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Johnson Controls GG9S*MP User's Manual

1. 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 Single Wire Twinning The control in the furnace has the single wire twinning feature With this feature a single wire is connected between the TWIN terminal on one furnace board to the TWIN terminal on the second furnace board The board then communicates the blower status from one furnace to the other along this wire This communication makes the second furnace blower come on at the same time and
2. no uo ap dwos a I SALON UOILOSUSPUO uoiscaJd op 1hs 051j IP WMH 9nb1J 29 9 S10 oy 118 PFW 4 0 0 Jn24120d05 dV Sid 2 D 9 2D dor04 JN WJOJSUDJ Sid p D 106 adodnos 9 Sid 21 0 920149293 01503290 i PNOY JDJ INS op UO 41 Ub 04 00155910 INIO nuUo INd OW jonpur NG Jn2 D DUO 91 105 LON a4 Jod JONI94 MAX WOD ASII 35 JIOULNOD DYNAN N315 033l X18 N3O 2Q 4SMW 41 99 4SnW 9220UJn Jol ji plwny Kn oy 041 2000 JOWJO SUO IAJOA 800 fOPSOWJOYY DM Josuas 900 10 0 1920 01 0 12117 NYO S5 Ste 5 OU YIM poljddns SO SILON WMH 118 dV UN AX M 151 LON N 391 I WOJ Id MAX DWASLL 18 IH ma 33 03345 313 4018 LAVH 335 X18 d34 SON IHAVQ3S HILIMS LNOTION INO SVH 2 LNdNI 000 0 DVASLL 9 Q 63 SsieuJnoJ 66 JUBWAPIOI eY 0 3 0 U9pUO QOLIMS 92155924 J9UD9 2 JID 21002293 qus pJboq 0J1U0D UO 9205 UId 2 02004 0 00 UO 0 UId p 1000 0J U0
3. RESIDENTIAL GAS FURNACE MODELS TG9S MP GG9S MP 95 5 AFUE Single Stage Multi position ll mr hc dal 8288 48 4 1 Bh RS eee eC BC DU Whee 17 UP NR ZEE 802 Ll A a a AED X b Il b 0 1 34H w A4 EM 0 St lL A9 Aam ERA WM GS Mi 2 7 1 4 Pai HN 1 2E EM NEM uw LAO ADM o OW AD LL LM 2 WB MA Ee BM M Ku wQ AU 1 Y OM Z7 A M I le NN on AND on E 10 D 1 1010 CRC _ ___ x LL LLL E A EC 427 I 2 E L8 Aw UNUM AE A A Uu UM 1 w v IBBU O A A WM A DUM LL 1 21 A UM Lu LL 3 hl DEM 1 1 E 3 ________ _ ___3 ______ L I 1 OU Ap WW OM UD AJ BB M aM Uu UU I D Jg I E 1 14207 ie CT 1 M WM 2 0 D M 0M LL lll DM 0 M J4D 9 M D I 2 m e 1 3 Lo _ LEM 2 E OM AO D E L ww Ui 3 hM S i DM A uM P oL 9 L EO E 1002 08008 CE O A S WE EFFICIENCY RATING CERTIFIED j inp REGIS m ISO 9001 Certified Quality Management System LIST OF SECTIONS SAPETY cigar tater EE Vi nU ud OP d 1 COMBU
4. nance can cause injury or property damage Failure to carefully read and follow all instructions in this manual can result in fur nace malfunction death personal injury and or property dam age Only a qualified contractor installer or service agency should install this product 364861 UIM B 0708 364861 UIM B 0708 SPECIFIC SAFETY RULES AND PRECAUTIONS 1 2 Only Natural gas or Propane LP gas are approved for use with this furnace Install this furnace only in a location and position as specified in these instructions A gas fired furnace for installation in a residential garage must be installed as specified in these instructions Provide adequate combustion and ventilation air to the furnace space as specified in these instructions Combustion products must be discharged outdoors Connect this furnace to an approved vent system only as specified in SEC TION VIII COMBUSTION AIR and VENT SYSTEM of these instructions Test for gas leaks as specified in these instructions 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 prop erty damage personal injury or loss of life Always install the furnace to operate
5. SUPPLY END RETURN END FIGURE 12 Dimensions Table 3 Cabinet and Duct Dimensions Approximate Operating Weights 80076 120040 B 1712 444 1638 as 337 122 80984 1200040 1712 444 i638 416 i434 375 1 120851 160453 D 2412 62 2338 594 2134 552 153 120051 2000 566 D 2412 622 2338 594 zi34 552 156 180981 2000668 D 2412 622 2838 594 NoHole NoHoe 160 BTUH kW Nominal Cabinet Cabinet Dimensions Inches 7 T fias SECTION 111 FILTERS Table 4 Recommended Filter Sizes High Velocity 600 FPM FILTER INSTALLATION CFM Cabinet Side Bottom All applications require the use of a field installed filter All filters and in mounting provision must be field supplied Filters must be installed external to the furnace cabinet DO NOT attempt to install filters inside the furnace NOTE Single side return above 1800 CFM is approved as long as the 1200 34 0 16 x 25 16 x 25 filter velocity does not exceed filter manufacturer s recommendation 1600 453 16 x 25 16 x 25 and a transition is used to allow use on a 20x25 filter 2200 62 3 2 16 x 25 20 x 25 2000 56 6 D 2 16x25 22 x 25 NOTES 1 Air velocity through throwaway type filters may not exceed 300 feet per minute 91 4 m min All velocities over this
6. testing of the gas supply piping system at pressures equal to or less but may be converted to operate on propane LP gas by using a fac than 1 2 psig 3 5 kPa tory supplied LP conversion kit Follow the instructions supplied with the LP kit A CAUTION HIGH ALTITUDE GAS ORIFICE CONVERSION The gas valve body is a very thin casting that cannot take any This furnace is constructed at the factory for natural gas fired operation external pressure Never apply a pipe wrench to the body of the gas at 0 5 000 feet 0 m 1 524 m above sea level valve when installing piping A wrench must be placed on the octa a gon hub located on the gas inlet side of the valve Placing a wrench The manifold pressure must be changed in order to maintain proper to the body of the gas valve will damage the valve causing improper and safe operation when the furnace IS installed location where the operation and or the valve to leak altitude is greater than 5 000 feet 1 524 m above sea level Refer to Table 5 Nominal Manifold Pressure High Fire for proper manifold Gas piping may be connected from either side of the furnace using any pressure settings of the gas pipe entry knockouts on both sides of the furnace Refer to Figure 12 Dimensions HIGH ALTITUDE PRESSURE SWITCH CONVERSION For installation where the altitude is less than 5 000 feet 1 524m it is not required that the pressure switch be changed unless you are in an area subject to low pressu
7. 10 1d92X3 Q3AI3O3M SV LH9IM TVLNOZIHOH uonisod 8191 9SOU ojesuopuoo anon pepiAoJd 06 94 uleJp ojesuapuoo MO 14a UOI ISOd 610 MO 138IV qa3lvLOs IVLNOZIHOH jou eoeuunj SU esneo YOIUM pue 108 02 sdoo ou zey os Ho 1no eq 5 sesou BurnnoaJolJ J sDBuiuedo pesn un deo euns eq peuinbeJ seDueuo esou ueuM FIGURE 26 Horizontal Right Configuration Johnson Controls Unitary Products 20 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 instr
8. 1 21 Combustible Floor Base Accessory 7 HOME ILAYOUL PET 23 Horizontal 2 ees s i ntm eee 7 Termination Configuration 1 Pipe 24 Typical Attic Installation 7 Termination Configuration 2 Pipe 24 Typical Suspended Furnace Crawl Space Installation 7 Termination Configuration 2 Pipe Basement 24 __ 8 Double Horizontal Combustion Air Intake and Vent Termination 24 Side Return Cutout Markings 9 Double Vertical Combustion Air Intake and Vent Termination 24 Gas VAI 9 Direct Vent Air Intake Connection and Vent Connection 25 Upflow Downflow Gas Piping 9 Combustion Airflow Path Through The Furnace Casing 25 Horizontal Gas Piping 9 Outside and Ambient Combustion 26 Electical WING nimc po reeks eee pba owe 11 Attic and Crawl Space Combustion Air Termination 27 Thermostat Chart Single Stage AC with GaS VAVE serae sirean raie eE eee esas 30 Single Stage PSC Furnaces 12 Reading Gas Pressure 30 Thermostat Chart Single Stage HP wi
9. FIGURE 24 Downflow Configuration Johnson Controls Unitary Products 18 364861 UIM B 0708 uonisod 10 esou uieJp Sjeuiqeo JOPIM UUM SI jeu uoisuojxe Ae 3 LON pepi oud 06 94 0 uonoeuuoo uonisod esou 1ejyn6 ules eAo A ojesuopuoo ebueuD 9 IPPON 104 1092 9 SV YSONGNI 1491 IWLNOZINOH MO 14 du uonisod siu 0 9509 06 84 uonisod Siu 0 esou T JOpIM pepi oJd si esou JeBuo y euinbeJ 3 LON uonisod SIU 9SOU YOUMS 9JnssaJd Z MO 14 ae l4d 1l WLNOZIYOH jou 0 y esneo YOIUM pue 108 02 sdoo ou zey os Ho 1no eq pjnoyus sseoxe sesou J sDBuiuedo pesn un deo eq peJuinbeJ Bunos esou ueuM FIGURE 25 Horizontal Left Configuration 19 Johnson Controls Unitary Products 364861 UIM B 0708 UOIISOd 10 0 9509 UO ISOd siy esou pepi oud Bum Jenn SAO CET 06 94 0 uonoeuuoo ojesuepuoo 2 5 ISpOIN
10. Heater Ventilated Crawl Space FIGURE 36 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 appli ance Refer to AIR SOURCE FROM OUTDOORS AND VENT AND SUPPLY AIR SAFETY CHECK in these instructions for additional information and safety check procedure 2 The duct shall be either metal or a material meeting the class 1 requirements of CAN4 S110 Standard for Air Ducts 3 The duct shall be least the same cross sectional area as the free area of the air supply inlet opening to which it connects 4 The duct shall terminate within 12 in 30 5 cm above and within 24 in 61 cm horizontally from the burner level of the appliance having the largest input 5 A square or rectangular shaped duct shall only be used when the required free area of the supply opening is 9 in 58 06 cm or larger When a square or rectangular duct is used its small dimen sion shall not be less than 3 in 7 6 cm 6 Anair 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 26 Ventilated Table 13 Free Area Minimum Free Area Required for
11. 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 2 CONTROL BOARD FURNACE 1 CONTROL BOARD COR TWIN Y ISOLATION RELAY mm WALL THERMOSTAT FIGURE 21 Single Stage Twinning Wiring Diagram STAGING This control can also be used along with a two stage wall thermostat to stage two twinned furnaces making them operate like a single two stage furnace This allows only one furnace to supply heat during times when the heat output from one furnace is sufficient to satisfy the demand When one duct system is used for two furnaces it is neces sary that the two blowers operate in unison The twinning function of this board ensures that both blowers turn on and off simultaneously and operate on the same blower speed Even when only one furnace is supplying heat both furnace blowers must run Single Wire Staging The single wire twinning feature of this board can also be used for stag ing of two furnaces With this feature a single wire is connected between the TWIN terminal on one furnace board to the TWIN terminal on the second furnace board The board then communicates the blower status from one furnace to the other along this wire This communica tion makes the second furnace blower come on at the same ti
12. 23 4 65 90 65 90 65 80 000 23 4 90 100 000 29 3 100 000 29 3 90 27 4 29 3 pu qo __ 050 35 1 O PO PO IG AIG A G OD MD MO OE C3 120000583 __3076 9074 NE NEN STANDARD ELBOW LONG SWEEP ELBOW FIGURE 27 Dimensions TABLE 8 Elbow Dimensions Ebow A Dimension _ 2 Standard 2 5 16 3 Standard 3 1 16 Sweep 4 1 16 Dimensions are those required in Standard ASTM D 3311 21 364861 UIM B 0708 TABLE 9 Equivalent Length of Fittings Equivalent Length 5 feet of 2 pipe 2 1 2 feet of 2 pipe 10 feet of 2 pipe 2 90 sweep elbow 2 45 sweep elbow 2 90 standard elbow 2 45 standard elbow 3 90 sweep elbow 5 feet of 3 pipe 3 45 standard elbow Example An 80 000 BTUH furnace requires 32 feet of pipe and four 90 elbows Using 2 pipe and standard elbows the total equivalent length will be 32 feet of 2 pipe 4 90 standard 2 elbows 4x10 Total 32 equivalent feet 40 equivalent feet 72 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 4 90 standard 2 elbows 4x5 Total 32
13. equivalent feet 20 equivalent feet 52 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 4 90 standard 2 elbows 4x5 Total 32 equivalent feet 40 equivalent feet 72 equivalent feet of 3 pipe This is less than the 90 foot maximum equivalent length of 3 pipe allowed for that model and is thus acceptable TABLE 10 Combustion Air Intake and Vent Connection Size at Furnace All Models FURNACE VENT CONNECTION SIZES 40 100 MBH 120 130 MBH 17 5 29 3 kW 35 2 39 6 kW 2 5 1 cm 3 7 6 cm Furnace Input Intake Pipe Size Vent Pipe Size 2 5 1 cm 2 5 1 cm Vent pipe size must be increased to 3 diameter after connection to furnace on this model 22 IMPORTANT Accessory concentric vent intake termination kits 1CTO302 and 1C T0303 are available and approved for use with these furnaces Horizontal sidewall vent terminations kits 1HTO901 amp 1HT0902 are also approved for use with these furnaces 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 ver tical pipe section to allow proper drainage of condensate An offset using two 45 degree elbows will be required for plenum clear ance when
14. 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 A CAUTION DO NOT bottom out gas valve regulator adjusting screw This can result in unregulated manifold pressure and result in excess over fire and heat exchanger failures 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 9 for cubic feet of gas per hour 5 Multiply cubic feet per hour by heating valve BTU cu ft to obtain input If clocked rate does not match the input rate from the unit nameplate follow steps in next section to adjust the manifold pressure Repeat steps 2 5 until correct input is achieved A CAUTION Be sure to relight any gas appliances that were turned off at the start of this input check Johnson Controls Unitary Products 364861 UIM B 0708 Table 14 Gas Rate CU FT HR at Full Input Seconds For Size of Test Dial Seconds For Size of Test Dial Revolution Revolution i 1800 n 13 124 310 i 16 116 290 E 19 106 265 257 Johnson Controls Unitary Products 29 364861 UIM B 0708 ADJ USTMENT OF MANIFOL
15. 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 AA WL isis Aes Junction kr a read J Box TE 9 HI Connect ground p ENN lead to screw Electrical Entry L1 Hot BLK Neutral WHT AR s RR 89 17 rr E FIGURE 17 Electrical Wiring 1 Provide a power supply separate from all other circuits Install overcurrent protection and disconnect switch per local national electrical codes The switch should be close to the unit for conve nience in servicing With the disconnect or fused switch in the OFF position check all wiring against the unit wiring label Refer to the wiring diagram in this instruction 2 Remove the screws retaining the wiring box cover Route the power wiring through the opening in the unit into the junction box with a conduit connector or other proper connection In the junc tion box there will be 3 wires a Black Wire a White Wire Connect the power supply as shown on the unit wiring label on the inside of the blower compartment door or the wiring schematic in this sec tion The black furnace lead must be connected to the L1 hot wire from the power supply The white furnace screw must be con nected to neutral Connect the power supply ground to th
16. 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 Typical Twinned Furnace Application If furnace staging is desired with two single stage furnaces on a com mon duct where the gas burner on the first furnace operates on W1 and the gas burner on the second furnace operates on W2 then the use of an air mixing device in the plenum to mix the air from both fur naces is strongly recommended The mixing device must be installed before any ducts that supply air to occupied spaces Twinning causes both indoor fans to operate simultaneously If a mixing device is not used any ducts that are connected down stream from the furnace that operates on W2 will be supplying cold air in the Heating mode to the occupied spaces unless W2 is energized 14 Vent Pipe Gas Supply Both sides Electrical 1 Coil for Each Furnace 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 A CAUTION
17. on the same speed as the first furnace blower Single Wire Twinning Instructions Connect the control wiring as shown in Figure 21 Single Stage Twin ning Wiring Diagram 1 Connect the low voltage wiring from the wall thermostat to the ter minal strip on the control board of Furnace 1 2 Connect a wire from the TWIN terminal of Furnace 1 to the TWIN terminal of Furnace 2 3 Install a separate 24V relay as shown in the diagram below Use of this relay is required as it ensures that the transformers of the two furnaces are isolated thus preventing the possibility of any safety devices being bypassed Johnson Controls Unitary Products Single Wire Twinning Operation Heating On a call for heat W signal from the wall thermostat both furnaces will start the ignition sequence and the burners on both fur naces will light About thirty seconds after the burners light the blowers on both furnaces will come on in heating speed When the thermostat is satisfied the burners will all shut off and after the selected blower off delay time both blowers will shut off at the same time The twinning control ensures that both blowers come on and shut off at the same time Cooling On a call for cooling Y signal from the wall thermostat both furnace blowers will come on at the same time in cooling speed When the thermostat is satisfied both blowers will stay on for 60 seconds then will shut off at the same time Continuous Fan
18. 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 CONDENSATE PIPING AND FUR NACE VENTING CONFIGURATION for tubing connections 1 Blockage of vent piping or terminal 2 Failure of combustion air blower motor 3 Blockage of combustion air piping or terminals 4 Blockage of condensate drain piping 31 364861 UIM B 0708 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 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 SEQUENCE OF OPERATION The following describes the sequence of operation of the furnace Refer to Owners Manual for component location Continuous Blower Cooling heating thermostats have a fan switch that has an ON and AUTO position In the ON position the thermostat circuit is completed between terminals R and G The motor will operate continuously on the speed tap
19. require the use of high velocity filters 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 8 Johnson Controls Unitary Products SIDE RETURN Locate the L shaped corner locators These indicate the size of the cut out to be made in the furnace side panel Refer to Figure 13 Side Return Cutout Markings B A P L FIGURE 13 Side Return Cutout Markings 4 Furnace Side of Furnace Markings Install the side filter rack following the instructions provided with that accessory If a filter s is provided at another location in the return air system the ductwork may be directly attached to the furnace side IMPORTANT Some accessories such as electronic air cleaners and pleated media may require a larger side opening Follow the instructions supplied with that accessory for side opening requirements Do not cut the opening larger than the dimensions shown in Figure 12 Dimensions HORIZONTAL APPLICATION Horizontal Filters A CAUTION 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 suppo
20. the air conditioning and heating equipment and to and from the condi tioned space A CAUTION The cooling coil must be installed in the supply air duct down stream of the furnace Cooled air may not be passed over the heat exchanger When the furnace is used with a cooling coil the coil must be installed parallel with or in the supply air side of 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 temperatur
21. 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 jurisdiction provides an adequate supply of air for combustion and ventilation 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 23 26 for details FIGURE 37 Attic and Crawl Space Combustion Air Termination Johnson Controls Unitary Products 27 364861 UIM B 0708 SECTION IX START UP AND ADJ USTMENTS The initial start up of the furnace requires the following additional procedures IMPORTANT All electrical connections made in the field and in the factory should be checked for proper tightness When the gas supply is initially connected to the furnace the gas piping may be full of air In order to purge this air it is recommended that the ground union be loosened until the odor of gas is detected When gas is detected immediately retighten the union and check for leaks Allow five minutes for any gas
22. the furnace control board in the blower com partment Refer to Figure 40 Furnace Control Board and the unit wir ing label to change the blower speed To use the same speed tap for heating and cooling the heat terminal and cool terminal must be con nected using a jumper wire and connected to the desired motor lead Place all unused motor leads on Park terminals Two park terminals are provided A CAUTION Do not energize more than one motor speed at a time or damage to the motor will result ADJ USTMENT OF FAN CONTROL SETTINGS This furnace is equipped with a time on time off heating fan control The fan on delay is fixed at 30 seconds The fan off delay has 4 settings 60 90 120 and 180 seconds The fan off delay is factory set to 120 sec onds The fan off setting must be long enough to adequately cool the furnace but not so long that cold air is blown into the heated space The fan off timing may be adjusted by positioning the jumper on two of the four pins as shown in Figure 40 Furnace Control Board PARK PARK 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
23. the two vent pipes be tied together The combustion air side of the two pipe configuration shown in Figure 30 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 32 or 33 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 COMBUSTION AIR 274 MIN FIGURE 32 Double Horizontal Combustion Air Intake and Vent Termination FIGURE 33 Double Vertical Combustion Air Intake and Vent Termination Johnson Controls Unitary Products COMBUSTION AIR SUPPLY All installations must comply with Section 5 3 Air for Combustion and Ventilation of the National Fuel Gas Code ANSI 2223 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 attach
24. 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 FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in serious injury death or property damage Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections A fire or explosion may result causing property damage personal injury or loss of life IMPORTANT Burner ignition may not be satisfactory on first startup due to resid ual air in the gas line or until gas manifold pressure is adjusted The ignition control will make three attempts to light before locking out It is recommended that when the gas supply is first connected to the furnace the ground union be loosened until the odor of gas is detected When gas is detected immediately tighten the 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 pe
25. within the furnace s intended temperature rise range Only connect the furnace to a duct system which has an external static pressure within the allowable range as specified on the furnace rating plate When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace the return air shall also be handled by duct s sealed to the fur nace casing and terminating outside the space containing the fur nace It is permitted to use the furnace for heating of buildings or struc tures under construction where the application and use must com ply with all manufacturer s installation instructions including Proper vent installation e Furnace operating under thermostatic control Return air duct sealed to the furnace e Air filters in place Set furnace input rate and temperature rise per rating plate marking 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 completion of the construction process and verify furnace operating conditions including ignition input rate temperature rise and venting according to the manufacturer s instructions When installed in a Non HUD Approved Modular Home or building constructed on site c
26. 080K input furnaces the condensate drain is plumbed toward the right casing outlet from the factory eu seoeuJnj INdUI MOE JL 9 04 001 104 eu yo pequunjd si ureJp Buiuedo epis e eq ji dO JO SUOISIAOJG JOU J PON M OEL jou eoeuunj esneo YOIUM pue 108 02 sdoo ou zey os Ho 1no eq pjnous sseoxe sesou Huno J sDuiuedo pesn un deo oj euns eq p nb sebueuo esou uieJjp ueuM FIGURE 23 Upflow Configuration Johnson Controls Unitary Products 17 364861 UIM B 0708 ONLLN3A 3015 LHOIY QR 1331304 Q31V LOM G3LVLOY MOTJNMOQ siy 9509 UONISOd si 9509 Jeynb ules JapiM pepi oJd si jeu 9509 eui LON siy esou U91IMS eJnssaJd 9AO A 1 jou eoeuunj esneo YOIUM pue 99 09 sdoo ou zey os 1no eq pjnous sesou J sDBuiuedo pesn un deo oj euns eq p nb seDueuo Huno esou ueuM
27. 5 T G G9S080B12MP11 65 High 35 F 65 F 65 0 1 G G98060A10MP11 aa o 2 1 o 2 G T G G9S080C16MP11 90 35 F 65 F 6 66 95 Meg HOC G o 7 KCA 30 80 E 35 65 7 T G G98120D16MP11 90 0 G 7 89 T G G9S120D20MPT1 35 F 65 ae ___ ___ 1 For venting purposes one 90 sweep elbow is equal to 5 Ft of venting length one 90 standard elbow is equal to 10 equiva lent feet of vent length Vent termination elbows are not included in these calculations minimum required vent length is 15 ft 2 Must be changed if not in rise range 40 F 70 F 95100 16 1 3 2 Copyright 2008 by Johnson Controls Inc rights reserved LU LLL LL Supersedes 401260 URG B 0708 Johnson Controls Unitary Products 5005 York Drive Norman OK 73069 This document does not replace the installation instructions which must be referred to for detailed information SUPPLY END 2 Diameter RETURN END IMPORTANT Vent Connection Outlet T DURING INSTALLATION DOORS MUST REMAIN ON FURNACE WHEN MOVING catered OR LIFING Clips can be flipped into the up position Z 56 20 24 25 for coil cabinet or plenum attachment Combustion Air Inlet Combustion Air Inlet Condensate Drain i Downflow Gas Pipe Condensate Drain En
28. 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 The furnace requires OUTDOOR AIR for combustion when the furnace is located in any of the following environments Restricted Environments e Commercial buildings Buildings with indoor pools Furnaces installed in laundry rooms Furnaces installed in hobby or craft rooms e Furnaces installed near chemical storage areas Chemical exposure The furnace requires OUTDOOR AIR for combustion when the furnace is located in an area where the furnace is being exposed to the follow ing substances and or chemicals Permanent wave solutions Chlorinated waxes and cleaners Chlorine based swimming pool chemicals e Water softening chemicals De icing salts or chemicals Carbon tetrachloride Halogen type refrigerants Cleaning so
29. D 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 38 Gas Valve 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 manifold pressure must be taken at the port marked OUT 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 39 Reading Gas Pressure for connection details 1 Turn gas and electrical supplies on and follow the operating instructions to place the unit back in operation Table 15 Inlet Gas Pressure Range INLET GAS PRESSURE RANGE 1 NawaGes Propane 8 0 W C 1 99 kPa 13 0 8 24 kPa W C 4 5 W C 1 12 kPa 10 5 W C 2 61 kPa IMPORTANT The inlet gas pressure operating range table specifies what the minimum and maximum gas line pressures must be f
30. Each Opening Vertical Duct or Opening to Outside A000 DUM 4 000 BTUH 00 97 on 20 in 129 on asin 161 or 615 sto 7 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 Round Duct 4 000 BTUH Horizontal Duct Outlet Air b 7 air supply inlet opening from the outdoors shall be located not less than 12 30 5 cm above the outside grade level Combustion Air Source from Outdoors 1 Two permanent openings one within 12 in 30 5 mm of the top and one within 12 in 30 5 mm of bottom of the confined space Two permanent openings shall communicate directly or by means of ducts with the outdoors crawl spaces or attic spaces 2 One permanent openings commencing within 12 in 30 5 mm of the top of the enclosure shall be permitted where the equipment has clearances of at least 1 in 2 54 cm from the sides and back and 6 in 15 24 cm from the front of the appliance The opening shall communicate directly with the outdoors and shall have a min imum free area of a 1 square in per 3000 Btu per hour 6 45 cm3 per 0 879 kW of the total input rating of all equipment located in the enclosure b Not less than the sum of all vent connectors in the confined space 3 The du
31. FLASHES This indicates that after the unit was operating the pressure switch opened 4 times during the call for heat If the main blower is in a Delay on mode it will complete it and any subsequent delay off period 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 This no light condition occurred 3 times 2 retries during the call for heat before locking out Low gas pressure faulty gas valve dirty or faulty flame sensor faulty hot surface ignitor or burner problem may cause this The furnace will lock out for one hour and then restart 8 RED FLASHES This fault is indicated if the flame is lost 5 times 4 recycles during the heating cycle This could be caused by 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 or grounding problem 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 10 RED FLASHES Flame sensed with no call for heat Check gas valve and gas valve wiring 11 RED FLASHES This indicates that a primary or auxiliary limit switch has opened its normally closed contacts and has remained open for more than five minutes This condition is usually caused by a failed blower motor or blower wh
32. G 8 9 8 GF 8 9 E R RHS G 9F LF8 E ZD HP L Y M 8S G T G 8 9 S E B HGD G8C G T GLS SINGLE STAGE PSC FURNACE SINGLE STAGE HEAT PUMP SINGLE STAGE PSC DEMAND DEFROST Other Part Numbers SAP Legacy 265901 031 09166 FIGURE 19 Thermostat Chart Single Stage HP with Single Stage PSC Furnaces Johnson Controls Unitary Products FURNACE o CONTROL C C 24 Volt Common 24 Volt Common 2 Full Stage Compressor Compressor R R 24 Volt Hot 24 Volt Hot G Fan W W1 66 out Full Stage Heat Heat O Reversing Valve Energized in Cool X L Malfunction Light W Auxiliary Heat Part Numbers SAP Legacy 67297 031 01975 13 364861 UIM B 0708 ACCESSORY CONNECTIONS The furnace control will allow power switching control of various acces sories ELECTRONIC AIR CLEANER CONNECTION Two 1 4 0 64 cm spade terminals EAC and NEUTRAL for electronic air cleaner connections are located on the control board The terminals provide 115 VAC 1 0 amp maximum during circulating blower opera tion HUMIDIFIER CONNECTION Two 1 4 0 64 cm spade terminals HUM and NEUTRAL for humidi fier connections are located on the control board The terminals provide 115 VAC 1 0 amp maximum during heating system operation A mounting hole is provided on the control panel n
33. S 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 If a 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 temperature Flexible connectors are also allowed in the combustion air pipe 6 All models are supplied with 2 vent connections When the pipe must be increased to 3 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 immediately above the furnace For downflow or horizontal models the transition from 2 to 3 pipe should be done immediately after exiting the furnace 7 n Canada vents shall be certified to ULC S636 Standard for Type BH Gas Venting Systems IPEX System 636 PVC is certified to this standard 8 n Canada the first three feet 900 mm of the vent must be readily accessible for inspection 9 For single pipe systems it is recommended to install the combus tion air coupling provided and install approximately 18 of PVC pipe on the furnace 10 Minimum vent length for all models is 5 feet TABLE 7 Maximum Equivalent Pipe Length Maximum Equivalent length feet m 19 8 274 19 8 274 19 8 274 30 9 2 Model Input BTUH kW Pipe Size Inches cm 40 000 11 7 40 000 11 7 60 000 17 6
34. STION AIR and VENT SYSTEM 24 DUCTWORK ERES ACC 5 START UP AND ADJUSTMENTS 31 Pe dus 10 SAFELY CONIBOLS x d ek win de dan 34 GAS PIPING 12 REPLACEMENT PARTS LIST 39 ELECTRICAL POWER ew ben ade o e 13 REPLACEMENT PART CONTACT INFORMATION 39 TWINNING AND STAGING 0 cece eee 17 WIRING DIAGRAM 40 CONDENSATE PIPING AND FURNACE VENTING CONFIGURATION 19 LIST OF FIGURES Duct AllACHINGAL PTT 5 Single Stage Twinning Wiring Diagram 15 Vertical Applications 5 Two Stage Twinning Wiring Diagram 15 Coil zt 6 Upflow Configuration 17 Horizontal Right Application 6 Downflow Configuration 18 Horizontal Left Application 6 Horizontal Left Configuration 19 PC Series Upflow Coil Installation 6 Horizontal Right Configuration 20 Horizontal Left or Right application Right Shown 6 bici M
35. T be made if installing furnace in an area which may drop below freezing This can cause improper opera tion or damage to the equipment If the furnace is installed in an area that has the potential of freezing the drain line must be pro tected Use a 3 to 6 watt per foot at 115 vac 40 F 4 4 C self regulating shielded and waterproof heat tape Wrap the drain line outside of the furnace with the heat tape and secure with ties Fol low the heat tape manufacturer s recommendations Use only Propylene Glycol RV anti freeze to winterize the furnace Refer to the manufacturer s specification to ensure that it is compat ible with plastics and other components of the furnace DO NOT use Ethylene Glycol anti freeze in the furnace 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
36. TAGE PSC FURNACE SINGLE STAGE PSC FURNACE 24 Volt Common Y Y2 Full Stage Compressor R 24 Volt Hot G Fan W Full Stage Heat Other Part Numbers SAP Legacy 265901 031 09166 FIGURE 18 Thermostat Chart Single Stage AC with Single Stage PSC Furnaces 12 AC 5D Single Stage Air Conditioner Single Stage PSC Furnace SINGLE STAGE AIR CONDITIONER SINGLE STAGE AIR CONDITIONER 24 Volt Common Y Compressor Contactor Johnson Controls Unitary Products 364861 UIM B 0708 2 Single Stage Heat Pump Single Stage PSC Furnace THERMOSTAT THERMOSTAT THERMOSTAT BP21H50124 DN22U00124 BN21H00124 DP32H70124 DP21H40124 DN21H00124 C 24 Volt Common Y1 First Stage Compressor R 24 Volt Hot G Fan E Emergency Heat N A N A ve Third Stage Heat O Reversing Valve Energized in Cool L Malfunction Light Y2 Second Stage Compressor W1 Second Stage Aux Heat 3 External Humidistat Open on Humidity Rise 24VAC Humidifier Optional Optional Step 1 of Thermostat Installer Configuration Menu must be set to Heat Pump 1 Step 9 of Thermostat Installer Configuration Menu must be set to Pump OFF Part Number S1 2HU16700124 ID MODELS OD MODELS
37. UO 9205 010 2 J9410b1 9203115 Q21IMS 92155924 YE IMS 2000 ASIL 9566 Weed HUA jpuibrJ0 y yo Wiring Diagram FIGURE 42 Johnson Controls Unitary Products NOTES Subject to change without notice Printed in U S A 364861 UIM B 0708 Copyright 2008 by Johnson Controls Inc All rights reserved Supersedes 364861 UIM A 0608 Johnson Controls Unitary Products 5005 York Drive Norman OK 73069 QUICK REFERENCE GUIDE 95 5 SINGLE STAGE MULTI POSITION RESIDENTAL GAS FURNACES 33 TALL NOTES 1 Refer to the condensate management and drain hose 7 f thermoplastic evaporator A coil drain pans are to be plumbing for different configurations in this document No installed in the up flow horizontal configuration then extra 2 hose clamps are needed for the condensate pan hook up minimum spacing may be needed to ensure against drain 2 Dripleg in the gas line must be installed pan distortion 3 The furnace controls require correct polarity on the power 8 External filters required on all configurations supply and a proper ground Electrical entry is available on both sides of the casing 4 Y amp G must be connected to the control board for cooling 10 All 33 95 furnaces are approved for single pipe and 2 operation pipe systems For single pipe systems it is recommended to 5 measure total static pressure add supply duct pressure to install
38. age 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 so it is in the upward position and reinstall the screw then repeat this for all 4 flanges If the flanges are not used they must remain in the rotated down posi tion as 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 Johnson Controls Unitary Products 364861 UIM B 0708 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 Combustible Floor Base Accessory Follow the instruc tions supplied with the combustible floor base accessory This combustible floor base can be replaced with a match ing cooling coil properly sealed to prevent leaks Follow the instructions supplied with the cooling coil cabinet for install ing the cabinet to the duct connector Plug intake and
39. ate condensate drain in a chimney or where the drain line may freeze The line must terminate at an inside drain to prevent freezing of the condensate and possible property damage DO NOT trap the arain line at any other location than at the conden sate drain trap supplied with the furnace CONDENSATE DRAIN TRAP AND DRAIN FREEZE PROTECTION Special precautions MUST be made if installing furnace in an area which may drop below freezing This can cause improper operation or damage to the equipment If the furnace is installed in an area that has the potential of freezing the drain line must be protected Use a 3 to 6 watt per foot at 115 vac 40 F 4 4 C self regulating shielded and waterproof heat tape Wrap the drain line outside of the furnace with the heat tape and secure with ties Follow the heat tape manufacturer s rec Use only Propylene Glycol RV anti freeze to winterize the furnace Refer to the manufacturer s specification to ensure that it is compat ible with plastics and other components of the furnace DO NOT use Ethylene Glycol anti freeze in the furnace Johnson Controls Unitary Products 364861 UIM B 0708 OPIS uo jeuiqeo jixe IPPON MOE 104 deoxg 1 MOE 40J pasinbe sy ONLLN3A AIS LH9IM Q3AI3O3M SV ONLLN3A 3GIS 1437 da1vios YSONGNI MOT3dn Q31VLOM YSONANI GU For 040 060 amp
40. ature 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 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 Thermostat Calling for Heat Satisfied Seconds 02 17 22 52 0 30 Seconds THERMOSTAT INDUCER IGNITOR MAIN VALVE HUMIDIFIER ELECTRONIC AIR CLEANER CIRCULATING BLOWER FIGURE 41 Furnace Control Event Schedule Johnson Controls Uni
41. 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 e US Current edition of the NFGC and NFPA 908 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 Combustion 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 Soci ety of Heating Refrigeration and Air Conditioning Engineers ASHRAE 1997 Fundamentals Handbook Chapter 32 STEP 5 Acoustical Lining and Fibrous Glass Duct e US a
42. crawl space and terminates with a 1 4 6 35 mm mesh screen and no elbows Table 7 Maximum Equivalent Pipe Length for intake pipe sizing allowable length and elbow usage Follow all notes procedures and required materials in the COMBUSTION AIR VENT PIPE SIZING sec tion in these instructions when installing the combustion air pipe from the unit and into a ventilated attic space or crawl space DO NOT termi nate vent pipe in an Attic or Crawl Space AWARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monxide poisoning or death The following steps shall be followed for each appliance connected to the venting system being placed into operation while all other appliances connected to the venting system are not in operation Inspect the venting system for proper size and horizontal pitch Determine that there is no blockage restriction leakage corrosion or other deficiencies which could cause an unsafe condition Close all building doors and windows 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 ope
43. ct shall be least the same 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 11 Estimated Free Area Johnson Controls Unitary Products 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 364861 UIM B 0708 Ventilated Combustion Air Termination Refer to Figure 37 Attic and Crawl Space Combustion Air Termination for required attic termination for the combustion air intake pipe For attic termination use two 90 elbows with the open end in a downward posi tion Be sure to maintain 12 30 cm clearance 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
44. d into outlet of drain coupling FIGURE 35 Combustion Airflow Path Through The Furnace Casing This type of installation requires that the supply air to the appli ance s be of a sufficient amount to support all of the appliance s in the area Operation of a mechanical exhaust such as an exhaust fan kitchen ventilation system clothes dryer or fireplace may cre ate conditions requiring special attention to avoid unsatisfactory operation of gas appliances A venting problem or a lack of supply air will result in a hazardous condition which can cause the appli ance to soot and generate dangerous levels of CARBON MONOX IDE which can lead to serious injury property damage and or death An unconfined space is not less than 50 cu ft 1 42 m per 1 000 Btu hr 0 2928 kW input rating for all of the appliances installed in that area Rooms communicating directly with the space containing the appli ances are considered part of the unconfined space if doors are fur nished with openings or louvers A confined space is an area with less than 50 cu ft 1 42 m per 1 000 Btu hr 0 2928 kW 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 spec
45. e green screw equipment ground An alternate wiring method is to use a field provided 2 5 1 cm x 4 10 2 cm box and cover on the out side of the furnace Route the furnace leads into the box using a protective bushing where the wires pass through the furnace panel After making the wiring connections replace the wiring box cover and screws Refer to Figure 17 Electrical Wiring furnace s control system requires correct polarity of the power supply and a proper ground connection Refer to Figure 17 Elec trical Wiring Johnson Controls Unitary Products 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 Figure 18 Thermostat Chart Single Stage AC with Single Stage PSC Furnaces Electronic thermo stats may require the common wire to be connected Apply strain relief to thermostat wires passing through cabinet If air conditioning equip ment is installed use thermostat
46. e rise specified on the nameplate IMPORTANT The minimum plenum height is 12 80 5 cm The furnace will not operate properly on a shorter plenum height The minimum recom mended rectangular duct height is 4 inches 10 cm attached to the plenum If a matching cooling coil is used it may be placed directly on the fur nace outlet and sealed to prevent leakage If thermoplastic evaporator A coil drain pans are to be installed in the upflow horizontal configura tion then extra 2 minimum spacing may be needed to ensure against drain pan distortion Johnson Controls Unitary Products 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 The duct system must be properly sized to obtain the correct airflow for the furnace size that is being installed Refer to Table 6 Ratings amp Physical Electrical Data or the fur nace 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 dam
47. ed 12 inches 30 cm or in accordance with local 12 inches 30 cm or in accordance with local E Clearance to unventilated soffit installation codes and the requirements of the gas installation codes and the requirements of the gas supplier supplier 12 inches 30 cm or in accordance with local 12 inches 30 cm or in accordance with local F Clearance to outside corner installation codes and the requirements of the gas installation codes and the requirements of the gas supplier supplier G Clearance to inside corner 3 feet 91 cm 3 feet 91 cm Above a meter regulator assembly within 3 feet 91 cm Above a meter regulator assembly within 3 feet 91 H Clearance to each side of center line horizontally of the vertical center line of the regulator cm horizontally of the vertical center line of the regula extended above meter regulator assembly vent outlet to a maximum vertical distance of 15 feet tor vent outlet to a maximum vertical distance of 15 4 5 cm above the meter regulator assembly feet 4 5 cm above the meter regulator assembly CI 3 feet 91 cm or in accordance with local installation earance to service regulator vent outlet 3 feet 91 cm codes and the requirements of the gas supplier Two pipe direct vent applications 9 inches 23 cm 12 inches 30 cm for models lt 100 000 BTUH 30 kW for models lt 50 000 BTUH 15 kW 12 inches 30 36 inches 91 cm for models gt 100 000 BTUH 30 kW for models
48. ed 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 36 2 AMBIENT COMBUSTION AIR Combustion 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 instal lation 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 37 for attic and crawl space termination Only the combustion air intake may terminate in the attic The vent must terminate outside 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 30 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 30 is the furnace vent pipe Connects to collar on top of burner box Vent pipe cements into socket just above top panel Or vent pipe may be clamped into outlet of drain coupl
49. eel Cycle power 24 VAC to the control to reset the hard lockout condition after correcting the failure condition 12 RED FLASHES This code indicates an open igniter circuit which could be a disconnected or loose wire or a cracked or broken igniter 364861 UIM B 0708 STEADY ON RED Control failure Replace control board 60 MINUTE AUTOMATIC RESET FROM LOCKOUT This control includes a watchdog type circuit that will reset from a lockout condition after 60 minutes Operational faults 6 7 8 will be reset This provides protection to an unoccupied structure if a temporary condition exists causing a furnace malfunction An example would be a low incoming gas supply pressure preventing unit operation When the gas pressure is restored at some point the watchdog would restart the unit and pro vide heat for the house NOTE If a flame is detected the control flashes the LED for 1 8 of a second and then enters a flame stabilization period IGNITION CONTROL FLAME SENSE LEVELS Normal flame sense current is approximately 3 7 microamps DC Low flame signal warning starts at 1 5 microamps Low flame signal control lockout point is 0 1 microamps DC 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 fe
50. ent of the vent pipe Johnson Controls Unitary Products 23 364861 UIM B 0708 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 Termination 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 Figures 13 or 14 Maintain 12 minimum clearance above highest anticipa
51. 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 2 The maximum equivalent length listed in Table 7 Maximum Equivalent Pipe Length is for the vent piping and the air intake piping 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 Johnson Controls Unitary Products 364861 UIM B 0708 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 AB
52. er 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 professionals for the installation of hard wired carbon monoxide detectors a n the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level In the event that the requirements of this subdivision can not be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided however that during said thirty 30 day period a battery operated carbon mon oxide detector with an alarm shall be installed APPROVED CARBON MONOXIDE DETECTORS Each car bon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and IAS certified SIGNAGE A metal or plastic identification plate sha
53. es 32 During burner operation a momentary loss of power for 50 milliseconds or longer will de energize the gas valve When the power is restored the gas valve will remain de energized and the ignition sequence will immediately restart Hot Surface Ignition System AWARNING HOT SURFACE IGNITION SYSTEM Do not attempt to light this furnace by hand with a match or any other means There may be a potential shock hazard from the components of the hot surface ignition system The furnace can only be lit automatically by its hot surface ignition system TROUBLESHOOTING The following visual checks should be made before troubleshooting 1 Check to see that the power to the furnace and the ignition control module is ON 2 The manual shut off valves in the gas line to the furnace must open 3 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 AWARNING Never bypass any safety control to allow furnace opera tion To do so will allow furnace to operate under poten tially hazardous conditions Do not try to repair controls Replace defective controls with UPG Source 1 Parts Never adjust pressure switch to allow furnace operation FURNACE CONTROL DIAGNOSTICS The furnace has built i
54. ext to the furnace control board for mounting a humidifier transformer if required SECTION VI TWINNING AND STAGING In applications where more heating capacity or more airflow capacity is needed than what one furnace can deliver twinning can be used to make two furnaces operate in tandem When two furnaces are installed using the same duct system it is very important that the two furnace cir culating air blowers operate in unison If one blower starts before the second blower the duct system will become pressurized and the blower on the second furnace will turn backwards causing the second furnace to overheat resulting in damage to the furnace Twinning is used to make two furnaces operate in tandem using one duct system one room thermostat and causing both furnaces to turn on and off simulta AWARNING Before installing the relay and wiring disconnect electrical power to both furnaces Failure to cut power could result in electrical shock or equipment damage A CAUTION The relay must not be installed in any location where it could be exposed to water If the relay has been exposed to water in any way it must not be used TWINNING DUCT SYSTEM Twinned furnaces must only be applied on a common duct system A single air supply plenum must be used for both furnaces and coil s Separate plenums and supply ducts systems cannot be utilized A sin gle return air plenum common to both furnaces must be used It
55. for the amount of time set by the fan off delay jumper located on the control board See Figure 36 The heat ing cycle is now complete and ready for the start of the next heating cycle If the flame is not detected within 7 seconds of the gas valve opening the gas valve is shut off and a retry operation begins Also if the flame is lost for 2 seconds during the 10 second stabilization period the gas valve is shut off and a retry operation begins During a retry operation the vent motor starts a 15 second inter purge and the ignitor warm up time is extended to 27 seconds If the flame is established for more than 10 seconds after ignition during a retry the control will clear the ignition attempt retry counter If three retries occur during a call for heat the furnace will shut down for one hour If at the end of the one hour shut down there is a call for heat the furnace will 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 minut
56. gt 50 000 BTUH 15 kW Single pipe applications 4 feet K Clearance to a mechanical supply inlet 6 feet 1 83 m feet 91 om above ii WAIN IO Tee 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 the requirements of the gas supplier 12 inches 30 cm or in accordance with local installa M Clearance under veranda porch deck or balcony 12 inches 30 cm tion codes and the requirements of the gas supplier 1 accordance with the current CSA B149 1 00 Natural Gas and Propane Installation Code 2 In accordance with the current ANSI Z223 1 NFPA 54 National Gas Code In accordance with the current ANSI 421 47 CSA 2 3 American National Standard T Avent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings tt 12 inches 30 cm up from the bottom edge of the structure for Two pipe direct vent applications per ANSI Z223 1 54 National Gas Code i Permitted only if veranda porch deck or balcony is 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 1 foot 30 cm as specified in CSA B149 1 00 A vent shall not terminate less than 1 foot 30 cm above a grade leve
57. ific louver or grille is not known refer to Table 11 to estimate free area Table 11 Estimated Free Area Wood or Metal Louvers or Grilles Do not use less than 1 4 0 635 cm mesh Free area of louvers and grille varies widely the installer should follow louver or grille 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 2 Apertures in a fixed louver a grille or screen shall have no dimen sion smaller than 0 25 0 64 cm 3 A manually operated damper or manually adjustable louvers are not permitted for use 4 automatically operated damper or automatically adjustable lou vers shall be interlocked so that the main burner cannot operate unless either the damper or the louver is in the fully open position Wood 20 25 Metal 60 70 1 4 0 635 cm mesh or larger 10096 25 364861 UIM B 0708 When a Category furnace is removed or replaced the original venting system may no longer be correctly sized to properly vent the attached appliances An improperly sized vent system can cause CARBON MONOXIDE to spill into the living space causing personal injury and or death Table 12 Unconfined Space Minimum Area in Square Inch Vent Ventilated Attic Attic Optional Inlet a Insulation Water
58. ing FIGURE 34 Direct Vent Air Intake Connection and Vent Connection The combustion air intake pipe should be located either through the wall horizontal or side vent or through the roof vertical vent Care 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 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 It is not piped directly into the furnace A single properly sized pipe from the furnace vent connector to the outdoors must be provided It 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 Johnson Controls Unitary Products 364861 UIM B 0708 Vent pipe cements into socket just above top panel COMBUSTION AIR dg TLE Or vent pipe may be clampe
59. installation in a residential garage must be installed so the burner s and the ignition source are located not less than 18 inches 46 cm above the floor and the furnace must be located or protected to avoid physical damage by vehicles Table 1 Unit Clearances to Combustibles Upo Bowow Horizontai _ Foo Combustible Combustible Combustible Des ves Line Contact 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 SECTION Il DUCTWORK DUCTWORK GENERAL INFORMATION The duct system s design and installation must 1 Handle an air volume appropriate for the served space and within the operating parameters of the furnace specifications 2 Be installed in accordance of National Fire Protection Association as outlined in NFPA standard 90B latest editions or applicable national provincial state and local fire and safety codes 3 Create a closed duct system For residential and Non HUD Modu lar Home installations when a furnace is installed so that the sup ply ducts carry air circulated by the furnace to areas outside the space containing the furnace the return air shall also be handled by a duct s sealed to the furnace casing and terminating outside the space containing the furnace 4 Complete a path for heated or cooled air to circulate through
60. l 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 J Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance Consideration must be given for degradation of building materials by flue gases Sidewall termination may require sealing or shielding of building surfaces with a corro sion resistant material to protect against combustion product corrosion Consideration must be given to wind direction in order to prevent flue products and or conden4 sate 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 It is recommended that a retaining type collar be used that is attached to the building surface to prevent movem
61. lable 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 provide for safe limits of ambient temperature under normal oper ating conditions Ambient temperatures must not fall below 32 F 0 C unless the condensate system is protected from freezing 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 extended periods To do so may cause condensation to occur in the main heat exchanger leading to premature heat exchanger failure 3 If this furnace is installed in an unconditioned space and 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 4 Special precautions MUS
62. ll be perma nently mounted to the exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUC TIONS INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the 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 may have loosened in transit There are no shipping or spacer brackets which need to be removed from the interior of this unit 364861 UIM B 0708 FURNACE LOCATION AND CLEARANCES The furnace shall be located using the following guidelines 1 Where a minimum amount of air intake vent piping and elbows will be required 2 As centralized with the air distribution as possible 3 Where adequate combustion air will be avai
63. losing would typi cally cause this fault 2 RED FLASHES This indicates that the normally open pressure switch contacts are stuck in the closed position The control confirms these contacts are open at the beginning of each heat cycle This would indicate a faulty pressure switch or miswiring Johnson Controls Unitary Products 3 RED FLASHES This indicates the normally open pressure switch contact did not close after the inducer was energized This could be caused by a number of problems faulty inducer blocked vent pipe bro ken pressure switch hose or faulty pressure switch 4 RED FLASHES This indicates that the main limit switch has opened its normally closed contacts The control will operate the supply air blower and inducer This condition may be caused by dirty filter improperly sized duct system incorrect blower speed setting incorrect firing rate or faulty blower motor Also this fault code could be caused by a blown fuse located on the control board 5 RED FLASHES This fault is indicated if the normally closed contacts in the rollout switch opens The rollout control is manually reset If it has opened check for proper combustion air proper inducer operation and primary heat exchanger failure or burner problem Be sure to reset the switch and cycle power 24 VAC to the control after correcting the fail ure condition Also this fault code could be caused by a blown fuse located on the control board 6 RED
64. lug 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 MANIFOLD PRESSURE U TUBE CONNECTION OUTLET PRESSURE TAP GAS VALVE 1 4 TUBING MAINIFOLD FLAME SENSOR 3 5 IN WATER COLUMN GAS PRESSURE SHOWN BURNERS FIGURE 39 Reading Gas Pressure Johnson Controls Unitary Products ADJ USTMENT OF TEMPERATURE RISE 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 6 Ratings amp Physical Electrical Data The supply air temperature cannot exceed the Maximum Supply Air Temperature specified in these instructions and on the fur nace rating plate Under NO circumstances can the furnace be allowed to operate above the Maximum Supply Air Temperature Operating the furnace above the Maximum Supply Air Temperature will cause premature heat exchanger failure high levels of Carbon Monoxide a fire hazard personal injury property damage and or death After about 5 minutes of operation determine the furnace temperature rise Take readings of both the return air and the heated air in
65. lvents such as perchloroethylene Printing inks paint removers varnishes etc e Hydrochloric acid Cements and glues Antistatic fabric softeners for clothes dryers Masonry acid washing materials When outdoor air is used for combustion the combustion air intake duct system termination must be located external to the building and in an area where there will be no exposure to the substances listed above Johnson Controls Unitary Products 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 following on near or in contact with the fur nace 1 Spray or aerosol cans rags brooms dust mops vacuum cleaners or other cleaning tools Soap powders bleaches waxes or other cleaning com pounds plastic items or containers gasoline kerosene ciga rette lighter fluid dry cleaning fluids or other volatile fluid Paint thinners and other painting compounds Paper bags boxes or other paper products Never operate the furnace with the blower door removed To do so could result in serious personal injury and or equipment damage 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
66. me and on the same speed as the first furnace blower Johnson Controls Unitary Products 364861 UIM B 0708 Single Wire Staging Instructions Connect the control wiring as shown in Figure 22 Two Stage Twinning Wiring Diagram 1 Connect the low voltage wiring from the wall thermostat to the ter minal strip on the control board of Furnace 1 For staging applica tions the wire from thermostat W1 is connected to the W connection on the board on Furnace 1 The wire from thermostat W2 is connected to Furnace 2 through a separate relay as described below 2 Connect a wire from the TWIN terminal of Furnace 1 to the TWIN terminal of Furnace 2 3 Install a separate 24V relay as shown in the diagram below Use of this relay is required as it ensures that the transformers of the two furnaces are isolated thus preventing the possibility of any safety devices being bypassed Single Wire Staging Operation Heating On a call for first stage heat W1 signal from the wall thermo stat Furnace 1 will start the ignition sequence and the burners will light About thirty seconds after the burners light the blowers on both furnaces will come on in heating speed When the thermostat is satis fied the burners will shut off and after the selected blower off delay time both blowers will shut off at the same time On a call for second stage of heat the burners of Furnace 2 will also light and both blowers will run The twinning c
67. n self diagnostic capability If a system problem occurs a blinking LED can flash red green or amber to indicate various conditions The control continuously monitors its own operation and the operation of the system If a failure occurs the LED will indicate the failure code If the failure is internal to the control the light will stay on continuously In this case the entire control should be replaced as the control is not field repairable Flash sequence codes 1 through 11 are as follows LED will turn on for 1 4 second and off for 1 4 second This pattern will be repeated the number of times equal to the code For example six on flashes equals a number 6 fault code All flash code sequences are broken by a 2 sec ond off period SLOW GREEN FLASH Normal operation SLOW AMBER FLASH Normal operation with call for heat RAPID RED FLASH Twinning error incorrect 24V phasing Check twinning wiring RAPID 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 4 AMBER FLASHES The control is receiving a Y signal from the thermostat without a G signal indicating improper thermostat wiring 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 A gas valve that leaks or is slow c
68. n the proper orifice size Drilling out a gas orifice will cause misalignment of the burner flames causing premature heat exchanger burnout high levels of carbon monoxide excessive sooting a fire hazard personal injury property damage and or death SECTION V ELECTRICAL POWER ELECTRICAL POWER CONNECTIONS A CAUTION Field wiring to the unit must be grounded Electric wires that are field Use copper conductors only installed shall conform to the temperature limitation for 63 F 35 C rise wire when installed in accordance with instructions Refer to Table 6 Ratings amp Physical Electrical Data in these instructions for specific furnace electrical data 10 Johnson Controls Unitary Products 364861 UIM B 0708 Table 6 Ratings amp Physical Electrical Data Airflow 5 Over Current 75 1 Air Temp 40 17 38 111 800 227 80 955 3060 1733 15 14 155 683 60 176 57 167 1000 283 10 0 955 30 60 1936 15 14 155 683 60 176 57 167 1200 340 100 955 30 60 1936 15 14 160 71 1 Min wire Size Outlet 234 76 223 10 340 109 s 3565 18 4 16 735 234 76 223 160 453 ns 958 356 1936 15 4 234 76 223 50 623 170 958 3565 i936 3 0 12 _ 355 683_ 733 Annual Fuel Utilization Efficiency AFUE numbers are determined
69. nd 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 CANADA Canadian Electrical Code CSA C22 1 Johnson Controls Unitary Products 364861 UIM B 0708 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 FOR FURNACES INSTALLED IN THE COMMON WEALTH OF MASSACHUSETTS ONLY For all side wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for resi dential purposes including those owned or operated by the Com monwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following require ments shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumb
70. ng has at least 1 4 per foot slope towards the furnace Furnace is multi position and may be installed in any of the configurations shown The furnace condensate pan is self priming and contains an internal trap Do not install an external condensate trap When drain hose routing changes are required shown in red be sure to cap all unused 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 For 040 060 amp 080K input furnaces the condensate drain is factory set toward the right casing outlet UPFLOW 3 Move condensate drain DOWNFLOW AIRFLOW AO E poston Inducer must be rotated Move rain gutter 90 in either direction for NOTE Only side venting on 130K unit hose to this position this installation In upflow and downflow installation Condensate drain hose may go out either side AIRFLOW Iul 3 Change condensate drain connection to the 90 fitting provided Move condensate drain hose to this position 5 Move rain gutter hose to this position NOTE May require hose extension that is provided with wider cabinets HORIZONTAL LEFT AIRFLOW o Change condensate drain connection to the 90 fitting provided HORIZONTAL RIGHT 3 Move rain gutter hose to this position 4 Move condensate drain hose to this position
71. ombustion air shall not be supplied from occupied spaces The size of the unit should be based on an acceptable heat loss calculation for the structure ACCA Manual J or other approved methods may be used SAFETY REQUIREMENTS A CAUTION This product must be installed in strict compliance with the installa tion instructions and any applicable local state and national codes including but not limited to building electrical and mechanical codes 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 12 Dimensions 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 Mobile Home 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 e Check the rating plate and power supply to be sure that the elec trical characteristics match All models use nominal 115 VAC 1 Phase 60 Hertz power supply DO NOT
72. on through the coil 1 Position the coil casing over the furnace opening as shown in Fig ure 6 PC Series Upflow Coil Installation 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 A CAUTION Do not drill any holes or drive any screws into the front duct flange on the coil in order to prevent damaging coil tubing See Figure 6 PC Series Upflow Coil Installation Flexible Duct Collar Field Ductwork Do not drill or Screw this flange Dkr C V 4 Alternate Secondary Drain Location Drain FIGURE 6 PC Series Upflow Coil Installation Table 2 Coil Projection Dimensions PC Series Coils DIMENSION C INCH NOTE Dimension should be at least 2 3 of dimension See Fig ure 6 PC Series Upflow Coil Installation CRITICAL COIL PROJ ECTION 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 6 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 6 NOTE Each coil is
73. ontrol ensures that both blowers come on and shut off at the same time Cooling On a call for cooling Y signal from the wall thermostat both furnace blowers will come on at the same time When the thermostat is satisfied both blowers will stay on for 60 seconds then 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 2 CONTROL BOARD FURNACE 1 CONTROL BOARD Ow 0 os Os Oc OD OR TWIN Ov ISOLATION RELAY W1 G R Y W2 WALL THERMOSTAT FIGURE 22 Two Stage Twinning Wiring Diagram 15 364861 UIM B 0708 SECTION VII CONDENSATE PIPING AND FURNACE VENTING CONFIGURATION CONDENSATE DRAIN LOCATION As shipped from the factory e 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 Forall 100 120 amp 130K input furnaces the main drain is plumbed through the casing left side opening when viewed from the front of the furnace NOTE On 130K BTU models there is no provision for the vent to exit the top of the cabinet the vent must always exit one of the sides NOTE The Figures 23 26 show the condensate drain arrange men
74. or the furnace to operate safely The gas line pressure MUST BE a minimum of e 7 W C 1 74 KPA for Natural Gas e 11 W C 2 74 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 15 Inlet Gas Pressure Range turn the gas valve to OFF and turn the electrical supply switch to OFF then remove the flexi ble tubing from the gas valve pressure tap and tighten the pres sure 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 39 Reading Gas Pressure for connection IMPORTANT The cap for the pressure regulator must be removed entirely to gain access to the adjustment screw Loosening or tightening the cap does not adjust the flow of gas 30 NOTE The regulated outlet pressu
75. plications after configuring coil flanges as required see Coil Flange section below 364861 UIM B 0708 COIL FLANGE INSTALLATION The coils include removable flanges to allow proper fit up with furnaces having various inlet and outlet flange configurations The two flanges are attached to the top of the coil in the factory during production For proper configuration of flanges refer to Figure 3 Coil Flange FACTORY lt FLANGE LOCATION Used for upflow or horizontal ALTERNATE right installations FLANGE LOCATION Used for downflow or horizontal left installations FIGURE 3 Coil Flange FURNACE ASSEMBLY 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 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 SY lt 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 distributi
76. rate contin uously lest each appliance such as a water heater equipped with a draft hood for spillage down draft or no draft at the draft hood relief opening after 5 minutes of main burner operation Appliances that do not have draft hoods need to be checked at the vent pipe as close to the appliance as possible Use a combustion analyzer to check the CO2 and CO levels of each appliance Use a draft gauge to check for a downdraft or inadequate draft condition After it has been determined that each appliance properly vents when tested as outlined above return doors windows exhaust fans fire place dampers and any other gas burning appliance to their normal condition If improper venting is observed during any of the above tests a problem exists with either the venting system or the appliance does not have enough combustion air Supply Air from outside to complete combustion This condition must be corrected before the appliance can function safely NOTE An unsafe condition exists when the CO reading exceeds 40 ppm and the draft reading is not in excess of 0 1 in W C 25 kPa with all of the appliance s operating at the same time 8 Any corrections to the venting system and or to the supply outside air system must be in accordance with the National Fuel Gas Code 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
77. re has been calibrated at the factory Additional pressure adjustment should not be necessary If adjustment is necessary set to the following specifications After adjustment check for gas leakage 1 Refer to Figure 38 Gas Valve for location of pressure regulator adjustment cap and adjustment screws on main gas valve 2 Turn gas and electrical supplies on and follow the operating instructions to place the unit back in operation 3 Adjust manifold pressure by adjusting gas valve regulator screw for the appropriate gas per the following Table 16 Nominal Manifold Pressure NOMINAL MANIFOLD PRESSURE Natural Gas 3 5 w c 0 87 kPa 10 0 w c 2 488 kPa Propane LP Gas OUTLET PRESSURE PORT MAIN REGULATOF PRESSURE ADJUSTMENT PORT ON OFF SWITCH Shown in ON position FIGURE 38 Gas Valve IMPORTANT If gas valve regulator is turned in clockwise manifold pressure is increased If screw is turned out counterclockwise manifold pres sure will decrease 4 After the manifold pressure has been adjusted re calculate the furnace input to make sure you have not exceeded the specified input on the rating plate Refer to CALCULATING THE FURNACE INPUT NATURAL GAS 5 Once the correct BTU kW input has been established turn the gas valve to OFF and turn the electrical supply switch to OFF then remove the flexible tubing from the gas valve pressure tap and tighten the pressure tap p
78. re inversions Table 5 Nominal Manifold Pressure High Fire Manifold Pressures in wc Manifold Pressures kpa Altitude feet Altitude m 0 2437 2438 2742 2 43 3048 08 os 232009 BTU cu ft Gas Heating Value Gas Heating Value 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 been converted to the proper gas orifice size when the furnace is installed Do not attempt to drill out any orifices to obtai
79. rnace 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 HORIZONTAL APPLICATION FIGURE 9 Horizontal Application IMPORTANT This furnace may be installed in a horizontal position on either side as shown above It must not be installed on its back Johnson Controls Unitary Products 364861 UIM B 0708 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 4 Sheet metal in front of furnace C of 18 45 7 d 3X combustion air Openings is from the Recommended furnace 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 Typi When a furnace is installed in an attic or other insulated space keep all insulating materials at least 12 inches 30 5 cm away from furnace and burner combus
80. rsists 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 1 2 PSI 3 45 kPa The furnace must be isolated from the gas supply piping system by closing the equipment shutoff valve during any pressure testing of the gas supply system 28 IGNITION SYSTEM SEQUENCE 1 the gas supply ON at external valve and main gas valve 2 Set the thermostat above room temperature to call for heat 3 System start up will occur as follows a The induced draft blower motor will start and come up to speed Shortly after inducer start up the hot surface igniter will glow for about 17 seconds b After this warm up the ignition module will energize open the main gas valve After flame is established the supply air blower will start in about 30 seconds CALCULATING THE FURNACE INPUT NATURAL 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 orifices NOTE DO NOT set manifold pressure less than 3 2 in wc or more than 3 8 in wc for natural gas at sea level If manifold pressure is outside this range change main burner orifices NOTE If orifice hole appears damaged or it is suspected to have been redrilled check orifice
81. rts is required to support the weight of the external filter box Downflow Filters Downflow furnaces typically are installed with the filters located above the furnace extending into the return air plenum or duct Any branch duct rectangular or round duct attached to the plenum must attach to the vertical plenum above the filter height Filter s may be located in the duct system external to the furnace using an external duct filter box attached to the furnace plenum or at the end of the duct in a return filter grille s The use of straps and or supports is required to support the 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 PSI 14 w c 3 48 kPa Pressures exceeding 0 5 PSI 14 w c 8 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 Johnson Controls Unitary Products 364861 UIM B 0708 Outlet Pressure Port Main Regulator Pressure Adjustment Port On Off Switch Shown in ON position FIGURE 14 Gas Valve IMPORTANT Plan your gas supply before determining the correct gas pipe ent
82. ry Use 90 degree service elbow s or short nipples and conventional 90 degree elbow s to enter through the cabinet access holes GAS PIPING INSTALLATION Properly sized wrought iron approved flexible or steel pipe must be used when making gas connections to the unit If local codes allow the use of a flexible gas appliance connection always use a new listed con nector Do not use a connector that has previously serviced another gas appliance Some utility companies or local codes require pipe sizes larger than the minimum sizes listed in these instructions and in the codes The furnace rating plate and the instructions in 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 15 Upflow Downflow Gas Piping External Manual Shutoff Valve N Grounded Joint Union may be Installed Inside or Outside Unit Shut off Valve FIGURE 16 Horizontal 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 364861 UIM B 0708 The furnace must be isolated from the gas supply piping system by GAS ORIFICE CONVERSION FOR PROPANE LP closing its individual external manual shutoff valve during any pressure This furnace is constructed at the factory for natural gas fired operation
83. s 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 Johnson Controls Unitary Products 364861 UIM B 0708 VENT CLEARANCES VENT TERMINAL AIR SUPPLY AREA WHERE TERMINAL IS NOT PERMITTED OPERABLE FIGURE 28 Home Layout Direct Vent Terminal Clearances Canadian Installations US Installation A above grade veranda porch deck 45 inches 30 cm 12 inches 30 cm Two pipe direct vent applications 9 inches 23 cm 12 inches 30 cm for models lt 100 000 BTUH 30 kW for models lt 50 000 BTUH 15 kW 12 inches 30 cm 36 inches 91 cm for models gt 100 000 BTUH 30 kW for models gt 50 000 BTUH 15 kW tt Single pipe applications 4 feet C Clearance to permanently closed window 12 inches 30 cm 12 inches 30 cm D Vertical clearance to ventilated soffit located 12 inches 30 cm or in accordance with local 12 inches 30 cm or in accordance with local above the terminal within a horizontal distance installation codes and the requirements of the gas installation codes and the requirements of the gas sup of 2 feet 61 cm from the center line of the terminal supplier plier B Clearance to window or door that may be open
84. 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 6 Use tie plate supplied with coil Gas Furnace FIGURE 7 Horizontal Left or Right application Right Shown Johnson Controls Unitary Products DOWNFLOW DUCT CONNECTORS All downflow installations must use a suitable duct connector approved by the furnace manufacturer for use with this furnace The duct connec tors are designed to be connected to the 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 lt 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 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 fu
85. t for the various possible furnace and vent blower positions The condensate hoses must slope downwards at all points The condensate water will flow to the drain better id a tee with a short open end length of pipe is installed in the drain line The top of the pipe should terminate at least to the middle of the condensate pan which is located inside the furnace The furnace condensate pan is self priming and con tains 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 23 26 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 condensate drain from the furnace may be connected in com mon with the drain from an air conditioning coil if allowed by local code 16 IMPORTANT Condensate must be disposed of properly Follow local plumbing or wastewater codes The drain line must maintain a 1 4 per foot 0 635 cm per meter downward slope to the drain CONDENSATE DRAIN TERMINATION A condensate sump pump MUST be used if required by local codes or if no indoor floor drain is available The condensate sump pump must be approved for use with acidic condensate A WARNING DO NOT termin
86. tary Products Post Purgel 60 90 120 180 SEC Selectable Fan Off Delay 33 364861 UIM B 0708 SECTION XI REPLACEMENT PARTS LIST SHELF BLOWER RAIL BLOWER 2 Req d BAG PARTS BRACKET BLOWER TRACK 2 Req d KNOB QUARTER TURN 4 Req d HEAT EXCHANGER ASS Y DIAGRAM WIRING REPLACEMENT PART CONTACT INFORMATION This is a generic parts list To request a complete parts list refer to the contact information below e Visit our website at www source1parts 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 Drive Norman OK 73069 34 Johnson Controls Unitary Products 8090 2 QMh S99rv9 Vo11021 ddo Aq Adon UMDYS 01 2 9 0 JoMO Q 9 Jod Jobuouo puaanad 2601 4 124 1909 10 Jo Duij0J 9nj0Jodus o poop doJ SinW conbid juos SOJLUOW Jn9 0 1 USA 9 59 1A 51U3U9pJ0220J 2 35 364861 UIM B 0708 WIRING DIAGRAM SECTION XII 2601 4 122 010 nb p c2Jnj0Jodua Sap D 19 1 91 jUDAnOG 1 9 0 Un 294D
87. ted snow level Maximum 24 above roof FIGURE 29 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 30 Termination Configuration 2 Pipe 24 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 31 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 29 is 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 29 Each furnace must have a separate vent pipe Under NO circumstances can
88. th Furnace Control Board 31 Single Stage PSC Furnaces 13 Furnace Control Event Schedule 33 Typical Twinned Furnace Application 14 Wifing DISGEAETE a2 a 840 06s he Red a ba dda oe ad 35 LIST OF TABLES Unit Clearances to Combustibles 4 Combustion Air Intake and Vent Connection Size at Furnace All Mod Coil Projection Dimensions PC Series Coils 6 erc 22 Cabinet and Duct Dimensions 8 Estimated Free 25 Recommended Filter Sizes High Velocity 600 FPM 8 Unconfined Space Minimum Area in Square Inch 26 Nominal Manifold Pressure High Fire 10 RICO sorse ete ote ee d 26 Ratings Physical Electrical 11 Gas Rate CU FT HR at Full 29 Maximum Equivalent Pipe Length 21 Inlet Gas Pressure Range 30 Elbow Dimensions 21 Nominal Manifold Pressure 30 Equivalent Length of Fittings 22 These high efficiency compact units employ induced combustion reli able hot surface ignition and high heat transfer aluminized t
89. the combustion air coupling provided and install the return duct pressure add pressure drop across the A approximately 18 of PVC pipe on the furnace coil and add pressure drop across the filter Ignore negative 11 Do not install an external condensate trap on these fur signs on the readings naces as it will prevent the unit from operating correctly 6 Inlet gas pressure for natural gas should be 7 and that for propane should be 11 w c Nominal manifold gas pressure is 3 5 for natural gas and 10 w c for propane Airflow CFM Bottom Return without Filters Minimum Wire Total Unit Maximum 0 5 ESP Nominal Size awg 75 Amps Over Current Med Hi High One Way Protection p 9s we m 4 1 i GSSOBOETAMPTI ne S72 wee i23 a 109 e 38 TGJGSSONBIZMPTI 354 300 190 4 300 5 98 1250 4 5 mGjGssospczaWPTi 1285 1886 997 12 REM 08919087 8 woes nes 3459 fa SR 5t 5 185 M 8 15 qaes no 1439 739 1897 _ 29 TOCS ne ve mur 39 89 Maximum i 3 water _ Factory Heating Temperature Time For 1 ft Gas Speed Setting Rise Range UR 30 60F 309 60 T G G9S060B12MP11 Med Hi 30 F 60 F LG G9S040A08MP11 E 6
90. 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 Blower Off Delay Timer Adjustment Jumper in seconds 021 330 FIGURE 40 Furnace Control Board 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 SWITCH A CAUTION Main power to the unit must still be interrupted at the main power disconnect switch before any service or repair work is to be done to the unit Do not rely upon the interlock switch as a main power dis connect Blower and burner must never 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 Johnson Controls Unitary Products o o 06 gt 364861 UIM B 0708 All direct drive blowers have multi speed motors The blower motor speed taps are located on
91. the vent is increased to 3 7 6 cm COMBUSTION AIR AND VENT PIPING ASSEMBLY The final assembly procedure for the combustion air and vent piping is as follows 1 Cut piping 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 out side termination b Ventilated combustion air systems from the furnace to the attic or crawl space termination A CAUTION 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 hanger
92. tion air openings SUSPENDED FURNACE CRAWL SPACE INSTALLATION The furnace can be hung from floor joists or installed on suitable blocks or pad Blocks or pad installations shall provide adequate height to ensure 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 Angle supports should be placed at the supply air end and near the blower deck Do not support at return air end of unit All four sus pension points must be level to ensure quite furnace operation When suspending the furnace use a secure platform constructed of plywood or other building material secured to the floor joists Refer to for typical crawl space installation S rt Angle Iron LL Bracket 6 Min Between Rod amp Front of Furnace 1 Max Between Rod amp Back of Furnace FIGURE 11 Typical Suspended Furnace Crawl Space Installation 364861 UIM B 0708 LEFT SIDE RIGHT SIDE Combustion Air Inlet Combustion Air Inlet Condensate Drain Gas Pipe Downflow Entry Gas Pipe Condensate Drain Entry 04 Downflow Electrical Entry Electrical Entry Vent Outlet Condensate Drain Condensate 2 Drain Thermostat d Wiring Thermostat Optional Return Air Wir iring Cutout Either side M 20 5 For Cladded door add appoximately an additional 75 Combustion Air Inlet HIM A 24 25
93. try Q Downflow Vent Connection JC Q Electrical Outlet Entry Optional Return Air Cutout Either side LEFT SIDE RIGHT SIDE Follow all national local codes and standards in addition to this document The installation must comply with regulations of the serving gas supplier local building heating plumbing and other codes In absence of local codes the installation must comply with the national codes and all authorities having jurisdiction CLEARANCES DIMENSIONS Application Upfiow Downflow Horizontal All A Cabinet Furnaces 13 3 8 All B Cabinet Furnaces 17 1 2 16 3 8 All C Cabinet Furnaces 19 7 8 All D Cabinet Furnaces 24 1 2 23 3 8 EENNE EN E ZEN LED INDICATOR Combustible Combustible Combustible Slow Green Flash m mie 1 For combustible floors only when used with special e Normal operation with call for heat Jedi Any Red Flash Fault condition clearance in front an on side recommended for Ica B rase Any Rapid 4 Flash Potential fault codes conditions All furnaces approved for alcove and attic installation Gutter Hose Pressure Switch For 100 120 amp 130K input furnaces the condensate drain is factory set toward the left casing outlet MOST COMMON INSTALLATION CONFIGURATIONS MORE OPTIONS AVAILABLE WITH INDUCER ROTATION WHICH IS COVERED IN THE INSTALLATION MANUAL MULTI POSITION CONFIGURATION INFORMATION Ensure that all PVC venti
94. ubular heat exchangers The units are factory shipped for installation in upflow or horizontal applications and may be converted for downflow applica tions These furnaces are designed for residential installation in a basement closet alcove attic recreation room or garage and are also ideal for commercial applications All units are factory assembled wired and tested to assure safe dependable and economical installation and oper ation These units are Category 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 It is also used to alert against unsafe practices and hazards involving only property dam Improper installation may create a condition where the operation of the product could cause personal injury or property damage Improper installation adjustment alteration service or mainte
95. uctions IMPORTANT The VENT SYSTEM must be installed as specified in these instructions for Residential and Non HUD Modular Homes The direct vent system is the only configuration that can be installed in a Non HUD Modular Home 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 portion of a factory built or masonry chimney The furnace shall not be connected to a chimney flue serving a sep arate appliance designed to burn solid fuel A CAUTION 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 tem peratures such as routing through unheated areas or through an unused chimney COMBUSTION AIRAVENT 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 7 Maximum Equivalent Pipe Length lists the maximum equiva lent length of pipe allowed for each model of furnace The equivalent length of elbows is shown in Table 9 Equivalent Length of Fittings The
96. vent pipe holes in bottom panel and move grommet to desired vent side exit Downflow Air Conditioning Coil Cabinet The furnace should be installed with coil cabinet part number specifi cally intended for downflow application If a matching cooling coil is used it may be placed directly on the furnace outlet and sealed to pre vent leakage For details of the coil cabinet dimensions and installation requirements refer to the installation instructions supplied with the coil cabinet Attach the air conditioning coil cabinet to the duct connector and then position the furnace on top of the coil cabinet The connection to the fur nace air conditioning coil cabinet duct connector and supply air duct must be sealed to prevent air leakage COIL INSTALLATION IMPORTANT On all installations without a coil a removable access panel is rec ommended in the outlet duct such that smoke or reflected light would be observable inside the casing to indicate the presence of leaks in the heat exchanger This access cover shall be attached in such a manner as to prevent leaks COIL FURNACE ASSEMBLY MC FC PC SERIES COILS DOWNFLOW UPFLOW FIGURE 2 Vertical Applications FURNACE ASSEMBLY MC amp FC SERIES COILS These coils are factory shipped for installation in either upflow or down flow applications with no conversion Position the coil casing over or under the furnace opening as shown in Figure 2 Vertical Ap
97. wire that is connected to the HI COOL cooling terminal on the control board To obtain a constant air circulation at lower flow rate change the high speed wire to either the medium speed wire or the low speed wire Intermittent Blower Cooling Cooling heating thermostats have a fan switch that has an ON and AUTO position In the AUTO position the thermostat circuit is completed between terminals R and G when there is a call for cooling The motor will operate on the speed tap wire that is connected to the HI COOL cooling terminal on the control board The fan off setting is fixed at 60 seconds to improve cooling efficiency 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
98. wiring to connect the Y and C termi nals on the furnace control board to the proper wires on the condensing unit unit outside IMPORTANT Set the heat anticipator in the room thermostat to 0 4 amps Setting it lower will cause short cycles Setting it higher will cause the room temperature to exceed the set points IMPORTANT Some electronic thermostats do not have adjustable heat anticipa tors They should be set to six cycles per hour Follow the thermo stat manufacturer s instructions The 24 volt 40 VA transformer is sized for the furnace components only and should not be connected to power auxiliary devices such as humidifiers air cleaners etc The transformer may provide power for an air conditioning unit contactor 11 364861 UIM B 0708 For additional connection diagrams for all UPG equipment refer to Low Voltage System Wiring document available on line at www upgnet com in the Product Catalog Section THERMOSTAT PP11C70224 Full Stage Compressor RH 24 Volt Hot Heat XFMR G Fan RC 24 Volt Hot Cool XFMR W Full Stage Heat HM1 Humidistat ID MODELS G 8 9 S GF 8 9 G 9F LF8 L Y M 8S G T G 8 9 S G8C G T GLS 24VAC Humidifier Optional Clipping Jumper W914 for electric heat on thermostat is not necessary SINGLE S

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