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PDF Content Summary: INSTALLATION MANUAL TWO STAGE VARIABLE SPEED ECM RESIDENTIAL GAS FURNACES MODELS: TM9V*C Series (96% AFUE Multi-Position) LIST OF SECTIONS SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 CONDENSATE PIPING AND FURNACE VENTING CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . 16 COMBUSTION AIR AND VENT SYSTEM . . . . . . . . . . . . . . . . 22 START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . 30 SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 NORMAL OPERATION AND DIAGNOSTICS . . . . . . . . . . . . . 36 REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . 39 REPLACEMENT PART CONTACT INFORMATION . . . . . . . . 39 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 START UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 LIST OF FIGURES Duct Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Combustible Floor Base Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Furnace and Coil Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Horizontal Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Typical Attic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Typical Suspended Furnace / Crawl Space Installation . . . . . . . . . . . 7 Downflow Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Side Return Cutout Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Left Side Supply Gas Pipe Arrangement . . . . . . . . . . . . . . . . . . . . . . 9 Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Two-stage Furnace with Communicating AC or HP . . . . . . . . . . . . . 12 Furnace Control Board – Communications Connections . . . . . . . . . 13 Terminal Screw Wire Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Furnace with Variable Capacity AC or HP . . . . . . . . . . . . . . . . . . . . 13 Thermostat Chart - Single Stage Air Conditioner with Two Stage Variable Speed Furnace . . . . . . . . . . . . . . . . . . . . . . . . 14 Thermostat Chart - Single Stage Heat Pump with Two Stage Variable Speed Furnace . . . . . . . . . . . . . . . . . . . . . . . . 15 Thermostat Chart - Two Stage Air Conditioner with Two Stage Variable Speed Furnace . . . . . . . . . . . . . . . . . . . . . . . . 15 Thermostat Chart - Two Stage Heat Pump with Two Stage Variable Speed Furnace (Hot Heat Pump or Conventional) . . . . . . .16 Typical. Condensate Drain, Vertical Installation . . . . . . . . . . . . . . . .17 Upflow Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Downflow Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Horizontal Left Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Horizontal Right Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Home Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Termination Configuration - 1 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . .26 Termination Configuration - 2 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . .26 Termination Configuration - 2 Pipe Basement . . . . . . . . . . . . . . . . .26 Double Horizontal Combustion Air Intake and Vent Term. . . . . . . . .27 Double Vertical Combustion Air Intake and Vent Term. . . . . . . . . . .27 Downward Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Direct Vent Air Intake Connection and Vent Connection . . . . . . . . .27 Combustion Airflow Path Through The Furnace Casing . . . . . . . . .28 Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 Attic and Crawl Space Combustion Air Termination . . . . . . . . . . . . .30 Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 LIST OF TABLES Unit Clearances to Combustibles. All furnaces approved for alcove and attic installation . . . . . . . . . . . . . . . . . . 4 Cabinet and Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Recommended Filter Sizes (High Velocity 600 FPM) . . . . . . . . . 8 Nominal Manifold Pressure - High Fire . . . . . . . . . . . . . . . . . . . 10 Nominal Manifold Pressure - Low Fire . . . . . . . . . . . . . . . . . . . 10 Ratings & Physical / Electrical Data . . . . . . . . . . . . . . . . . . . . . 11 Maximum Equivalent Pipe Length . . . . . . . . . . . . . . . . . . . . . . . 23 High Altitude Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . 24 Elbow Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Equivalent Length of Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Combustion Air Intake and Vent Connection Size at Furnace (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Unconfined Space Minimum Area . . . . . . . . . . . . . . . . . . . . . . . 28 Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Gas Rate (CU FT/HR) at Full Input . . . . . . . . . . . . . . . . . . . . . . 32 Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Default Blower Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Air Flow Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 These high efficiency, compact units employ induced combustion, reli- able hot surface ignition and high heat transfer aluminized tubular heat exchangers. The units are factory shipped for installation in upflow or horizontal applications and may be converted for downflow applica- tions. These furnaces are designed for residential installation in a basement, closet, alcove, attic, recreation room or garage and are also ideal for commercial applications. All units are factory assembled, wired and tested to assure safe dependable and economical installation and oper- ation. These units are Category IV listed and may not be common vented with another gas appliance as allowed by the National Fuel Gas Code. Johnson Controls Ducted Systems 5750149-UIM-D-1219 5750149-UIM-D-1219 SECTION I: SAFETY • Means for providing outdoor air required for combustion; 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. • Return air temperature maintained between 55oF (13oC) and 80oF (27oC); • The air filter must be replaced upon substantial completion of the construction process; • Clean furnace, duct work and components upon substantial com- pletion of the construction process, and verify furnace-operating DANGER indicates an imminently hazardous situation, which, if not conditions including ignition, input rate, temperature rise and avoided, will result in death or serious injury. venting, according to the manufacturer’s instructions. WARNING indicates a potentially hazardous situation, which, if not 10. When installed in a non-HUD-Approved Modular Home or building avoided, could result in death or serious injury. constructed on-site, combustion air shall not be supplied from occu- CAUTION indicates a potentially hazardous situation, which, if not pied spaces. avoided may result in minor or moderate injury. It is also used to 11. The size of the unit should be based on an acceptable heat loss alert against unsafe practices and hazards involving only property dam- calculation for the structure. ACCA, Manual J or other approved age. methods may be used. 12. When moving or handling this furnace prior to installation, always leave the doors on the furnace to provide support and to prevent damage or warping of the cabinet. When lifting the furnace by the cabinet, support the ends of the furnace rather than lifting by the cabinet flanges at the return air openings (bottom or sides) or sup- ply air opening. 13. When lifting the furnace, it is acceptable to use the primary heat exchanger tubes as a lifting point provided that the tubes are lifted at the front of the heat exchangers where attached to the vestibule panel. Do not use the top return bend of the heat exchangers as lift- ing points as the tubes may shift out of position or their location brackets/baffles. SPECIFIC SAFETY RULES AND PRECAUTIONS 1. Only Natural gas or Propane (LP) gas are approved for use with this furnace. 2. Install this furnace only in a location and position as specified in these instructions. SAFETY REQUIREMENTS 3. A gas-fired furnace for installation in a residential garage must be installed as specified in these instructions. 4. Provide adequate combustion and ventilation air to the furnace space as specified in these instructions. 5. Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as specified in SECTION VII, "COMBUSTION AIR and VENT SYSTEM" of these instruc- tions. 6. Test for gas leaks as specified in these instructions. • 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 8. 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 upflow installation on combustible flooring shall not 7. Always install the furnace to operate within the furnace’s intended be installed directly on carpeting, tile or other combustible mate- temperature rise range. Only connect the furnace to a duct system rial other than wood flooring. which has an external static pressure within the allowable range, as • Check the rating plate and power supply to be sure that the elec- specified on the furnace rating plate. trical characteristics match. All models use nominal 115 VAC, 1 8. When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by duct(s) sealed to the furnace !WARNING Improper installation may create a condition where the operation of the product could cause personal injury or property damage. Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Failure to carefully read and follow all instructions in this manual can result in furnace mal- function, death, personal injury and/or property damage. Only a qualified contractor, installer or service agency should install this product. IMPORTANT: During installation, doors should remain on the furnace when moving or lifting. ! CAUTION This product must be installed in strict compliance with the installation instructions and any applicable local, state, and national codes including, but not limited to building, electrical, and mechanical codes. ! WARNING FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in serious injury, death or property damage. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life. Phase, 60-Hz power supply. DO NOT CONNECT THIS APPLI- ANCE TO A 50-Hz POWER SUPPLY OR A VOLTAGE ABOVE 130 VOLTS. casing and terminating outside the space containing the furnace. • Furnace shall be installed so the electrical components are pro- 9. 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; • Furnace operating under thermostatic control; • Return air duct sealed to the furnace; • Air filters in place; 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 • Set furnace input rate and temperature rise per rating plate mark- other safety precautions that may apply. ing; 2 Johnson Controls Ducted Systems 5750149-UIM-D-1219 COMBUSTION AIR QUALITY In the United States and Canada, follow all codes and standards for the (LIST OF CONTAMINANTS) following, using the latest edition available: STEP 1 - Safety • US: National Fuel Gas Code (NFGC) NFPA 54/ANSI Z223.1 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSI/NFPA 90B • CANADA: CAN/CGA-B149.1 National Standard of Canada. Natu- ral Gas and Propane Installation Codes (NSCNGPIC) STEP 2 - General Installation • US: Current edition of the NFGC and NFPA 90B. For copies, con- tact the National Fire Protection Association Inc. Batterymarch Park Quincy, MA 02269 or for only the NFGC, contact the American Gas Association, 400 N. Capital, N.W. The furnace requires OUTDOOR AIR for combustion when the furnace is located in any of the following environments. • Buildings with indoor pools • Chemical exposure • Commercial buildings • Furnaces installed in hobby or craft rooms • Furnaces installed in laundry rooms • Furnaces installed near chemical storage areas • Restricted Environments The furnace requires OUTDOOR AIR for combustion when the furnace Washington DC 20001 or 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 is located in an area where the furnace is being exposed to the follow- STEP 4 - Duct Systems ing substances and / or chemicals. • US and CANADA: Air Conditioning Contractors Association • Antistatic fabric softeners for clothes dryers • Carbon tetrachloride • Cements and glues • Chlorine based swimming pool chemicals • Chlorinated waxes and cleaners (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 • Cleaning solvents (such as perchloroethylene) • De-icing salts or chemicals • US and CANADA: Current edition of SMACNA and NFPA 90B as tested by UL Standard 181 for Class I Rigid Air Ducts • Halogen type refrigerants STEP 6 - Gas Piping and Gas Pipe Pressure Testing • Hydrochloric acid • US: NFGC; chapters 2, 3, 4, & 9 and National Plumbing Codes • Masonry acid washing materials • CANADA: NSCNGPIC Part 5 • Permanent wave solutions STEP 7 - Electrical Connections • Printing inks, paint removers, varnishes, etc. • US: National Electrical Code (NEC) ANSI/NFPA 70 • Water softening chemicals • CANADA: Canadian Electrical Code CSA C22.1 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. 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 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- WARNING The furnace area must not be used as a broom closet or for any other storage purposes, as a fire hazard may be created. Never store items such as the following on, near or in contact with the furnace. 1. Spray or aerosol cans, rags, brooms, dust mops, vacuum clean- ers or other cleaning tools. 2. Soap powders, bleaches, waxes or other cleaning compounds; plastic items or containers; gasoline, kerosene, cigarette lighter fluid, dry cleaning fluids or other volatile fluid. 3. Paint thinners and other painting compounds. 4. 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. 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. ing gas supplier, local building, heating, plumbing, and other codes. In absence of local codes, the installation must comply with the national codes listed below and all authorities having jurisdiction. Johnson Controls Ducted Systems 3 ! 5750149-UIM-D-1219 FOR FURNACES INSTALLED IN THE COMMON- WEALTH OF MASSACHUSETTS ONLY 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. For all side wall horizontally vented gas fueled equipment installed in Refer to “VENT CLEARANCES” located in SECTION VII of these every dwelling, building or structure used in whole or in part for resi- instructions. These minimum clearances must be maintained in the dential purposes, including those owned or operated by the Com- installation. monwealth and where the side wall exhaust vent termination is less 6. Where the unit will be installed in a level position with no more than than seven (7) feet above finished grade in the area of the venting, 1/4” (6.4 mm) slope side-to-side and front-to-back to provide proper including but not limited to decks and porches, the following require- condensate drainage. ments shall be satisfied: Installation in freezing temperatures: 1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the 1. Furnace shall be installed in an area where ventilation facilities pro- vide for safe limits of ambient temperature under normal operating conditions. Ambient temperatures must not fall below 32°F (0°C) unless the condensate system is protected from freezing. 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 2. Do not allow return air temperature to be below 55o 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. a. In the event that the side wall horizontally vented gas fueled 3. If this furnace is installed in an unconditioned space and an equipment is installed in a crawl space or an attic, the hard extended power failure occurs, there will be potential damage to the wired carbon monoxide detector with alarm and battery back- internal components. Following a power failure situation, do not up may be installed on the next adjacent floor level. operate the unit until inspection and repairs are performed. b. 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 monoxide detector with an alarm shall be installed. 2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon Clearances for access/service: monoxide detector as required in accordance with the above pro- visions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified. 3. SIGNAGE. A metal or plastic identification plate shall be perma- nently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heat- ing appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”. 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- 4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the !WARNING Improper installation in an ambient below 32oF (0.0° C) could create a hazard, resulting in damage, injury or death. ! WARNING Liquid anti-freeze will cause damage to internal plastic parts of this furnace. DO NOT attempt to winterize the furnace using liquid anti-freeze. ances for combustible materials where accessibility clearances are greater. installation unless, upon inspection, the inspector observes car- Installation in a residential garage: bon monoxide detectors and signage installed in accordance A gas-fired furnace for installation in a residential garage must be with the provisions of 248 CMR 5.08(2)(a)1 through 4. installed so the burner(s) and the ignition source are located not less than 18” (46 cm) above the floor, and the furnace must be located or INSPECTION protected to avoid physical damage by vehicles. 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 Table 1: Unit Clearances to Combustibles. All furnaces approved for alcove and attic installation should be noted on the carrier’s freight bill. A separate request for Application Upflow Downflow Horizontal inspection by the carrier’s agent should be made in writing. Also, before Top 1" 0" 0" 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. Vent Rear Side 0" 0" 0" 0" 0" 0" 0" 0" 1" FURNACE LOCATION AND CLEARANCES Front1 The furnace shall be located using the following guidelines: 1. Where a minimum amount of air intake/vent piping and elbows will be required. 2. As centralized with the air distribution as possible. 3. Where adequate combustion air will be available (particularly when the appliance is not using outdoor combustion air). 0" 0" 0" Floor Combustible Combustible2 Combustible Closet Yes Yes Yes Line Contact No No Yes 1. 24" clearance in front and 18" on side recommended for service access. 2 For combustible floors only when used with special sub-base. 4 Johnson Controls Ducted Systems 5750149-UIM-D-1219 SECTION II: DUCTWORK DUCTWORK GENERAL INFORMATION 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 The duct system’s design and installation must: heat exchanger. This access cover shall be attached in such a manner 1. Handle an air volume appropriate for the served space and within as to prevent leaks. the operating parameters of the furnace specifications. 2. Be installed in accordance of National Fire Protection Association as outlined in NFPA standard 90B (latest editions) or applicable national, provincial, state, and local fire and safety codes. 3. Create a closed duct system. For residential and non-HUD Modular Home installations, when a furnace is installed so that the supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by a duct(s) sealed to the furnace casing and terminating outside the 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. space containing the furnace. 4. Complete a path for heated or cooled air to circulate through the air conditioning and heating equipment and to and from the condi- )RU GXFW DWWDFKPHQW LI QHHGHG )DFWRU\ LQVWDOOHG tioned space. !CAUTION The indoor coil must be installed in the supply air duct, downstream of the furnace. Cooled air may not be passed over the heat exchanger. When the furnace is used with an indoor 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 DUCTWORK INSTALLATION AND SUPPLY PLENUM cool position. CONNECTION - UPFLOW/HORIZONTAL When replacing an existing furnace, if the existing plenum is not the Attach the supply plenum to the furnace outlet. The use of same size as the new furnace then the existing plenum must be an approved flexible duct connector is recommended on all removed and a new plenum installed that is the proper size for the new installations. This connection should be sealed to prevent furnace. If the plenum is shorter than 12” (30.5 cm) the turbulent air flow air leakage. The sheet metal should be crosshatched to may cause the limit controls not to operate as designed, or the limit con- eliminate any popping of the sheet metal when the indoor trols may not operate at all. fan is energized. 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 FLOOR BASE AND DUCTWORK INSTALLATION - DOWNFLOW so that the furnace operates at the specified external static pressure Installations on combustible material or directly on any and within the air temperature rise specified on the nameplate. floors must use a combustible floor base shown in Figure 2. IMPORTANT: The minimum plenum height is 12” (30.5 cm). The fur- nace will not operate properly on a shorter plenum height. The mini- mum recommended rectangular duct height is 4” (10.2 cm) attached to the plenum. Follow the instructions supplied with the combustible floor base accessory. This combustible floor base can be replaced with a matching indoor coil, properly sealed to pre- vent leaks. Follow the instructions supplied with the indoor coil cabinet for installing the cabinet to the duct connector. Plug intake and vent pipe holes in bottom panel and move ! WARNING grommet to desired vent side exit. Downflow Air - Indoor Coil Cabinet The duct system must be properly sized to obtain the correct airflow for the furnace size that is being installed. Refer to the furnace rating plate for the correct rise range and static pressures or to Table 6 for the correct rise range. The furnace should be installed with coil cabinet part number specifi- cally intended for downflow application. If a matching indoor 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 If the ducts are undersized, the result will be high duct static pres- requirements, refer to the installation instructions supplied with the coil sures and/or high temperature rises which can result in a heat exchanger OVERHEATING CONDITION. This condition can result in premature heat exchanger failure, which can result in personal injury, property damage, or death. FIGURE 1: Duct Attachment cabinet. Attach the indoor coil cabinet to the duct connector, and then position the furnace on top of the coil cabinet. The connection to the furnace, air conditioning coil cabinet, duct connector, and supply air duct must be If a matching cased indoor coil is used, it may be placed directly on the sealed to prevent air leakage. furnace outlet and sealed to prevent leakage. If an uncased indoor coil with a thermoplastic drain pan is to be installed in the upflow/horizontal configuration, then extra 2” (5.1 cm) minimum spacing may be needed to ensure against drain pan distortion. Johnson Controls Ducted Systems 5 5750149-UIM-D-1219 COIL INSTALLATION IMPORTANT: On all installations without a coil, a removable access panel is recommended 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 indoor coil must be mounted on the supply side of the furnace as shown in Figure 3. Refer to the Installation Instructions provided with each indoor coil. FIGURE 2: Combustible Floor Base Accessory 83)/2: '2:1)/2: $33/,&$7,21 $33/,&$7,21 )851$&( &2,/ &2,/ 5,*+7 )/2: $33/,&$7,21 )851$&( )851$&( &2,/ &2,/ )851$&( /()7 )/2: $33/,&$7,21 127( 9HULI\ WKDW DOO GUDLQV DUH WUDSSHG RU SOXJJHG '5$,1 3/8* )25 +25,=217$/ 6(&21'$5< '5$,1 '5$,1 3/8* )25 9(57,&$/ 6(&21'$5< '5$,1 6(&21'$5< '5$,1 35,0$5< '5$,1 75$3 &211(&7,21 75$3 &211(&7,21 35,0$5< '5$,1 75$3 &211(&7,21 $ FIGURE 3: Furnace and Coil Attachment RESIDENTIAL AND MODULAR HOME UPFLOW BOTTOM RETURN AND ATTIC INSTALLATIONS RETURN PLENUM CONNECTION Bottom return applications normally pull return air through a base plat- Return air may enter the furnace through the side(s) or bottom depend- form or return air plenum. Be sure the return platform structure or return ing on the type of application. Return air may not be connected into the air plenum is suitable to support the weight of the furnace. rear panel of the unit. The internal bottom panel must be removed for this application. SIDE RETURN APPLICATION Side return applications pull return air through an opening cut in the Attic installations must meet all minimum clearances to combustibles and have floor support with required service accessibility. side of the furnace casing. This furnace is supplied with a bottom block- off panel that should be left in place if a side return is to be used. If the furnace is to be installed on a flat, solid surface, this bottom panel will provide an adequate seal to prevent air leakage through the unused bottom opening. However, if the furnace is to be installed on a surface that is uneven, or if it is to be installed on blocks or otherwise raised off the floor, it will be necessary to seal the edges of the bottom panel to the casing using tape or other appropriate gasket material to prevent air leakage. 6 Johnson Controls Ducted Systems )851$&( :$50 $,5 3/(180 :,7+ ́ )/$1*(6 ),%(5*/$66 ,168/$7,21 ),%(5*/$66 7$3( 81'(5 )/$1*( &20%867,%/( )/225 %$6( $&&(6625< $ 5750149-UIM-D-1219 HORIZONTAL APPLICATION 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- FIGURE 4: Horizontal Application pension points must be level to ensure quite furnace operation. When IMPORTANT: This furnace may be installed in a horizontal position on either side as shown above. It must not be installed on its back. suspending the furnace use a secure platform constructed of plywood or other building material secured to the floor joists. Refer to Figure 6 for typical crawl space installation. 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 5. 6XSSRUW 5RG /,1( &217$&7 21/< 3(50,66,%/( %(7:((1 /,1(6 )250(' %< 7+( ,17(56(&7,21 2) )851$&( 723 $1' 7:2 6,'(6 $1' %8,/',1* -2,676 678'6 25 )5$0,1* 6833/< $,5 9(17 0DLQWDLQ UHTXLUHG FOHDUDQFHV WR FRPEXVWLEOHV 6XSSRUW $QJOH [ 0DLQWDLQ ́ PLQLPXP ),/7(5 5$&. 0867 %( $ 0,1,080 ',67$1&( *$6 3,3,1* 2) ́ FP )520 7+( )851$&( 6+((7 0(7$/ ,1 )5217 2) $ FOHDUDQFH EHWZHHQ VXSSRUW URGV DQG IURQW RI IXUQDFH )851$&( ́ &20%867,21 $,5 23(1,1*6 ,6 5(&200(1'(' FIGURE 6: Typical Suspended Furnace / Crawl Space Installation DOWNFLOW APPLICATION ́ To apply the furnace in a downflow position, it will be necessary to ́ 0,1 :25. $5($ rotate the vent blower 90° left or right so that the vent pipe passes through the side of the furnace casing. See Figure 7. 5(7851 $,5 6(',0(17 /()7 6,'( 9(17 5,*+7 6,'( 9(17 75$3$ FIGURE 5: Typical Attic Installation ! WARNING When a furnace is installed in an attic or other insulated space, keep all insulating materials at least 12” (30.5 cm) away from furnace and burner combustion air openings. 5RWDWH YHQW IMPORTANT: During installation, doors should remain on the EORZHU furnace when moving or lifting. HLWKHU ZD\ When moving or handling this furnace prior to installation, always leave the doors on the furnace to provide support and to prevent damage or warping of the cabinet. When lifting the furnace, support the ends of the furnace rather than lifting by the cabinet flanges at the return air open- ings (bottom or sides) or supply air opening. $ It is acceptable to use the primary heat exchanger tubes as a lifting point provided that the tubes are lifted at the front of the heat exchang- FIGURE 7: Downflow Venting ers where attached to the vestibule panel. Do not use the top return bend of the heat exchangers as lifting points as the tubes may shift out of position or their location brackets/baffles. Johnson Controls Ducted Systems 7 5750149-UIM-D-1219 /()7 6,'( &RPEXVWLRQ $LU ,QOHW )5217 5,*+7 6,'( &RPEXVWLRQ $LU ,QOHW &RQGHQVDWH 'UDLQ *DV 3LSH 'RZQIORZ (QWU\ ́ 9HQW (OHFWULFDO &RQQHFWLRQ (QWU\ 2XWOHW &RQGHQVDWH *DV 3LSH (QWU\ &RQGHQVDWH 'UDLQ 'RZQIORZ (OHFWULFDO (QWU\ ́ 9HQW &RQQHFWLRQ 'UDLQ 7KHUPRVWDW &RQGHQVDWH 'UDLQ 2XWOHW ́ :LULQJ 7KHUPRVWDW :LULQJ 2SWLRQDO 5HWXUQ $LU &XWRXW (LWKHU VLGH ́ ́ ́ $ ́ ́ ́ ́ ́ ́ 9HQW &RQQHFWLRQ 2XWOHW % &RPEXVWLRQ $LU ,QOHW & % ́ ́ 6833/< (1' ́ ́ 5(7851 (1' $ FIGURE 8: Dimensions Table 2: Cabinet and Duct Dimensions BTUH (kW) Nominal Cabinet Input CFM (m3/min) 8 Johnson Controls Ducted Systems Cabinet Size Dimensions (Illustrated in Figure 8) Approximate Operating Weights A (in) A (cm) B (in) B (cm) C (in) C (cm) Lbs (kg) 40 (11.7) 1000 (28.3) A 14 1/2 36.8 13 3/8 34.0 11 3/4 29.8 113 (51.2) 60 (17.6) 1200 (34.0) B 17 1/2 44.4 16 3/8 41.6 13 1/4 33.7 122 (55.3) 80 (23.4) 1200 (34.0) B 17 1/2 44.4 16 3/8 41.6 14 3/4 37.5 126 (57.1) 80 (23.4) 1600 (45.3) C 21 53.3 19 7/8 50.5 16 1/2 41.9 136 (61.7) 100 (29.3) 1600 (45.3) C 21 53.3 19 7/8 50.5 18 1/4 46.4 142 (64.4) 100 (29.3) 2000 (56.6) C 21 53.3 19 7/8 50.5 18 1/4 46.4 145 (65.8) 120 (35.1) 2000 (56.6) D 24 1/2 62.2 23 3/8 59.4 21 3/4 55.2 156 (70.7) SECTION III: FILTERS FILTER INSTALLATION CAUTION All filters and mounting provision must be field supplied. All installa- tions must have a filter installed. All applications require the use of a field installed filter. All filters and mounting provision must be field supplied. Filters must be installed external to the furnace cabinet. DO NOT attempt to install filters inside the furnace. NOTICE Single side return above 1800 CFM is approved as long as the filter velocity does not exceed filter manufacturer’s recommendation and a transition is used to allow use on a 20x25 filter. Table 3: Recommended Filter Sizes (High Velocity 600 FPM) CFM (m3/min) Cabinet Size Side (in) Bottom (in) ! 1000 (28.3) A 16 x 25 14 x 25 1200 (34.0) B 16 x 25 16 x 25 1600 (45.3) C 16 x 25 20 x 25 2000 (56.6) C (2) 16 x 25 20 x 25 2000 (56.6) D (2) 16 x 25 22 x 25 1. Air velocity through throwaway type filters may not exceed 300 feet per minute (91.4 m/min). All velocities over this 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. 5750149-UIM-D-1219 SIDE RETURN GAS PIPING INSTALLATION Locate the “L” shaped corner locator's. These indicate the size of the cutout to be made in the furnace side panel. Refer to Figures 8 and 9. IMPORTANT: Ensure that the gas connections have a 1/2” National Pipe Thread (NPT). Properly sized wrought iron, approved flexible or steel pipe must be used when making gas connections to the unit. Some utility companies )5217 2) or local codes require pipe sizes larger than the minimum sizes listed in )851$&( these instructions and in the codes. The furnace rating plate and the 6,'( 2) )851$&( instructions in this section specify the type of gas approved for this fur- nace. &251(5 0$5.,1*6 $ For left side supply gas pipe arrangement, two 1/2” elbows and two 1/2” x 1-1/2” pipe nipples must be used. The arrangement shown in Figure 11 aligns entrance hole in furnace casing with supply gas pipe. Furnace FIGURE 9: Side Return Cutout Markings casing does not support installations completed using street-elbows. Install the side filter rack following the instructions provided with that accessory. If a filter(s) is provided at another location in the return air system, the ductwork may be directly attached to the furnace side panel. IMPORTANT: Some accessories such as electronic air cleaners and pleated media may require a larger side opening. Follow the instruc- tions supplied with that accessory for side opening requirements. Do not cut the opening larger than the dimensions for the “Optional Return Air Cutout” shown in Figures 8 and 9. HORIZONTAL FILTERS Any branch duct (rectangular or round duct) attached to the plenum must attach to the vertical plenum before the filter. The use of straps and/or supports is required to support the weight of the external filter box. DOWNFLOW FILTERS Downflow furnaces typically are installed with the filters located above the furnace, extending into the return air plenum or duct. Any branch FIGURE 11: Left Side Supply Gas Pipe Arrangement duct (rectangular or round duct) attached to the plenum must attach to If local codes allow the use of a flexible gas appliance connection, the vertical plenum above the filter height. always use a new listed connector. Do not use a connector that has Filter(s) may be located in the duct system external to the furnace using previously serviced another gas appliance. Use only approved gases. an external duct filter box attached to the furnace plenum or at the end Use a drip leg and ground union as required. Refer to Figure 12. 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 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. GAS SAFETY The furnace must be isolated from the gas supply piping system by ! DANGER closing its individual external manual shutoff valve during any pressure testing of the gas supply piping system at pressures equal to or less than 0.5 psig (3.5 kPa). 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 CAUTION does not exceed 0.5 psig [14" w.c. (3.48 kPa)]. Pressures exceeding 0.5 psig [14” w.c. (3.48 kPa)] at the gas valve will cause damage to the gas valve, resulting in a fire or explosion or cause damage to the furnace or some of its components that will result in property damage and loss of life. ́ [ ́ 3,3( 1,33/( (/%2: *$6 9$/9( ́ [ ́ 3,3( 1,33/( 72 *$6 6833/< (/%2: $ ! The gas valve body is a very thin casting that cannot take any exter- nal pressure. Never apply a pipe wrench to the body of the gas valve when installing piping. A wrench must be placed on the octagon hub located on the gas inlet side of the valve. Placing a wrench to the body of the gas valve will damage the valve causing improper opera- IMPORTANT: Plan the gas supply routing before determining the tion and/or the valve to leak. correct gas pipe entry. Use 90-degree conventional elbow(s) and short pipe nipples to enter through the cabinet access holes. Gas piping may be connected from either side of the furnace using any of the gas pipe entry knockouts on both sides of the furnace. Refer to 287/(7 35(6685( +,*+ 67$*( 5(*8/$725 $'-8670(17 Figures 8 and 12. GAS ORIFICE CONVERSION FOR PROPANE (LP) 3257 9(17 This furnace is constructed at the factory for natural gas-fired operation, 3257 but may be converted to operate on propane (LP) gas by using a ,1/(7 factory-supplied LP conversion kit. Follow the instructions supplied with the LP kit. :5(1&+ %266 ,1/(7 35(6685( 3257 21 2)) 6:,7&+ $ /2: 67$*( 5(*8/$725 $'-8670(17 FIGURE 10: Gas Valve Johnson Controls Ducted Systems 9 287/(7 5750149-UIM-D-1219 $ FIGURE 12: Gas Piping HIGH ALTITUDE GAS ORIFICE CONVERSION HIGH ALTITUDE PRESSURE SWITCH CONVERSION This furnace is constructed at the factory for natural gas-fired operation For installation where the altitude is less than 5,000 feet (1,524m), it is at 0 – 7,999 feet (0 – 2,438 m) above sea level. not required that the pressure switch be changed unless you are in an The manifold pressure must be changed in order to maintain proper area subject to low pressure inversions. and safe operation when the furnace is installed in a location where the altitude is greater than 7,999 feet (2,438 m) above sea level. Refer to Table 4 for proper manifold pressure settings. Table 4: Nominal Manifold Pressure - High Fire Manifold Pressures Manifold Pressures Gas Heating Value (BTU/cu ft.) 0-7999 in. w.c. 8000-8999 9000-9999 in. w.c. in. w.c. Altitude (m) 0-2437 2438-2742 2743-3048 kPa kPa kPa 800 3.5 3.5 3.5 29.8 0.87 0.87 0.87 850 3.5 3.5 3.5 31.7 0.87 0.87 0.87 900 3.5 3.5 3.5 33.5 0.87 0.87 0.87 950 3.5 3.5 3.3 35.4 0.87 0.87 0.81 1000 3.5 3.2 2.9 37.3 0.87 0.80 0.73 1050 3.5 2.9 2.7 39.1 0.87 0.73 0.67 1100 3.2 2.7 2.4 41.0 0.80 0.66 0.61 2500 (LP) 9.8 8.2 7.5 93.2 (LP) 2.44 2.03 1.86 Table 5: Nominal Manifold Pressure - Low Fire Manifold Pressures Manifold Pressures Gas Heating Value (BTU/cu ft.) 10 Johnson Controls Ducted Systems Altitude (feet) Gas Heating Value (MJ/cu m) Altitude (feet) Altitude 0-7999 8000-8999 9000-9999 in. w.c. in. w.c. in. w.c. Gas Heating Value (MJ/cu m) 0-2437 kPa (m) 2438-2742 2743-3048 kPa kPa 800 1.7 1.7 1.7 29.8 0.42 0.42 0.42 850 1.7 1.7 1.7 31.7 0.42 0.42 0.42 900 1.7 1.7 1.7 33.5 0.42 0.42 0.42 950 1.7 1.7 1.5 35.4 0.42 0.42 0.38 1000 1.6 1.5 1.4 37.3 0.41 0.37 0.34 1050 1.5 1.4 1.3 39.1 0.37 0.34 0.31 1100 1.3 1.2 1.1 41.0 0.34 0.31 0.28 2500 (LP) 4.1 3.8 3.5 93.2 (LP) 1.03 0.95 0.87 5750149-UIM-D-1219 ! DANGER 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 obtain the proper orifice size. Drilling out a gas orifice will cause misalignment of the burner flames, caus- ing premature heat exchanger burnout, high levels of carbon monoxide, excessive sooting, a fire hazard, personal injury, property damage and/or death. SECTION V: ELECTRICAL POWER ELECTRICAL POWER CONNECTIONS CAUTION Use copper conductors only. Johnson Controls Ducted Systems 11 Field wiring to the unit must be grounded. Electric wires that are field installed shall conform to the temperature limitation for 63°F (35°C) rise wire when installed in accordance with instructions. Refer to Table 6 in ! these instructions for specific furnace electrical data. Table 6: Ratings & Physical / Electrical Data Model Input Output High/Low High/Low Nominal Airflow Cabinet Width High Fire Air Temp. Rise Annual Fuel Utilization Efficiency (AFUE) numbers are determined in accordance with DOE Test procedures. Wire size and over current protection must comply with the National Electrical Code (NFPA-70-latest edition) and all local codes. The furnace shall be installed so that the electrical components are protected from water. Low Fire Air Temp. Rise MBH kW MBH kW CFM m3/min in. cm °F °C °F °C TM9V040A10 40/26 12/8 38/25 11/7 1000 28.3 14-1/2 36.8 30 - 60 17-33 20 - 50 11-28 TM9V060B12 60/39 18/11 58/37 17/11 1200 34 17-1/2 44.4 35 - 65 19-36 35 - 65 19-36 TM9V080B12 80/52 23/15 77/50 22/14 1200 34 17-1/2 44.4 40 - 70 22-39 35 - 65 19-36 TM9V080C16 80/52 23/15 77/50 22/14 1600 45.3 21 53.3 35 - 65 19-36 35 - 65 19-36 TM9V100C16 100/65 29/19 96/62 28/18 1600 45.3 21 53.3 35 - 65 19-36 30 - 65 17-33 TM9V100C20 100/65 29/19 96/62 28/18 2000 56.6 21 53.3 35 - 65 19-36 35 - 65 19-36 TM9V120D20 120/78 35/23 115/75 33/22 2000 56.6 24-1/2 62.2 35 - 65 19-36 35 - 65 19-36 Model Max. Outlet Air Temp. Blower Blower Wheel Size AFUE Total Unit Amps °F °C HP Amps inches cm % Recommended Fuse or Circuit Breaker Amps Gas Pipe Connection, Operating Weight NPT Lbs. kg. TM9V040A10 190 88 1/2 7.7 11 x 8 27.9 x 20.3 96 9.6 15 1/2” 113 51.2 TM9V060B12 190 88 1/2 7.7 11 x 8 27.9 x 20.3 96 9.6 15 1/2” 122 55.3 TM9V080B12 190 88 1/2 7.7 11 x 8 27.9 x 20.3 96 9.6 15 1/2” 126 57.1 TM9V080C16 190 88 3/4 9.6 11 x 10 27.9 x 25.4 96 11.5 15 1/2” 136 61.7 TM9V100C16 190 88 3/4 9.6 11 x 10 27.9 x 25.4 96 11.5 15 1/2” 142 64.4 TM9V100C20 190 88 1 12.8 11 x 11 27.9 x 27.9 96 14.7 20 1/2” 145 65.7 TM9V120D20 190 88 1 12.8 11 x 11 27.9 x 27.9 96 14.7 20 1/2” 156 70.7 5750149-UIM-D-1219 SUPPLY VOLTAGE CONNECTIONS This furnace may be used with the Communicating Thermostat Control and a non-communicating outdoor air conditioner by installing the AC Communicating Control Board Kit to the outdoor unit. This system allows full communication between the furnace and thermostat and lim- -XQFWLRQ ited communication to the outdoor unit. See Figure 14. %R[ &RQQHFW JURXQG OHDG WR VFUHZ/ +RW 1HXWUDO 1. Provide a power supply separate from all other circuits. Install over- current protection and disconnect switch per local/national electrical codes. The switch should be close to the unit for convenience in servicing. With the disconnect or fused switch in the OFF position, check all wiring against the unit wiring label. Refer to the wiring dia- gram in this instruction. 2. Remove the wiring box cover screws. Route all power wiring through a conduit connector or other proper bushing that is field installed into the unit opening and the junction box. In the junction box there is a black wire, a white wire and a green ground screw. Connect the power supply as shown on the unit’s wiring label located on the inside of the blower compartment door, or the wiring schematic in this section. Connect the black wire to L1 (hot) from the power supply. Connect the white wire to neutral. Connect the ground wire (installer-supplied) to the green (equipment ground) screw. An alternate wiring method is to use a field-provided 2” (5.1 cm) x 4” (10.2 cm) box and cover on the outside of the furnace. CONTROL WIRING USING COMMUNICATING 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 13. 3. The furnace's control system requires correct polarity of the power supply and a proper ground connection. Refer to Figure 13. CONTROLS (NON-VARIABLE CAPACITY OUTDOOR MODELS) Use the wiring diagram to connect the furnace control, Communicating Control (wall thermostat) and communicating outdoor unit. Be sure that all of the “A” terminals are connected together, all of the “B” terminals are connected together, all of the “GND” or “C” terminals are connected together and all of the “R” terminals are connected together. See Figure 14. When using a fully communicating system, the large screw termi- nals (C, G, R, etc.) on the furnace control are not used. The four small screw terminals in the terminal block on the labeled “communications” furnace control should be used. CONTROL WIRING This furnace can be connected to the wall thermostat and outdoor A/C or heat pump using either conventional low voltage (24 VAC) thermo- stat wiring OR using four-wire digital communications wiring. To use conventional low voltage wiring, see the section entitled “Conventional Low Voltage Control Wiring”. To use four-wire communications control wiring, see the section below entitled “Control Wiring using Communi- cating Controls”. The Communicating System consists of several intelligent communicat- Float Switch Input ing components including the Communicating Thermostat Control (touch-screen wall thermostat), variable speed furnace, communicating capable air conditionr or heat pump which continually communicate with each other via a four-wire connection called the A-R-C-B. An optional switch may be connected to the FLT SWT terminals on the control board. This feature is only functional when used with the Com- municating Control. It is intended for use with a water overflow switch that has contacts in either the normally open (NO) or (NC) position. Do Commands, operating conditions, and other data are passed continu- NOT install a float switch in series with any thermostat wiring when ally between components over the A-R-C-B. See Figure 14. The result using communicating controls. is a new level of comfort, versatility, and simplicity. In order to use this furnace in full communications (COMM) mode, it MUST be installed with the matching touch-screen Communicating Control (wall thermostat) and an outdoor air conditioner or heat pump with a fully communicating control. 7RXFK 6FUHHQ &RPPXQLFDWLQJ FRQWURO (OHFWULFDO (QWU\ $ %/.5:+7 &% $ FIGURE 13: Electrical Wiring FIGURE 14: Two-stage Furnace with Communicating AC or HP IMPORTANT: The power connection leads and wiring box may be relocated to the opposite side of the furnace. Remove the screws and cut wire tie holding excess wiring. Reposition on the opposite side of the furnace and fasten using holes provided. IMPORTANT: Do not place more than one wire under any single communication terminal screw (there are four communication termi- nal screws). If more than one wire must be connected, attach only the terminal end of a one wire pigtail no longer than 6“, and use a wire connector to connect the other end of the pigtail to the other wires. Failure to do this will result in nuisance communication error faults. See Figure 16. Auxiliary Switch Input An optional switch may be connected to the AUX SWT terminals on the control board. This feature is only functional when used with the Com- munication Control. Refer to Communication Control Installation Man- ual. 12 Johnson Controls Ducted Systems $LU &RQGLWLRQHU +HDW 3XPS )XUQDFH &RPPXQLFDWLQJ FRQWURO &RPPXQLFDWLQJ FRQWURO $ $ 55&*1' % % 2 '+80 : < < < : : 5*& $ 5750149-UIM-D-1219 &20081,&$7,216 ',$*1267,& /,*+7 /$67 (5525 %87721 &)0 ,1',&$725 )/2$7 $ 5 & % $ 5 & % 6:,7&+ &211(&7,21 &20081,&$7,216 $ 5 & % $ 5 & % 67$786 (5525 /$67 7(03 6:7 $8; 6:7 )/7 1(875$/6 &219(17,21$/ /2: 92/7$*( 767$7 &211(&7,216 &&)0 *5: &20081,&$7,1* 767$7 &211(&7,216 7(03 6(1625 &211(&7,216 $8;,/,$5< 6:,7&+ &211(&7,216 : < < < +80,',67$7 6(/(&7,21 $,5)/2: : 6(/(&7,21 '( &217,18286 +80 )$1 63((' +($7 3803 2 6(/(&7,21 +80 +, +($7 '(/$< ($& %/2:(5 67$*,1* )$1 63((' +80 67$7 &22/ '(/$< 2)) '(/$<%/2:(5 '(/$< +($73803 +($7 $'-867 $ FIGURE 15: Furnace Control Board – Communications Connections MODULATING FURNACE Connect COMMUNICATING WIRE CONTROL CONNECTOR NOTE FIGURE 16: Terminal Screw Wire Connection Johnson Controls Ducted Systems 13 a short piece of thermostat wire (18 gage minimum) to the ARCB terminals on the furnace control board. Use wire connectors to connect this wire to the room thermostat wire and the outdoor unit ther- mostat wire. The outdoor unit contains its own control transformer. DO ENSURE ONLY ONE WIRE UNDER NOT run a thermostat “R” wire to the outdoor unit. See Figure 17 for TERMINAL SCREW. details. TO CONNECT MORE THAN ONE WIRE: THERMOSTAT 1. CONNECT ONLY TERMINAL END OF 6” WIRE PIGTAIL. IMPORTANT: Do not place more than one wire under any single A+communication terminal screw (there are four communication termi- TERMINAL SCREW RC2. USE WIRE CONNECTOR TO CONNECT nal screws). If more than one wire must be connected to a terminal OTHER END OF PIGTAIL TO OTHER WIRES. screw, attach only the terminal end of a one wire pigtail no longer than 6“, and use a wire connector to connect the other end of the pigtail to B- the other wires. Failure to do this will result in nuisance communica- tion error faults. See Figure 16. OUTDOOR UNIT INDOOR UNIT +[ 7+(50267$7 70 )851$&( 9$5,$%/( &$3$&,7< A0236-001 &20081,&$7,1* &21752/ &20081,&$7,1* $& +($7 3803 &21752/ &20081,&$7,1* &21752/CONTROL WIRING USING COMMUNICATING $ $ $ CONTROLS (VARIABLE CAPACITY OUTDOOR 55MODELS) The Communicating System consists of several intelligent communicat- &&&ing components including the HxTM Thermostat, the variable speed fur- % % % nace and the variable capacity air conditioner or heat pump. These components continually communicate with each other via the wire con- nections shown in Figure 17. Commands, operating conditions, and other data are passed continually between components over the A-R- C-B and A-C-B bus. The result is a new level of comfort, versatility, and $ simplicity. 5In order to use this furnace with a variable capacity outdoor unit, it must be installed with a communicating Hx thermostat. &Use the wiring diagram in Figure 17 to connect the furnace control % and the HxTM Thermostat (wall thermostat) to the communicating out- door unit. Be sure that all of the “A+” terminals are connected together, all of the “B-” terminals are connected together, all of the “C” terminals FIGURE 17: Furnace with Variable Capacity AC or HP $ are connected together and the “R” terminals from the Hx thermostat to the indoor unit are connected together. Do NOT connect the “R” wire to the outdoor unit. The four small screw terminals in the terminal block on the furnace control should be used. ,1'225 ((9 &21752/ $ 5&% 5750149-UIM-D-1219 Float Switch Input CONVENTIONAL LOW VOLTAGE CONTROL WIRING An optional switch may be connected to the FLT SWT terminals on the Install the field-supplied thermostat by following the instructions that control board. This feature is only functional when used with the Com- come with the thermostat. With the thermostat set in the OFF position municating Control. It is intended for use with a water overflow switch and the main electrical source disconnected, connect the thermostat that has contacts in either the normally open (NO) or (NC) position. Do wiring from the wiring connections on the thermostat to the terminal NOT install a float switch in series with any thermostat wiring when board on the ignition module, as shown in Figures 18 - 21. Electronic using communicating controls. thermostats may require the common wire to be connected. Apply Auxiliary Switch Input An optional switch may be connected to the AUX SWT terminals on the control board. This feature is only functional when used with the Com- munication Control. Refer to Communication Control Installation Man- strain relief to thermostat wires passing through cabinet. If air condition- ing equipment is installed, use thermostat wiring to connect the Y and C terminals on the furnace control board to the proper wires on the con- densing unit (unit outside). ual. 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 anticipators. They should be set to six cycles per hour. Follow the thermostat manufacturer's instructions. The 24-volt, 40 VA transformer is sized for the furnace components only, and should not be connected to power auxiliary devices such as humidifiers, air cleaners, etc. The transformer may provide power for an air conditioning unit or heat pump. 6LQJOH 6WDJH $LU &RQGLWLRQHU ± 7ZR 6WDJH 9DULDEOH 6SHHG )XUQDFH 7:2 67$*( 7+(50267$7 9$5,$%/( 63((' )851$&( 6,1*/( 67$*( $,5 &21',7,21(5 & & & ± 9ROW &RPPRQ ± 9ROW &RPPRQ ± 9ROW &RPPRQ 5 5 5 ± 9ROW +RW ± 9ROW +RW ± 9ROW +RW **)DQ )DQ < )LUVW 6WDJH &RPSUHVVRU < < )XOO 6WDJH &RPSUHVVRU RU 2 5HYHUVLQJ 9DOYH FIGURE 18: Thermostat Chart - Single Stage Air Conditioner with Two Stage Variable Speed Furnace 14 Johnson Controls Ducted Systems < )LUVW 6WDJH &RPSUHVVRU : : : )LUVW 6WDJH +HDW )LUVW 6WDJH +HDW : 6HFRQG 6WDJH +HDW : < < 6HFRQG 6WDJH )LUVW 6WDJH &RPSUHVVRU &RPSUHVVRU '(+80 'HKXPLGL¿FDWLRQ 9$& +XPLGLVWDW 2SWLRQDO $ 5750149-UIM-D-1219 6LQJOH 6WDJH +HDW 3XPS ± 7ZR 6WDJH 9DULDEOH 6SHHG )XUQDFH 7:2 67$*( 7+(50267$7 9$5,$%/( 63((' 6,1*/( 67$*( +($7 3803 )851$&( 127( 5RRP WKHUPRVWDW 0867 FRQWURO IRVVLO IXHO RSHUDWLRQ & & & ± 9ROW &RPPRQ ± 9ROW &RPPRQ ± 9ROW &RPPRQ 5 5 5 ± 9ROW +RW ± 9ROW +RW ± 9ROW +RW **)DQ )DQ < )LUVW 6WDJH &RPSUHVVRU < < )XOO 6WDJH &RPSUHVVRU < )LUVW 6WDJH &RPSUHVVRU : )LUVW 6WDJH +HDW : : : : 6HFRQG 6WDJH +HDW )LUVW 6WDJH +HDW : 287 $X[ +HDW < < 6HFRQG 6WDJH )LUVW 6WDJH &RPSUHVVRU &RPSUHVVRU RU 2 2 5HYHUVLQJ 9DOYH 5HYHUVLQJ 9DOYH : 6HFRQG 6WDJH +HDW 9$& +XPLGLVWDW '(+80 2SWLRQDO 'HKXPLGL¿FDWLRQ $ FIGURE 19: Thermostat Chart - Single Stage Heat Pump with Two Stage Variable Speed Furnace 7ZR 6WDJH $LU &RQGLWLRQHU ± 7Z R 6WDJH 9DULDEOH 6SHHG )XUQDFH 7:2 67$*( 7+(50267$7 9$5,$%/( 63((' )851$&( < )LUVW 6WDJH &RPSUHVVRU RU 2 5HYHUVLQJ 9DOYH FIGURE 20: Thermostat Chart - Two Stage Air Conditioner with Two Stage Variable Speed Furnace Johnson Controls Ducted Systems 15 7:2 67$*( $,5 &21',7,21(5 & & & ± 9ROW &RPPRQ ± 9ROW &RPPRQ ± 9ROW &RPPRQ 5 5 5 ± 9ROW +RW ± 9ROW +RW ± 9ROW +RW **)DQ )DQ < )LUVW 6WDJH &RPSUHVVRU < &RPSUHVVRU &RQWDFWRU < 6HFRQG 6WDJH &RPSUHVVRU < < )XOO 6WDJH &RPSUHVVRU : : : )LUVW 6WDJH +HDW )LUVW 6WDJH +HDW '(+80 'HKXPLGL¿FDWLRQ < 6HFRQG 6WDJH &RPSUHVVRU : 6HFRQG 6WDJH +HDW : 9$& +XPLGLVWDW 2SWLRQDO $ 5750149-UIM-D-1219 7ZR 6WDJH +HDW 3XPS ± 7ZR 6WDJH 9DULDEOH 6SHHG )XUQDFH 7:2 67$*( 7+(50267$7 9$5,$%/( 63((' 7:2 67$*( +($7 3803 )851$&( & & & ± 9ROW &RPPRQ ± 9ROW &RPPRQ ± 9ROW &RPPRQ 5 5 5 ± 9ROW +RW ± 9ROW +RW ± 9ROW +RW **)DQ )DQ < < < )LUVW 6WDJH )LUVW 6WDJH )LUVW 6WDJH &RPSUHVVRU &RPSUHVVRU &RPSUHVVRU : )LUVW 6WDJH +HDW : : : : : 287 6HFRQG 6WDJH +HDW )LUVW 6WDJH +HDW $X[ +HDW : : 2XW 6HFRQG 6WDJH +HDW 6HFRQG 6WDJH +HDW RU 2 5HYHUVLQJ 9DOYH 2 < 6HFRQG 6WDJH &RPSUHVVRU < < )XOO 6WDJH &RPSUHVVRU < 6HFRQG 6WDJH &RPSUHVVRU < 287 6HFRQG 6WDJH &RPSUHVVRU 9$& +XPLGLVWDW '(+80 2SWLRQDO 'HKXPLGL¿FDWLRQ NOTICE The Figures 23 - 26 show the condensate drain arrangement for the various possible furnace and vent blower positions. CAUTION The furnace condensate pan is self priming and contains an internal trap to prevent flue gas leaking. Do not install an external condensate trap. 16 Johnson Controls Ducted Systems $ FIGURE 21: Thermostat Chart - Two Stage Heat Pump with Two Stage Variable Speed Furnace (Hot Heat Pump or Conventional) ACCESSORY CONNECTIONS SECTION VI: CONDENSATE PIPING AND The furnace control will allow power-switching control of various accessories. FURNACE VENTING CONFIGURATION ELECTRONIC AIR CLEANER CONNECTION CONDENSATE DRAIN LOCATION Two 1/4” (6.4 mm) spade terminals (EAC and NEUTRAL) for electronic As shipped from the factory: air cleaner connections are located on the control board. The terminals • For all 040, 060, & 080K input furnaces the main drain is plumbed provide 115 VAC (1.0 amp maximum) during circulating blower through the casing right-side opening when viewed from the front operation. of the furnace. HUMIDIFIER CONNECTION Two 1/4” (6.4 mm) spade terminals (HUM and NEUTRAL) for humidifier connections are located on the control board. The terminals provide • For all 100, 120, & 130K input furnaces the main drain is plumbed through the casing left-side opening when viewed from the front of the furnace. 115 VAC (1.0 amp maximum) during heating system operation. A mounting hole is provided on the control panel next to the furnace control board for mounting a humidifier transformer if required. SINGLE STAGE THERMOSTAT If a single stage thermostat is used for gas heating, the high/low input The condensate hoses must slope downwards at all points. staging will be controlled by the furnace control board using the staging jumper. If the staging jumper is set to the 10, 15, or 20 position, the fur- nace will switch from low fire to high fire after 10, 15, or 20 minutes and ! will stay in high fire until the thermostat is satisfied. If the staging jumper is left in the OFF position and a single stage thermostat is used, the fur- nace will only operate at low fire. TWINNING When drain hose routing changes are required (shown in Figures 23- These furnaces are not to be twinned. If more than one furnace is 26), be sure to cap all un-used openings. needed in an application, each furnace must have its own complete If rerouting hoses - excess length should be cut off so that no sagging duct system and its own wall thermostat. 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. 5750149-UIM-D-1219 IMPORTANT: The furnace, indoor coil, and humidifier drains may be combined and drained together. The indoor coil drain may have an external, field-supplied trap prior to the furnace drain connection to prevent conditioned air leakage. All drain connections (furnace, indoor coil, or humidifier) must be terminated into an open or vented drain as close to the respective equipment as possible. Regular main- tenance is required on condensate drainage system. CAUTION It is possible for condensation to form inside the combustion air (intake) pipe in the summer months if significant length of combustion air pipe passes through conditioned space. This problem can be averted by installing the supplied vent drain and drain hose located in the loose parts bag. The intake drain hose is to be installed by con- necting it to the inlet pipe coupling and to the collector box as shown IMPORTANT: Condensate must be disposed of properly. Follow in Figures 23, 25, and 26. The drain hose must not sag or droop after local plumbing or wastewater codes. The drain line must maintain a 1/ 4” per foot (20 mm/m) downward slope to the drain. it is installed. If glue is used when connecting the intake pipe to the intake coupling, the drain opening in the vent drain must not be plugged. If the intake drain is used, the bird screen cannot be IMPORTANT: If an external exhaust vent tee is being installed, then it must have its own condensate trap before it is disposed into an open or vented drain. This is not to be considered as a second trap as referenced elsewhere in this document. installed. This is only approved for upflow and horizontal applications when the intake pipe is located on the top of the furnace. This is true for all long horizontal venting in any furnace configuration. This will keep condensate from entering the furnace. WARNING NOTICE DO NOT terminate the condensate drain in a chimney, or where the drain line may freeze. If the drain line will be exposed to temperatures A loop has been added to the pressure switch vacuum hose. How- ever, ensure that all pressure switch hoses are routed such that they prevent any condensate from entering the pressure switch. !The condensate will flow to the drain better if an open stand pipe is installed in the drain line. See Figure 22. If indoor coil or humidifier drains are combined with the furnace drain, do not drain into the top opening of the vent stand pipe. Instead, install 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 second tee in the vented drain tube below the furnace drain tee and route additional drainage through the new tee. !below freezing, adequate measures must be taken to prevent the drain line from freezing. Failure to provide proper protection from freezing can result in improper operation or damage to the equipment and possible property damage. When exposed to temperatures below freezing, use of a 3 to 6 watt per foot at 115 VAC, 40°F (4.4°C) self-regulating, shielded and waterproof heat tape is recommended on the drain line outside the furnace. DO NOT trap the drain line at any location. The furnace has a con- densate drain trap built into the drain pan. ! WARNING Liquid anti-freeze will cause damage to internal plastic parts of this furnace. DO NOT attempt to winterize the furnace using liquid 23(1 67$1' 3,3( anti-freeze. $QWL VLSKRQ DLU YHQW ́ 0D[ 7(( 72 23(1 25 9(17(' '5$,1 $ FIGURE 22: Typical. Condensate Drain, Vertical Installation Johnson Controls Ducted Systems 17 5750149-UIM-D-1219 A0945-001 FIGURE 23: Upflow Configuration 18 Johnson Controls Ducted Systems 5750149-UIM-D-1219 FIGURE 24: Downflow Configuration Johnson Controls Ducted Systems 19 AIRFLOW AIRFLOW
Move rain gutter hose to this position. DOWNFLOW - INDUCER ROTATED FOR LEFTSIDE VENTINGDOWNFLOW - INDUCER ROTATED FOR RIGHTSIDE VENTING Move pressure switch hose to this position. NOTE: May require NOTE: May require the longer hose that the longer hose that the longer hose that is provided with wider cabinets. wider cabinets. wider cabinets. Move condensate Move condensate Move condensate Move condensate drain hose to this drain hose to this drain hose to this drain hose to this position (may exit position (may exit position (may exit position (may exit position (may exit position (may exit either side of the either side of the either side of the either side of the either side of the either side of the cabinet). Move rain gutter cabinet). Move rain gutter cabinet). Move rain gutter cabinet). Move rain gutter cabinet). Move rain gutter cabinet). Move rain gutter cabinet). Move rain gutter hose to this position. When drain hose routing changes are required, 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. 1 2 4 3 A0970-001
5750149-UIM-D-1219 A0946-001 FIGURE 25: Horizontal Left Configuration 20 Johnson Controls Ducted Systems 5750149-UIM-D-1219 A0946-001 FIGURE 26: Horizontal Right Configuration Johnson Controls Ducted Systems 21 5750149-UIM-D-1219 SECTION VII: COMBUSTION AIR AND VENT SYSTEM COMBUSTION AIR AND VENT SAFETY 4. All PVC or ABS combustion air and vent pipe must conform to American National Standards Institute (ANSI) and American Soci- ety for Testing and Materials (ASTM) standards D1785 (Schedule 40 PVC), D2665 (PVC-DWV), F891 (PVC-DWV Cellular Core), 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- D2261 (ABS-DWV) or F628 (Schedule 40 ABS). Pipe cement and primer must conform to ASTM Standard D2546 (PVC) or D2235 (ABS). If ABS pipe is to be used, any joint where ABS pipe is joined to PVC pipe must be glued with cement that is approved for use with BOTH materials. Metallic materials must not be used for vent- ing or air intake. bustion and Ventilation, of the National Fuel Gas Code Z223.1/NFPA 54 5. If a flexible connector is used in the vent system, it must be made of (latest edition), or Sections 7.2, 7.3 or 7.4 of CSA B149.1, National Gas and Propane Codes (latest edition) or applicable provisions of the local building code and these instructions. a material that is resistant to acidic exposure and to at least 225°F (107.2°C) temperature. Flexible connectors are also allowed in the combustion air pipe. 6. All models are supplied with 2" (5.1 cm) vent connections. When the pipe must be increased to 3" (7.6 cm) diameter, the transition from 2" to 3" must be done as close to the furnace as possible. The 2” to 3” increase should be installed in the vertical position as to not create an area that will pool water. 7. In Canada, vents shall be certified to ULC S636, Standard for Type BH Gas Venting Systems. 8. In Canada, the first three feet (91.4 cm) of the vent must be readily accessible for inspection. 9. For single pipe systems it is recommended to install the combustion air coupling provided and install approximately 18” of PVC pipe on the furnace. 10. Minimum vent length for all models is 5 feet (1.5 m). POLYPROPYLENE VENT/INTAKE PIPING The ULC S636 approved polypropylene (PP) vent piping materials listed below have been tested and approved for use with this furnace. DO NOT mix parts made by different manufacturers. The entire vent/air intake system must be made from pipe, fittings and termination made by the same manufacturer. Only single-wall rigid polypropylene pipe is approved for these furnaces. Use of flexible polypropylene pipe is not allowed. Selkirk Polyflue (Hart & Cooley) part numbers • Horizontal concentric termination - 2" - 2PF-HCT • Horizontal concentric termination - 3" - 3PF-HCT COMBUSTION AIR/VENT PIPE SIZING • Locking band - PF-LB The size of pipe required will be determined by the furnace model, the Consult the Polyflue installation instructions for assembly details. total length of pipe required and the number of elbows required. For other Polyflue pipe and fitting part numbers, visit website Table 7 lists the maximum equivalent length of pipe allowed for each polyflue.com model of furnace. The equivalent length of pipe for each elbow installed is listed in Table 10. The equivalent length of the vent system is the total length of straight pipe PLUS the equivalent length of all of the elbows. The following rules must also be followed: 1. Drain, waste, and vent (DWV) elbows with a long radius (sweep) are recommended. Standard DWV 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 or pres- sure) elbows are not allowed for venting. The standard dimensions Duravent PolyPro part numbers • Adapter to air intake coupling - 2PPS-ADL • Adapter connector - PPS-PAC • Twin pipe horizontal termination - 2" - 2PPS-HTPL • Twin pipe horizontal termination - 3" - 3PPS-HTPL Consult the PolyPro installation instructions for assembly details. For other PolyPro pipe and fitting part numbers, visit website duravent.com of the acceptable elbows are shown in Figure 27. Centrotherm InnoFlue 2. The maximum equivalent length listed in Table 7 is for the vent pip- • Adapter to air intake coupling - ISAGL0202 ing 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. 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. WARNING This furnace may not be common vented with any other appliance, since it requires separate, properly sized air intake and vent lines. The furnace shall not be connected to any type of B, BW or L vent or vent connector, and not connected to any portion of a factory-built or masonry chimney. The furnace shall not be connected to a chimney flue serving a sepa- rate appliance designed to burn solid fuel. CAUTION When combustion air pipe is installed above a suspended ceiling or when it passes through a warm and humid space, the pipe may need insulated 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. • Adapter to draft inducer blower - ISAAL0202 • Low profile wall termination - 2" - ISLPT0202 • Low profile wall termination - 3" - ISLPT0303 Consult the InnoFlue installation instructions for assembly details. For other InnoFlue pipe and fitting part numbers, visit website centrotherm.us.com 22 Johnson Controls Ducted Systems !! 5750149-UIM-D-1219 Table 7: Maximum Equivalent Pipe Length Elevation Sea level - 2000 Elevation 6001 - 7000 Model Input (BTUH) Pipe Size (in) Max. equivalent Length (ft) Model Input (BTUH) Pipe Size (in) Max. equivalent Length (ft) 40,000 2 65 40,000 2 40 40,000 3 90 40,000 3 65 40,000 4 150 40,000 4 130 60,000 2 65 60,000 2 40 60,000 3 90 60,000 3 65 60,000 4 150 60,000 4 130 80,000 2 65 80,000 2 30 80,000 3 90 80,000 3 65 80,000 4 150 80,000 4 130 100,000 2 30 100,000 2 5 100,000 3 90 100,000 3 65 100,000 4 150 100,000 4 130 120,000 3 90 120,000 3 65 120,000 4 150 120,000 4 130 Elevation 2001 - 4000 Elevation 7001-8000 Model Input (BTUH) Pipe Size (in) Max. equivalent Length (ft) Model Input (BTUH) Pipe Size (in) Max. equivalent Length (ft) 40,000 2 55 40,000 2 35 40,000 3 80 40,000 3 60 40,000 4 145 40,000 4 125 60,000 2 55 60,000 2 35 60,000 3 80 60,000 3 60 60,000 4 145 60,000 4 125 80,000 2 55 80,000 2 25 80,000 3 80 80,000 3 60 80,000 4 145 80,000 4 125 100,000 2 20 100,000 2 NA 100,000 3 80 100,000 3 60 100,000 4 145 100,000 4 125 120,000 3 80 120,000 3 60 120,000 4 145 120,000 4 125 Elevation 4001 - 5000 Elevation 8001-9000 Model Input (BTUH) Pipe Size (in) Max. equivalent Length (ft) Model Input (BTUH) Pipe Size (in) Max. equivalent Length (ft) 40,000 2 50 40,000 2 30 40,000 3 75 40,000 3 55 40,000 4 140 40,000 4 120 60,000 2 50 60,000 2 30 60,000 3 75 60,000 3 55 60,000 4 140 60,000 4 120 80,000 2 50 80,000 2 20 80,000 3 75 80,000 3 55 80,000 4 140 80,000 4 120 100,000 2 15 100,000 2 NA 100,000 3 75 100,000 3 55 100,000 4 140 100,000 4 120 120,000 3 75 120,000 3 55 120,000 4 140 120,000 4 120 Elevation 5001 - 6000 Elevation 9001-10000 Model Input (BTUH) Pipe Size (in) Max. equivalent Length (ft) Model Input (BTUH) Pipe Size (in) Max. equivalent Length (ft) 40,000 2 45 40,000 2 25 40,000 3 70 40,000 3 50 40,000 4 135 40,000 4 115 60,000 2 45 60,000 2 25 60,000 3 70 60,000 3 50 60,000 4 135 60,000 4 115 80,000 2 35 80,000 2 15 80,000 3 70 80,000 3 50 80,000 4 135 80,000 4 115 100,000 2 10 100,000 2 NA 100,000 3 70 100,000 3 50 100,000 4 135 100,000 4 115 120,000 3 70 120,000 3 50 120,000 4 135 120,000 4 115 Johnson Controls Ducted Systems 23 5750149-UIM-D-1219 Table 8: High Altitude Pressure Switches High Altitude Pressure Switches required for all installations above 5000 Feet Part Number Models S1-1PS3308 All $ $ TABLE 11: Combustion Air Intake and Vent Connection Size at Furnace (All Models) FURNACE VENT CONNECTION SIZES Furnace Input All Intake Pipe Size 2” (5.1 cm) Vent Pipe Size 2” (5.1 cm) IMPORTANT: Furnace vent pipe connections are sized for 2” (5.1 cm). pipe. Any pipe size change must be made outside the furnace 67$1'$5' (/%2: /21* 6:((3 (/%2: $ casing in a vertical pipe section to allow proper drainage of conden- sate. An offset using two 45o (degree) elbows will be required for ple- FIGURE 27: Dimensions num clearance when the vent is increased to 3” (7.6 cm). TABLE 9: Elbow Dimensions Elbow “A” Dimension (Illustrated in Figure 27) 2" Standard 2-5/16" IMPORTANT: Accessory concentric vent / intake termination kits 1CT0302 and 1CT0303, and for Canadian applications 1CT0302-636 and 1CT0303-636 are available and approved for use with these fur- 3" Standard 3-1/16" naces. Horizontal sidewall vent terminations kits 1HT0901 & 2" Sweep 3-1/4" 1HT0902 are also approved for use with these furnaces. 3" Sweep 4-1/16" TABLE 10: Equivalent Length of Fittings Fitting Equivalent Length 2" 90° sweep elbow 5 feet of 2" pipe 2" 45° sweep elbow 2-1/2 feet of 2" pipe 2" 90° standard elbow 7 feet of 2" pipe 2" 45° standard elbow 3-1/2 feet of 2" pipe 3" 90° sweep elbow 5 feet of 3" pipe 3" 45° sweep elbow 2-1/2 feet of 3" pipe 3" 90° standard elbow 7 feet of 3" pipe 3" 45° standard elbow 3-1/2 feet of 3" pipe 4" 90° elbow (sweep or standard) 5 feet of 4" pipe 4" 45° elbow (sweep or standard) 2-1/2 feet of 4" pipe 2" corrugated connector 10 feet of 2" pipe 3" corrugated connector 10 feet of 3" pipe 4" corrugated connector 10 feet of 4" pipe 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 outside termination. b. Ventilated combustion air systems from the furnace to the attic or crawl space termination. 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 32 feet of 2" pipe = 32 equivalent feet 5 - 90o standard 2" elbows = (5 x 7) = 35 equivalent feet Total = 67 equivalent feet of 2" pipe 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. Install the combustion air and vent piping such that it has a 1/4” per foot (21 mm/m) grade so that condensate flows back toward the fur- nace. Piping should be supported with pipe hangers to prevent sag- ging. 32 feet of 2" pipe = 5 - 90o sweep 2" elbows = (5 x 5) = Dimensions are those required in Standard ASTM D-3311. ! Example: An 80,000 BTUH furnace requires 32 feet of pipe and five 90o elbows. Using 2" pipe and standard elbows, the total equivalent length will be: 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 equivalent feet 25 equivalent feet 9. Seal around the openings where the combustion air and / or vent piping pass through the roof or sidewalls. Total = 57 equivalent feet of 2" pipe COMBUSTION AIR / VENTING This is less than the 65 foot maximum equivalent length of 2" pipe allowed for that model and is thus acceptable. IMPORTANT: The vent must be installed with the minimum required clearances, and must comply with local codes and requirements. Alternatively, using 3" pipe and standard elbows, the total equivalent length will be: 32 feet of 3" pipe = 32 equivalent feet 5 - 90o standard 3" elbows = (5 x 7) = 35 equivalent feet Total = 67 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. 24 Johnson Controls Ducted Systems 5750149-UIM-D-1219 VENT CLEARANCES * ,16,'( &251(5 '(7$,/ + $ Direct Vent Terminal Clearances Canadian Installations1,3 US Installation2,3 A. Clearance balcony 9 $ 9 9(17 7(50,1$/ ' ),;(' 9 ( &/26(' % % ;$,5 6833/< / 9 % &%9 , 9 0 9 . ; $5($ :+(5( 7(50,1$/ ,6 127 3(50,77(' ) 9 % 9 9 - ; ),;(' % 23(5$%/( &/26(' FIGURE 28: Home Layout above grade, veranda, porch, deck, or 12” (30.5 cm) 12” (30.5 cm) Two-pipe (direct vent) applications: 9” (23 cm) for B. Clearance to window or door that may be opened 12” (30.5 cm) for models £100,000 BTUH (30 kW), 36” (91.4 cm) for models >100,000 BTUH (30 kW). models £50,000 BTUH (15 kW), 12” (30.5 cm) for models >50,000 BTUH (15 kW). †† Single-pipe applications: 4 feet (1.2 m). C. Clearance to permanently closed window 12” (30.5 cm) 12” (30.5 cm) D. Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet (61 cm) from the center line of the terminal † A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings. †† 12” (30.5 cm) up from the bottom edge of the structure for Two-pipe (direct vent) applications per ANSI Z223.1 / NFPA 54, National Gas Code. ‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor and the distance between the top of the vent termina- tion and the underside of the veranda, porch, or deck is greater than 12” (30.5 cm) as specified in CSA B149.1-00. A vent shall not terminate less than 12” (30.5 cm) above a grade level. Any fresh air or make up inlet for dryer or furnace area is considered to be forced air inlet. Avoid areas where condensate drippage may cause problems such as above planters, patios, or adjacent to windows where steam may cause fogging. A terminus of a vent shall be fitted with a cap in accordance with the vent manufacturer’s installation instructions, or in accordance with the installation instructions for a special venting system. Responsibility for the provision of proper adequate venting and air supply for application shall rest with the installer. Vent shall extend high enough above building, or a neighboring obstruction, so that wind from any direction will not create a positive pressure in the vicinity of the vent. Johnson Controls Ducted Systems 25 12” (30.5 cm) or in accordance with local installation codes and the requirements of the gas supplier. 12” (30.5 cm) or in accordance with local installation codes and the requirements of the gas supplier. E. Clearance to unventilated soffit 12” (30.5 cm) or in accordance with local installation codes and the requirements of the gas supplier. 12” (30.5 cm) or in accordance with local installation codes and the requirements of the gas supplier. F. Clearance to outside corner 12” (30.5 cm) or in accordance with local installation codes and the requirements of the gas supplier. 12” (30.5 cm) or in accordance with local installation codes and the requirements of the gas supplier. G. Clearance to inside corner 3 feet (91.4 cm) 3 feet (91.4 cm) H. Clearance to each side of center line extended above meter/regulator assembly Above a meter/regulator assembly within 3 feet (91.4 cm) horizontally of the vertical center-line of the regulator vent outlet to a maximum vertical distance of 15 feet (4.5 m) above the meter/regulator assembly. Above a meter/regulator assembly within 3 feet (91.4 cm) horizontally of the vertical center-line of the regulator vent outlet to a maximum vertical distance of 15 feet (4.5 m) above the meter/regulator assembly. I. Clearance to service regulator vent outlet 3 feet (91.4 cm) 3 feet (91.4 cm) or in accordance with local installation codes and the requirements of the gas supplier. J. Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance Two-pipe (direct vent) applications: 9” (23 cm) for 12” (30.5 cm) for models £100,000 BTUH (30 kW), models £50,000 BTUH (15 kW), 12” (30.5 cm) for 3 feet (91.4 cm) for models >100,000 BTUH (30 kW). models >50,000 BTUH (15 kW). Single-pipe applications: 4 feet (1.2 m). K. Clearance to a mechanical supply inlet 6 feet (1.83 m) 3 feet (91.4 cm) above if within 10 feet (3 m) horizontally. L. Clearance above paved sidewalk or paved driveway located on public property 7 feet (2.13 m)† 7 feet (2.13 m) or in accordance with local installation codes and the requirements of the gas supplier. M. Clearance under veranda, porch, deck, or balcony 12” (30.5 cm)‡ 12” (30.5 cm) or in accordance with local installation codes and the requirements of the gas supplier. 1. In 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. 3. In accordance with the current ANSI Z21.47 * CSA 2.3 American National Standard. IMPORTANT: Consideration must be given for degradation of building materials by flue gases. Sidewall termination may require sealing or shield- ing of building surfaces with a corrosion resistant material to protect against combustion product corrosion. Consideration must be given to wind direction in order to prevent flue products and/or condensate from being blown against the building surfaces. If a metal shield is used it must be a stainless steel material at a minimum dimension of 20” (51 cm). It is recommended that a retaining type collar be used that is attached to the build- ing surface to prevent movement of the vent pipe. 5750149-UIM-D-1219 VENT SYSTEM This furnace is certified to be installed with one of two possible vent configurations. 0DLQWDLQ ́ PLQLPXP FOHDUDQFH DERYH ́ YHUWLFDO VHSDUDWLRQ 1. Horizontal vent system. This vent system can be installed com- pletely horizontal or combinations of horizontal, vertical, or offset KLJKHVW DQWLFLSDWHG VQRZ OHYHO 26 Johnson Controls Ducted Systems EHWZHHQ FRPEXVWLRQ DLU LQWDNH DQG YHQW ́ PLQLPXP EHORZ RYHUKDQJ ́ PLQLPXP VHSDUDWLRQ EHWZHHQ using elbows. ERWWRP RI 2. Vertical vent system. This vent system can be installed completely vertical or a combination of horizontal, vertical, or offset using FRPEXVWLRQ DLU SLSH DQG ERWWRP RI YHQW elbows. 0DLQWDLQ ́ VENT APPLICATIONS AND TERMINATION PLQLPXP FOHDUDQFH DERYH KLJKHVW When selecting the location for a combustion air / vent termination, the following should be considered: DQWLFLSDWHG VQRZ OHYHO RU JUDGH ZKLFKHYHU LV KLJKHU 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 FIGURE 30: Termination Configuration - 2 Pipe gases. 4. Termination should be located where it will not be damaged or exposed to flying stones, balls, etc. ́ 0,1 5. Termination should be positioned where vent vapors are not objec- tionable. 6. Horizontal portions of the vent system must slope upwards and be ́ 0,1 supported to prevent sagging. 7. Direct vent systems must be installed so the vent and the combus- tion air pipes terminate in the same atmospheric zone. Refer to Fig- ures 30 or 31. ́ 0LQLPXP EHORZ RYHUKDQJ 29(5+$1* ́ 0LQLPXP VHSDUDWLRQ EHWZHHQ ERWWRP RI FRPEXVWLRQ DLU LQWDNH DQG ERWWRP RI YHQW 0DLQWDLQ ́ PLQLPXP FOHDUDQFH DERYH KLJKHVW DQWLFLSDWHG VQRZ OHYHO 0D[LPXP ́ DERYH URRI 0DLQWDLQ ́ PLQLPXP FOHDUDQFH DERYH KLJKHVW DQWLFLSDWHG VQRZ OHYHO RU JUDGH ZKLFKHYHU LV KLJKHU $ 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 36 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 both vents terminating as ! shown in Figure 29. Each furnace must have a separate vent pipe. Under NO circumstances can the two vent pipes be tied together. The combustion air side of the two-pipe configuration shown in Figure 35 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. ́ 0LQ ́ 0LQ FIGURE 29: Termination Configuration - 1 Pipe WARNING Condensation in Intake Pipe Installations where the furnace and intake pipe are to be located in a conditioned space and in a region that may have hot, humid weather extending several consecutive days will have condensate form in the intake pipe. Use of the supplied intake drain will ensure that any con- densate will be safely diverted away from the internal components of the furnace. Proper venting installation (of both intake and exhaust) and sealing any equipment air leaks that might contact the intake pipe will help reduce condensation. 5750149-UIM-D-1219 COMBUSTION AIR SUPPLY All installations must comply with Section 5.3, Air for Combustion and 9(17 Ventilation of the National Fuel Gas Code, ANSI Z223.1 or Sections 7.2, 7.3 or 7.4 of CAN/CGA B149.1 or B149.2 Installation Code - latest editions. This furnace is certified to be installed with one of three possible com- bustion air intake configurations. 1. OUTDOOR COMBUSTION AIR: This is a direct vent configuration where the combustion air is supplied through a PVC or ABS pipe that is connected to the PVC coupling attached to the furnace and is terminated in the same atmospheric zone as the vent. This type &20%867,21 $,5 of installation is approved on all models. Refer to Figure 35. 2. AMBIENT COMBUSTION AIR: Combustion air is supplied from ́0,1 $ FIGURE 32: Double Horizontal Combustion Air Intake and Vent Term. 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 29 for vent termina- tions. Refer to "Ambient Combustion Air Supply" for proper installa- tion. Refer to Figures 36 and 37. 3. VENTILATED COMBUSTION AIR: Combustion air is supplied 0,1 ́ through a PVC or ABS pipe that is connected to the PVC coupling attached to the burner box and is terminated in a ventilated attic or crawl space. The combustion air and the vent pipes are not termi- nated in the same atmospheric zone. Refer to Figure 38 for attic and crawl space termination. Only the combustion air intake may terminate in the attic. The vent must terminate outside. Outdoor Combustion Air Combustion Air Intake/Vent Connections This installation requires combustion air to be brought in from outdoors. $ FIGURE 33: Double Vertical Combustion Air Intake and Vent Term. This requires a properly sized pipe (Shown in Figure 35) that will bring air in from the outdoors to the furnace combustion air intake collar on DOWNWARD VENTING In some applications, it may be necessary to run the vent pipe and air the burner box. The second pipe (Shown in Figure 35) is the furnace vent pipe. intake downwards. If this is to be done, the following rules must be fol- lowed. NOTICE • A condensate trap hose must be connected to both the air intake An optional plastic birdscreen is shipped in the loose parts bag with pipe and the vent pipe at the lowest part of the horizontal run. every furnace. This may be installed in the intake collar to prevent • The condensate drain trap must have a trap of a minimum of six any small objects from entering the furnace. inches. • The total vertical downward distance must not exceed sixteen feet. • The condensate drain hose must be connected to a condensate &211(&76 72 &2//$5 21 723 2) %851(5 %2; 9(17 3,3( &(0(176 ,172 62&.(7 -867 drain pump, a open or vented drain or into the condensate drain $%29( 723 3$1(/ line from the furnace. • The condensate drain lines must not pass through unconditioned spaces where the temperature may fall below freezing. • The condensate drain line must be primed at the initial start-up 25 9(17 3,3( 0$< %( &/$03(' ,172 prior to the start of heating season. 287/(7 2) '5$,1 &283/,1* ¶ 0$; $ FIGURE 35: 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. ́ 0,1 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 ́ 0,1 listed in Section #1 “Outdoor Air Contaminants.” $ FIGURE 34: Downward Venting Johnson Controls Ducted Systems 27 5750149-UIM-D-1219 Ambient Combustion Air Supply Table 12: Estimated Free Area 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 Wood or Metal Wood 20-25%* Louvers or Grilles Metal 60-70% * within the space in a non-confined location or it may be brought into the Screens+ furnace area from outdoors through permanent openings or ducts. It is 1/4” (6.4 mm) mesh or larger 100% 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 and 18” (46 cm) of pipe be attached to the furnace to prevent accidental blockage of the combus- tion air intake. * Do not use less than 1/4” (6.4 mm) mesh * Do not use less than 1/4” (6.4mm) 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- &20%867,21 $,5 9HQW SLSH FHPHQWV LQWR VRFNHW MXVW DERYH WRS SDQHO An unconfined space is not less than 50 cu.ft (1.42 m3) per 1,000 Btu/ hr (0.2928 kW) input rating for all of the appliances installed in that area. Rooms communicating directly with the space containing the appli- ances are considered part of the unconfined space, if doors are fur- nished with openings or louvers. A confined space is an area with less than 50 cu.ft (1.42 m3) per 1,000 Btu/hr (0.2928 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 specific louver or grille is not known, refer to Table 12, to estimate free area. 28 Johnson Controls Ducted Systems 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 1/4” (6.4 mm). 3. A manually operated damper or manually adjustable louvers are not permitted for use. 2U YHQW SLSH PD\ EH 4. A automatically operated damper or automatically adjustable lou- FODPSHG LQWR RXWOHW vers shall be interlocked so that the main burner cannot operate RI GUDLQ FRXSOLQJ unless either the damper or the louver is in the fully open position. WARNING When a Category I furnace is removed or replaced, the original vent- ing system may no longer be correctly sized to properly vent the attached appliances. $ An improperly sized vent system can cause CARBON MONOXIDE to FIGURE 36: Combustion Airflow Path Through The Furnace Casing spill into the living space causing personal injury, and or death. ! WARNING This type of installation requires that the supply air to the appliance(s) Table 13: Unconfined Space Minimum Area BTUH Input Rating Minimum Free Area Required for Each Opening be of a sufficient amount to support all of the appliance(s) in the area. 40,000 Operation of a mechanical exhaust, such as an exhaust fan, kitchen ventilation system, clothes dryer or fireplace may create conditions 60,000 40 in2 (258 cm2) 60 in2 (387 cm2) requiring special attention to avoid unsatisfactory operation of gas 80,000 80 in2 (516 cm2) appliances. A venting problem or a lack of supply air will result in a hazardous condition, which can cause the appliance to soot and gen- 100,000 100 in2 (645 cm2) erate dangerous levels of CARBON MONOXIDE, which can lead to 120,000 120 in2 (742 cm2) serious injury, property damage and / or death. Table 14: Free Area BTUH Input Rating ! Minimum Free Area Required for Each Opening Horizontal Duct (2,000 BTUH) Vertical Duct or Opening to Out- side (4,000 BTUH) Round Duct (4,000 BTUH) 40,000 20 in2 (129 cm2) 10 in2 (64 cm2) 4” (10 cm) 60,000 30 in2 (193 cm2) 15 in2 (97 cm2) 5” (13 cm) 80,000 40 in2 (258 cm2) 20 in2 (129 cm2) 5” (13 cm) 100,000 50 in2 (322 cm2) 25 in2 (161 cm2) 6” (15 cm) 120,000 60 in2 (387 cm2) 30 in2 (193 cm2) 7” (18 cm) 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 5750149-UIM-D-1219 *DV *DV *DEOH 9HQW 9HQW *DEOH 9HQW 9HQW 9HQWLODWHG $WWLF *DV 9HQW 2SWLRQDO ,QOHW D 9HQWLODWHG $WWLF 7RS $ERYH ,QVXODWLRQ 7RS $ERYH ,QVXODWLRQ 6RIILW 2XWOHW 9HQW $LU D 6RIILW 9HQW 2XWOHW $LU D *DV $ &UDZO 6SDFH 9HQWLODWHG 2XWOHW $LU E *DV :DWHU +HDWHU :DWHU +HDWHU ,QOHW $LU D *DV ,QOHW ,QOHW $LU E $LU E :DWHU +HDWHU ,QOHW $LU D FIGURE 37: Ambient Combustion Air Air Supply Openings and Ducts 3. The duct shall be least the same cross-sectional area as the free 1. An opening may be used in lieu of a duct to provide to provide the area of the air supply inlet opening to which it connects. outside air supply to an appliance unless otherwise permitted by 4. The blocking effects of louvers, grilles and screens must be given the authority having jurisdiction. The opening shall be located within consideration in calculating free area. If the free area of a specific 12” (30.5 cm) horizontally from, the burner level of the appliance. louver or grille is not known. Refer to Table 12. 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. 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 4. The duct shall terminate within 12” (30.5 cm) above, and within 24” or crawl space and a second pipe that extends from the furnace vent (61 cm) horizontally from, the burner level of the appliance having the largest input. connection (top right of unit) to the exterior of the building. Refer to Table 7 for intake pipe sizing, allowable length and elbow usage. Follow 5. A square or rectangular shaped duct shall only be used when the required free area of the supply opening is 9 in2 (58.06 cm2) or all notes, procedures and required materials in the "COMBUSTION AIR/VENT PIPE SIZING" section in these instructions when installing larger. When a square or rectangular duct is used, its small dimen- the combustion air pipe from the unit and into a ventilated attic space or sion shall not be less than 3” (7.6 cm). crawl space. DO NOT terminate vent pipe in an Attic or Crawl Space. 6. An air inlet supply from outdoors shall be equipped with a means to prevent the direct entry of rain and wind. Such means shall not reduce the required free area of the air supply opening. 7. An air supply inlet opening from the outdoors shall be located not less than 12” (30.5 cm) above the outside grade level. Combustion Air Source from Outdoors Ventilated Combustion Air Termination Refer to Figure 38 for required attic termination for the combustion air intake pipe. For attic termination, use two 90° elbows with the open end in a downward position. Be sure to maintain 12” (30.5 cm) clearance above any insulation, flooring or other material. A crawl space combustion air installation consists of a straight pipe 1. Two permanent openings, one within 12” (30.5 cm) of the top and from the PVC coupling on the burner box that extends into the crawl one within 12” (30.5 cm) of bottom of the confined space, Two per- space and terminates with a 1/4” (6.4 mm) mesh screen and no elbow. manent openings, shall communicate directly or by means of ducts with the outdoors, crawl spaces or attic spaces. 2. One permanent openings, commencing within 12” (30.5 cm) of the top of the enclosure shall be permitted where the equipment has clearances of at least 1” (2.54 cm) from the sides and back and 6” (15.2 cm) from the front of the appliance. The opening shall com- municate directly with the outdoors and shall have a minimum free area of: a. 1 in.2 / 3,000 BTU/hr (700mm2/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. Johnson Controls Ducted Systems 29 5750149-UIM-D-1219 ! WARNING 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: 1. Inspect the venting system for proper size and horizontal pitch. Determine that there is no blockage, restriction, leakage, corrosion or other defi- ciencies, which could cause an unsafe condition 2. Close all building doors and windows and all doors. 3. 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. 4. Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so the appliance shall operate continu- ously. 5. Test each appliance (such as a water heater) equipped with a draft hood for spillage (down-draft or no draft) at the draft hood relief opening after 5 minutes of main burner operation. Appliances that do not have draft hoods need to be checked at the vent pipe as close to the appliance as possible. Use a combustion analyzer to check the CO2 and CO levels of each appliance. Use a draft gauge to check for a downdraft or inad- equate draft condition. 6. After it has been determined that each appliance properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their normal condition. 7. 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. 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 appro- priate tables in Appendix G of the above codes or for this appliance. VENT BLOWER ROTATION ́ 0,1,080 %(7:((1 %27720 2) $,5 ,17$.( $1' 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 $1< 0$7(5,$/ %(/2: rotated so that the vent exits through either side of the cabinet. See Fig- ́ 0,1 ures 23-26 for illustrations of different inducer rotation positions. SECTION VIII: START-UP AND ADJUSTMENTS The following start-up checks MUST be performed by the furnace installer on every new furnace installation. 1. Gas piping leak check. 2. Furnace input rate check. $ 3. Air temperature rise check. FIGURE 38: Attic and Crawl Space Combustion Air Termination Specially Engineered Installations Instructions on how to perform each of these required installation checks are listed in the sections below. 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. When the gas supply is initially connected to the furnace, the gas piping ! WARNING 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 Be sure to instruct the owner not to block this intake pipe. detected, immediately retighten the union and check for leaks. Allow five minutes for any gas to dissipate before continuing with the start-up procedure. Be sure proper ventilation is available to dilute and carry away any vented gas. 30 Johnson Controls Ducted Systems IMPORTANT: All electrical connections made in the field and in the factory should be checked for proper tightness. 5750149-UIM-D-1219 GAS PIPING LEAK CHECK ! WARNING HOT SURFACE IGNITION SYSTEM Do not attempt to light this furnace by hand (with a match or any other means). There may be a potential shock hazard from the components of the hot surface ignition system. The furnace can only be lit auto- matically by its hot surface ignition system. NOTICE 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 DO NOT set manifold pressure less than 3.2” w.c. or more than 3.8” w.c. for natural gas at sea level. If manifold pressure is outside this range, change main burner orifices. 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. NOTICE With furnace in operation, check all of the pipe joints, gas valve connec- tions and manual valve connections for leakage using an approved gas detector, a non-corrosive leak detection fluid or other leak detection methods. Take appropriate action to stop any leak. If a leak persists, If orifice hole appears damaged or it is suspected to have been redrilled, check orifice hole with a numbered drill bit of correct size. Never redrill an orifice. A burr-free and squarely aligned orifice hole is essential for proper flame characteristics. 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- CAUTION sures in excess of 0.5 psig (3.45 kPa). DO NOT bottom out gas valve regulator adjusting screw. This can The furnace must be isolated from the gas supply piping system by closing the equipment shutoff valve during any pressure testing of the WARNING !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 CALCULATING THE FURNACE INPUT (NAT. GAS) damage, personal injury or loss of life. Burner orifices are sized to provide proper input rate using natural gas with a heating value of 1030 BTU/Ft3 (38.4 MJ/m3). If the heating value IMPORTANT: Burner ignition may not be satisfactory on first startup due to residual air in the gas line or until gas manifold pressure is of your gas is significantly different, it may be necessary to replace the orifices. adjusted. The ignition control will make three attempts to light before locking out. !result in unregulated manifold pressure and result in excess overfire and heat exchanger failures. gas supply system. Verify natural gas input rate by clocking meter. IGNITION SYSTEM SEQUENCE 1. Turn off all other gas appliances and pilots. 1. Turn the gas supply ON at external valve and main gas valve. 2. Run furnace for a minimum of 3 minutes in heating operation. 2. Set the thermostat above room temperature to call for heat. 3. Measure time (in sec) for gas meter to complete 1 revolution and 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 note reading. The 2 cubic feet dial provides a more accurate mea- surement of gas flow. 4. Refer to Table 15 for cubic feet of gas per hour. about 17 seconds. 5. Multiply cubic feet per hour by heating value (BTU/cu ft) to obtain b. After this warm up, the ignition module will energize (open) the main gas valve. c. After flame is established, the supply air blower will start in about 30 seconds. 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. ! CAUTION Be sure to relight any gas appliances that were turned off at the start of this input check. Johnson Controls Ducted Systems 31 5750149-UIM-D-1219 Table 15: Gas Rate (CU FT/HR) at Full Input Seconds For 1 Revolution 32 Johnson Controls Ducted Systems Size of Test Dial Seconds For 1 Revolution Size of Test Dial 1 Cu Ft 2 Cu Ft 5 Cu Ft 1 Cu Ft 2 Cu Ft 5 Cu Ft 10 360 720 1800 55 65 131 327 11 327 655 1636 56 64 129 321 12 300 600 1500 57 63 126 316 13 277 555 1385 58 62 124 310 14 257 514 1286 59 61 122 305 15 240 480 1200 60 60 120 300 16 225 450 1125 62 58 116 290 17 212 424 1059 64 56 112 281 18 200 400 1000 66 54 109 273 19 189 379 947 68 53 106 265 20 180 360 900 70 51 103 257 21 171 343 857 72 50 100 250 22 164 327 818 74 48 97 243 23 157 313 783 76 47 95 237 24 150 300 750 78 46 92 231 25 144 288 720 80 45 90 225 26 138 277 692 82 44 88 220 27 133 267 667 84 43 86 214 28 129 257 643 86 42 84 209 29 124 248 621 88 41 82 205 30 120 240 600 90 40 80 200 31 116 232 581 92 39 78 196 32 113 225 563 94 38 76 192 33 109 218 545 96 38 75 188 34 106 212 529 98 37 74 184 35 103 206 514 100 36 72 180 36 100 200 500 102 35 71 178 37 97 195 486 104 35 69 173 38 95 189 474 106 34 68 170 39 92 185 462 108 33 67 167 40 90 180 450 110 33 65 164 41 88 176 439 112 32 64 161 42 86 172 429 116 31 62 155 43 84 167 419 120 30 60 150 44 82 164 409 124 29 58 145 45 80 160 400 128 28 56 141 46 78 157 391 133 27 54 135 47 76 153 383 138 26 52 130 48 75 150 375 144 25 50 125 49 73 147 367 150 24 48 120 50 72 144 360 157 23 46 115 51 71 141 355 164 22 44 110 52 69 138 346 171 21 42 105 53 68 136 340 180 20 40 100 54 67 133 333 ADJUSTMENT OF MANIFOLD GAS PRESSURE & INPUT RATE Inlet and manifold gas pressure may be measured by connecting the “U” tube manometer to the gas valve with a piece of tubing. Follow the appropriate section in the instructions below. Refer to Figure 39 for 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 Table 16: Inlet Gas Pressure Range valve marked Out P and In P. INLET GAS PRESSURE RANGE 1. The manifold pressure must be taken at the port marked OUT P. 2. The gas line pressure must be taken at the port marked IN P. 3. Using a 3/32” (2.4 mm) hex head wrench, loosen the set screw by turning it 1 turn counter clockwise. DO NOT REMOVE THE SET Natural Gas Propane (LP) Minimum 4.5” w.c. (1.12 kPa) 8.0” w.c. (1.99 kPa) Maximum 10.5” w.c. (2.61 kPa) 13.0” w.c. (3.24 kPa) SCREW FROM THE PRESSURE PORT. Read the inlet gas pressure Connect the positive side of the manometer to the IN P Tap on the gas valve. Do not connect any tubing to the negative side of the manometer, as it will reference atmospheric pressure. Refer to Figure 40 for connec- tion details. 1. Turn gas and electrical supplies on and follow the operating instruc- tions to place the unit back in operation. 5750149-UIM-D-1219 IMPORTANT: The inlet gas pressure operating range table specifies IMPORTANT: If gas valve regulator is turned in (clockwise), manifold what the minimum and maximum gas line pressures must be for the pressure is increased. If screw is turned out (counterclockwise), man- furnace to operate safely. The gas line pressure MUST BE a mini- ifold pressure will decrease. mum of: • 7” w.c. (1.74 kPA) for Natural Gas • 11” w.c. (2.74 kPA) for Propane (LP) Gas in order to obtain the BTU input s1pecified on the rating plate and/or the nominal manifold pressure specified in these instructions and on 4. After the manifold pressure has been adjusted, re-calculate the fur- nace input to make sure you have not exceeded the specified input on the rating plate. Refer to “CALCULATING THE FURNACE INPUT (NATURAL GAS)”. the rating plate. 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 2. Once the correct gas inlet pressure has been established, see remove the flexible tubing from the gas valve pressure tap and Table 16, turn the gas valve to OFF and turn the electrical supply tighten the pressure tap plug using the 3/32” (2.4 mm) hex head switch to OFF; then remove the flexible tubing from the gas valve wrench. pressure tap and tighten the pressure tap plug using the 3/32” (2.4 mm) hex head 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 3. Turn the electrical and gas supplies back on, and with the burners port for leakage using an approved non-corrosive gas leak detec- in operation, check for gas leakage around the gas valve pressure tion fluid, or other non-flammable leak detection methods. 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 Read the manifold gas pressure Connect the positive side of the manometer to 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 Figures 39 and 40 for connection details. IMPORTANT: The cap for the pressure regulator must be removed entirely to gain access to the adjustment screw. Loosening or tighten- ing the cap does not adjust the flow of gas. This gas valve has separate regulator adjustment screws for high fire and low fire, as shown in Figure 39. The procedure below is used to adjust either the high fire manifold pressure or the low fire manifold pressure. NOTICE FIGURE 40: Reading Gas Pressure Gas manifold pressure must be set on high fire before adjusting low AIRFLOW SETTINGS fire pressure. Cooling Airflow Settings 1. Refer to Figure 39 for location of pressure regulator adjustment cap This unit is equipped with an electronically commutated (ECM) blower and adjustment screws on main gas valve. motor. The motor and blower are capable of delivering airflow over a 2. Turn gas and electrical supplies on and follow the operating instruc- wide range of operating conditions. tions to place the unit back in operation. The desired cooling airflow may be selected by placing the COOL 3. Place jumper wire from W1 to W2 to R on the furnace control board jumper on the control board in the desired position A, B, C or D. The “A” for the furnace to operate HIGH fire. Once correct manifold pres- position will give the highest airflow and the “D” position gives the low- sure is set (HI), remove jumper from W2 for the furnace to operate est. Additional fine tuning of the cooling airflow can be done by using on low fire. Set the manifold pressure (LO) to correct manifold pres- the ADJUST jumper. The nominal ADJUST setting is “A”, while the “B” sure. jumper position will give a 10% increase in airflow over the “A” position Table 17: Nominal Manifold Pressure and the “C” ADJUST jumper position will give a 10% decrease from the “A” position. Consult the blower airflow tables in this manual for the NOMINAL MANIFOLD PRESSURE expected airflow at each speed setting. The speed should be selected Natural Gas (High Fire) 3.5" w.c. (0.87 kPa) so as to deliver approximately 350-400 CFM per ton of A/C cooling Natural Gas (Low Fire) 1.6" w.c. (0.40 kPa) capacity. Use of airflow outside of this range may result in diminished Propane (LP) Gas (High Fire) 9.8" w.c. (2.488 kPa) Propane (LP) Gas (Low Fire) 4.0" w.c. (0.99 kPa) 287/(7 35(6685( 3257 *$6 9$/9( ́ 78%,1* )/$0( 6(1625 0$1,)2/' 3,3( ,1 :$7(5 &2/801 *$6 *$6 %851(56 8 78%( 0$120(7(5 35(6685( 6+2:1$ air conditioning performance and may result in lower overall energy effi- ciency and higher electric utility bills. See Table 18 for default cooling blower settings. +,*+ 67$*( 5(*8/$725 Table 18: Default Blower Speeds 287/(7 $'-8670(17 35(6685( 3257 9(17 3257 Model Number Default Blower Speeds HEAT COOL FAN SPEED Jumper Jumper Jumper ,1/(7 060B12 B A L 287/(7 080B12 C A L :5(1&+ 080C16 D A L %266 100C16 B A L ,1/(7 35(6685( 100C20 B A L 3257 21 2)) /2: 67$*( 5(*8/$725 120D20 B A L $ 6:,7&+ $'-8670(17 FIGURE 39: Gas Valve Johnson Controls Ducted Systems 33
5750149-UIM-D-1219 Continuous Fan Airflow Settings The default blower speed for continuous fan operation is L (Low) speed. This furnace may be operated in continuous fan mode by setting the wall thermostat FAN switch to ON. To select the desired continuous fan airflow, set the FAN SPEED jumper on the control board to the desired position. There are three options: 1. With the FAN SPEED jumper in the “H” position the blower will run during continuous fan operation at 100% of the selected high stage cooling speed. 2. With the FAN SPEED jumper in the “M” position the blower will run during continuous fan operation at 70% of the selected high stage cooling speed. 3. With the FAN SPEED jumper in the “L” position the blower will run during continuous fan operation at 40% of the selected high stage cooling speed. The default position is with the FAN SPEED jumper in the “L” position. In certain circumstances, it may be necessary to move the continuous fan speed to a different speed tap. However, doing so is not recom- mended since it will result in higher than normal electrical energy usage and higher than normal electric utility bills. Gas Heating Airflow Setting The default heating blower speed is shown in Table 18. This unit is equipped with an electronically commutated (ECM) blower motor. The motor and blower are capable of delivering airflow over a wide range of operating conditions. The desired heating airflow may be selected by placing the HEAT jumper on the control board in the desired position A, B, C or D. The “A” position will give the highest airflow and the “D” position gives the low- est. Consult the blower airflow tables in this manual for the expected airflow at each speed setting. The heating blower speed is set at the factory to the default blower speed, which is the blower speed that will deliver the correct airflow for proper heating operation in most applica- tions. The default heating blower speed for each model is shown in Table 18. Use of a heating speed other than the default heating blower speed may result in reduced energy efficiency and higher electric utility bills. In certain circumstances, it may be necessary to move the heating blower speed to a different motor speed tap. Not all motor heating speeds are appropriate for gas heating operation for all models and all applications. The use of heating airflow on a speed other than the default speed will result in diminished heating performance and may cause the furnace temperature limit controls to shut down the furnace. Measurement of Temperature Rise After about ten minutes of operation, determine the furnace tempera- ture rise. Measure the temperature of both the return air and the heated air in the ducts, about six feet (1.83 m) from the furnace where they will not be affected by radiant heat. Increase the blower speed to decrease the temperature rise; decrease the blower speed to increase the rise. ADJUSTMENT OF FAN CONTROL SETTINGS This furnace is equipped with a time-on/time-off heating fan control. The fan on delay is fixed at 30 seconds. The fan off delay has 4 settings (60, 90, 120 and 180 seconds). The fan off delay is factory set to 120 sec- onds. The fan-off setting must be long enough to adequately cool the furnace, but not so long that cold air is blown into the heated space. The fan-off timing may be adjusted by positioning the jumper on two of the four pins as shown in Figure 25. TAKING A FLUE GAS SAMPLE If it becomes necessary to obtain a flue gas sample for analysis, it is permissible to drill a small hole in the plastic flue pipe for a sample probe, provided that the vent piping is PVC and the hole is properly sealed afterwards. If using a polypropylene vent system, the vent sys- tems manufacturer test port fitting must be used. DONOT drill a test port hole in polypropylene piping. Use the following procedure: 1. Drill a 11/32” hole in the side wall of the PVC vent pipe. If the hole is in a horizontal section of the vent pipe, ensure that it is located away from the bottom where condensation may be flowing back toward the furnace. 2. Operate the furnace a minimum of (10 minutes) to ensure stable operation of the combustion process. 3. Sample the flue gas as necessary to obtain CO readings. 4. Using a 1/8” pipe tap, cut threads into the sampling hole of the PVC ! DANGER DANGER The temperature rise, or temperature difference between the return air and the supply (heated) air from the furnace, must be within the range shown on the furnace rating plate and within the application limitations shown in SECTION V. The supply air temperature cannot exceed the “Maximum Supply Air Temperature” specified in these instructions and on the furnace rating plate. Under NO circumstances can the furnace be allowed to operate above the Maximum Supply Air Temperature. Operating the furnace above the Maximum Supply Air Temperature will cause pre- mature heat exchanger failure, high levels of Carbon Monoxide, a fire hazard, personal injury, property damage, and/or death.
34 Johnson Controls Ducted Systems pipe. 5. Use high temp RTV as a sealant on the threads of a 1/8” brass MPT plug and insert it 3 turns into the hole to correctly seal it. HEAT PUMP If heat pump is installed with a furnace the HEAT PUMP jumper must be set to YES. 5750149-UIM-D-1219 $ 5 & % $ 5 & % &20081,&$7,216 ',$*1267,& /$67 &)0 )/2$7 /,*+7 (5525 ,1',&$725 6:,7&+ %87721 &211(&7,21 &219(17,21$/ /2: 92/7$*( $ 5 & % $ 5 & % 767$7 &211(&7,216 &20081,&$7,1* 767$7 &211(&7,216 7(03 6(1625 &211(&7,216 $ Table 19: Air Flow Data HIGH / LOW SPEED COOLING AND HEAT PUMP CFM 040A10 060B12 080B12 080C16 Jumper Settings HIGH COOL LOW COOL HIGH COOL LOW COOL HIGH COOL LOW COOL HIGH COOL LOW COOL COOL Tap ADJ Tap 1033 749 1425 838 1228 834 1741 1049 A B 941 666 1087 714 1058 739 1505 916 B B 950 675 1200 771 1143 781 1446 946 A A 877 611 996 658 952 686 1343 843 B A 886 620 1075 703 1037 728 1402 858 A C 785 538 861 579 845 611 1255 799 C B 804 547 895 590 866 622 1167 769 B C 685 483 669 454 686 505 1005 666 D B 740 492 782 533 792 568 1108 710 C A 630 428 613 421 632 473 916 593 D A 666 437 714 477 739 526 990 637 C C 565 428 556 421 579 473 828 534 D C 100C16 100C20 120D20 Jumper Settings HIGH COOL LOW COOL HIGH COOL LOW COOL HIGH COOL LOW COOL COOL Tap ADJ Tap 1757 1093 2105 1423 2176 1374 A B 1531 966 1724 1121 1733 1100 B B 1474 995 1945 1282 1986 1248 A A 1376 896 1583 1021 1585 1016 B A 1432 910 1744 1141 1775 1121 A C 1291 854 1543 961 1501 973 C B 1206 825 1423 880 1374 910 B C 1051 727 1302 800 1248 847 D B 1150 769 1423 840 1332 889 C A 966 656 1182 700 1163 784 D A 1037 698 1242 760 1206 805 C C 882 600 1081 599 1037 699 D C Continued on next page Johnson Controls Ducted Systems 35 $8;,/,$5< 6:,7&+ &211(&7,216 +80,',67$7 6(/(&7,21 &217,18286 )$1 63((' +($7 3803 6(/(&7,21 +, +($7 '(/$< %/2:(5 2)) '(/$< $,5)/2: 6(/(&7,21 FIGURE 41: Furnace Control Board 5750149-UIM-D-1219 Table 19: Air Flow Data (Continued) HIGH/LOW HEAT CFM 040A10 060B12 080B12 080C16 Jumper Settings HIGH HEAT LOW HEAT HIGH HEAT LOW HEAT HIGH HEAT LOW HEAT HIGH HEAT LOW HEAT HEAT Jumper ADJ Jumper 890 770 1200 870 1366 1156 1580 1156 A Any 790 660 1070 770 1293 1022 1422 1027 B Any 711 578 970 693 1185 924 1293 924 C Any 646 514 890 630 1094 840 1185 840 D Any 100C16 100C20 120D20 Jumper Settings HIGH HEAT LOW HEAT HIGH HEAT LOW HEAT HIGH HEAT LOW HEAT HEAT Jumper ADJ Jumper 1975 1444 1975 1284 2250 1539 A Any 1778 1284 1778 1156 2133 1385 B Any 1616 1156 1616 1050 1939 1259 C Any 1481 1050 1481 963 1778 1154 D Any All CFM’s are shown at 0.5” w.c. external static pressure.These units have variable speed motors that automatically adjust to provide constant CFM from 0.0” to 0.6” w.c. static pressure. From 0.6” to 1.0” static pressure, CFM is reduced by 2% per 0.1” increase in static. Operation on duct systems with greater than 1.0” w.c. external static pressure is not recommended. NOTE: At some settings, LOW COOL and/or LOW HEAT airflow may be lower that what is required to operate an airflow switch on certain models of electronic air clean- ers. Consult the instructions for the electronic air cleaner for further details. * The ADJ “D” tap should not be used. SECTION IX: SAFETY CONTROLS LIMIT 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. 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. If the indoor fan motor should fail. BLOWER DOOR SAFETY SWITCH 3. Too many supply or return registers closed or blocked off. CAUTION The control module will lockout if the limit trips 5 consecutive times. If this occurs, control will reset & try ignition again after 1 hour. Main power to the unit must still be interrupted at the main power dis- connect switch before any service or repair work is to be done to the unit. Do not rely upon the interlock switch as a main power discon- nect. SECTION DIAGNOSTICS X: NORMAL OPERATION AND NORMAL OPERATION SEQUENCE Blower and burner must never be operated without the blower panel in place. Heating and Cooling Airflow The heating and the cooling airflows are preset at the factory. The heat- This unit is equipped with an electrical interlock switch mounted in the burner compartment. This switch interrupts all power at the unit when the panel covering the blower compartment is removed. Electrical supply to this unit is dependent upon the panel that covers the blower compartment being in place and properly positioned. ROLLOUT SWITCH CONTROLS These controls are mounted on the burner assembly. If the temperature ing airflow is set to the maximum CFM. The cooling airflow is set to pro- vide 90 percent of the maximum CFM. The heating and cooling airflows must be field adjusted to match the HVAC system at installation. See Table 19 for the HEAT, COOL, and ADJUST (or ADJ) jumper settings to use for specific airflows. CFM Board - Delay Taps Selection The set of jumper pins on the control board labeled DELAY are used to set the delay profiles for the furnace. These can be chosen so as to in the area surrounding burner exceeds its set point, the gas valve is maximize the comfort and sound levels for various regions of the coun- de-energized. The operation of this control indicates a malfunction in try. the combustion air blower, heat exchanger or a blocked vent pipe con- nection. Corrective action is required. These are manual reset controls that must be reset before operation can continue. Tap A is the default profile. It provides a 30-second ramp-up from zero airflow to full capacity and a 30-second ramp-down from full capacity back to zero airflow. Whenever there is a change in airflow mode, such PRESSURE SWITCHES This furnace is supplied with three pressure switches, which monitor the flow through the combustion air/vent piping and condensate drain sys- tem. These switches de-energize the gas valve if any of the following conditions are present. Refer to SECTION VI, "CONDENSATE PIPING AND FURNACE VENTING CONFIGURATION" for tubing connections. 1. Blockage of vent piping or terminal. ! as from low heat to high heat, the motor will take 30 seconds to ramp from one speed to the other. Tap B is the humid profile. This profile is best-suited for installations where the humidity is frequently very high during cooling season, such as in the southern part of the country. On a call for cooling, the blower will ramp up to 50% of full capacity and will stay there for two minutes, then will ramp up to 82% of full capacity and will stay there for five min- utes, and then will ramp up to full capacity, where it will stay until the 2. Failure of combustion air blower motor. wall thermostat is satisfied. In every case, it will take the motor 30 sec- 3. Blockage of combustion air piping or terminals. onds to ramp from one speed to another. 4. Blockage of condensate drain piping. Tap C is the dry profile. This profile is best suited to parts of the country where excessive humidity is not generally a problem, where the sum- mer months are usually dry. On a call for cooling the motor will ramp up to full capacity and will stay there until the thermostat is satisfied. At the end of the cooling cycle, the blower will ramp down to 50% of full capac- ity where it will stay for 60 seconds. Then it will ramp down to zero. In every case, it will take the motor 30 seconds to ramp from one speed to another. 36 Johnson Controls Ducted Systems 5750149-UIM-D-1219 Tap D is the normal profile, best suited for most of the country, where neither excessive humidity nor extremely dry conditions are the norm. On a call for cooling, the motor will ramp up to 63% of full capacity and will stay there for 90 seconds, then will ramp up to full capacity. At the end of the cooling cycle, the motor will ramp down to 63% of full capac- ity and will stay there for 30 seconds, then will ramp down to zero. In every case, it will take the motor 30 seconds to ramp from one speed to another. Continuous Blower Operation The blower will run continuously whenever the wall thermostat fan switch is in the ON position. The furnace blower will run at a speed based on a percentage of the CFM selected on the COOL and ADJ tab. There are 3 selections on the FAN SPEED tab (H=100% CFM, M=70% CFM, L=40% CFM). Furnace is shipped with jumper in L position. Intermittent Blower Cooling On cooling/ heating thermostats with a fan switch, when the fan switch is set in the auto position and the thermostat calls for cooling, a circuit is completed between the R, Y and G terminals. The motor is energized through the Y1 cool terminal and runs on the speed selected on the COOL tap of the control board. The fan off setting is fixed at 60 seconds for SEER enhancement. The control board can accommodate two- stage cooling. When a two-stage cool thermostat is connected to the Y1 and Y2 terminals on the board, the blower will operate on LOW COOL speed when Y1 is energized and on HI COOL speed when Y1 and Y2 are energized. Intermittent Blower Heating On cooling/ heating thermostats with a fan switch, when the fan switch is set in the auto position and the thermostat calls for heating, a circuit is completed between the R and W terminals. The indoor fan motor is energized through the W1 heat terminal and runs on the speed selected on the HEAT tap of the control board. Humidistat When a humidistat is installed in the system, the HUM STAT jumper on the control board should be moved to the YES position. The cooling CFM will then be reduced by 15% whenever the humidistat indicates high humidity. If using a communicating control, set the HUM STAT jumper to YES. 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 switches will close, the ignition control pro- vides a 17-second ignitor warm-up period, the gas valve then opens, the gas starts to flow, ignition occurs and the flame sensor begins its sensing function. The blower motor will energize 30 seconds after the gas valve opens, if a flame is detected. Normal furnace operation will continue until the thermostat circuit between R and W is opened, which causes the ignition system and gas valve to de-energize and the burner flames to be extinguished. The vent motor will operate for 15 seconds and the blower motor will operate for the amount of time set by the BLOWER OFF DELAY jumper located on the control board. See Figure 41. The heating cycle is now complete, and ready for the start of the next heating cycle. This is a 2 stage furnace. Ignition is always estab- lished at the high fire rate. After flame has been established for 10 sec- onds and there is no thermostat input on the furnace control WZ terminal, the furnace control will shift to low fire heating. 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. Johnson Controls Ducted Systems 37 A momentary loss of gas supply, flame blowout, or a faulty flame probe circuit will result in a disruption in the flame and be sensed within 1.0 seconds. The gas valve will de-energize and the control will begin a recycle operation. A normal ignition sequence will begin after a 15 sec- ond inter-purge. If during the five recycles the gas supply does not return, or the fault condition is not corrected the ignition control will lock- out for 60 minutes. During burner operation, a momentary loss of power for 50 milliseconds or longer will de-energize the gas valve. When the power is restored, the gas valve will remain de-energized and the ignition sequence will immediately restart. TROUBLESHOOTING The following visual checks should be made before troubleshooting: 1. Check to see that the power to the furnace and the ignition control module is ON. 2. The manual shut-off valves in the gas line to the furnace must be open. 3. Make sure all wiring connections are secure. 4. Review the sequence of operation. Start the system by setting the thermostat above the room temperature. Observe the system’s response. Then use the troubleshooting section in this manual to check the system’s operation. FURNACE CONTROL DIAGNOSTICS The furnace has built-in, self-diagnostic capability. A blinking LED light on the control board can flash red, green or amber to indicate various conditions. The control continuously monitors its own operation and the operation of the system. If a failure occurs, the LED light will indicate the failure code. The SLOW flash speed is two seconds on and two seconds off. The other flash codes listed below have the following timing: LED light will turn on for 1/3 second and off for 1/3 second. This pattern will be repeated the number of times equal to the code. There will be a two- second pause between codes. For example, the six red flash code will flash the LED light on and off six times, then will be off for two seconds. This pattern will repeat as long as the fault condition remains. The con- tinuous flash codes listed below will flash the LED light on and off con- tinuously, with no breaks or longer pauses. SLOW GREEN FLASH: Normal operation, no thermostat calls. SLOW AMBER FLASH: Normal operation with call for heat. LED STEADY OFF – If the LED light does not flash at all, check for power to the board and check for a blown fuse on the board. If the board is properly powered and the fuse is not blown, the control board may need to be replaced. STEADY ON ANY COLOR: Control failure. Turn power to the furnace off and back on. If the fault code returns, the control board must be replaced. The control board is not field-repairable. CONTINUOUS AMBER FLASH: Flame sense current is below 1.5 microamps. Check and clean flame sensor. Check for proper gas flow. Verify that current is greater than 1.5 microamps at flame current test pad. 1 RED FLASH: This indicates that flame was sensed when there was not a call for heat. The control will turn on both the inducer motor and supply air blower. Check for a leaking or slow-closing gas valve. 2 RED FLASHES: This indicates that the pressure switch is closed when it should be open. The control confirms that the pressure switch contacts are open at the beginning of each heat cycle and will not let the ignition sequence continue if the pressure switch contacts are closed when they should be open. Check for a faulty pressure switch or miswiring. ! WARNING Never bypass any safety control to allow furnace operation. To do so will allow furnace to operate under potentially hazardous conditions. Do not try to repair controls. Replace defective controls with UPG Source 1 Parts. Never adjust pressure switch to allow furnace operation.
5750149-UIM-D-1219 3 RED FLASHES: This indicates the pressure switch contacts are open when they should be closed. Check for faulty inducer, blocked vent pipe, broken pressure switch hose, disconnected pressure switch or inducer wires or faulty pressure switch. 4 RED FLASHES: This indicates that the main limit switch has opened its normally closed contacts. The control will turn on the supply air blower and inducer. Check for a dirty filter, improperly sized duct sys- tem, incorrect blower speed setting, incorrect firing rate, loose limit switch wiring or faulty blower motor. If the limit switch has not closed within five minutes, the control will assume that the blower is not functioning, will start a hard lockout and will begin to flash the 11 Red Flashes error code. If, after fifteen min- utes, the main limit still has not closed, the control will assume that a manual-reset rollout switch has opened and will begin to flash the 5 Red Flash error code. See the description of “5 Red Flashes” and “11 Red Flashes” below. If the main limit switch opens five times within a single call for heat, the control will indicate 4 Red Flashes and will enter a one-hour soft lock- out. 5 RED FLASHES: This fault is indicated if the limit circuit is open for more than fifteen minutes, usually indicating that a manual-reset rollout switch has opened. Check for proper combustion air, proper inducer operation, and primary heat exchanger failure or burner problem. The control will enter a hard lockout and power will have to be cycled off and on to reset the control after the problem has been corrected. 6 RED FLASHES: This indicates that while the unit was operating, the pressure switch opened four times during the call for heat. Check for faulty inducer, blocked vent pipe or faulty pressure switch. The furnace will lock out for one hour and then restart. 7 RED FLASHES: This fault code indicates that the flame could not be established during three trials for ignition. Check that the gas valve switch is in the ON position. Check for low or no gas pressure, faulty gas valve, dirty or faulty flame sensor, faulty hot surface ignitor, loose wires or a burner problem. The furnace will lock out for one hour and then restart. 8 RED FLASHES: This fault is indicated if the flame is lost five times (four recycles) during the heating cycle. Check for low gas pressure, dirty or faulty flame sensor or faulty gas valve. The furnace will lock out for one hour and then restart. 9 RED FLASHES: Indicates reversed line voltage polarity, grounding problem or reversed low voltage transformer wires. Both heating and cooling operations will be affected. Check polarity at furnace and branch. Check furnace grounding. Check that flame probe is not shorted to chassis. The furnace will not start the ignition sequence until this problem is corrected. 10 RED FLASHES: Gas valve energized with no call for heat. The main blower and inducer blower will run and no ignition sequence will be started as long as this condition exists. Check gas valve and gas valve wiring. 11 RED FLASHES: This indicates that the limit circuit has remained open for more than five minutes and less than fifteen minutes. This con- dition is usually caused by a failed blower motor or blower wheel. The control will enter a hard lockout and power will have to be cycled off and on to reset the control after the problem has been corrected. 12 RED FLASHES: This indicates a loose or missing model ID plug. 13 RED FLASHES: This indicates that the high-fire pressure switch is open when it should be closed. Check for a partially blocked vent pipe, a loose or disconnected wire, and vent pressure. 4 AMBER FLASHES: The control is receiving a “Y” signal from the thermostat without a “G” signal. The furnace will operate normally in both heating and cooling, but this fault code will be displayed in order to alert the user that there is a wiring problem. Verify that the “G” wire from the thermostat is connected properly. SOFT LOCKOUT: This control includes a soft lockout that will reset automatically after one hour. This provides protection to an unoccupied structure if a temporary condition exists causing a furnace malfunction. An example of this is a temporary interruption in gas supply that would prevent the furnace from lighting. The control will keep trying to light each hour and will resume normal operation if the gas supply is restored. HARD LOCKOUT: Some fault conditions result in a hard lockout, which requires power to the control to be turned off and then back on to reset the control. The control will not automatically restart. IGNITION CONTROL FLAME SENSE LEVELS Normal flame sense current is approximately 3.7 microamps DC (ma) Low flame signal warning starts at 1.5 microamps. Low flame signal control lockout point is 0.1 microamps DC (ma) DIAGNOSTIC FAULT CODE STORAGE AND RETRIEVAL The control in this furnace is equipped with memory that will store up to five error codes to allow a service technician to diagnose problems more easily. This memory will be retained even if power to the furnace is lost. This feature should only be used by a qualified service tech- nician. If more than five error codes have occurred since the last reset, only the five most recent will be retained. The furnace control board has a but- ton, labeled LAST ERROR that is used to retrieve error codes. This function will only work if there are no active thermostat signals. So any call for heating, cooling or continuous fan must be terminated before attempting to retrieve error codes. 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 and the button is released, then will resume the normal slow green flash after a five-second pause.
38 Johnson Controls Ducted Systems
5750149-UIM-D-1219 SECTION XI: REPLACEMENT PARTS LIST DESCRIPTION MOTOR MOTOR, DIRECT DRIVE BLOWER BLOWER, COMBUSTION 2-STAGE ELECTRICAL CAPACITOR, RUN SWITCH, LIMIT CONTROL, FURNACE 2-STAGE VS IGNITER SENSOR, FLAME SWITCHES, PRESSURE SWITCH, DOOR TRANSFORMER VALVE, GAS 2-STAGE CONTROL, TEMPERATURE AIR MOVING HOUSING, BLOWER WHEEL, BLOWER FABRICATED PARTS RESTRICTOR, COMBUSTION BLOWER BURNER, MAIN GAS BRACKET, IGNITER SHELF, BLOWER RAIL, BLOWER (2 Req’d) BRACKET, BLOWER TRACK (2 Req’d) HEAT EXCHANGER ASS’Y DESCRIPTION FABRICATED PARTS Continued MANIFOLD, GAS PAN, BOTTOM PANEL, TOP PANEL, DOOR (2 Req’d) PANEL, BLOCKOFF MISCELLANEOUS ORIFICE, BURNER (Natural #45) SIGHT GLASS, OVAL (2 Req’d) GASKET, FOAM (Door) (1.5 ft req’d) PAN, CONDENSATE BRACKET, DOOR HARNESS, WIRING FERRULE (3 Req’d) GROMMET (3 Req’d) MOTOR MOUNT TUBING, SILICON HOSE, RAIN GUTTER HOSE, CONDENSATE PLUG, SEAL, 7/8” PLUG, SEAL, 2-3/8” PLUG, VENT PIPE BAG, PARTS KNOB, QUARTER TURN (4 Req’d) DIAGRAM, WIRING 2-STAGE VS
Johnson Controls Ducted Systems 39 REPLACEMENT PART CONTACT INFORMATION This is a generic parts list. To request a complete parts list, refer to the contact information below: • Visit our website at 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 Ducted Systems Consumer Relations 5005 York Drive Norman, OK 73069 5750149-UIM-D-1219 SECTION XII: WIRING DIAGRAM Wiring Diagram 96% Two-Stage COMM Furnace CAUTION PRECAUTION OPEN ALL DISCONNECTS BEFORE OUVREZ LES DISJONCTEURS AVANT SERVICING THIS UNIT 115VAC NEUT. DE PROCEDER AVEC LE SERVICE DOOR N.O.SW BLK RED BLK NO C BLK 115VAC LINE MGRN YEL DI WHT P3/S3 M1 WHT HSI 2WHT WHT CGAS VALVE 1600/2000 CFM MODELS ONLY F PBLK HI YEL PS2 BLK GND M UHC AEWHT ORG C NO BLOWER GRN BLK MOTOR WHT BRN HUM NEUTRALS EAC 115V PRI LINE 24V SEC LOAD (8) PUR (16) ORG (7) EMPTY (15) GRN 417 10 25 8 11RED/WHT 3 6912 ORG/BLK ROS2 ROS1 LS NO PS3 (6) EMPTY (14) EMPTY (5) EMPTY (13) EMPTY RED RED/BLK RED (4) EMPTY (12) EMPTY (3) BLK/WHT (11) EMPTY D NG(1) EMPTY (9) EMPTY RED/GRN (2) EMPTY (10) RED PUR FLAME SENSOR FURNACE CONTROL DE- Legend W/W1HUM W2 DS - Door switch C G RY/Y2 Y1O ROS - Rollout switch XFMR - Transformer Diagnostic Fault Codes HSI - Hot surface igniter PF- Power factor choke Flashes Fault Condition PS1 - Pressure switch, 1 stage PS2 - Pressure switch, 2 stage N.O.SW DOOR SWITCH None Power Off PS3 - Pressure switch, condensate DS POWER SUPPLY 115-1-60 NO C 1600/2000 CFM Slow Green Normal Operation IDM - Inducer motor Slow Amber Normal Operation with call for heat EAC - Electronic air cleaner MODELS ONLY BLOWER D NGRapid Amber Low flame sense current LS - Limit switch PF MOTOR 4 Amber No G from thermostat HUM - Humidifier Steady on Red Control Failure EAC 1 Red Flame present with gas off 2 Red Check pressure switch wiring HUMIDIFIER HSI 3 Red Vent OR termination problem 4 Red Airflow problem 5 Red Flame Rollout 6 Red Repeated 3 Red 7 Red Failed to light burners 8 Red Loss of flame during call for heat DS - ROS - XFMR - HSI - PF - NO PS1 C ROS1 MLegende Commutateur de porte HIGH IDM LOW Commutateur de roulement Transformeur Ignition de surface chaud 115VPRI COM Transformeur de facteur 1T (40VA) 24V SEC RRW1W1WW1ST STAGE CW2 W2C HIGGGAS VALVE 9 Red Hot/Neutral reversed OR poor ground/neutral 10 Red Gas valve shorted "ON" 11 Red Check blower motor/wiring de puissance PS1 - Commutateur de pression, premier stage PS2- Commutateur de pression, Y1Y1Y2Y2 LS ROS2 PS2 NO 2-STAGE HEATING 2ND STAGE deuxieme stage 2-STAGE COOLING ROOM THERMOSTAT D NG13 Red Vent OR termination problem PS3- Commutateur de pression, TO AIR CONDITIONER condensation YYCONTROLS IDM- D'induct moteur CCCOMMON T'STAT CONNECTION EAC- Filtre électrique LS - Commutateur de limite HUM - Humidificateur NOTES: 1. If any of the original wire as supplied with the furnace must be replaced, it must be replaced with wiring material having a temperature rating of at least 221 degrees F (105 degrees C). 2. Connectors suitable for copper conductors only. 1034866-UWD-C-0519 FIGURE 42: Wiring Diagram 40 Johnson Controls Ducted Systems Fault Code Retrieval Notice - Only a qualified service technician should use this feature. Fault code retrieval functions will work only if there are no active thermostat signals. NOTES: To retrieve fault codes, push and release ERROR button on control board. The LED will flash the 1. Si l'un des fils d'origine fourni avec ce four doit filage doit être remplacé, last five error codes, beginning with the most recent. If there are no fault codes in memory, the LED il doit être remplacé avec le fil ayant un degré de température d'au will give two green flashes. To clear the fault code memory, push and hold the ERROR button for moins 221 degrés F (105 degrés C ). at least five seconds. The LED will give three green flashes when the memory has been cleared. 2. Seulement des marettes pour fil de cuivre. DNG WHT 321 ORG GRY GRY BRN 1236 5 44 15 236WHT BLK 1235 4 PUR GRN BLK/WHT RED GRN BRN GRN U LBC PS3 C NO PS1 NO WHT C Refer to Installation Manual for more detailed information. 5750149-UIM-D-1219 SECTION XIII: START UP SHEET Proper furnace start up is critical to customer comfort and equipment longevity Start-Up Date Technician Performing Start-Up Installing Contractor Name Owner Information Name Address City State or Province Zip or Postal Code Equipment Data Furnace Model Furnace Serial Indoor Coil Model Indoor Coil Serial Outdoor Unit Model Outdoor Unit Serial Furnace Configuration Upflow Downflow Horizontal Left Horizontal Right Filter, Thermostat, Accessories Filter Type Filter Size Filter Location(s) Thermostat Type Other System Equipment and Accessories Connections -- All Per Installation Instructions and Local Code Unit is level or tilted slightly forward Gas piping is connected (including drip leg) Vent system is connected Supply plenum and return air are connected Condensate Management Condensate tubing is correctly installed for the furnace position Condensate drain is connected Venting Intake Size # of 90 Degree Ells # of 45 Degree Ells Length Exhaust Roof Termination Sidewall Exhaust Size # of 90 Degree Ells # of 45 Degree Ells Length Venting system is the proper size, within the limitations of the chart in the installation instructions, properly connected to the furnace, and properly pitchedIntake Termination Sidewall Electrical: Line Voltage Polarity is correct (black is L1 (hot), white is N (neutral) Ground wire is connected from the furnace to electrical panel Line voltage value to furnace (volts AC) Thermostat wiring is complete Thermostat heat anticipator set to .4 or (6 cycles per hour for electronic thermostats) Low voltage value between "R" and "C" on furnace control board (volts AC) Thermostat Staging: OFF 10 MIN 15 AUTO 20 MIN Continued on next Page Johnson Controls Ducted Systems 41 Roof Attic Electrical: Low Voltage Staging: Gas Side Gas Type Natural Gas LP Gas (Requires LP conversion kit) LP Gas Conversion Kit Part # Used Burner flame inspected -- flames are blue and extending directly into the primary heat exchanger cells Air Side: Continuous Fan (PSC) Clean Up LP Conversion Kit Installed By Inlet Gas Pressure (in. w.c.") Low Fire Manifold Gas Pressure (in. w.c.") High Fire Manifold Gas Pressure (in. w.c.") Calculated input in btuh - clock the gas meter in high fire (Nat Gas Only) Air Side: System External Static Pressure Supply static before indoor coil (in w.c.") Return Static (in w.c.") before filter Total External Static Pressure D Installation debris disposed of and furnace area cleaned up? Owner Education Supply static after indoor coil (in w.c.") Return Static (in w.c.") after filter (furnace side) Air Side: Heating (PSC) Low Heat Blower Speed Selected Red (Low) Yel (Med Low) Blue (Med/Med High) Black (High) High Heat Blower Speed Selected Red (Low) Yel (Med Low) Blue (Med/Med High) Black (High) Temperature rise in degrees F measured in low fire Temperature rise in degrees F measured in high fire Air Side: Heating (Variable Speed ECM) Other Jumpers Heat Speed Selected A B C De-humidistat Temperature rise in degrees F measured in Low fire Temperature rise in degrees F measured in high fire Cooling CFM delivery (use Blower Performance Data Chart) Hi Low Blower Speed Selected Lo Heat HI Heat Lo Cool Hi Cool Cycle Test Give owner the owner's manual provided Explain operation of system to equipment owner Explain the importance of regular filter replacement and equipment maintenance Explain thermostat use and programming (if applicable) to owner Yes No Heat Pump Yes No Air Side: Cooling (PSC) Low Cool Blower Speed Selected Red (Low) Yel (Med Low) Blue (Med/Med High) Black (High) High Cool Blower Speed Selected Red (Low) Yel (Med Low) Blue (Med/Med High) Black (High) Air Side: Cooling (Variable Speed ECM) COOL Speed Selected A B C D ADJUST Setting A B C D DELAY Setting A B C D Air Side: Continuous Fan (Variable Speed ECM) Blower (5-Speed) Selected Lo Cool HI Cool Hi Heat oL oL taeH taeH VSG Blower (3-Speed) Selected L (Low) M (Med) H (High) Operate the furnace through several heating cycles from the thermostat, noting and correcting any problems Operate the furnace through continuous fan cycles from the thermostat, noting and correcting any problems Operate the furnace through cooling cycles (as applicable), noting and correcting any problems Subject to change without notice. Published in U.S.A 5750149-UIM-D-1219 Copyright © 2019 by Johnson Controls. All rights reserved. Supersedes: 5750149-UIM-C-1019 York International Corp. 5005 York Drive Norman, OK 73069
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