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Johnson Controls TM9T*MP User's Manual

1. RESIDENTIAL GAS FURNACE MODELS TM9T MP 96 AFUE Two Stage Multi position 4 1 E q AA UU A d L b MP E EE e 4E e A 1 AS WD NEM sn AED lt E 4 Zw ti bh IR NM ll lat aa w A4 EM ha ERA F A UU WM Mi 2 7 1 4 LN ff WW EZ COU EM NEM WE MM AD LL LM 2 oa nn WW NM WENN D WW WENN 4 eel O_o WM Z7 A 2 XS 4 A E M WW 4 21 JA WW LEE CRC MM DCO A 2 E M4 R I MA WO MY ee 3 0 y A WM A MM w WW A EM Lu 3 hl DEM 1 CTE x na LR 2 2 E A A 10 1 AM A Au AM E A Aj I Ms A NM DM LAE 0 1 LL 0 A A M A 11 100 A j I E m 1 K LEES 22 21 Te E ll 2 ll uM EEE A L E E NS P 6 ULU E EE WE N Ov 2 RATING CERTIFIED b Ann REGIS m ISO 9001 Certified Quality Management System LIST OF SECTIONS SAFETY copies tote come ra s 2 COMBUSTION AIR and VENT SYSTEM 22 DUCTWORK sia BY ap al ba a Y Rh s n 5 START UP AND 5 29 FILTERS tara m R m 9 SAFETY CONTROLS s 34 GAS PIPING 406405 cians R R ERE bob DR b ak Da k b 10 NORMAL OPERATION AND DIAGNOSTICS 34 ELECTRI
2. m Heat XFMR 24 Volt Hot 24 Volt Hot 24 Volt Hot G G G Fan Fan Fan VV 7 VV1 First Stage Heat wa T e We Second Stage Heat g Second Stage Heat Aux Heat RC Y Y2 24 Volt Hot Second or Full Cool XFMR Stage Compressor Y2 Y2 Y2 Second Stage Second Stage Second Stage Compressor Compressor Compressor W EAV1 First Stage Heat First Stage Aux Heat External Humidistat Optional Open on Humidity Rise 24VAC Humidifier Optional Connection of the C Connection of the C terminal 24 Volt common terminal 24 Volt common is optional when used with is optional when used with batteries batteries Thermostat Installer Setup 0170 System Type must be set to 8 2 Heat 2 Cool Multistage Conventional Part Numbers SAP Legacy 265903 031 09168 449573 1 Part Number S1 2HU16700124 FIGURE 18 Thermostat Chart Single Stage AC with Single Stage PSC Furnaces Johnson Controls Unitary Products 13 505309 UIM D 051 1 HP 22A Two Stage Heat Pump Two Stage PSC Furnace Hot Heat Pump or Conventional ID MODELS OD MODELS PT 8 9 YZE F L 8 9 T YZH G L 8
3. 8 m So LM 2 5 m os T m To T 39 m i s m T vi r owe 25 038 29 49 000 sm m o 171 164 157 150 144 138 133 30 Johnson Controls Unitary Products 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 39 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 Out P and In P 1 The manifold pressure must be taken at the port marked OUT P 2 The gas line pressure must be taken at the port marked IN P 3 Using a 3 32 2 4 mm 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 40 for connec tion details 1 Turn gas and electrical supplies on and follow the operating instruc tions to place the unit back in operation Table 16 Inlet Gas Pressure Range INLET GAS PRESSURE RANGE Natural Gas Propane LP 4 5 w c 1 12 kPa 8
4. 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 squarely 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 overlire and heat exchanger failures Verify natural gas input rate by clocking meter 1 Turn off all other gas appliances 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 15 for cubic feet of gas per hour 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 em ACAUTION Be sure to relight any gas appliances that were turned off at the start of this input check 29 505309 UIM D 051 1 Table 15 Gas Rate CU FT HR at Full Input Seconds For Size of Test Dial Seconds For Size of Test Dial Size of Test iat Revolution 39 3 72 399 5 3 32 o 3 6 r s s 38 T Co t m m mme 7 s m
5. 3 Make sure all wiring connections are secure 4 Review the sequence of operation 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 A WARNING Never bypass any safety control to allow furnace operation To do so will allow furnace to operate under potentially hazardous conditions Do not try to repair controls Replace defective controls with Johnson Controls Unitary Products Source1 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 f 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
6. 3 5 kPa 10 External Manual Shut off HIGH STAGE REGULATOR ADJUSTMENT OUTLET PRESSURE PS E DY X INLET y s 2 INLET PRESSURE PORT LOVV STAGE REGULATOR ADJUSTMENT ON OFF SWITCH FIGURE 15 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 f 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 this 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 16 NOTE Ground Union maybe installed inside or outside unit Ground Drip Leg External Manual Shut off Valve H ha Horizontal Drip ACAUTION The gas valve body is a very thin casting that cannot take any exter nal pressure Never apply a pipe wrench to the body of t
7. 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 installed 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 17 Electrical Wiring 1 Provide a power supply separate from all other circuits Install over current protection and disconnect switch per local national electrical codes The switch should be close to the unit for convenience in servicing With the disconnect or fused switch in the OFF position check all wiring against the unit wiring label Refer to the wiring dia gram in this instruction 2 Remove the wiring box cover screws Route all power wiring through a conduit connector or other proper bushing that has been installed into the unit opening and the junction box In the junction box there is a black wire a white wire and a green ground screw Connect the power supply as shown on the unit s wiring label located on the inside of the blower compartment door or the wiring schematic in this section Connect the black wire to L1 hot from the power supply Connect the white wire to neutral Connect the ground wire installer supplied to the green equipment ground screw An alternate wi
8. B Clearance to window or door that may be opened g 4 cm for models gt 100 000 BTUH 30 kW single pipe applications 4 feet 1 2 m C Clearance to permanently closed vvindovv 12 30 5 cm 12 30 5 cm D Vertical clearance to ventilated soffit located above the terminal vvithin a horizontal distance of 2 feet 61 cm from the center line of the terminal E 12 30 5 cm or in accordance with local installation 12 30 5 cm or in accordance with local installation codes and the requirements of the gas supplier codes and the requirements of the gas supplier 12 30 5 cm or in accordance with local installation 12 30 5 cm or in accordance with local installation F Clearance to outside corner I codes and the requirements of the gas supplier codes and the requirements of the gas supplier G Clearance to inside corner 3 feet 91 4 cm 3 feet 91 4 cm Above a meter regulator assembly within 3 feet Above a meter regulator assembly within 3 feet H Clearance to each side of center line 91 4 cm horizontally of the vertical center line of the 1 91 cm horizontally of the vertical center line of the extended above meter regulator assembly regulator vent outlet to a maximum vertical distance of regulator vent outlet to a maximum vertical distance of 15 feet 4 5 m above the meter regulator assembly 15 feet 4 5 m above the meter regulator assembly L CI 3 feet 91 4 cm or in accordance with
9. 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 property owner to secure the services of qualified licensed pro fessionals 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 3
10. 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 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 US National Fuel Gas Code NFGC NFPA 54 ANSI Z223 1 and the Installation Standards Warm Air Heating and Air Conditioning Systems ANSI NFPA 90B CANADA CAN CGA B149 1 National Standard of Canada Natu ral Gas and Propane Installation Codes NSCNGPIC STEP 2 General Installation 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 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 US Section 5 3 of the NFGC air for Comb
11. 0 w c 1 99 kPa 13 0 w c 3 24 kPa 10 5 w c 2 61 kPa IMPORTANT The inlet gas pressure operating range table specifies what the mini mum 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 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 16 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 3 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 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 40 for connection details IMPORTANT The cap for the pressure regulator must be removed entirely to gain access to the ad
12. 8969 ee eo 40 98 os os 932 P First Stage Manifold Pressures kPa Altitude feet Altitude m 0 7999 za T 2652782 2653645 1 1 3 5 3 3 3 3 3 2 2 Gas Heating Value D D 5 5 5 3 2 9 9 A 7 4 2 5 8 BTU cu ft Gas Heating Value Gas Heating Value i 15 i 4 i 32 1 7 1 7 1 7 1 7 1 5 1 4 1 2 3 8 38 S25 ADANGER PROPANE AND HIGH ALTITUDE CONVERSION KITS It is very important to choose the correct kit and or gas orifices for the altitude 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
13. Coil Projection Dimensions PC Series Coils 7 Combustion Air Intake and Vent Connection Cabinet and Duct Dimensions 9 Size at Furnace All 23 Recommended Filter Sizes High Velocity 600 FPM 9 Estimated Free Area ues a ea dada aia 27 Nominal Manifold Pressure High Fire 11 Unconfined Space Minimum Area 27 Nominal Manifold Pressure Low Fire 11 Free Area 0 I 27 Ratings 8 Physical Electrical Data 12 Gas Rate CU FT HR at Full nput 20 30 Maximum Equivalent Pipe Length 22 Inlet Gas Pressure Range 31 Elbow Dimensions 23 Nominal Manifold Pressure 31 Blower Performance CFM Any Position without filter 33 505309 UIM D 0511 505309 UIM D 051 1 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 applica
14. J T 9jesuopuoo YDUMS 2JnssaJd ESd 938 SE YIJMS 9JnssaJd ZSd Joyoedey dv 938 si YDUMS 9JnsSaJd TSd A PA SED AD J931U3 9I8J1NS JOH ISH Josuas awe Sy J ue j 11e 31004329 3 DVI J9UJJOJSUEJ HINIX J ljipluunH ANH JOJOW J95npuU WO YIUMS 1nollod SOY YIUMS YUI S J0 0U Sune n24I LOIN YIUMS 1000 SQ QN3511 HOIIJINNO2 1Y15 1 NOMHOD S 1081802 4101110893 l gu 1VISOWB391 WODY O ONE 1002 30V165 2 3ATYA 5 9 1091 ON SNII1Y3H 39Y15 6 LI A woo 1434 a l CELE ELI MH JION 335 lt 09 1 511 44 5 3004 HOD WE ON 3Sd Se3S OML 9596 Wieliselg SUHIAA Wiring Diagram FIGURE 43 37 Johnson Controls Unitary Products Subject to change without notice Published in U S A 505309 UIM D 051 1 Copyright O 2011 by Johnson Controls Inc All rights reserved Supersedes 505309 UIM C 0910 Johnson Controls Unitary Products 5005 York Drive Norman OK 73069
15. 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 The furnace requires OUTDOOR AIR for combustion when the furnace is located in any of the following environments e Buildings with indoor pools Chemical exposure Commercial buildings Furnaces installed in hobby or craft rooms Furnaces installed in laundry rooms Furnaces installed near chemical storage areas Restricted Environments 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 Antistatic fabric softeners for clothes dryers Carbon tetrachloride Cements and glues e Chlorine based swimming pool chemicals Chlorinated waxes and cleaners Cleaning solvents such as perchloroethylene De icing salts or chemicals Halogen type refrigerants Hydrochloric acid Masonry acid washing materials Permanent wave solutions Printing inks paint removers varnishes etc e Water softening chemicals Johnson Controls Unitary Products 505309 UIM D 051 1 When outdoor air is used for combustion
16. above any insulation flooring or other material A crawl space combustion air installation consists of a straight pipe from the PVC coupling on the burner box that extends into the crawl space and terminates with a 1 4 6 4 mm mesh screen and no elbows A WARNING Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon CARBON MONOXIDE POISONING HAZARD 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 and all doors 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 the 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 operat
17. 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 caus ing premature heat exchanger burnout high levels of carbon monoxide excessive sooting a fire hazard personal injury property damage and or death 2500 LP 4 1 SECTION V ELECTRICAL POWER Field wiring to the unit must be grounded Electric wires that are field ELECTRICAL POWER CONNECTIONS installed shall conform to the temperature limitation for 63 F 35 C rise wire when installed in accordance with instructions Refer to Table 7 in ACAUTION these instructions for specific furnace electrical data Use copper conductors only Johnson Controls Unitary Products 11 505309 UIM D 051 1 Table 7 Ratings amp Physical Electrical Data Input HI LO Output HI LOW Nominal Air Flow AFUE Hi Fire Air Temp Rise Lo Fire Air Temp Rise CFM F o F o W VER varmi 2 80 52 80 52 100 65 2315 2919 77 50 96 62 e 453 77 75 10 96 35 65 19 5 36 35 65 19 5 36 o T 95 45 75 29 416 20 80 Ti1 278 48 9 45757 55 9 35 65 _ aime 25 418 20 50 11 278 ir S 25 418 185 36 25 41 6 19 5 36 13 9 30 5 19 5 36 35 65 Max Outlet Ar Temp Max Over Curreni Operating Weight O 75fLone way 170 173 12
18. cross sectional area as the free area of the air supply inlet opening to which it connects 4 The blocking effects of louvers grilles and screens must be given consideration in calculating free area If the free area of a specific louver or grille is not known Refer to Table 12 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 Z223 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 Refer to Table 8 for intake pipe sizing allowable length and elbow usage Follow all notes procedures and required materials in the COMBUSTION AIR VENT PIPE SIZING section in these instructions when installing the combustion air pipe from the unit and into a ventilated attic space or crawl space DO NOT terminate vent pipe in an Attic or Crawl Space Ventilated Combustion Air Termination Refer to Figure 38 for required attic termination for the combustion air intake pipe For attic termination use two 90 elbows with the open end in a downward position Be sure to maintain 12 30 5 cm clearance
19. damage by vehicles Table 1 Unit Clearances to Combustibles Application Horizontal Top Ra 0 Side Front Combustible Combustible Combustible ve Cost Ye Line Conta 1 For combustible floors only when used with special sub base 24 clearance in front and 18 on side recommended for service access All furnaces approved for alcove and attic installation 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 Modular Home installations when a furnace is installed so that the supply 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 downstream of the furnace Cooled a
20. least 12 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 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 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 water 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
21. local installation earance to service regulator vent outlet 3 feet 91 4 cm codes and the requirements of the gas supplier 2 5 one E me o 12 30 5 cm for models lt 100 000 BTUH 30 kW Two pipe direct vent applications 12 30 5 cm SE the combustion air inlet to any other 36 91 cm for models gt 100 000 BTUH 30 kW Single pipe applications 4 feet 1 2 m 3 feet 91 4 cm above if within 10 feet 3 m K Clearance to a mechanical supply inlet 6 feet 1 83 m horizontally L Clearance above paved sidewalk or paved 7 feet 2 13 m or in accordance with local installation 7 feet 2 13 m T driveway located on public property codes d the requirements of the gas supplier 12 80 5 cm or in accordance with local installation M Clearance under veranda porch deck or balcony 112 30 5 cm t codes and the requirements of the gas supplier In accordance with the current CSA B149 1 00 Natural Gas and Propane Installation Code In accordance with the current ANSI Z223 1 NFPA 54 National Gas Code In accordance with the current ANSI Z21 47 CSA 2 3 American National Standard A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings T 12 30 5 cm up from the bottom edge of the structure for Two pipe direct vent applications per ANSI Z223 1 NFPA 54 National Gas Code Permitted only if veranda porch deck or balcony is
22. 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 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 switch 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 41 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
23. that a manual reset rollout switch has opened 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 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 fur
24. 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 initiate 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 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 The manual shut off valves in the gas line to the furnace must be open
25. 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 microamps DC ua Low flame signal warning starts at 1 5 microamps Low flame signal control lockout point is 0 1 microamps DC 35 505309 UIM D 051 1 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 If 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 XII REPLACEMENT PARTS LIST DESCRIPTION MOTOR BLOWER COMBUSTION MOTOR DIRECT DRIVE BLOWER ELECTRICAL CONTROL FURNACE CONTROL TEMPERATURE IGNITER SENSOR FLAME SWITCH DOOR SWITCH LIMIT SWITCHES PRESSURE TRANSFORMER VALVE GAS AIR MOVING HOUSING BLOWER WHEEL BLOWER FABRICATED PARTS BRACKET BLOWER
26. 0 days to comply with the above requirements provided however that during said thirty 30 day period a battery operated carbon monoxide detector with an alarm shall be installed APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above pro visions 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 heat ing 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 OBSTRUCTIONS INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation 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
27. 9 T H 5 THERMOSTAT THERMOSTAT TMO H 8 PP32U70124 DN22H00124 TWO STAGE PSC TWO STAGE DP22U70124 FURNACE HEAT PUMP e TWO STAGE PSC O YORKGUARD VI FURNACE CONTROL C C C C 24 Volt Common 24 Volt Common 24 Volt Common 24 Volt Common r d Sin ESE e i d First Stage Compressor First Stage Compressor 9 g Single Stage Compressor Compressor R R R R 24 Volt Hot Fee Heat XFMR 24 Volt Hot m 24 Volt Hot 24 Volt Hot G G G Fan Fan Fan E VV 7 VV1 VV1 OUT Emergency Heat First Stage Heat First Stage Heat e we em 5 9 Second Stage Heat Second Stage Heat Aux Heat RC Y Y2 Y2 OUT 24 Volt Hot Second or Full Second Stage Cool XFMR Stage Compressor Compressor O B 9 Revereinq Valla Reversing Valve Reversing Valve g Energized in Cool E Energized in Cool L L X L Malfunction Light Malfunction Light Malfunction Light Y2 Y2 Y2 Second Stage Second Stage Second Stage Compressor Compressor m Compressor AUX E VV1 W Auxiliary Heat First Stage Aux Heat Auxiliary Heat BSG External Humidistat s Sensor E Bonnet Sensor Optional Optional Open on Humidity Rise wm BS 24VAC Humidifier x Optional Thermostat Installer Setup Step 1 of Thermostat 0170 System Type Installer Configuration Change FFuel jumper must be setto 12 Menu must be set to HP2 on the heat pump control 3 Heat 2 Heat Pump Selection of GAS ELEC to ON Thermostat Installer Setup switch on thermostat Change Hot Heat Pump 0190 Changeover
28. AUTION Solvent cements are flammable and must be used in well ventilated areas only Keep them away from heat sparks and open flames Do not breathe vapors and avoid contact with skin and eyes 6 Disassemble the combustion air and vent piping apply cement primer and the cement per the manufactures instructions Primer and cement must conform to ASTM D2564 for PVC or ASTM D2235 for ABS piping 7 All joints must provide a permanent airtight and watertight seal 8 Support the combustion air and vent piping such that it is angled a minimum of 1 4 per foot 21 mm m so that condensate will flow back towards the furnace Piping should be supported with pipe hangers to prevent sagging 9 Seal around the openings where the combustion air and or vent piping pass through the roof or sidewalls COMBUSTION AIR VENTING IMPORTANT The vent must be installed with the minimum required clearances and must comply with local codes and requirements 23 505309 UIM D 051 1 VENT CLEARANCES V VENT TERMINAL O0 AIR SUPPLY SN AREA WHERE TERMINAL IS NOT PERMITTED OPERABLE FIGURE 29 Home Layout Direct Vent Terminal Clearances Vent Terminal Clearances Canadian Installations US Installation A above grade veranda porch deck or 12 30 5 cm 12 30 5 cm balcony 12 30 5 cm for models x100 000 BTUH 30 kW Two pipe direct vent applications 12 30 5 cm TT
29. CAL POWER Us se LA l 11 REPLACEMENT PARTS LIST 36 TWINNING a RE xS acera 15 REPLACEMENT PART CONTACT INFORMATION 36 CONDENSATE PIPING AND FURNACE WIRING DIAGRAM 37 VENTING CONFIGURATION 16 LIST OF FIGURES Duct Attachment 5 Typical Condensate drain vertical installation 16 Vertical Applications 6 Typical Combustion Pipe Drain Tee 17 A 6 Upflow Configuration 18 Horizontal Right Application 6 Downflow Configuration 19 Horizontal Left Application 6 Horizontal Left Configuration 20 PC Series Upflow Coil Installation 7 Horizontal Right Configuration 21 Horizontal Left or Right application Right Shown 7 DIMENSIONS serca Ga Su pa FE arre Para hed 23 Combustible Floor Base Accessory 7 Honig Layout s c ronda r 24 Horizontal Application 8 Termination Configuration 1 Pipe 25 Typical Attic Installation 8 Termination Configuration 2 Pipe 25 Typi
30. Drive Norman OK 73069 36 Johnson Controls Unitary Products 505309 UIM D 0511 WIRING DIAGRAM SECTION XIII 0180 4 0 61 9 uoneoi dde sed ja ajapow 9 uo s 1u An d siew SanbidAj 1uos sanbipur 1na e 11uaA np 1na330U np Ss 21A IPULI3 e suoixeuuoo SI Z 2S0T 4 IZZ Sulow Ne p ap un juede I a Jane 23439 HOP e2ejduuaJ HOP INO 39Ae DUISINO p S L Sep UN IS T 1n 1eoljipiuinH WAH uonesu puo uoissaJd op In 1e1nuuuuo2o ESd Jn9uJJ0JSUeJ 93 5 uoissaJd ap INIJEINULIO 7Sd zes op adednos AD adejs JaluJaJd uolss id ap In 1e1nuuuuo2 TSd nbin l 943 14 JVJ 331111 SP J1n91e1nuJuJO S1 oeJins ap uous ISH uue J ap 1na1de sy Jn zow 39Npul d WG u w jnou ep INIJEINUWUIO SOY Jn 1l52ede2o dy H LHnOS NJON LOW ap In 1e1nuuuuoo sd J0N3i931 8064 312VMHIi Wey Sad H SN TS WAV 14 3411 418 194 ASII N345 701H 18 039 duz 1508 E31 H2 ps 1 9 LOH 1 3H 2vA II 1411 mas i CR MS O N 4000 uoneoijdde pue japow Ag Aea Aew anq eoid 94e UMOUS suomooeuuoo p ds 1070W 8 Z 2401 4 TZZ 15e9 1e jo SuneJ inel d l e duiney 1 SULIM YUM p 2e d 1 aq 3snu 31 pe ej daJ aq 1snuu o euunj v YUM p liddns se aw eurSi40 v jo Aue
31. Furnace All Models FURNACE VENT CONNECTION SIZES Intake Pipe Size 2 5 1 cm 2 5 1 cm IMPORTANT Furnace vent pipe connections are sized for 2 5 1 cm pipe Any pipe size change must be made outside the furnace casing in a verti cal pipe section to allow proper drainage of condensate An offset using two 45 degree elbows will be required for plenum clearance when the vent is increased to 3 7 6 cm Vent Pipe Size IMPORTANT Accessory concentric vent intake termination kits 1CT0302 and 1CT0302 636 and 1CT0303 and for Canadian applications 1CT0303 636 are available and approved for use with these fur naces Horizontal sidewall vent terminations kits 1HT0901 amp 1HT0902 are also approved for use with these furnaces COMBUSTION AIR AND VENT PIPING ASSEMBLY The final assembly procedure for the combustion air and vent piping is as follows 1 Cutpiping to the proper length beginning at the furnace 2 Deburr the piping inside and outside 3 Chamfer bevel the outer edges of the piping 4 Dry fit the vent piping assembly from the furnace to the outside ter mination checking for proper fit support and slope 5 Dry fit the combustion air piping assembly checking for proper fit support and slope on the following systems a Sealed combustion air systems from the furnace to the outside termination b Ventilated combustion air systems from the furnace to the attic or crawl space termination AC
32. RECAUTIONS 1 Only Natural gas or Propane LP gas are approved for use with this furnace 2 Install this furnace only in a location and position as specified in these instructions 3 A gas fired furnace for installation in a residential garage must be installed as specified in these instructions 4 Provide adequate combustion and ventilation air to the furnace space as specified in these instructions 5 Combustion products must be discharged outdoors Connect this furnace to an approved vent system only as specified in SECTION VIII COMBUSTION AIR and VENT SYSTEM of these instruc tions 6 Test for gas leaks as specified in these instructions A VARNING 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 all connections A fire or explosion may result causing property damage personal injury or loss of life 7 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 8 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
33. TRACK 2 Req d BRACKET IGNITER BURNER MAIN GAS HEAT EXCHANGER ASS Y MANIFOLD GAS PANEL BLOCKOFF PAN BOTTOM PANEL DOOR 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 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 FERRULE 3 Req d GROMMET 3 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 You can contact us by mail Just send a written request to Johnson Controls Unitary Products Consumer Relations 5005 York
34. Top Above Insulation 505309 UlM D 0511 2 Apertures in a fixed louver a grille or screen shall have no dimen sion smaller than 1 4 6 4 mm 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 A VARNING When a Category furnace is removed or replaced the original vent ing 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 13 Unconfined Space Minimum Area BTUH Input Rating 120 000 Table 14 Free Area Minimum Free Area Required for Each Opening Horizontal Duct 0500 Round Duct 2 000 BTUH 4 000 BTUH 4 000 BTUH 30 in 198 om ioi 258 om am 50 1n 322 om sem T 18 om EXAMPLE Determining Free Area Appliance 1 Appliance 2 Total Input 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 Inlet Air b Air a 4 The duct shall terminate within 12 30 5 cm above and within 24 61 cm horizontally from the burner level of the appliance having the la
35. Valve not necessary jumper on the heat pump must be set to 0 control to ON if Hot Heat O B terminal Pump Operation is desiredi Energized in Cooling Part Numbers Thermostat Installer Setup z 0200 Backup Heat Source SAF Legacy Part Numbers 126768 031 09137 must be setto 1 Part Number SAP Legacy 18395 031 01996 Heat Pump Backup Heat 11 ql 265903 031 09168 340512 031 09178 Source is Fossil Fuel Thermostat Installer Setup 449573 0210 External Fossil Fuel FIGURE 19 Thermostat Chart Two Stage HP with Two Stage PSC Furnace 14 Johnson Controls Unitary Products ACCESSORY CONNECTIONS The furnace control will allow power switching control of various accessories ELECTRONIC AIR CLEANER CONNECTION Two 1 4 6 4 mm 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 operation HUMIDIFIER CONNECTION Two 1 4 6 4 mm spade terminals HUM and NEUTRAL for humidifier 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 SINGLE STAGE THERMOSTAT If a single stage thermostat is used the high low input staging will be controlled by the furnace control board using the staging
36. WITCH A CAUTION Main power to the unit must still be interrupted at the main power dis connect 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 discon nect Blower and burner must never 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 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 two pressure switches which monitor the flow through the combustion air vent piping and condensate drain sys tem These switches de energize the gas valve if any of the following conditions are present Refer to SECTION VII CONDENSATE PIPING AND FURNACE VENTING CONFIGURATION for tubing connections 1 Blockage of vent piping or term
37. are should be taken to locate side vented systems where trees or shrubs will not block or restrict supply air from entering the terminal Also the terminal assembly should be located as far as possible from a swimming pool or a location where swimming pool chemicals might be stored Be sure the terminal assembly follows the outdoor clearances listed in Section 1 Outdoor Air Contaminants Connects to Vent pipe cements 77 into socket just above top panel Or vent pipe may be clamped into outlet of drain coupling FIGURE 36 Direct Vent Air Intake Connection and Vent Connection 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 t is not piped directly into the furnace A single properly sized pipe from the furnace vent connector to the outdoors must be provided t is recom mended that the supplied intake coupling amp 18 of pipe be attached to the furnace to prevent accidental blockage of the combustion air intake Vent pipe cements into socket just above top panel COMBUSTION AIR Or vent pipe may be clamped into outlet of drain coupling FIGURE 37 Combustion Airflow Path Through The Furnace Casi
38. cal Suspended Furnace Crawl Space Installation 8 Termination Configuration 2 Pipe Basement 25 Downflow Venting 8 Double Horizontal Combustion Air Intake and Vent Termination 25 Dimensions 22 00 224000526405 cestas oes een edad bee anaes 9 Double Vertical Combustion Air Intake and Vent Termination 25 Side Return Cutout Markings 9 Downward Venting 26 VAG MCCC 10 Direct Vent Air Intake Connection and Vent Connection 26 GAS iPIDINO m 10 Combustion Airflow Path Through The Furnace Casing 26 Ea e 12 Outside and Ambient CombustionAir 27 Thermostat Chart Single Stage AC with Attic and Crawl Space Combustion Air Termination 28 Single Stage PSC Furnaces 13 Gas VaWe a 3 030003 9030303000 006n 31 Thermostat Chart Tvvo Stage HP vvith Reading Gas Pressure 32 Tue Stage PSC FUMACE ces b Furnace Control Board 32 Typical Tinaco Purace APpicano ssp ides ines pens 15 Wiring Diagram a ud aom i PR dU ite i o en eh em 37 Twinning Wiring Diagram 16 LIST OF TABLES Unit Clearances to Combustibles 4 Equivalent Length of Fittings 23
39. con tinuous flash codes listed below will flash the LED light on and off con tinuously with no breaks or longer 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 f 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 RED 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 pr
40. d 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 weight 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 psig 14 w c 3 48 kPa Pressures exceeding 0 5 psig 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 To Gas To Gas Suppl 7 External FIGURE 16 Gas Piping 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 0 5 psig
41. d from the gas supply piping system by closing the equipment shutoff 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 Setthe thermostat above room temperature to call for heat Johnson Controls Unitary Products 505309 UIM D 0511 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 A WARNING 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 auto matically by its hot surface ignition system CALCULATING THE FURNACE INPUT NAT GAS 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 heating value of your gas is significantly different it may be necessary to replace the NOTICE DO NOT set manifold pressure less than 3 2 w c or more than 3 8 w c for natural gas at sea level If manifold pressure is outside this range change main burner orifices NOTICE
42. dditional 75 Combustion Air Inlet 20 SUPPLY END RETURN END FIGURE 13 Dimensions Table 3 Cabinet and Duct Dimensions Approximate BTUH kW Nominal Cabinet Cabinet Dimensions Inches Operating Weights Input CFM m min Size 60 17 6 1200840 B 732 444 1688 416 1314 337 122 80934 1200 640 B 1712 444 1638 416 i434 378 1 80 23 4 1600 45 3 C 21 53 3 136 100 29 3 1600 653 142 mee 2000668 145 120851 2000 566 D 2442 622 2336 594 2134 552 156 SECTION Ili FILTERS SIDE RETURN FILTER INSTALLATION Locate the L shaped corner locators These indicate the size of the cut All applications require the use of a field installed filter All filters and mounting provision must be field supplied Filters must be installed external to the furnace cabinet DO NOT attempt to install filters inside the furnace NOTICE Single side return above 1800 CFM is approved as long as the filter velocity does not exceed filter manufacturer s recommendation and a transition is used to allow use on a 20x25 filter Front of l m 7 Q A A 4 Furnace Side of Furnace L QQ QQ QQ Markings Table 4 Recommended Filter Sizes High Velocity 600 FPM FIGURE 14 Side Return Cutout Markings CFM m3 min Cabinet Size Side in Bottom in Install the side filter rack following the instructions provided with
43. dium Low 937 826 853 838 794 776 760 711 High 1252 ET Medium High MS Medium Low 761 690 707 r O Ge Low 798 oe 953 Low 306 938 820 Left Side Airflow Data SCFM Ext Static Pressure in H20 01 02 03 04 05 06 07 08 09 10 High 320 775 828 osostampii Medium Figh 980 er 545 Medium Low 970 957 853 796 745 66O 568 793 781 756 724 694 653 585 530 Figh 940 osostampii Medium Figh Ze Medium Low 393 953 708 896 757 708 642 574 High 1209 osoctempii C Medium High 1099 Medium Low 967 906 goz 903 745 Figh 1272 sooci mpi Medium Figh 1100 Medium 977 788 Tez 756 732 690 en High 1365 sooceomei Medium Figh e Medium Low 1022 Low 950 784 High Ei per Medium Figh m7 Medium Low 42 988 Low 993 937 882 782 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 Speed m m m eg O o O o E cO c co ohnson Controls Unitary Products 3 505309 UIM D 051 1 SECTION X 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 S
44. ds at all points 16 ACAUTION The furnace condensate pan is self priming and contains an internal trap to prevent flue gas leaking Do not install an external condensate trap When drain hose routing changes are required shown in Figures 24 27 be sure to cap all un used openings If rerouting hoses excess length should be cut off so that no sagging loops will collect and hold condensate which will cause the furnace to not operate No hose clamps are needed for connecting to the condensate pan IMPORTANT The furnace evaporator coil and humidifier drains may be combined and drained together The evaporator coil drain may have an exter nal field supplied trap prior to the furnace drain connection to prevent conditioned air leakage All drain connections furnace evaporator coil or humidifier must be terminated into an open or vented drain as close to the respective equipment as possible Regular maintenance is required on condensate drainage system IMPORTANT Condensate must be disposed of properly Follow local plumbing or wastewater codes The drain line must maintain a 1 4 per foot 20 mm m downward slope to the drain IMPORTANT If an external vent tee is being installed then it must have its own condensate trap before it is disposed into an open or vented drain This is not to be considered as a second trap as referenced else where in this document Open Stand Pipe Anti siphon air vent To O
45. e Home Johnson Controls Unitary Products This furnace is not approved for installation in trailers or recre ational vehicles Furnaces for installation on combustible flooring shall not be installed directly on carpeting tile or other combustible material other than wood flooring Check the rating plate and power supply to be sure that the electri cal characteristics match All models use nominal 115 VAC 1 Phase 60 Hz power supply DO NOT CONNECT THIS APPLI ANCE TO A 50 Hz POWER SUPPLY OR A VOLTAGE ABOVE 130 VOLTS Furnace shall be installed so the electrical components are pro tected from water 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 When 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 COMBUSTION AIR QUALITY LIST OF CONTAMINANTS A WARNING The furnace area must not be used as a broom closet or for any other storage purposes as a fire hazard may be created Never store items such as the follovving on near or in contact vvith the furnace 1 Spray or aerosol cans rags brooms dust mops vacuum cleaners or other cleaning tools
46. e 6 Johnson Controls Unitary Products Flexible Duct Collar Field Fabricated Ductwork Do not drill or Screvv Upflovv this flange Coil P o Upflovv YTT N 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 Dimension C should be at least 2 3 of dimension D See Figure 6 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 Johnson Controls Unitary Products 505309 UIM D 051 1 DOWNFLOW DUCT CONNECTORS All downflow installations must use a suitable duct connector approved by t
47. e 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 sup ply 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 lift ing 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 installation instructions and any applicable local state and national codes including but not limited to building electrical and mechanical codes Refer to the 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 13 The plenum must be installed according to the instructions Provide clearances from combustible materials as listed under Clearances to Combustibles Provide clearances for servicing ensuring that service access is allowed for both the burners and blower These models ARE NOT CSA listed or approved for installation into a HUD Approved Modular Home or a Manufactured Mobil
48. e 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 FURNACE 2 CONTROL BOARD CONTROL BOARD OW OW Os Oc Oc OR TWIN s R TWIN OY ISOLATION OY 124 RELAY TO AIC WG R Y WALL THERMOSTAT FIGURE 21 Twinning Wiring Diagram SECTION VII CONDENSATE PIPING AND FURNACE VENTING CONFIGURATION CONDENSATE DRAIN LOCATION As shipped from the factory For all 040 060 amp 080K input furnaces the main drain is plumbed through the casing right side opening when viewed from the front of the furnace For all 100 120 amp 130K input furnaces the main drain is plumbed through the casing left side opening when viewed from the front of NOTICE The Figures 24 27 show the condensate drain arrangement for the various possible furnace and vent blower positions The condensate hoses must slope downwar
49. ed periods To do so may cause condensation to occur in the main heat exchanger leading to premature heat exchanger failure 3 f this furnace is installed in an unconditioned space and an extended power failure occurs there will be potential damage to the internal components Following a power failure situation do not operate the unit until inspection and repairs are performed A WARNING Liquid anti freeze will cause damage to internal plastic parts of this furnace DO NOT attempt to winterize the furnace using liquid anti freeze 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 replace ment 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 46 cm above the floor and the furnace must be located or protected to avoid physical
50. erminal on one furnace board to the TWIN terminal on the second furnace board The board then com municates 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 15 505309 UIM D 051 1 Twinning Instructions Connect the control wiring as shown in Figure 21 1 Connect the low voltage wiring from the wall thermostat to the termi nal 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 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 24V common wires of furnace 1 to the 24V common terminal of furnace 2 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 Th
51. essure is increased If screw is turned out counterclockwise manifold pres sure will decrease 4 After the manifold pressure has been adjusted re calculate the fur nace 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 31 505309 UIM D 051 1 MANIFOLD PRESSURE U TUBE CONNECTION OUTLET PRESSURE TAP GAS VALVE 1 4 TUBING MAINIFOLD FLAME PIPE SENSOR 3 5 IN WATER COLUMN GAS PRESSURE BURNERS SHOWN MANOMETER BR FIGURE 41 Reading Gas Pressure ADJUSTMENT 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 Table 7 The supply air temperature cannot exceed the Maximum Supply Air Temperature
52. essure switch contacts are closed when they should be open Check for a faulty pressure switch or misvviring 3 RED FLASHES This indicates the pressure svvitch 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 turn on the supply air blower and inducer Check for a dirty filter improperly sized duct sys tem 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 f after fifteen min utes the main limit still has not closed the control will assume that a manual reset rollout switch has opened and will begin to flash the 5 Red Flash error code See the description of 5 Red Flashes and 11Red Flashes belovv If the main limit svvitch opens five times vvithin a single call for heat the control will indicate 4 Red Flashes and will enter a one hour soft lock out Johnson Controls Unitary Products 505309 UIM D 0511 5 RED FLASHES This fault is indicated if the limit circuit is open for more than fifteen minutes usually indicating
53. 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 41 CONTINUOUS FAN SPEED JUMPER BLOWER SP DIAGNOSTIC ERROR CODE RETRIEVAL BUTTON O ozo o o o HUMIDIFIER TERMINAL DD 0 ELECTRONIC AIR CLEANER TERMINAL FIGURE 42 Furnace Control Board 32 Johnson Controls Unitary Products 505309 UIM D 051 1 Blower Performance CFM Any Position without filter Bottom Airflow Data SCFM EE EMT Ext Static Pressure in H20 oz os o4 os os or os o 10 Hin 1492 i442 1378 1325 1248 Ti76 1075 966 849 655 abu 590 986 950 757 708 600 510 Low 824 795 783 744 659 624 554 389 925 080812MP11 998 928 972 798 Low 987 016 900 877 854 817 775 639 560 High 1201 ee Medium High 1084 Me
54. feet of 4 pipe 10 feet of 2 pipe 10 feet of 3 pipe 10 feet of 4 pipe 3 90 standard elbow 3 45 standard elbow 4 90 elbow sweep or standard 4 45 elbow sweep or standard 2 corrugated connector 3 corrugated connector 4 corrugated connector Example An 80 000 BTUH furnace requires 32 feet of pipe and five 90 elbows Using 2 pipe and standard elbows the total equivalent length will be 32 feet of 2 pipe 5 90 standard 2 elbows 5 x 7 Total 32 equivalent feet 35 equivalent feet 67 equivalent feet of 2 pipe This exceeds the 65 foot maximum equivalent length of 2 pipe allowed for that model and is thus not acceptable By using sweep elbows the total equivalent length will be 32 feet of 2 pipe 5 90 sweep 2 elbows 5 x 5 Total 32 equivalent feet 25 equivalent feet 57 equivalent feet of 2 pipe This is less than the 65 foot maximum equivalent length of 2 pipe allowed for that model and is thus acceptable Alternatively using 3 pipe and standard elbows the total equivalent length will be 32 feet of 3 pipe 5 90 standard 3 elbows 5 x 7 Total 32 equivalent feet 35 equivalent feet 67 equivalent feet of 3 pipe Johnson Controls Unitary Products 505309 UIM D 0511 This is less than the 90 foot maximum equivalent length of 3 pipe allowed for that model and is thus acceptable TABLE 11 Combustion Air Intake and Vent Connection Size at
55. fully open on a minimum of two sides beneath the floor and the distance between the top of the vent termina tion and the underside of the veranda porch or deck is greater than 12 30 5 cm as specified in CSA B149 1 00 A vent shall not terminate less than 12 30 5 cm above a grade level Any fresh air or make up inlet for dryer or furnace area is considered to be forced air inlet Avoid areas where condensate drippage may cause problems such as above planters patios or adjacent to windows where steam may cause fogging A terminus of a vent shall be fitted with a cap in accordance with the vent manufacturer s installation instructions or in accordance with the installation instructions for a special venting system Responsibility for the provision of proper adequate venting and air supply for application shall rest with the installer Vent shall extend high enough above building or a neighboring obstruction so that wind from any direction will not create a positive pressure in the vicinity of the vent IMPORTANT 12 80 5 cm or in accordance with local installation 12 80 5 cm or in accordance with local installation codes and the requirements of the gas supplier codes and the requirements of the gas supplier c N Consideration must be given for degradation of building materials by flue gases Sidewall termination may require sealing or shielding of building surfaces with a corrosion resistant material to protec
56. he furnace manufacturer for use with this furnace The duct connec tors are designed to be connected to the rectangular 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 COMBUSTIBLE FLOOR BASE ACCESSORY FIGURE 8 Combustible Floor Base Accessory 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 pre
57. he gas valve when installing piping A wrench must be placed on the octagon 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 opera tion and or the valve to leak Gas piping may be connected from either side of the furnace using any of the gas pipe entry knockouts on both sides of the furnace Refer to Figure 13 Johnson Controls Unitary Products 505309 UIM D 0511 GAS ORIFICE CONVERSION FOR PROPANE LP 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 7 999 feet 2 438 m above sea level Refer to Table 5 for proper manifold pressure settings 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 factory supplied LP conversion kit Follow the instructions supplied with the LP kit HIGH ALTITUDE PRESSURE SWITCH CONVERSION HIGH ALTITUDE GAS ORIFICE CONVERSION For installation where the altitude is less than 5 000 feet 1 524m it is This furnace is constructed at the factory for natural gas fired operation not required that the pressure switch be changed unless you are in an at 0 7 999 feet 0 2 438 m above sea level area subiect to lovv pressure inversions Table 5 Nominal Manifold Pressure High Fire Manifold Pressures fin ws Aude esi 8000
58. inal 2 Failure of combustion air blower motor 3 Blockage of combustion air piping or terminals 4 Blockage of condensate drain piping 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 registers 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 SECTION XI NORMAL OPERATION AND DIAGNOSTICS NORMAL OPERATION SEQUENCE 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 selected with the BLOWER SPEED jumper on the control board HI COOL LO COOL HI HEAT or LO HEAT 34 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
59. indoor floor drain is available The condensate sump pump must be approved for use with acidic condensate A WARNING DO NOT terminate the condensate drain in a chimney or where the drain line may freeze If the drain line will be exposed to temperatures below freezing adequate measures must be taken to prevent the drain line from freezing Failure to provide proper protection from freezing can result in improper operation or damage to the equipment and possible property damage When exposed to temperatures below freezing use of a 3 to 6 watt per foot at 115 VAC 40 F 4 4 C self regulating shielded and waterproof heat tape is recommended on the drain line outside the furnace DO NOT trap the drain line at any other location than at the conden sate drain trap supplied with the furnace A WARNING Liquid anti freeze will cause damage to internal plastic parts of this furnace DO NOT attempt to winterize the furnace using liquid anti freeze 17 505309 UIM D 051 1 ONILNSA 3GIS He 03 SV ONILNSA 4015 1471 d z GAIVLOY Y39NUONI MO lait eod d z VLOd OPIS Jeujie uo ulqEo SOU uos eunssead yxa euu uieJp UOnisod siy o sou Jeynb ules AO N uejous pue ajnoJ ay esou uleJ USuoys CL sou YOUMS O oJnssoJd u lious E N AJ0198J eu WO ino Buise2o ya au pieAo paquun d SI ajesusapuos ay seoeuunj ind
60. ion 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 CO 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 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 Z223 1 or CAN CGA B149 1 Natural Gas and Propane 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 Specially Engineered Installations The above requirements shall be permitted to be waived where special engineering approved by the authority having jurisdictio
61. ir 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 the 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 heigh
62. jumper If the staging jumper is set to the 10 15 or 20 position the furnace will switch from low fire to high fire after 10 15 or 20 minutes and will stay in high fire until the thermostat is satisfied f the staging jumper is left in the OFF position and a single stage thermostat is used the furnace will only operate at low fire SECTION VI 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 When two furnaces are installed using the same duct system it is very important that the two furnace cir culating air blovvers operate in unison f one blower starts before the second blovver the duct system vvill become pressurized and the blovver on the second furnace vvill turn backvvards causing the second furnace to overheat resulting in damage to the furnace Tvvinning 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 A WARNING 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 ap
63. justment screw Loosening or tightening the cap does not adjust the flow of gas Johnson Controls Unitary Products 505309 UIM D 051 1 NOTICE The regulated outlet pressure has been calibrated at the factory Additional pressure adjustment should not be necessary If adjust ment is necessary set to the following specifications After adjust ment check for gas leakage This gas valve has separate regulator adjustment screws for high fire and low fire as shown in Figure 39 The procedure below is used to adjust either the high fire manifold pressure or the low fire manifold pressure 1 Refer to Figure 39 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 instruc tions to place the unit back in operation 3 Adjust manifold pressure by adjusting gas valve regulator screw for the appropriate gas per the following Table 17 Nominal Manifold Pressure NOMINAL MANIFOLD PRESSURE Natural Gas High Fire 3 5 w c 0 87 kPa Natural Gas Low Fire 1 6 w c 0 40 kPa Propane LP Gas High Fire 9 8 w c 2 488 kPa Propane LP Gas Low Fire 4 0 w c 0 99 kPa HIGH STAGE REGULATOR ADJUSTMENT OUTLET PRESSURE EZ RE YE Y QA S UPN na S PRESSURE PORT LOW STAGE REGULATOR SWITCH ADJUSTMENT FIGURE 40 Gas Valve IMPORTANT If gas valve regulator is turned in clockwise manifold pr
64. 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 Ihe furnace shall be located using the following guidelines 1 Where a minimum amount of air intake vent piping and elbows will be required 2 Ascentralized 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 5 Where the outdoor vent terminal will not be blocked or restricted Refer to VENT CLEARANCES located in SECTION VII of these instructions These minimum clearances must be maintained in the installation 6 Where the unit will be installed in a level position with no more than 1 4 6 4 mm slope side to side and front to back to provide proper condensate drainage Installation in freezing temperatures 1 Furnace shall be installed in an area where ventilation facilities pro vide for safe limits of ambient temperature under normal operating conditions Ambient temperatures must not fall below 32 F 0 C unless the condensate system is protected from freezing A WARNING 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 return air temperature to be below 55 F 13 C for extend
65. mination should be positioned where vent vapors are not objec tionable 6 Horizontal portions of the vent system must slope upwards and be supported to prevent sagging 7 Direct vent systems must be installed so the vent and the combus tion air pipes terminate in the same atmospheric zone Refer to Fig ures 30 or 31 Maintain 12 minimum clearance above highest anticipated snow level Maximum 24 above roof FIGURE 30 Termination Configuration 1 Pipe 12 vertical separation between combustion air intake and vent Maintain 12 minimum clearance above highest anticipated snow level 12 minimum below overhang 12 minimum separation between bottom of combustion air pipe and bottom of vent Maintain 12 minimum clearance above highest anticipated snow level or grade whichever is higher FIGURE 31 Termination Configuration 2 Pipe Johnson Controls Unitary Products 505309 UIM D 051 1 12 Minimum below overhang 12 Minimum separation between bottom of combustion air intake and bottom of vent Maintain 12 minimumclearance above highest anticipated snow level or grade whichever is higher FIGURE 32 Termination Configuration 2 Pipe Basement VENTING MULTIPLE UNITS Multiple units can be installed in a space or structure as either a single pipe configuration or a two pipe configuration The combustion air side of the single pipe configuration shown in Figure 30 i
66. n provides an adequate supply of air for combustion and ventilation A WARNING 12 minimum between bottom of air intake and any material below Be sure to instruct the owner not to block this intake pipe VENT BLOWER ROTATION For ease of venting the vent blower may be rotated 90 in either direc tion For upflow installations the vent may exit through the top or either side of the cabinet For downflow installations the vent blower must be rotated so that the vent exits through either side of the cabinet See Fig ures 24 27 for details FIGURE 39 Attic and Crawl Space Combustion Air Termination 28 Johnson Controls Unitary Products SECTION IX 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 tighiness When the gas supply is initially connected to the furnace the gas piping may be full of air n 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 GAS PIPING LEAK CHECK A WARNING FIRE OR EXPLOSION HAZARD Failure to follow the safety warning
67. nace 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 condition exists Check gas valve and gas valve wiring 11 RED FLASHES This indicates that the limit circuit has remained open for more than five minutes and less than fifteen minutes This con dition 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
68. nd air intake downwards If this is to be done the following rules must be fol lowed A condensate trap hose must be connected to both the air intake pipe and the vent pipe at the lowest part of the horizontal run The condensate drain trap must have a trap of a minimum of six inches The total vertical downward distance must not exceed sixteen feet The condensate drain hose must be connected to a condensate drain pump a open or vented drain or into the condensate drain line from the furnace The condensate drain lines must not pass through unconditioned spaces where the temperature may fall below freezing The condensate drain line must be primed at the initial start up prior to the start of heating season FIGURE 35 Downward Venting COMBUSTION AIR SUPPLY All installations must comply with Section 5 3 Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 or Sections 7 2 7 3 or 7 4 of CAN CGA B149 1 or 2 Installation Code latest edi tions This furnace is certified to be installed with one of three possible com bustion air intake configurations 1 OUTDOOR COMBUSTION AIR This is a direct vent configuration where the combustion air is supplied through a PVC or ABS pipe that is connected to the PVC coupling attached to the furnace and is terminated in the same atmospheric zone as the vent This type of installation is approved on all models Refer to Figure 35 2 AMBIENT COMBUSTION AIR Combus
69. nfiguration of flanges refer to Figure 3 FACTORY FLANGE LOCATION Used for upflow or horizontal right installations ALTERNATE FLANGE LOCATION Used 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 hd OC 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 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 Figure 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 Figur
70. ng Johnson Controls Unitary Products A VARNING This iype of installation requires that the suppiy air to the appliance s be of a sufficient amount to support all of the appliance s in the area Operation of a mechanical exhaust such as an exhaust fan kitchen ventilation system clothes dryer or fireplace may create 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 appliance to soot and gen erate dangerous levels of CARBON MONOXIDE which can lead to serious injury property damage and or death An unconfined space is not less than 50 cu ft 1 42 m3 per 1 000 Btu hr 0 293 kW h 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 m per 1 000 Btu hr 0 293 kW h 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 known refer to Table 12 t
71. o 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 six cycles per hour Follow the thermostat 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 505309 UIM D 051 1 For additional connection diagrams for all Johnson Controls Unitary Products equipment refer to Low Voltage System Wiring document available on line at www upgnet com in the Product Catalog Section AC 15A Two Stage Air Conditioner Two Stage PSC Furnace ID MODELS PT 8 9 F L 8 9 T G L 8 9 T THERMOSTAT THERMOSTAT TM9 vam 1 TWO STAGE PSC TWO STAGE DP22U70124 FURNACE ris CONDITIONER 2 TWO STAGE PSC FURNACE C C C C 24 Volt Common 24 Volt Common 24 Volt Common 24 Volt Common Y Y1 SCH Single Stage emm _ First Stage Compressor First Stage Compressor C First Stage Compressor ompressor R R R R 24 Volt Hot
72. o estimate free area Table 12 Estimated Free Area Wood or Metal Wood 20 2596 Louvers or Grilles Metal 60 70 Screens mesh or larger 100 Do not use less than 1 4 6 4 mm mesh Free area of louvers and grille varies widely the installer should follow louver or grille manufacturer s instructions Dampers Louvers and Grilles Canada Only 1 The 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 Gable Vent Ventilated Attic Attic Top Above nsulatio Optional Inlet a Ventilated Crawl Space FIGURE 38 Outside and Ambient Combustion Air Air Supply Openings and Ducts 1 An opening may be used in lieu of a duct to provide to provide the 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 AIR SOURCE FROM OUTDOORS AND VENT AND SUPPLY AIR SAFETY CHECK in these instructions for additional informa tion 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 The duct shall be least the same cross sectional area as the free area of the air supply inlet opening to which it connects Johnson Controls Unitary Products Ventilated
73. o 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 shipped 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 t
74. o 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 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 505309 UIM D 051 1 COIL INSTALLATION IMPORTANT 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 man ner as to prevent leaks COIL FURNACE ASSEMBLY MC FC PC SERIES COILS UPFLOW DOWNFLOW 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 co
75. ove the furnace For downflow or horizontal models the transition from 2 to 3 pipe should be done immediately after exit ing the furnace 7 n Canada vents shall be certified to ULC S636 Standard for Type BH Gas Venting Systems 8 In Canada the first three feet 91 4 cm of the vent must be readily accessible for inspection 9 For single pipe systems it is recommended to install the combustion air coupling provided and install approximately 18 46 cm of PVC pipe on the furnace 10 Minimum vent length for all models is 5 feet 1 5 m TABLE 8 Maximum Equivalent Pipe Length Maximum Equivalent length feet m 65 19 8 90 27 4 Model Input BTUH kW 60 000 60 000 60 000 Pipe Size Inches cm 2 5 1 3 7 6 80 000 2 5 1 65 19 8 45 7 100 000 4 10 2 150 45 7 120 000 2 5 1 30 9 1 120 000 3 7 6 90 27 4 4 10 2 50 45 7 Johnson Controls Unitary Products l l STANDARD ELBOW LONG SWEEP ELBOW FIGURE 28 Dimensions TABLE 9 Elbow Dimensions Elbow A Dimension Dimensions are those required in Standard ASTM D 3311 TABLE 10 Equivalent Length of Fittings 2 90 sweep elbow 5 feet of 2 pipe 2 45 sweep elbow 2 1 2 feet of 2 pipe 2 90 standard elbow 7 feet of 2 pipe 2 45 standard elbow 3 1 2 feet of 2 pipe 3 90 sweep elbow 5 feet of 3 pipe 3 45 sweep elbow 2 1 2 feet of 3 pipe 7 feet of 3 pipe 3 1 2 feet of 3 pipe 5 feet of 4 pipe 2 1 2
76. pen Or J Vented Drain FIGURE 22 Typical Condensate drain vertical installation Johnson Controls Unitary Products The condensate will flow to the drain better if an open stand pipe is installed in the drain line See Figure 22 If evaporator coil or humidifier drains are combined with the furnace drain then the open stand pipe could be raised higher above the 5 minimum NOTICE A loop has been added to the pressure switch vacuum hose How ever ensure that all pressure switch hoses are routed such that they prevent any condensate from entering the pressure switch ACAUTION It is possible for condensation to form inside the combustion air intake pipe in the summer months if significant length of combustion air pipe passes through conditioned space This problem can be averted by the addition of a simple drain tee or a drain tee with a drain on the combustion air pipe as close to the furnace as possible as shown in Figure 23 This is true for all long horizontal venting in any furnace configuration This will prevent the condensate from entering the furnace K Exhaust Pipe al xn T I Trap Combustion Air Pipe Tee with Drain Trap Connect to Drain FIGURE 23 Typical Combustion Pipe Drain Tee Johnson Controls Unitary Products 505309 UIM D 051 1 CONDENSATE DRAIN TERMINATION A condensate sump pump MUST be used if required by local codes or if no
77. plied 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 20 Johnson Controls Unitary Products 505309 UIM D 051 1 If furnace staging is desired with two furnaces on a common duct where the gas burner on the first furnace operates on W1 and the gas burner on the second furnace operates on VV2 then the use of an air mixing device in the plenum to mix the air from both furnaces 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 Vent Pipe P P v Electrical Eu Gas Supply Supply mos side
78. rgest input o 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 When a square or rectangular duct is used its small dimen sion shall not be less than 3 7 6 cm 6 An air inlet supply from outdoors shall be equipped with a means to prevent the direct entry of rain and wind 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 27 505309 UIM D 051 1 Combustion Air Source from Outdoors 1 Two permanent openings one within 12 30 5 cm of the top and one within 12 30 5 cm of bottom of the confined space Two per manent openings shall communicate directly or by means of ducts with the outdoors crawl spaces or attic spaces 2 One permanent openings commencing within 12 30 5 cm of the top of the enclosure shall be permitted where the equipment has clearances of at least 1 2 54 cm from the sides and back and 6 15 2 cm from the front of the appliance The opening shall com municate directly with the outdoors and shall have a minimum free area of a 1 square inch per 3000 BTU per hour 322 cm 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
79. ring method is to use a field provided 2 5 1 cm x 4 10 2 cm box and cover on the outside 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 wiring connections replace the wiring box cover and screws Refer to Figure 17 3 The furnace s control system requires correct polarity of the power supply and a proper ground connection Refer to Figure 17 12 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 18 or 19 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 t
80. s 1 Coil for T Each Furnace Cop S ir m FIGURE 20 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 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 The control in the furnace has the twinning feature With this feature a wire is connected between the TWIN t
81. s 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 residual air in the gas line or until gas manifold pressure is adjusted The igni tion 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 union and check for gas leaks Allow five minutes for any gas to dissipate before continuing with the startup 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 shutoff valve must be disconnected from the gas supply during any pressure testing of that system at test pres sures in excess of 0 5 psig 3 45 kPa The furnace must be isolate
82. s referred to in these instructions as ambient combustion air supply Follow the instructions for ambient combustion air installations paying particular attention to the section on air source from inside the building The vent for a single pipe system must be installed as specified in the venting section of these instructions with the vent terminating as shown in Figure 30 Each furnace must have a separate vent pipe Under NO circumstances can the two vent pipes be tied together The combustion air side of the two pipe configuration shown in Figure 31 can be installed so the combustion air pipe terminates as described in outdoor combustion air or ventilated combustion air sections in these instructions Follow the instructions for outdoor combustion air or venti lated combustion air and the instructions for installing the vent system with the vent terminating as shown in Figures 33 or 34 The two pipe system must have a separate combustion air pipe and a separate vent pipe for each furnace Under NO circumstances can the two combus tion air or vent pipes be tied together The combustion air and vent pipes must terminate in the same atmospheric zone COMBUSTIONAIR gt Pq MIN FIGURE 33 Double Horizontal Combustion Air Intake and Vent Termination FIGURE 34 Double Vertical Combustion Air Intake and Vent Termination 25 505309 UIM D 051 1 DOWNWARD VENTING In some applications it may be necessary to run the vent pipe a
83. separately For example if the table allows 65 equivalent feet for a particular model then the vent can have 65 equivalent feet of pipe AND the combustion air intake can have another 65 equivalent feet of pipe 3 Three vent terminal elbows two for the vent and one for the com bustion air intake are already accounted for and need not be included in the equivalent length calculation 4 All combustion air and vent pipe must conform to American National Standards Institute ANSI and American Society for Test ing and Materials ASTM standards D1785 Schedule 40 PVC D2665 PVC DWV F891 PVC DWV Cellular Core D2261 ABS DWV or F628 Schedule 40 ABS Pipe cement and primer must conform to ASTM Standard D2546 PVC or D2235 ABS If ABS pipe is to be used any joint where ABS pipe is joined to PVC pipe must be glued with cement that is approved for use with BOTH materials Metallic materials must not be used for venting or air intake 5 Ifa flexible connector is used in the vent system it must be made of a material that is resistant to acidic exposure and to at least 225 F 107 C temperature Flexible connectors are also allowed in the combustion air pipe 6 All models are supplied with 2 5 1 cm vent connections When the pipe must be increased to 3 7 6 cm diameter the transition from 2 to 3 must be done as close to the furnace as possible For upflow models the transition from 2 to 3 should be done immedi ately ab
84. shall also be handled by duct s sealed to the furnace casing and terminating outside the space containing the furnace 9 t 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 Proper vent installation Furnace operating under thermostatic control Return air duct sealed to the furnace Air filters in place Set furnace input rate and temperature rise per rating plate mark Ing Means for providing outdoor air required for combustion Return air temperature maintained between 55 F 13 C and 80 F 27 C The air filter must be replaced upon substantial completion of the construction process Clean furnace duct work and components upon substantial com pletion of the construction process and verify furnace operating conditions including ignition input rate temperature 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 occu pied spaces 11 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 always leave the doors on the furnace to provide support and to prevent damag
85. specified in these instructions and on the furnace 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 pre mature heat exchanger failure high levels of Carbon Monoxide a fire hazard personal injury property damage and or death BLOWER OFF DELAY JUMPER 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 41 and the unit wiring label to change the blower speed 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
86. ss Sx sasoy J sBuluado p sn un e deo o auns aq p uinb i sie sebueyo Sunnol esou uieJjp U UAA FIGURE 27 Horizontal Right Configuration 21 Johnson Controls Unitary Products 505309 UIM D 051 1 SECTION VIII COMBUSTION AIR AND VENT SYSTEM COMBUSTION AIR AND VENT SAFETY This Category IV dual certified direct vent furnace is designed for resi dential application It may be installed without modification to the con densate system in a basement garage equipment room alcove attic or any other indoor location where all required clearance to combusti bles and other restrictions are met The combustion air and the venting system must be installed in accordance with Section 5 3 Air for Com bustion 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 IMPORTANT The VENT SYSTEM must be installed as specified in these instruc tions for Residential and non HUD Modular Homes The direct vent system is the only configuration that can be installed in a non HUD A WARNING This furnace may not be common vented with any other appliance since it requires separate properly sized air intake and vent lines The furnace shall not be connected to any type of B BW or L vent or vent connector and not connected to any por
87. t against combustion product corrosion Consideration must be given to wind direction in order to prevent flue products and or condensate from being blown against the building surfaces If a metal shield is used it must be a stainless steel material at a minimum dimension of 20 inches 51 cm lt is recommended that a retaining type collar be used that is attached to the building sur face to prevent movement of the vent pipe 24 Johnson Controls Unitary Products VENT SYSTEM This furnace is certified to be installed with one of two possible vent configurations 1 Horizontal vent system This vent system can be installed com pletely horizontal or combinations of horizontal vertical or offset using elbows 2 Vertical vent system This vent system can be installed completely vertical or a combination of horizontal vertical or offset using elbows VENT APPLICATIONS AND TERMINATION When selecting the location for a combustion air vent termination the following should be considered 1 Observe all clearances listed in vent clearances in these instruc tions 2 Termination should be positioned where vent vapors will not dam age plants or shrubs or air conditioning equipment 3 Termination should be located where it will not be affected by wind gusts light snow airborne leaves or allow recirculation of flue gases 4 Termination should be located where it will not be damaged or exposed to flying stones balls etc 5 Ter
88. t is 4 10 2 cm attached to the ple num 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 5 1 cm minimum spacing may be needed to ensure against drain pan distortion 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 Johnson Controls Unitary Products 505309 UIM D 051 1 A WARNING The duct system must be properly sized to obtain the correct airflow for the furnace size that is being installed Refer to Table 7 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 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 s
89. that 1200 34 0 E 16 x 25 16 x 25 accessory If a filter s is provided at another location in the return air 1600 45 3 16 x 25 20 x 25 system the ductwork may be directly attached to the furnace side 2000 56 6 2 16 x 25 20 x25 pane 2000 56 6 D 216x25 22x 25 Some accessories such as electronic air cleaners and pleated media 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 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 13 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 side return with a transition to allow use of a 20x25 filter Johnson Controls Unitary Products 9 505309 UIM D 051 1 HORIZONTAL APPLICATION ACAUTION 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 locate
90. 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 Maintain 6 minimum clearance between support rods and front of furnace FIGURE 11 Typical Suspended Furnace Crawl Space Installation DOWNFLOW APPLICATION To apply the furnace in a downflow position it will be necessary to rotate the vent blower 90 left or right so that the vent pipe passes through the side of the furnace casing See Figure 12 Rotate vent blower 90 either way LEFT SIDE VENT RIGHT SIDE VENT FIGURE 12 Downflow Venting Johnson Controls Unitary Products 505309 UIM D 0511 LEFT SIDE RIGHT SIDE Combustion Air Inlet Combustion Air Inlet 31 Drain Gas Pipe Gas Pipe anlamasa Drain ownflow Entry Entry Od Downflow Electrical I Entry Electrical Entry Vent Outlet Condensate Drain Condensate O e 23 Drain Thermostat il il VViring Thermostat Optional Return Air Ni iring Cutout Either side NY 2 29 5 For Cladded door add appoximately an a
91. tion air is supplied from the area surrounding the furnace through openings in the furnace casing The combustion air and the vent pipes are not terminated in the same atmospheric zone Refer to Figure 21 for vent termina tions Refer to Ambient Combustion Air Supply for proper installa tion Refer to Figure 36 3 VENTILATED COMBUSTION AIR Combustion air is supplied through a PVC or ABS pipe that is connected to the PVC coupling attached to the burner box and is terminated in a ventilated attic or crawl space The combustion air and the vent pipes are not termi nated in the same atmospheric zone Refer to Figure 38 for attic and crawl space termination Only the combustion air intake may terminate in the attic The vent must terminate outside 26 Outdoor Combustion Air Combustion Air Intake Vent Connections This installation requires combustion air to be brought in from outdoors This requires a properly sized pipe Shown in Figure 35 that will bring air in from the outdoors to the furnace combustion air intake collar on the burner box The second pipe Shown in Figure 35 is the furnace vent pipe NOTICE An optional plastic birdscreen is shipped in the loose parts bag with every furnace This may be installed in the intake collar to prevent any small objects from entering the furnace The combustion air intake pipe should be located either through the wall horizontal or side vent or through the roof vertical vent C
92. tion of 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 ACAUTION When combustion air pipe is installed above a suspended ceiling or when it passes through a warm and humid space the pipe must be insulated with 1 2 Armaflex or other heat resistant type insulation if two feet or more of pipe is exposed Vent piping must be insulated if it will be subjected to freezing temper atures such as routing through unheated areas or through an unused chimney COMBUSTION AIR VENT PIPE SIZING The size of pipe required will be determined by the furnace model the total length of pipe required and the number of elbows required Table 8 lists the maximum equivalent length of pipe allowed for each model of furnace The equivalent length of elbows is shown in Table 9 The equivalent length of the vent system is the total length of straight pipe PLUS the equivalent length of all of the elbows The following rules must also be followed 1 Long radius sweep elbows are recommended Standard elbows may be used but since they have a longer equivalent length they will reduce the total length of pipe that will be allowed Short radius plumbing vent elbows are not allowed The standard dimensions of the acceptable elbows are shown below 22 2 The maximum equivalent length listed in Table 8 is for the vent pip ing and the air intake piping
93. tions All units are factory assembled wired and tested to assure safe dependable and economical installation and oper ation These units are Category IV listed and may not be common vented with another gas appliance as allowed by the National Fuel Gas Code SECTION I 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 lt is also used to alert against unsafe practices and hazards involving only property dam A WARNING Improper installation may create a condition where the operation of the product could cause personal injury or property damage Improper installation adjustment alteration service or maintenance can cause injury or property damage Failure to carefully read and follow all instructions in this manual can result in furnace mal function death personal injury and or property damage Only a qualified contractor installer or service agency should install this product SPECIFIC SAFETY RULES AND P
94. u o asoy Jonn ules AOVN uieJp ojesuepuoo Bueuo S daJ3Al3938 SV YSONANI 1331 WLNOZIYOH O 138IV 4011800 51 o esou uieJp ojesuepuoo AOV N Bum 06 au DOE siu O esou UOn uuo UIEID J pn ules AO N O ojesuepuoo eDueu v SI UIQE JOPIM iM 51 ey esou m y aumbas Ae J LON uonisod SIU SOU uojMs eJnsseJd AO N per sou eJint SIU O MOTJAIV da31VW1084 ea3oridNi 1331 WLNOZIYOH 8jeJedo jou o eoeuunj ay esneo IAA YOIUM ejesuspuos DIOU pue 199 09 IAA sdoo buibbes ou zey os jo 1no eq pinous u Bu sseoxe sesou Huno y s5ulu do p snun Ile deo o euns aq sie seDueuo Hunnos sou uieJjp U UAA FIGURE 26 Horizontal Left Configuration Johnson Controls Unitary Products 20 505309 UIM D 051 1 UOIISOA siy o SSOY d nin ures SAO uonisod 511 o sou ureJp pepiAoid Bum O ANNE ERE ejesuepuoo Bueuo 03 1 SV YSONANI LHOIY IVLNOZIHOH MO 13 UOnisod siu O sou UleJp ojesuapuoo AOVN pepi oJd Bu 06 ay UOIj2euuoo UleJp ojesuepuoo oDueu 0111504 SIU sou Jeyn6 ules AOV 5 MO 138IV 031 YSONGNI 1H9IY TVLNOZIHOH eje1edo jou o eoeuunj SU esneo YOIUM esu puoo DIOU pue 199 09 m sdoo buibbes ou zey os yo 1no eq pinous u Bu
95. ul YOZ 001 104 For 060 080K input furnaces the condensate drain is plumbed toward the right casing outlet from the factory eje1edo jou o v esneo JIM YOIUM SjesUSpuos DIOU pue 199 09 m sdoo buibbes ou zey os yo 1nd eq pinous yjBua sseoxe sasoy Bunno a J sBuluado p sn un e deo o euns aq sie sebueuo Sunnol esou uieJjp usy Upflow Configuration FIGURE 24 Johnson Controls Unitary Products 18 505309 UIM D 051 1 ONILNSAA ACIS 1 404 ONLLN3A 4015 1441 403 031 1 04 43I9NUONI MOTANMOd 0317 104 43I9NMUONI MO 14 q ulqeo y JO epis Joie yxa Aew uonisod si O sou UIeIP YESU PUO AOVN f UOnnisod siy o esou Jon ules 9AO A S JQUIQLI JOpIM D DIAO1d si 18 esou au oJinbeJ BIN 2 LON UOnisod siy o sou U91IMS 95 AOVN 2 uonisod stu o sou Jaymb UIeJ 9AO A O ejeJedo jou o eoeuunj ay esneo YOIUM ejesuapuos DIOU pue 199 09 IAA sdoo buibbes ou zey os yo 1no eq pinous ujBbua sseoxe sasoy BunnoJa J sDuiuedo p sn un e deo oj euns aq sue sebueuo Huno esou uieJp U UAA FIGURE 25 Downflow Configuration Johnson Controls Unitary Products 19 505309 UIM D 051 1 uonisod SJQUIGED UUM p piAO1d 51 15U pepi oJd SIU O asoy uieJp uoIsua xa asoy aJmbal Ap 3 LON Bull 06 eu 0 uonoeuuoo ojesuepuoo OAOIN uonisod si
96. ustion and Ventilation 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 Society of Heating Refrigeration and Air Conditioning Engineers ASHRAE 1997 Fundamentals Handbook Chapter 32 STEP 5 Acoustical Lining and Fibrous Glass Duct e 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 CANADA NSCNGPIC Part 5 STEP 7 Electrical Connections 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 standards 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 505309 UIM D 051 1 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
97. vent air leakage BOTTOM RETURN AND ATTIC INSTALLATIONS 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 505309 UIM D 051 1 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 from the furnace Sediment Trap FIGURE 10 Typical Attic Installation This appliance is certified for line contact when the furnace is installed in the horizontal 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 A WARNING When a furnace is installed in an attic or other insulated space keep all insulating materials at

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