu eS 7 7 116 8 1 151 in 1 19 38 e0 23 5 64 188 1800 453 800 2555 1431 T65 683 1 2 75 TTx10 i 10177 Eo See ee L 0 100 1205 80 234 1200 340 80 0 40 70 22 39 100 29 3 80 23 4 1600 453 80 0 35 65 19 36 165 733 1 2 75 T1x10 100 23 80 234 2000 566 800 25 55 14 31 155 83 T s mn 20 170 75 T 337 96 263 1600 453 80 0 40 70 2230 i 5 120 337 96 269 2000 565 e00 30 60 17 33 Te0 7 T 1 145 Annual Fuel Utilization Efficiency AFUE numbers are determined in accordance with DOE Test procedures Wire size and over current protection must comply with the National Electrical Code NFPA 70 latest edition and all local codes The furnace shall be instal
80. unit rating plate for the furnace model number and then see the dimensions page of this instruction for return air ple num dimensions in Figure 12 The plenum must be installed according to the instructions e Provide clearances from combustible materials as listed under Clearances to Combustibles e Provide clearances for servicing ensuring that service access is allowed for both the burners and blower e These models ARE NOT CSA listed or approved for installation into a HUD Approved Modular Home or a Manufactured Mobile Home e This furnace is not approved for installation in trailers or recre ational vehicles e Furnaces for installation on combustible flooring shall not be installed directly on carpeting tile or other combustible material other than wood flooring e Check the rating plate and power supply to be sure that the elec trical characteristics match All models use nominal 115 VAC 1 Phase 60 Hertz power supply DO NOT CONNECT THIS APPLI ANCE TO A 50 HZ POWER SUPPLY OR A VOLTAGE ABOVE 130 VOLTS e Furnace shall be installed so the electrical components are pro tected from water e Installing and servicing heating equipment can be hazardous due to the electrical components and the gas fired components Only trained and qualified personnel should install repair or service gas heating equipment Untrained service personnel can perform basic maintenance functions such as cleaning and replacing the air filters W

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