Johnson Controls YM8M-YMLM-MP, TM8M-TMLM-MP, CM8M-CMLM-MP, LM8M-LMLM-MP User Manual

INSTALLATION MANUAL
RESIDENTIAL GAS FURNACE WITH PSC MOTOR
MODELS: TM8M/TMLM*MP, YM8M/YMLM*MP, CM8M/CMLM*MP, LM8M/LMLM*MP
(80% Modulating Multi-position / Low NOx)
LIST OF SECTIONS
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TWINNING AND STAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
VENT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
LIST OF FIGURES
Duct Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Vertical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Coil Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Horizontal Right Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Horizontal Left Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PC Series Upflow Coil Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Horizontal Left or Right application (Right Shown) . . . . . . . . . . . . . . 8
Combustible Floor Base Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Horizontal Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Typical Attic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Typical Suspended Furnace / Crawl Space Installation . . . . . . . . . . . 9
Downflow Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Downflow Installation - Gas Valve Rotation . . . . . . . . . . . . . . . . . . . . 9
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Side Return Cutout Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Upflow/Downflow Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Horizontal Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
LIST OF TABLES
Unit Clearances to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Coil Projection Dimensions - PC Series Coils . . . . . . . . . . . . . . . . . . 6
Cabinet and Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Recommended Filter Sizes (High Velocity 600 FPM) . . . . . . . . . . . . 8
High Altitude Orifices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Ratings & Physical / Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . 10
Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . 20
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
NORMAL OPERATION AND DIAGNOSTICS . . . . . . . . . . . . . 25
REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . 27
REPLACEMENT PART CONTACT INFORMATION . . . . . . . . 27
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Thermostat Chart - Single Stage Air Conditioner –
Variable Speed or PSC Modulating Furnace . . . . . . . . . . . . . . . . . .14
Thermostat Chart - Two Stage Air Conditioner –
Variable Speed or PSC Modulating Furnace . . . . . . . . . . . . . . . . . .15
Thermostat Chart - Two Stage Air Conditioner with Single Stage
Thermostat – Variable Speed or PSC Modulating Furnace . . . . . . .16
Thermostat Chart - Single Stage Heat Pump –
Variable Speed or PSC Modulating Furnace . . . . . . . . . . . . . . . . . .17
Thermostat Chart - Single Stage Heat Pump –
Variable Speed or PSC Modulating Furnace . . . . . . . . . . . . . . . . . .18
Thermostat Chart - Two Stage Heat Pump –
Variable Speed or PSC Modulating Furnace . . . . . . . . . . . . . . . . . .19
Combustion Air Inducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Combustion Airflow Path Through The Furnace
Casing to the Burner Compartment . . . . . . . . . . . . . . . . . . . . . . . . .20
Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . .21
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Unconfined Space Minimum Area in Square Inch . . . . . . . . . . . . . .19
Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Gas Rate (CU FT/HR) at Full Input . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Cooling Airflow - A/C Capacity in Tons . . . . . . . . . . . . . . . . . . . . . . .24
EFFICIENCY RATING CERTIFIED
ISO 9001
Certified Quality
Management System
These high efficiency, compact units employ induced combustion, reli­able 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 applica­tions. These furnaces are designed for residential installation in a basement, closet, alcove, attic, recreation room or garage and are also ideal fo r commercial applications. All units are factory assembled, wired and tested to assure safe dependable and economical installation and oper­ation. These units are Category I listed and may be common vented with another gas appliance as allowed by the National Fuel Gas Code.
SECTION I: SAFETY
This is a safety alert symbol. When you see this symbol on labels or in manuals, be alert to the potential for personal injury.
Understand and pay particular attention to the signal words DANGER,
WARNING, or CAUTION.
DANGER indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury
WARNING indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury
CAUTION indicates a potentially hazardous situation, which, if not
avoided may result in m inor or moderate injury. alert against unsafe practices and hazards involving only property dam­age.
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 malfunction, death, personal injury and/or property dam­age. Only a qualifie d contractor, installer or service agency should
install this product.
.
.
It is also used to
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368261-UIM-A-0508
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.
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 of these instructions.
6. Test for gas leaks as specified in these instructions.
FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in serious
injury, death or property damage. Never test for gas leaks with an open flame. Use a commercially
available soap solution made specifically for detection of leaks to check all connections. A fire or explosion may result causing prop­erty damage, personal injury or loss of life.
7. Always install the furnace to operate within the furnace’s intended temperature rise range. Only connect the furnace to a duct system which has an external static pressure within the allowable range, as specified on the furnace rating plate.
8. When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by duct(s) sealed to the fur­nace casing and terminating outside the space containing the fur­nace.
9. It is permitted to use the furnace for heating of buildings or struc­tures under construction where the application and use must com­ply with all manufacturer’s installation instructions including:
• Proper vent installation;
• Furnace operating under thermostatic control;
• Return air duct sealed to the furnace;
• Air filters in place;
• Set furnace input rate and temperature rise per rating plate
marking;
• Means for providing outdoor air required for combustion;
• 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
completion of the construction process, and verify furnace­operating conditions including ignition, input rate, temperature rise and venting, according to the manufacturer’s instructions.
10. When installed in a Non-HUD-Approved Modular Home or building constructed on-site, combustion air shall not be supplied from occupied spaces.
11. The size of the unit should be based on an acceptable heat loss calculation for the structure. ACCA, Manual J or other approved methods may be used.
SAFETY REQUIREMENTS
This product must be installed in strict compliance with the installa­tion instructions and any applicable local, state, and national codes including, but not limited to building, electrical, and mechanical codes.
• Refer to the unit rating plate for the furnace model number, and then see the dimensions page of this instruction for return air ple­num dimensions in Figure 14, "Dimensions". The plenum must be installed according to the instructions.
• Provide clearances from combustible materials as listed under Clearances to Combustibles.
• Provide clearances for servicing ensuring that service access is allowed for both the burners and blower.
• These models ARE NOT into a HUD Approved Modular Home (Mobile) Home.
• This furnace is not approved for installation in trailers or recre­ational vehicles.
• Furnaces for installation on combustible flooring shall not be installed directly on carpeting, tile or other combustible material other than wood flooring.
• Check the rating plate and power supply to be sure that the elec­trical characteristics match. All models use nominal 115 VAC, 1 Phase, 60-Hertz power supply. DO NOT CONNECT THIS APPLI­ANCE TO A 50 HZ POWER SUPPLY OR A VOLTAGE ABOVE 130 VOLTS.
• Furnace shall be installed so the electrical components are pro­tected 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 precau­tions in the manuals and on the labels attached to the unit and other safety precautions that may apply.
CSA listed or approved for installation
or a Manufactured
COMBUSTION AIR QUALITY (LIST OF CONTAMINANTS)
The furnace requires OUTDOOR AIR for combustion when the furnace is located in any of the following environments.
• Restricted Environments
• Commercial buildings
• Buildings with indoor pools
• Furnaces installed in laundry rooms
• Furnaces installed in hobby or craft rooms
• Furnaces installed near chemical storage areas
• Chemical exposure
The furnace requires OUTDOOR AIR for combustion when the furnace is located in an area where the furnace is being exposed to the follow­ing substances and / or chemicals.
• Permanent wave solutions
• Chlorinated waxes and cleaners
• Chlorine based swimming pool chemicals
• Water softening chemicals
• De-icing salts or chemicals
• Carbon tetrachloride
• Halogen type refrigerants
• Cleaning solvents (such as perchloroethylene)
• Printing inks, paint removers, varnishes, etc.
• Hydrochloric acid
• Cements and glues
• Antistatic fabric softeners for clothes dryers
• Masonry acid washing materials
When outdoor air is used for combustion, the combustion air intake duct system termination must be located external to the building and in an area where there will be no exposure to the substances listed above.
2 Johnson Controls Unitary Products
The furnace area must not be used as a broom closet or for any other storage purposes, as a fire hazard may be created. Never store items such as the following on, near or in contact with the fur­nace.
1. Spray or aerosol cans, rags, brooms, dust mops, vacuum cleaners 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.
CODES AND STANDARDS
Follow all national, local codes and standards in addition to this installa­tion manual. The installation must comply with regulations of the serv­ing gas supplier, local building, heating, plumbing, and other codes. In absence of local codes, the installation must comply with the national codes listed below and all authorities having jurisdiction.
In the United States and Canada, follow all codes and standards for the following, using the latest edition available:
STEP 1 -Safety
• US: National Fuel Gas Code (NFGC) NFPA 54/ANSI Z223.1 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSI/NFPA 90B
• CANADA: CAN/CGA-B149.1 National Standard of Canada. Natu­ral Gas and Propane Installation Codes (NSCNGPIC)
STEP 2 -General Installation
• US: Current edition of the NFGC and NFPA 90B. For copies, con­tact the
National Fire Protection Association Inc. Batterymarch Park Quincy, MA 02269
or for only the NFGC, contact the
American Gas Association, 400 N. Capital, N.W. Washington DC 20001
or www.NFPA.org
• CANADA: NSCNGPIC. For a copy contact:
Standard Sales, CSA International 178 Rexdale Boulevard Etobicoke, (Toronto) Ontario Canada M9W 1RS
STEP 3 -Combustion and Ventilation Air
• US: Section 5.3 of the NFGC, air for Combustion and Ventilation
• CANADA: Part 7 of NSCNGPIC, Venting Systems and Air Supply for Appliances
STEP 4 -Duct Systems
• US and CANADA: Air Conditioning Contractors Association (ACCA) Manual D, Sheet Metal and Air Conditioning Contractors Association National Association (SMACNA), or American Soci­ety of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) 1997 Fundamentals Handbook Chapter 32.
STEP 5 -Acoustical Lining and Fibrous Glass Duct
• US and CANADA: Current edition of SMACNA and NFPA 90B as tested by UL Standard 181 for Class I Rigid Air Ducts
STEP 6 -Gas Piping and Gas Pipe Pressure Testing
• US: NFGC; chapters 2, 3, 4, & 9 and National Plumbing Codes
• CANADA: NSCNGPIC Part 5
STEP 7 -Electrical Connections
• US: National Electrical Code (NEC) ANSI/NFPA 70
• CANADA: Canadian Electrical Code CSA C22.1
368261-UIM-A-0508
These instructions cover minimum requirements and conform to exist­ing national standards and safety codes. In some instances these instructions exceed certain local codes and ordinances, especially those who have not kept up with changing residential and non-HUD modular home construction practices. These instructions are required as a minimum for a safe installation.
FOR FURNACES INSTALLED IN THE COMMON­WEALTH OF MASSACHUSETTS ONLY
For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for resi­dential purposes, including those owned or operated by the Com­monwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following require­ments shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors
a. In the event that the side wall horizontally vented gas
fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.
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 monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
3. SIGNAGE. A metal or plastic identification plate shall be perma­nently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, "GAS VENT
DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUC­TIONS".
4. INSPECTION. The state or lo cal gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes car­bon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4.
INSPECTION
As soon as a unit is received, it should be inspected for possib le dam­age during transit. If damage is evident, the extent of the damage should be noted on the carrier’s freight bill. A separate request for inspection by the carrier’s agent should be made in writing. Also, before installation, the unit should be checked for screws or bolts which may have loosened in transit. There are no shipping or spacer brackets which need to be removed from the interior of this unit.
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FURNACE LOCATION AND CLEARANCES
The furnace shall be located using the following guidelines:
1. Where a minimum amount of air intake/vent piping and elbows will be required.
2. As centralized with the air distribution as possible.
3. Where adequate combustion air will be available.
4. Where it will not interfere with proper air circulation in the confined space.
5. Where the outdoor vent terminal will not be blocked or restricted. Refer to “VENT CLEARANCES” located in SECTION VII of these instructions. These minimum clearances must be maintained in the installation.
6. Where the unit will be installed in a level position with no more than 1/4” (6.4 mm) slope side-to-side and front-to-back.
Installation in freezing temperatures:
1. Furnace shall be installed in an area where ventilation facilities provide for safe limits of ambient temperature under normal oper­ating conditions.
Table 1: Unit Clearances to Combustibles (All Dimensions in Inches, and All Surfaces Identified with the Unit in an Upflow Configuration)
Application
Upflow B-Vent 1 (2.5) 3 (7.6) 0 (0.0) 0 (0.0) 0 (0.0) 1 (2.5) Combustible Yes Yes Yes No Downflow B-Vent 1 (2.5) 3 (7.6) 0 (0.0) 0 (0.0) 0 (0.0) 1 (2.5) Horizontal B-Vent 1 (2.5) 3 (7.6) 0 (0.0) 0 (0.0) 0 (0.0) 1 (2.5) Combustible No Yes Yes
1.Special floor base or air conditioning coil required for use on combustible floor.
2.Line contact only permitted between lines formed by the intersection of the rear panel and side panel (top in horizontal position) of the furnace jacket and building joists, studs or framing.
Top Front Rear Left Side Right Side Flue
In. (cm) In. (cm) In. (cm) In. (cm) In. (cm) In. (cm)
SECTION II: DUCTWORK
DUCTWORK GENERAL INFORMATION
The duct system’s design and installation must:
1. Handle an air volume appropriate for the served space and within the operating parameters of the furnace specifications.
2. Be installed in accordance of National Fire Protection Association as outlined in NFPA standard 90B (latest editions) or applicable national, provincial, state, and local fire and safety codes.
3. Create a closed duct system. For residential and Non-HUD Modu­lar Home installations, when a furnace is installed so that the sup­ply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by a duct(s) sealed to the furnace casing and terminating outside the space containing the furnace.
4. Complete a path for heated or cooled air to circulate through the air conditioning and heating equipment and to and from the condi­tioned space.
The cooling 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 a cooling coil, the coil must be installed parallel with, or in the supply air side of the furnace to avoid condensa­tion in the primary heat exchanger. When a parallel flow arrangement is used, dampers or other means used to control airflow must be ade­quate to prevent chilled air from entering the furnace. If manually oper­ated, the damper must be equipped with means to prevent the furnace or the air conditioner from operating unless the damper is in full heat or cool position.
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.
Clearances for access/service:
Ample clearances should be provided to permit easy access to the unit. The following minimum clearances are recommended:
1. Twenty-four (24) inches (61 cm) between the front of the furnace and an adjacent wall or another appliance, when access is required for servicing and cleaning.
2. Eighteen (18) inches (46 cm) at the side where access is required for passage to the front when servicing or for inspection or replace­ment of flue/vent connections.
In all cases, accessibility clearances shall take precedence over clear­ances for combustible materials where accessibility clearances are greater.
Installation in a residential garage:
A gas-fired furnace for installation in a residential garage must be installed so the burner(s) and the ignition source are located not less than 18 inches (46 cm) above the floor, and the furnace must be located or protected to avoid physical damage by vehicles.
Floor/
Bottom
1 (25.4)
When replacing an existing furnace, if the existing plenum is not the same size as the new furnace then the existing plenum must be removed and a new plenum installed that is the proper size for the new furnace. If the plenum is shorter than 12” (30.5 cm) the turbulent air flow may cause the limit controls not to operate as designed, or the limit con­trols may not operate at all.
The duct system is a very important part of the installation. If the duct
system is improperly sized the furnace will not operate properly.
The ducts attached to the furnace plenum, should be of sufficient size so that the furnace operates at the specified external static pressure and within the air temperature rise specified on the nameplate.
The minimum plenum height is 12” (30.5 cm). The furnace will not operate properly on a shorter plenum height. The minimum recom­mended rectangular duct height is 4 inches (10 cm) attached to the plenum.
If a matching cooling coil is used, it may be placed directly on the fur­nace outlet and sealed to prevent leakage. If thermoplastic evaporator ‘A’ coil drain pans are to be installed in the upflow/horizontal configura­tion, then extra 2” minimum spacing may be needed to ensure against drain pan distortion.
The duct system must be properly sized to obtain the correct airflow for the furnace size that is being installed.
Refer to Table6, "Ratings & Physical / Electrical Data" or the fur­nace rating plate for the correct rise range and static pressures.
If the ducts are undersized, the result will be high duct static pres­sures 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.
Closet Alcove Attic
1
Yes Yes Yes No
Line
Contact
Yes
2
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368261-UIM-A-0508
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 should remain in the rotated down posi­tion as shipped.
For duct attachment, if needed.
Factory installed
FIGURE 1: Duct Attachment
DUCTWORK INSTALLATION AND SUPPLY PLENUM CONNECTION - UPFLOW/HORIZONTAL
Attach the supply plenum to the furnace outlet. The use of an approved flexible duct connector is recommended on all installations. This connection should be sealed to prevent air leakage. The sheet metal should be crosshatched to eliminate any popping of the sheet metal when the indoor fan is energized.
FLOOR BASE AND DUCTWORK INSTALLATION ­DOWNFLOW
Installations on combustible material or directly on any floors must use a combustible floor base shown in Figure 8, "Combustible Floor Base Accessory". Follow the instruc­tions supplied with the combustible floor base accessory. This combustible floor base can be replaced with a match­ing cooling coil, properly sealed to prevent leaks. Follow the instructions supplied with the cooling coil cabinet for install­ing the cabinet to the duct connector. Plug intake and vent pipe holes in bottom panel and move grommet to desired vent side exit.
Downflow Air Conditioning Coil Cabinet
The furnace should be installed with coil cabinet part number specifi­cally intended for downflow application. If a matching cooling coil is used, it may be placed directly on the furnace outlet and sealed to pre­vent leakage. For details of the coil cabinet dimensions and installation requirements, refer to the installation instructions supplied with the coil cabinet.
Attach the air conditioning coil cabinet to the duct connector, and then position the furnace on top of the coil cabinet. The connection to the fur­nace, air conditioning coil cabinet, duct connector, and supply air duct must be sealed to prevent air leakage.
COIL INSTALLATION
COIL/FURNACE ASSEMBLY - MC/FC/PC SERIES COILS
Furnace
Furnace
UPFLOW
DOWNFLOW
FIGURE 2: Vertical Applications
FURNACE ASSEMBLY - MC & FC SERIES COILS
These coils are factory shipped for installation in either upflow or down­flow applications with no conversion.
Position the coil casing over or under the furnace opening as shown in Figure 2, "Vertical Applications" after configuring coil flanges as required see “Coil Flange” section below.
COIL FLANGE INSTALLATION
The coils include removable flanges to allow proper fit up with furnaces having various inlet and outlet flange configurations. The two flanges are attached to the top of the coil in the factory during production. For proper configuration of flanges refer to Figure 3, "Coil Flange".
FACTORY
FLANGE
LOCATION
(Used for upflow
or horizontal
ALTERNATE FLANGE LOCATION (Used for downflow or horizontal left installations)
right installations)
FIGURE 3: Coil Flange
FURNACE ASSEMBLY - MC SERIES COILS ONLY
MC coils are supplied ready to be installed in a horizontal position. A horizontal pan is factory installed. MC coils should be installed in all hor­izontal applications with the horizontal drain pan side down.
On all installations without a coil, a removable access panel is rec-
Mounting Plate
ommended in the outlet duct such that smoke or reflected light would be observable inside the casing to indicate the presence of leaks in the heat exchanger. This access cover shall be attached in such a manner as to prevent leaks.
Furnace
FIGURE 4: Horizontal Right Application
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368261-UIM-A-0508
For horizontal left hand applications no conversion is required to an MC coil when used with a downflow/horizontal furnace. A mounting plate, supplied with every coil should always be installed on the side desig­nated as top side. See Figures 4 & 5.
Mounting Plate
Furnace
FIGURE 5: Horizontal Left Application
FURNACE ASSEMBLY - PC SERIES COILS
These upflow coils are designed for installation on top of upflow fur­naces only.
If the coil is used with a furnace of a different size, use a 45° transition to allow proper air distribution through the coil.
1. Position the coil casing over the furnace opening as shown in Fig­ure 6, "PC Series Upflow Coil Installation".
2. Place the ductwork over the coil casing flange and secure.
3. Check for air leakage between the furnace and coil casing and seal appropriately.
Do not drill any holes or drive any screws into the front duct flange on the coil in order to prevent damaging coil tubing. See Figure 6, "PC Series Upflow Coil Installation"
C
(Min)
D
CRITICAL COIL PROJECTION
The coil assembly must be located in the duct such that a minimum dis­tance is maintained between the top of the coil and the top of the duct. Refer to Table 2, "Coil Projection Dimensions - PC Series Coils".
COIL / FURNACE ASSEMBLY - HC SERIES COILS
These coils are supplied ready to be installed in a right hand position or a left hand position. When used in conjunction with a horizontal furnace (blow through) application, the coil should be oriented with the opening of the “A” coil closest to the furnace. See Figures 7.
NOTE: Each coil is shipped with an external tie plate that should be used to secure the coil to the furnace. It should be installed on the back side of the coil using the dimpled pilot holes. See Figures 7.
Use tie plate supplied with coil
Gas Furnace
Air flow
FIGURE 7: Horizontal Left or Right application (Right Shown)
DOWNFLOW DUCT CONNECTORS
All downflow installations must use a suitable duct connector approved by the furnace manufacturer for use with this furnace. The duct connec­tors are designed to be connected to the rectangular duct under the floor and sealed. Refer to the instructions supplied with the duct con­nector for proper installation. Refer to the separate accessory parts list at the end of these instructions for the approved accessory duct con­nectors.
Flexible Duct Collar
Field Fabricated Ductwork
Upflow Coil
Upflow Furnace
Primary
Drain
Secondary
Drain
Do not drill or Screw this flange
Alternate
Drain Location
FIGURE 6: PC Series Upflow Coil Installation
Table 2: Coil Projection Dimensions - PC Series Coils
COIL SIZE DIMENSION “C” INCH
PC18 3-1/2 PC24 4-1/2
PC30, PC32, PC35 4-1/2
PC42, PC43, PC36, PC37 5-1/2
PC48 6-1/2 PC60 9
NOTE: Dimension “C” should be at least 2/3 of dimension “D”. See Fig­ure 6, "PC Series Upflow Coil Installation"
FURNACE
WARM AIR PLENUM WITH 1” FLANGES
FIBERGLASS INSULATION
FIBERGLASS TAPE UNDER FLANGE
COMBUSTIBLE FLOOR BASE ACCESSORY
FIGURE 8: Combustible Floor Base Accessory
RESIDENTIAL AND MODULAR HOME UPFLOW RETURN PLENUM CONNECTION
Return air may enter the furnace through the side(s) or bottom depend­ing on the type of application. Return air may not be connected into the rear panel of the unit.
6 Johnson Controls Unitary Products
BOTTOM RETURN AND ATTIC INSTALLATIONS
Bottom return applications normally pull return air through a base plat­form or return air plenum. Be sure the return platform structure or return air plenum is suitable to support the weight of the furnace.
The internal bottom panel must be removed for this application. Attic installations must meet all minimum clearances to combustibles
and have floor support with required service accessibility.
HORIZONTAL APPLICATION
FIGURE 9: Horizontal Application
This furnace may be installed in a horizontal position on either side as shown above. It must not be installed on its back.
368261-UIM-A-0508
When a furnace is installed in an attic or other insulated space, keep all insulating materials at least 12 inches (30.5 cm) away from furnace and burner combustion air openings.
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 sus­pension points must be level to ensure quite furnace operation. When suspending the furnace use a secure platform constructed of plywood or other building material secured to the floor joists. Refer to for typical crawl space installation.
ATTIC INSTALLATION
Line contact only permissible between lines formed by the intersection of furnace top and two sides and building joists, studs or framing
Filter rack must be a minimum distance of 18” (45.7 cm) from the furnace
Return Air
Gas Piping
Sediment
Trap
30” MIN. Work Area
FIGURE 10: Typical Attic Installation
This appliance is certified for line contact when the furnace is installed in the horizontal left or right position. The line contact is only permissible between lines that are formed by the intersection of the top and two sides of the furnace and the building joists, studs or framing. This line may be in contact with combustible material. Refer to Figure 10, "Typi­cal Attic Installation".
12”
12”
Supply Air
Vent (Maintain required clearances to combustibles)
Sheet metal in front of furnace combustion air Openings is Recommended
Angle Iron Bracket
6” Min. Between Rod & Front of Furnace
1” Max. Between Rod & Back of Furnace
Support Bracket
FIGURE 11: Typical Suspended Furnace / Crawl Space Installation
DOWNFLOW APPLICATION
To apply the furnace in a downflow position, it will be necessary to rotate the vent blower 90° left or right so that the vent pipe passes through the side of the furnace casing rather than the end. See Figure 12, "Downflow Venting".
For modulating furnaces to be used in the downflow position, it is necessary to rotate the gas valve so that it is upright when the fur­nace is installed. Loosen the pipe union between the gas valve and manifold, rotate the valve as far upward as it will go, and tighten the union. See Figure 13, "Downflow Installation - Gas Valve Rotation".
For downflow installation,rotate
Rotate vent blower 90°
gas valve upwards, as shown
either way
LEFT SIDE VENT
RIGHT SIDE VENT
FIGURE 12: Downflow Venting FIGURE 13: Downflow Installation - Gas Valve Rotation
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LEFT SIDE
(For Cladded door add
appoximately an additional .75”)
.5”
B
.5”
24.38”
SUPPLY END
20”
28.5”
29.5”
Vent Outlet
Electrical Entry
Gas Pipe Entry
Thermostat Wiring
Vent Outlet
C
FRONT
A
33”
Electrical Entry
Vent Outlet
Gas Pipe Entry
Thermostat Wiring
B
RIGHT SIDE
23”
24.25”
RETURN END
FIGURE 14: Dimensions Table 3: Cabinet and Duct Dimensions
BTUH (kW)
Input
Nominal
CFM (m
3
/min)
Cabinet
Size
AA (cm)BB (cm)CC (cm) Lbs
Cabinet Dimensions (Inches)
60 (17.6) 1200 (34.0) A 14 1/2 36.8 13 1/2 34.3 10.3 26.2 94 80 (23.4) 1200 (34.0) B 17 1/2 44.4 16 1/2 41.9 11.8 29.9 103
80 (23.4) 1600 (45.3) C 21 53.3 20 50.8 13.6 34.5 114 100 (29.3) 1600 (45.3) C 21 53.3 20 50.8 13.6 34.5 118 100 (29.3) 2000 (56.6) C 21 53.3 20 50.8 13.6 34.5 122 120 (35.1) 2000 (56.6) C 21 53.3 20 50.8 15.8 40.1 129
14”
1.5”
.5”
1”
.5”
Approximate
Operating Weights
SECTION III: FILTERS
FILTER INSTALLATION
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. Table 4: Recommended Filter Sizes (High Velocity 600 FPM)
CFM
(m³/min)
1200 (34.0) 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
NOTES:
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.
Cabinet
Size
Side
(in)
Bottom
(in)
SIDE RETURN
Locate the “L” shaped corner locators. These indicate the size of the cut­out to be made in the furnace side panel. Refer to Figure 15, "Side Return Cutout Markings".
Front of Furnace
Side of Furnace
Corner Markings
FIGURE 15: Side Return Cutout Markings Install the side filter rack following the instructions provided with that
accessory. If a filter(s) is provided at another location in the return air system, the ductwork may be directly attached to the furnace side panel.
Some accessories such as electronic air cleaners and pleated media may require a larger side opening. Follow the instructions supplied with that accessory for side opening requirements. Do not cut the opening larger than the dimensions shown in Figure 14, "Dimensions".
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HORIZONTAL APPLICATION
Horizontal Filters
All filters and mounting provision must be field supplied. All installa­tions must have a filter installed.
Any branch duct (rectangular or round duct) attached to the plenum must attach to the vertical plenum before the filter. The use of straps and / or supports is required to support the weight of the external filte r box.
Downflow Filters
Downflow furnaces typically are installed with the filters located above the furnace, extending into the return air plenum or duct. Any branch duct (rectangular or round duct) attached to the plenum must attach to the vertical plenum above the filter height.
Filter(s) may be located in the duct system external to the furnace using an external duct filter box attached to the furnace plenum or at the end of the duct in a return filter grille(s). The use of straps and/or supports is required to support the weight of the external filter box.
SECTION IV: GAS PIPING
GAS SAFETY
An overpressure protection device, such as a pressure regulator, must be installed in the gas piping system upstream of the furnace and must act to limit the downstream pressure to the gas valve so it does not exceed 0.5 PSI (14" w.c. (3.48 kPa). Pressures exceeding
0.5 PSI (14” w.c. (3.48 kPa) at the gas valve will cause damage to the gas valve, resulting in a fire or explosion or cause damage to the furnace or some of its components that will result in property damage and loss of life.
External Manual Shutoff Valve
To Gas Supply
Drip Leg
FIGURE 17: Upflow/Downflow Gas Piping
FIGURE 18: Horizontal Gas Piping
An accessible manual shutoff valve must be installed upstream of the furnace gas controls and within 6 feet (1.8 m) of the furnace.
Grounded Joint Union
may be Installed
Inside or Outside Unit.
Manual Shut-off Valve
Gas Pipe
Gas Pipe
Drip Leg
To Gas Supply
Drip Leg
Gas Burners
Gas Valve
Manual Shut-off Valve
On/Off Knob
Inlet Pressure Tap
FIGURE 16: Gas Valve
Plan your gas supply before determining the correct gas pipe entry. Use 90-degree service elbow(s), or short nipples and conventional 90-degree elbow(s) to enter through the cabinet access holes.
Main Regulator Adjustment
Outlet Pressure Tap
GAS PIPING INSTALLATION
Properly sized wrought iron, approved flexible or steel pipe must be used when making gas connections to the unit. If local codes allow the use of a flexible gas appliance connection, always use a new listed con­nector. Do not use a connector that has previously serviced another gas appliance.
Some utility companies or local codes require pipe sizes larger than the minimum sizes listed in these instructions and in the codes. The furnace rating plate and the instructions in this section specify the type of gas approved for this furnace - only use those approved gases. The instal­lation of a drip leg and ground union is required. Refer to Figure 17, "Upflow/Downflow Gas Piping".
The furnace must be isolated from the gas supply piping system by closing its individual external manual shutoff valve during any pressure testing of the gas supply piping system at pressures equal to or less than 1/2 psig (3.5 kPa).
The gas valve body is a very thin casting that cannot take any external pressure. Never apply a pipe wrench to the body of the gas valve when installing piping. A wrench must be placed on the 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 operation and/or the valve to leak.
Gas piping may be connected from either side of the furnace using any of the gas pipe entry on both sides of the furnace. Refer to Figure 14, "Dimensions".
GAS CONVERSION FOR PROPANE (LP)
This furnace is constructed at the factory for natural gas-fired operation, but may be converted to operate on propane (LP) gas by using a fac­tory-supplied LP conversion kit which includes a LP gas valve. Follow the instructions supplied with the LP kit.
LoNOx furnaces requiring propane (LP) gas must have the LoNOx screens removed prior to installation and operation. See propane instructions.
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HIGH ALTITUDE NATURAL GAS ORIFICE CONVERSION
The National Fuel Gas Code requires that gas appliances installed above 2,000 feet elevation have their inputs de-rated by 4% per 1,000 feet above sea level. The modulating furnaces automatically de-rate for altitude by measuring the inducer blower pressure and using that to determine if there is adequate air to support good combustion. If there is not enough combustion air to properly support 100% of the furnace nameplate input rate, the control will reduce the input to the point that there will be good combustion.
The factory gas orifice sizes are based on a ga s heating value of 1030 BTU/Cu.ft., so if your gas value is significantly higher or lower than that, it may be necessary to change to smaller or larger gas orifices.
The chart below shows recommended gas orifice sizes to use at vari­ous altitudes and at various de-ration levels. To use the chart, follow these instructions:
1. Clock the gas meter and calculate the actual input rate using your local gas heating value. See "CALCULATING THE FURNACE INPUT (NATURAL GAS)" in this manual.
2. Divide that input rate by the input rate shown on the furnace rating plate to get the actual de-ration percent.
3. Read down the left-hand “Actual Rate” column to find the closest number to your actual de-ration percent.
4. Read across that row to the column for the elevation at your loca­tion. The number listed there is the orifice size that is proper for your unit.
Example – You have a 100,000 BTU/H furnace installed at an elevation of 6,000 feet. You clock the gas meter and find that the furnace is actu­ally fired at 64,000 BTU/H. Divide 64,000 by 100,000, which gives 0.64 (64%). The closest number to 64% in the left-hand “Actual Rate” col­umn is 65. Read across that row to the column for 6,000 feet elevation, which shows “#43”. You should change from the factory #45 orifices to larger #43 orifices, which will bring the input rate back up to approxi­mately 76,000 BTU/H, which is what it should be for that furnace at 6,000 feet.
Table 5: High Altitude Orifices
Actual Rate
(percent of
nameplate)
100 48 49 49 50 51 51 52
95 47 48 49 50 50 50 51 90 46 47 48 49 49 49 50 85 45 46 47 48 49 49 50 80 45 45 46 47 48 48 49 75 44 45 45 45 47 47 49 70 43 44 44 45 45 45 48 65 42 43 43 44 45 45 47 60 41 42 42 43 44 45 46 55 40 41 41 32 43 43 44 50 39 40 40 40 43 42 42
4,000 5,000 6,000 7,000 8,000 9,000 10,000
84% 80% 76% 72% 68% 64% 60%
Elevation in Feet Above Sea Level
Orifice Drill Size
PROPANE 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. Propane (LP) conversions are required in order for the appliance to satisfactory meet the application. An authorized distributor or dealer must make all gas conversions. In Canada, a certified conversion station or other qualified agency, using factory specified and/or approved parts, must perform the conversion. The installer must take every precaution to insure that the furnace has been converted to the proper gas orifice size when the furnace is installed. Do not attempt to drill out any orifices to obtain the proper orifice size. Drilling out a gas orifice will cause misalignment of the burner flames, causing premature heat exchanger burnout, high levels of carbon monoxide, excessive sooting, a fire hazard, personal injury, property damage and/or death.
SECTION V: ELECTRICAL POWER
ELECTRICAL POWER CONNECTIONS
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, "Ratings & Physical / Electrical Data" in these instructions for specific furnace electrical data.
Table 6: Ratings & Physical / Electrical Data
Input
Max/Min
MBH kW MBH kW CFM 60/30 17.6/8.8 48/24 14.1/7.0 1200 34.0 7.0 80.0 35-65 19-36 20-50 11-28 15 14 165 73.9 80/40 23.5/11.8 64/32 18.8/9.4 1200 34.0 7.5 80.0 40-70 22-39 20-50 11-28 15 14 170 76.7
80/40 23.5/11.8 64/32 18.8/9.4 1600 45.3 10.0 80.0 40-70 22-39 20-50 11-28 15 14 170 76.7
100/50 29.3/14.7 80/40 23.4/11.7 1600 45.3 10.0 80.0 40-70 22-39 20-50 11-28 15 14 170 76.7 100/50 29.3/14.7 80/40 23.4/11.7 2000 56.6 17.0 80.0 35-65 19-36 20-50 11-28 20 12 165 73.9 120/60 33.7/16.9 96/48 28.1/14.1 2000 56.6 17.0 80.0 45-75 25-42 25-55 13-31 20 12 175 79.4
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.
Output
Max/Min
Nominal
Airflow
3
m
/min
Total Unit
Amps
Air Temp. Rise
AFUE
Use copper conductors only.
Air Temp. Rise
Max Input
°F °C °F °C °F °C
Min Input
Max
Over-Current
Protect
Min. wire Size
(awg) @ 75 ft
one way
Max. Outlet
Air Temp
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SUPPLY VOLTAGE CONNECTIONS
Junction Box
Connect ground lead to screw
Electrical Entry
BLK
L1-Hot
Neutral
FIGURE 19: Electrical Wiring
1. Provide a power supply separate from all other circuits. Install overcurrent protection and disconnect switch per local/national electrical codes. The switch should be close to the unit for 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 diagram in this instruction.
2. Remove the screws retaining the wiring box cover. Route the power wiring through the opening in the unit into the junction box with a conduit connector or other proper connection. In the junc­tion box there will be 3 wires, a Black Wire, a White Wire. Connect the power supply as shown on the unit-wiring label on the inside of the blower compartment door or the wiring schematic in this sec­tion. The black furnace lead must be connected to the L1 (hot) wire from the power supply. The white furnace screw must be con­nected to neutral. Connect the power supply ground to the green screw (equipment ground) An alternate wiring method is to use a field provided 2” (5.1 cm) x 4” (10.2 cm) box and cover on the out­side of the furnace. Route the furnace leads into the box using a protective bushing where the wires pass through the furnace panel. After making the wiring connections replace the wiring box cover and screws. Refer to Figure 19, "Electrical Wiring".
3. The furnace's control system requires correct polarity of the power supply and a proper ground connection. Refer to Figure 19, "Elec­trical Wiring"
The power connection leads and wiring box may be relocated to the left side of the furnace. Remove the screws and cut wire tie holding excess wiring. Reposition on the left side of the furnace and fasten using holes provided.
WHT
LOW VOLTAGE CONTROL WIRING CONNECTIONS
Install the field-supplied thermostat by following the instructions that come with the thermostat. With the thermostat set in the OFF position and the main electrical source disconnected, connect the thermostat wiring from the wiring connections on the thermostat to the terminal board on the ignition module, as shown in Figures 20-25, Thermostat Charts. Electronic thermostats may require the common wire to be con­nected as shown in Figure 16, "Gas Valve". Apply strain relief to ther­mostat wires passing through cabinet.
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.
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 contactor.
AIR CONDITIONER CONNECTIONS
This furnace may be used with single-stage or two-stage air condition­ing units.
For Single-Stage A/C - Connect the low voltage wiring as shown in Figures 20, Thermostat Chart.
For Two-Stage A/C - Use a two-stage thermostat, connect the low volt­age wiring as shown in Figures 21, Thermostat Chart.
For Two-Stage A/C using a Single-Stage Thermostat - connect the low voltage wiring as shown in Figures 21, Thermostat Chart.
This furnace control board can control a two-stage A/C using only a sin­gle-stage thermostat. In this case, the furnace control switches between high cool and low cool based on the calculated cooling load.
ZONING OPERATION
This furnace may be used in zoning systems, using a separate after­market zoning control. For use in zoned systems, put the ZONE CON­TROL jumper on the furnace control board in the “YES” position.
HEAT PUMP OPERATION
This furnace may be used in conjunction with a heat pump in dual fuel applications. For heat pump applications, put the HEAT PUMP jumper on the furnace control board in the “YES” position. Connect the low volt­age wiring as shown in Figures 20-25, Thermostat Charts. If a two­stage heat pump is to be used, a two-stage thermostat is required.
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For additional connection diagrams for all UPG equipment refer to “Low Voltage System Wiring” document available online at www.upgnet.com in the Product Catalog Section.
ID MODELS
TM(8,L)M YM(8,L)M
THERMOSTAT
CM(8,L)M
LM(8,L)M
*PP11C70224
Y
Full Stage Compressor
RH 24 – Volt Hot (Heat XFMR)
G
Fan
RC 24 – Volt Hot (Cool XFMR)
W
Full Stage Heat
HM1
Humidistat
External Humidistat
2
(Optional)
Open on Humidity Rise
Clipping Jumper W914 for electric heat on thermostat
is not necessary
MODULATING
FURNACE
MODULATING
FURNACE CONTROL
C
24 – Volt Common
Y1
Single
Stage Compressor
R
24 – Volt Hot
G
Fan
W
Modulating Heat
Y/Y2
Second or Full
Stage Compressor
O
Reversing Valve
Energized in Cool
LO COMP
Single Stage
Compressor (OUT)
HI COMP
Second Stage
Compressor (OUT)
DHUM
Dehumidification-
Open on Humidity Rise
Move HUMIDISTAT
jumper to “YES”
if humidistat is to be used.
SINGLE STAGE SINGLE STAGE
AIR
AIR CONDITIONER
CONDITIONER
1
C
24 – Volt Common
Y
Y
Compressor
Compressor Contactor
2
Part Number:
S1-2HU16700124
Part Numbers:
SAP = Legacy
1
FIGURE 20: Thermostat Chart - Single Stage Air Conditioner – Variable Speed or PSC Modulating Furnace
12 Johnson Controls Unitary Products
THERMOSTAT
THERMOSTAT
368261-UIM-A-0508
ID MODELS
TM(8,L)M YM(8,L)M CM(8,L)M
LM(8,L)M
*DN22U00124
C
24 – Volt Common
Y1
First Stage Compressor
R
24 – Volt Hot
(Heat XFMR)
G
Fan
E/W1
First Stage Heat
W2
Second Stage Heat
R
24 – Volt Hot
(Cool XFMR)
Y2
Second Stage
Compressor
*PP32U70124
C
24 – Volt Common
Y1
First Stage Compressor
R 24 – Volt Hot (Heat XFMR)
G
Fan
E/W1
Emergency Heat
AUX
Auxiliary Heat
R 24 – Volt Hot (Cool XFMR)
Y2
Second Stage
Compressor
MODULATING
FURNACE
MODULATING
FURNACE CONTROL
C
24 – Volt Common
Y1
Single
Stage Compressor
R
24 – Volt Hot
G
Fan
W
Modulating Heat
Y/Y2
Second or Full
Stage Compressor
O
Reversing Valve
Energized in Cool
LO COMP
Single Stage
Compressor (OUT)
HI COMP
Second Stage
Compressor (OUT)
TWO STAGE
AIR
CONDITIONER
1
C
24 – Volt Common
Y1
First Stage Compressor
R
24 – Volt Hot
Y2
Second Stage
Compressor
DHUM
Dehumidification-
Open on Humidity Rise
Move HUMIDISTAT
jumper to “YES”
if humidistat is to be used.
Part Numbers:
SAP = Legacy
1
Connection of the “C”
terminal, 24-volt common
is optional when used with
batteries
Thermostat Installer Setup
1-System Type-must
be set to 6-2 Heat/2 Cool
Multistage Conventional
Thermostat Installer Setup 15-Compressor Protection
-must be set to 5
External Humidistat
2
2
(Optional)
Open on Humidity Rise
Connection of the “C”
terminal, 24-Volt common
is optional when used with
batteries
Thermostat Installer Setup
0170-System Type-must
be set to 8-2 Heat/2 Cool
Multistage Conventional
Part Number:
S1-2HU16700124
FIGURE 21: Thermostat Chart - Two Stage Air Conditioner – Variable Speed or PSC Modulating Furnace
Johnson Controls Unitary Products 13
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THERMOSTAT
ID MODELS
TM(8,L)M YM(8,L)M CM(8,L)M
LM(8,L)M
*PP11C70224
Y
Full Stage Compressor
RH
24 – Volt Hot
(Heat XFMR)
G
Fan
RC 24 – Volt Hot (Cool XFMR)
W
Full Stage Heat
HM1
Humidistat
External Humidistat
2
(Optional)
Open on Humidity Rise
Clipping Jumper W914 for
electric heat on thermostat
is not necessary
MODULATING
FURNACE
MODULATING
FURNACE CONTROL
C
24 – Volt Common
Y1
Single
Stage Compressor
R
24 – Volt Hot
G
Fan
W
Modulating Heat
Y/Y2
Second or Full
Stage Compressor
O
Reversing Valve
Energized in Cool
LO COMP
Single Stage
Compressor (OUT)
HI COMP
Second Stage
Compressor (OUT)
DHUM
Dehumidification-
Open on Humidity Rise
Move HUMIDISTAT
jumper to “YES”
if humidistat is to be used.
TWO STAGE
AIR
CONDITIONER
1
C
24 – Volt Common
Y1
First Stage Compressor
R
24 – Volt Hot
Y2
Second Stage
Compressor
2
Part Number:
S1-2HU16700124
Part Numbers:
SAP = Legacy
1
FIGURE 22: Thermostat Chart - Two Stage Air Conditioner with Single Stage Thermostat – Variable Speed or PSC Modulating Furnace
14 Johnson Controls Unitary Products
368261-UIM-A-0508
THERMOSTAT
*DN22U00124
N/A
THERMOSTAT
*BP21H50124 *BN21H00124 *DP21H40124
*DN21H00124
N/A
THERMOSTAT
*DP32H70124
C
24 – Volt Common
Y1
First Stage Compressor
R
24 – Volt Hot
G
Fan
E
Emergency Heat
W2
Third Stage Heat
O
Reversing Valve
Energized in Cool
L
Malfunction Light
Second Stage Compressor
3
Y2
W1
Second Stage Aux. Heat
External Humidistat
(Optional)
Open on Humidity Rise
ID MODELS
TM(8,L)M YM(8,L)M CM(8,L)M
LM(8,L)M
MODULATING
FURNACE
MODULATING
FURNACE CONTROL
C
24 – Volt Common
Y1
Single
Stage Compressor
R
24 – Volt Hot
G
Fan
W
Modulating Heat
Y/Y2
Second or Full
Stage Compressor
O
Reversing Valve
Energized in Cool
LO COMP
Single Stage
Compressor (OUT)
HI COMP
Second Stage
Compressor (OUT)
DHUM
Dehumidification-
Open on Humidity Rise
OD MODELS
E*R*
E*ZD
E*B*
*RHS
HP*
*HGD
SINGLE STAGE
HEAT PUMP
2
DEMAND DEFROST
CONTROL
C
24 – Volt Common
Y
Compressor
R
24 – Volt Hot
W1/66(out)
Heat
O
Reversing Valve
Energized in Cool
X/L
Malfunction Light
W
Auxiliary Heat
1
Step 1 of Thermostat
Installer / Configuration
Menu must be set to
Heat Pump 1
Step 9 of Thermostat
Installer / Configuration
Menu must be set to
Pump OFF
3
Part Number:
S1-2HU16700124
Move HUMIDISTAT
jumper to “YES”
if humidistat is to be used.
Part Numbers:
SAP = Legacy
2
Part Numbers:
SAP = Legacy
67297 = 031-01975
1
FIGURE 23: Thermostat Chart - Single Stage Heat Pump – Variable Speed or PSC Modulating Furnace
Johnson Controls Unitary Products 15
368261-UIM-A-0508
THERMOSTAT
*DN22U00124
C
24 – Volt Common
Y1
First Stage Compressor
R 24 – Volt Hot (Heat XFMR)
G
Fan
E
Emergency Heat
R
24 – Volt Hot
(Cool XFMR)
O/B
Reversing Valve
L
Malfunction Light
Y2
Second
Stage Compressor
AUX
Auxiliary Heat
THERMOSTAT
*BP21H50124 *BN21H00124 *DP21H40124 *DN21H00124
C
24 – Volt Common
Y1
First Stage Compressor
R
24 – Volt Hot
G
Fan
E
Emergency Heat
O
Reversing Valve
Energized in Cool
L
Malfunction Light
Y2
Second
Stage Compressor
W2
Second Stage Heat
THERMOSTAT
*DP32H70124
C
24 – Volt Common
Y1
First Stage Compressor
R
24 – Volt Hot
G
Fan
E
Emergency Heat
W2
Third Stage Heat
O
Reversing Valve
Energized in Cool
L
Malfunction Light
Y2
Second
Stage Compressor
W1
Second Stage Aux. Heat
External Humidistat
3
(Optional)
Open on Humidity Rise
ID MODELS
TM(8,L)M YM(8,L)M CM(8,L)M LM(8,L)M
MODULATING
FURNACE
MODULATING
FURNACE CONTROL
C
24 – Volt Common
Y1
Single
Stage Compressor
R
24 – Volt Hot
G
Fan
W
Modulating Heat
Y/Y2
Second or Full
Stage Compressor
O
Reversing Valve
Energized in Cool
LO COMP
Single Stage
Compressor (OUT)
HI COMP
Second Stage
Compressor (OUT)
DHUM
Dehumidification-
Open on Humidity Rise
2
Bonnet Sensor
(Optional)
OD MODELS
YZB YMB
H*3
SINGLE STAGE
HEAT PUMP
YORKGUARD VI
CONTROL
C
24 – Volt Common
Y1
Single
Stage Compressor
R
24 – Volt Hot
W1 OUT
First Stage Heat
W2 OUT
Second Stage Heat
Y2 OUT Second
Stage Compressor
O
Reversing Valve
Energized in Cool
X/L
Malfunction Light
Y2
Second
Stage Compressor
W
Auxiliary Heat
BSG
Bonnet Sensor
BS
Bonnet Sensor
1
Thermostat Installer Setup 1-System Type-must be set to 5 – 2 Heat/1 Heat Pump
Thermostat Installer Setup
2-Changeover Valve-must
be set to 0 – O/B terminal
Energized in Cooling
B/O Switch on Thermostat
must be in the O position
Step 1 of Thermostat
Installer / Configuration
Menu must be set to
Heat Pump 1
3
Part Number:
S1-2HU16700124
Move HUMIDISTAT
jumper to “YES”
if humidistat is to be used.
Part Numbers:
SAP = Legacy
FIGURE 24: Thermostat Chart - Single Stage Heat Pump – Variable Speed or PSC Modulating Furnace
Change FFuel jumper
on the heat pump control
to “ON”
Change Hot Heat Pump
jumper on the heat
pump control to “ON” if
Hot Heat Pump
Operation is desired.
2
Part Numbers:
SAP = Legacy
126768 = 031-09137 18395 = 031-01996 340512 = 031-09178
1
16 Johnson Controls Unitary Products
368261-UIM-A-0508
THERMOSTAT
*PP32U70124
C
24 – Volt Common
Y
First Stage Compressor
R 24 – Volt Hot (Heat XFMR)
G
Fan
E
Emergency Heat
RC
24 – Volt Hot
(Cool XFMR)
O/B
Reversing Valve
L
Malfunction Light
Y2
Second
Stage Compressor
AUX
Auxiliary Heat
THERMOSTAT
*DN22H00124
*DP22U70124
C
24 – Volt Common
Y1
First Stage Compressor
R
24 – Volt Hot
G
Fan
W2
Second Stage Aux. Heat
O
Reversing Valve
Energized in Cool
L
Malfunction Light
Y2
Second
Stage Compressor
E/W1
First Stage Aux. Heat
External Humidistat
3
(Optional)
Open on Humidity Rise
ID MODELS
TM(8,L)M YM(8,L)M CM(8,L)M LM(8,L)M
MODULATING
FURNACE
MODULATING
FURNACE CONTROL
C
24 – Volt Common
Y1
Single
Stage Compressor
R
24 – Volt Hot
G
Fan
W
Modulating Heat
Y/Y2
Second or Full
Stage Compressor
O
Reversing Valve
Energized in Cool
LO COMP
Single Stage
Compressor (OUT)
HI COMP
Second Stage
Compressor (OUT)
DHUM
Dehumidification-
Open on Humidity Rise
OD MODELS
YZE
YZH
H*5 H*8
TWO STAGE
HEAT PUMP
2
Bonnet Sensor
(Optional)
YORKGUARD VI
CONTROL
C
24 – Volt Common
Y1
Single
Stage Compressor
R
24 – Volt Hot
W1 OUT
First Stage Heat
W2 OUT
Second Stage Heat
Y2 OUT
Second
Stage Compressor
O
Reversing Valve
Energized in Cool
X/L
Malfunction Light
Y2
Second
Stage Compressor
W
Auxiliary Heat
BSG
Bonnet Sensor
BS
Bonnet Sensor
1
Thermostat Installer Setup
0170-System Type-
must be set to 12
3 Heat/2 Heat Pump
Thermostat Installer Setup
0190-Changeover Valve-
must be set to 0
O/B terminal
Energized in Cooling
Thermostat Installer Setup
0200-Backup Heat Source-
must be set to 1
Heat Pump Backup Heat
Source is Fossil Fuel
Thermostat Installer Setup
0210-External Fossil Fuel
Kit- must be set to 1
Heat Pump Control
is Controlling Heat Pump
Backup Heat
Step 1 of Thermostat
Installer/Configuration
Menu must be set to “HP2”
Selection of GAS/ELEC
switch on thermostat
not necessary
Move HUMIDISTAT
jumper to “YES”
if humidistat is to be used.
Part Numbers:
SAP = Legacy
2
Change FFuel jumper
on the heat pump control
to “ON”
Change Hot Heat Pump
jumper on the heat
pump control to “ON” if
Hot Heat Pump
Operation is desired.
Part Numbers:
SAP = Legacy
126768 = 031-09137 18395 = 031-01996 340512 = 031-09178
1
FIGURE 25: Thermostat Chart - Two Stage Heat Pump – Variable Speed or PSC Modulating Furnace
Johnson Controls Unitary Products 17
368261-UIM-A-0508
)
ACCESSORY CONNECTIONS
The furnace control will allow power-switching control of various acces­sories.
ELECTRONIC AIR CLEANER CONNECTION
Two 1/4” (0.64 cm) spade terminals (EAC and NEUTRAL) for electronic air cleaner connections are located on the control board. The terminals provide 115 VAC (1.0 amp maximum) during circulating blower opera­tion.
HUMIDIFIER CONNECTION
Two 1/4” (0.64 cm) spade terminals (HUM and NEUTRAL) for humidi­fier connections are located on the control board. The terminals provide 115 VAC (1.0 amp maximum) during heating system operation.
A mounting hole is provided on the control panel next to the furnace control board for mounting a humidifier transformer if required.
HUMIDISTAT CONNECTION
For better humidity control during cooling operation, an external humi­distat may be used. When using a external humidistat, put the HUMI­DISTAT jumper in the “YES” position. Connect the low voltage wiring as shown in Figures 20-25, Thermostat Charts.
SECTION VI: TWINNING AND STAGING
Twinning and staging is NOT allowed for modulating furnaces.
SECTION VII: VENT SYSTEM
VENT CONNECTIONS
Figure 26, "Combustion Air Inducer" shows the furnace as it is shipped from the factory. To convert to a horizontal or downflow position, remove the four screws that secure the inducer assembly and rotate 90° being careful not to damage the gasket. Reinstall screws. Remove cap from appropriate vent outlet location on the cabinet cut insulation in cabinet to same size as the hole provided and reinstall cap in the hole in the top panel.
The furnace shall be connected to a type B vent connector, and shall be connected to a type B vent only. The furnace shall not be connected to a chimney flue serving a separate appliance designed to burn solid fuel. Single-wall vent pipe is not allowed.
It is recommended that the appliance is installed in a location where the space temperature is 32 °F (0°C) or higher. If the appliance is installed in a location where the ambient temperature is below 32 °F (0°C), the combustion byproducts could condense causing damage to the appli­ance heat exchanger.
This appliance may be common vented with another gas appliance for residential installations as allowed by the codes and standards listed in these instructions.
VENTING
Category I venting consists of vertically venting one or more appliances in B-vent or B-vent connectors. Type B-vent system extends in a gen­eral vertical direction and does not contain offsets exceeding 45°. A vent system having not more than one 60° offset is permitted.
VENTING INTO AN EXISTING CHIMNEY
This furnace may not be connected to any masonry chimney. However, an existing masonry chimney may be used on as a chase through which the metal vent pipe passes.
FAN-ASSISTED COMBUSTION SYSTEM
This appliance is equipped with an integral mechanical means to draw products of combustion through the heat exchanger.
Ambient Combustion Air Supply
This type installation will draw the air required for combustion from within the space surrounding the appliance and from areas or rooms adjacent to the space surrounding the appliance. This may be from within the space in a non-confined location or it may be brought into the furnace area from outdoors through permanent openings or ducts. A single, properly sized pipe from the furnace vent connector to the out­doors must be provided. For upflow models combustion air is brought into the furnace through the unit top panel opening.
In downflow applications, do not block the combustion air inlet. The furnace must be installed on a coil cabinet or subbase to allow com­bustionair to enter the burner compartment.
COMBUSTION AIR INDUCER
90° 90°
Pressure Switch Tube Routing
FIGURE 26: Combustion Air Inducer
CATEGORY 1 - 450 F. MAX. VENT TEMP.
The venting system must be installed in accordance with Section 5.3, Air for Combustion and Ventilation, of the National Fuel Gas Code Z223.1/NFPA 54 (latest edition), or Sections 7.2, 7.3 or 7.4 of CSA B149.1, National Gas and Propane Codes (latest edition) or applicable provisions of the local building code and these instructions.
Mounting Screw (Remove)
Flue Transition (Do Not Remove
Pressure Switch
Mounting Screw (Remove)
COMBUSTION
AIR
FIGURE 27: Combustion Airflow Path Through The Furnace Casing to
the Burner Compartment
This type of installation requires that the supply air to the appli­ance(s) be of a sufficient amount to support all of the appliance(s) in the area. Operation of a mechanical exhaust, such as an exhaust fan, kitchen ventilation system, clothes dryer or fireplace may cre­ate conditions requiring special attention to avoid unsatisfactory operation of gas appliances. A venting problem or a lack of supply air will result in a hazardous condition, which can cause the appli­ance to soot and generate dangerous levels of CARBON MONOX­IDE, which can lead to serious injury, property damage and / or death.
18 Johnson Controls Unitary Products
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 appli­ances are considered part of the unconfined space, if openings are fur­nished with openings or louvers.
3
A confined space is an area with less than 50 cu.ft (1.42 m
) per 1,000 Btu/hr (0.2928 kW) input rating for all of the appliances installed in that area. The following must be considered to obtain proper air for combus­tion and ventilation in confined spaces.
Combustion Air Source From Outdoors
The blocking effects of louvers, grilles and screens must be given con­sideration in calculating free area. If the free area of a specific louver or grille is not known, refer to Table 7, to estimate free area.
Table 7: Estimated Free Area
Wood or Metal
Louvers or Grilles
Screens+
* Do not use less than 1/4”(0.635 cm) mesh + Free area of louvers and grille varies widely; the installer should follow
louver or grille manufacturer’s instructions.
Wood 20-25%* Metal 60-70% *
1/4” (0.635 cm)
mesh or larger 100%
Dampers, Louvers and Grille s (C anada Only)
1. The free area of a supply air opening shall be calculated by sub-
tracting the blockage area of all fixed louvers grilles or screens from the gross area of the opening.
2. Apertures in a fixed louver, a grille, or screen shall have no dimen-
sion smaller than 0.25” (0.64 cm).
3. A manually operated damper or manually adjustable louvers are
not permitted for use.
4. A automatically operated damper or automatically adjustable lou-
vers shall be interlocked so that the main burner cannot operate unless either the damper or the louver is in the fully open position.
Gas
Attic
Outlet Air (a)
Vent
Soffit Vent
Gable Vent
Ventilated
Attic
Top Above Insulation
Soffit Vent
Gable Vent
Optional Inlet (a)
Ventilated
Top Above Insulation
368261-UIM-A-0508
When a Category I furnace is removed or replaced, the original venting system may no longer be correctly sized to properly vent the attached appliances.
An improperly sized vent system can cause CARBON MONOXIDE to spill into the living space causing personal injury, and or death.
Table 8: Unconfined Space Minimum Area in Square Inch
BTUH Input Rating
60,000
80,000 100,000 120,000
Table 9: Free Area
Minimum Free Area Required for Each Opening
BTUH Input
Rating
60,000
80,000 100,000 120,000
Horizontal Duct
(2,000 BTUH)
30 in 40 in 50 in
60 in 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
Gas Vent
Outlet Air (b)
Minimum Free Area in Square Feet
Required for Each Opening
60 (387 cm
80 (516 cm 100 (645 cm 120 (742 cm
Vertical Duct or
Opening to Outside
(4,000 BTUH)
2
(193 cm2) 15 in2 (97 cm2)
2
(258 cm2) 20 in2 (129 cm2)
2
(322 cm2) 25 in2 (161 cm2)
2
(387 cm2) 30 in2 (193 cm2)
2 2
2 2
Gas Vent
) )
) )
Round Duct
(4,000 BTUH)
5” (13 cm) 5” (13 cm) 6” (15 cm) 7” (18 cm)
Outlet Air (a)
Gas Water Heater
Ventilated
Crawl Space
Furnace
Inlet Air (b)
Gas Water Heater
Furnace
Inlet Air (a)
Inlet Air (b)
Gas
Water
Heater
Furnace
Inlet Air (a)
FIGURE 28: Outside and Ambient Combustion Air
Air Supply Openings and Ducts
1. An opening may be used in lieu of a duct to provide to provide the outside air supply to an appliance unless otherwise permitted by the authority having jurisdiction. The opening shall be located within 12” (30.5 cm) horizontally from, the burner level of the appli­ance. Refer to “COMBUSTION AIR SOURCE FROM OUTDOORS and VENT AND SUPPLY AIR SAFETY CHECK” in these instruc­tions for additional information and safety check procedure.
2. The duct shall be either metal, or a material meeting the class 1 requirements of CAN4-S110 Standard for Air Ducts.
3. The duct shall be least the same cross-sectional area as the free area of the air supply inlet opening to which it connects.
4. The duct shall terminate within 12 in (30.5 cm) above, and within 24 in (61 cm) horizontally from, the burner level of the appliance having the largest input.
5. A square or rectangular shaped duct shall only be used when the required free area of the supply opening is 9 in
2
(58.06 cm2) or larger. When a square or rectangular duct is used, its small dimen­sionshall not be less than 3 in (7.6 cm).
6. An air inlet supply from outdoors shall be equipped with a means to prevent the direct entry of rain and 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
1. Two permanent openings, one within 12 in (30.5 mm) of the top and one within 12 in (30.5 mm) of bottom of the confined space, Two permanent openings, shall communicate directly or by means of ducts with the outdoors, crawl spaces or attic spaces.
Johnson Controls Unitary Products 19
368261-UIM-A-0508
2. One permanent openings, commencing within 12 in (30.5 mm)of the top of the enclosure shall be permitted where the equipment has clearances of at least 1 in (2.54 cm) from the sides and back and 6 in (15.24 cm) from the front of the appliance. The opening shall communicate directly with the outdoors and shall have a min­imum free area of:
a. 1 square in per 3000 Btu per hour (6.45 cm3 per 0.879 kW) of
the total input rating of all equipment located in the enclosure.
b. Not less than the sum of all vent connectors in the confined
space.
3. The duct shall be least the same cross-sectional area as the free area of the air supply inlet opening to which it connects.
4. The blocking effects of louvers, grilles and screens must be given consideration in calculating free area. If the free area of a specific louver or a grille is not known. Refer to Table 7, "Estimated Free Area" to estimate free area.
Ventilated Combustion Air
The ventilated attic space or a crawl space from which the combustion air is taken must comply with the requirements specified in “AIR SOURCE FROM OUTDOORS” in this instruction or in Section 5.3, Air for Combustion and Ventilation of the National Fuel Gas Code, ANSI Z223.1 (latest edition). This type installation requires two properly sized pipes. One brings combustion air from a properly ventilated attic space or crawl space and a second pipe that extends from the furnace vent connection (top right of unit) to the exterior of the building.
Vent and Supply (Outside) Air Safety Check Procedure
For Category I furnaces, vent installations shall be in accordance with Parts 7 and 11 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, and or Section 7 and Appendix B of the CSA B149.1, Natural Gas and Propane Installation Codes, the local building codes, furnace and vent manufacture's instructions.
Multi-story or common venting systems are permitted and must be installed in accordance with the National Fuel Gas Code, ANSI Z223.1/ NFPA 54 and / or the CSA B149.1, Natural Gas and Propane Installa­tion Codes, local codes, and the manufacture's instructions.
Vent connectors serving Category I furnaces shall not be connected into any portion of mechanical draft systems operating under positive pressure.
Horizontal portions of the venting system shall be supported to prevent sagging using hangers or perforated straps and must slope upwards not less than 1/4" per foot (0.635 cm/m) from the furnace to the vent ter­minal.
It is recommended that you follow the venting safety procedure below. This procedure is designed to detect an inadequate ventilation system that can cause the appliances in the area to operate improperly causing unsafe levels of Carbon Monoxide or an unsafe condition to occur.
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 carbon­monxide 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 deficiencies, 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 contin­uously.
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 inadequate 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.
NOTE: An unsafe condition exists when the CO reading exceeds 40 ppm and the draft reading is not in excess of - 0.1 in. W.C. (-25 kPa) with
all of the appliance(s) operating at the same time.
8. Any corrections to the venting system and / or to the supply (outside) air system must be in accorda nce with the National Fuel Gas Code Z223.1 or CAN/CGA B149.1 Natural Gas and Propane Installation Code (latest editions). If the vent system must be resized, follow the appropriate tables in Appendix G of the above codes or for this appliance.
SECTION VIII: START-UP AND ADJUSTMENTS
NOTE: In order that this furnace will operate properly, it is required that all of the startup procedures in this section be followed.
NOx SCREEN REMOVAL (Lo-NOx Models Only)
If the furnace is equipped with NOx screens and is to be used with LP (propane) gas, the screens must be removed prior to start-up.
1. Make sure that the electrical power to the unit is turned off and that the gas supply is turned off at the shut-off valve.
2. Remove the blower compartment and burner compartment access doors.
3. Disconnect the gas supply piping at the union to permit removal of the entire burner and gas control assembly from the vestibule panel. Use the wrench boss on the gas valve when removing or installing the piping.
4. Unplug the igniter from the wire harness. Disconnect the flame sensor wires located on top of the air shield. Unplug the gas valve from the wiring harness.
5. Remove the screws holding the burner assembly to the vestibule panel.
20 Johnson Controls Unitary Products
368261-UIM-A-0508
6. Remove the burner assembly. It should be possible to swing the burner assembly out of the way without disconnecting the remain­ing wires.
7. With the burner assembly out of the way, simply slide the NOx screens out of the heat exchanger tubes and discard the screens.
8. Replace all components in reverse order. Reconnect all wiring.
GAS PIPING LEAK CHECK
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warnings exactly could result in serious injury, death or property damage.
Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life.
Burner ignition may not be satisfactory on first startup due to resid­ual air in the gas line or until gas manifold pressure is adjusted. The ignition control will make three attempts to light before locking out.
It is recommended that when the gas supply is first connected to the furnace, the ground union be loosened until the odor of gas is detected. When gas is detected, immediately tighten the union and check for gas leaks. Allow five minutes for any gas to dissipate before continuing with the startup procedure. Be sure that proper ventilation is available to dilute and carry away any vented gas.
With furnace in operation, check all of the pipe joints, gas valve connec­tions and manual valve connections for leakage using an approved gas detector, a non-corrosive leak detection fluid or other leak detection methods. Take appropriate action to stop any leak. If a leak persists, replace the faulty component.
The furnace and its equipment shutoff valve must be disconnected from the gas supply during any pressure testing of that system at test pres­sures in excess of 1/2 PSI (3.45 kPa).
The furnace must be isolated from the gas supply piping system by closing the equipment shutoff valve during any pressure testing of the gas supply system.
SETUP TEST MODE
During normal operation, the furnace input rate can vary between 50% and 100% of full nameplate input, making it difficult to check for proper operation. To help with the furnace startup process, the control has a TEST MODE available that allows the furnace input rate to stay at a constant input rate. To access this TEST MODE perform the following sequence:
1. With power to the board on and with no thermostat calls (no call for heating, cooling or continuous fan), push and hold the TEST but­ton on the board for one second. The LED on the board will glow red.
2. Release the TEST button. The LED on the board will flash a rapid green signal, indicating that TEST MODE is activated.
3. Turn the thermostat to call for heat (R & W signal).
4. The furnace will light and operate at high (100%) firing rate. T he furnace firing rate should be checked at this level to confirm that the furnace is not overfired or underfired.
5. To run the furnace at minimum rate (50%), press the ERROR but­ton once. The LED will flash one green flash to confirm.
6. To run the furnace at a middle rate (70%), press the ERROR but­ton twice within a five-second period. The LED will flash green two times to confirm.
7. To again operate the furnace at maximum (1 00%) rate, press the ERROR button three times within a five-second period. The LED will flash green three times to confirm.
8. If the thermostat call for heat is removed, the LED will flash a rapid green signal, indicating that the furnace is still in TEST MODE.
9. When startup tests are completed, turning off power to the board will take the furnace out of TEST MODE and will restore normal operation. The furnace will automatically return to normal opera­tion after 150 minutes if power is not cycled.
CALCULATING THE FURNACE INPUT (NATURAL GAS)
NOTE: Burner orifices are sized to provide proper input rate using natu­ral gas with a heating value of 1030 BTU/Ft ing value of your gas is significantly different, it may be necessary to replace the orifices.
NOTE: DO NOT set manifold pressure less than 3.2 in wc or more than
3.8 in wc for natural gas at sea level. If manifold pressure is outside this
range, change main burner orifices.
DO NOT bottom out gas valve regulator adjusting screw. This can result in unregulated manifold pressure and result in excess over­fire and heat exchanger failures.
NOTE: If orifice hole appears damaged or it is suspected to have been redrilled, check orifice hole with a numbered drill bit of correct size. Never redrill an orifice. A burr-free and sqaurely aligned orifice hole is essential for proper flame characteristics.
DO NOT bottom out gas valve regulator adjusting screw. This can result in unregulated manifold pressure and result in excess over­fire and heat exchanger failures.
Verify natural gas input rate by clocking meter.
1. Turn off all other gas appliances and pilots.
2. Run furnace for a minimum of 3 minutes in heating operation.
3. Measure time (in sec) for gas meter to complete 1 revolution and note reading. The 2 cubic feet dial provides a more accurate mea­surement of gas flow.
4. Refer to Table 10, "Gas Rate (CU FT/HR) at Full Input" for cubic feet of gas per hour.
5. Multiply cubic feet per hour by heating valve (BTU/cu ft) to obtain input.
If clocked rate does not match the input rate from the unit nameplate. follow steps in next section to adjust the manifold pressure. Repeat steps 2 - 5 until correct input is achieved.
Be sure to relight any gas appliances that were turned off at the start of this input check.
3
(38.4 MJ/m3). If the heat-
Johnson Controls Unitary Products 21
368261-UIM-A-0508
Table 10: Gas Rate (CU FT/HR) at Full Input
Seconds For 1 Revolution
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
1 Cu Ft 2 Cu Ft 5 Cu Ft 1 Cu Ft 2 Cu Ft 5 Cu Ft
Size of Test Dial
Seconds For 1 Revolution
Size of Test Dial
22 Johnson Controls Unitary Products
ADJUSTMENT OF MANIFOLD GAS PRESSURE
Be sure to relight any gas appliances that were turned off at the start of this input check.
Table 11: Inlet Gas Pressure Range
INLET GAS PRESSURE RANGE
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” (3.24 kPa) W.C.
* The gas line pressure MUST BE
• 7” W.C. (1.74 kPA) for Natural Gas
• 11” W.C. (2.74 kPA) for Propane (LP) Gas
in order to obtain the BTU input specified on the rating plate and/or the nominal manifold pressure specified in these instructions and on the rating plate.
The inlet gas pressure operating range table specifies what the minimum and maximum gas line pressures must be for the furnace to operate safely.
Follow the appropriate section in the instructions below. Refer to Figure 29, "Gas Valve" for a drawing of the locations of the pressure ports on the gas valve.
T urn gas off at the ball valve or gas cock on gas supply line before the gas valve.
1. The manifold pressure must be taken at the port marked OUT PRESS TAP.
2. The inlet gas line pressure must be taken at the port marked IN PRESS TAP.
3. Using a 3/16” allen wrench, remove the plugs from the inlet and outlet pressure ports. Connect a 1/8” UPT barbed hose fitting to each pressure port.
The cap for the pressure regulator must be removed entirely to gain access to the adjustment screw. Loosening or tightening the cap does not adjust the flow of gas.
4. Refer to Figure 29, "Gas Valve" for location of pressure regulator adjustment cap and adjustment screws on main gas valve.
5. Turn gas and electrical supplies on and follow the operating instructions to place the unit back in operation.
6. Adjust manifold pressure by adjusting gas valve regulator screw for the appropriate gas per the following:
TABLE 12:
Nominal Manifold Pressure
NOMINAL MANIFOLD PRESSURE
Natural Gas (Max) 3.5" w.c. (0.87 kPa)
Natural Gas (Min) 0.9" w.c. (0.22 kPa)
Propane (LP) Gas (Max) 10.0" w.c. (2.49 kPa)
Propane (LP) Gas (Min) 2.5" w.c. (0.62 kPa)
368261-UIM-A-0508
On/Off Knob
Inlet Pressure Tap
FIGURE 29: Gas Valve
If gas valve regulator is turned in (clockwise), manifold pressure is increased. If screw is turned out (counterclockwise), manifold pres­sure will decrease.
7. After the manifold pressure has been adjusted, re-calculate the furnace input to make sure you have not exceeded the specified input on the rating plate. Refer to "CALCULATING THE FURNACE INPUT (NATURAL GAS)".
8. Once the correct BTU (kW) input has been established, turn the gas valve to OFF and turn the electrical supply switch to OFF; then remove the flexible tubing and fittings from the gas valve pressure tap and the pressure reference hose from the burner box and replace the pressure tap plugs. Replace the burner box front cover (if it was removed) and place the pressure reference hose back on the gas valve.
9. Turn the electrical and gas supplies back on, and with the burners in operation, check for gas leakage around the gas valve pressure port for leakage using an approved gas detector, a non-corrosive leak detection fluid, or other leak detection methods.
Main Regulator Adjustment
Outlet Pressure Tap
ADJUSTMENT OF TEMPERATURE RISE
The temperature rise, or temperature difference between the return air and the supply (heated) air from the furnace, must be within the range shown on the furnace rating plate and within the application limitations shown in Table 6, "Ratings & Physical / Electrical Data"
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 premature heat exchanger failure, high levels of Carbon Monoxide, a fire hazard, personal injury, property damage, and/or death.
After about 5 minutes of operation, determine the furnace temperature rise. Take temperature readings of both the return air and the heated air in the ducts about six feet away from the furnace, where they will not be affected by radiant heat. Increase or decrease the temperature rise by changing the ATR jumper on the furnace control board. The jumper is factory-set to deliver an air temperature rise near the midpoint of the nameplate temperature rise range. If more air is desired (lower temper­ature rise), move the jumper to the -10 position. If less air is desired (higher temperature rise), move the jumper to the +10 position.
Do not move the motor wires to different positions on the furnace control board!
Johnson Controls Unitary Products 23
368261-UIM-A-0508
ADJUSTMENT OF FAN CONTROL SETTINGS
Cooling - The airflow delivered by the furnace during cooling operation can be adjusted to match the cooling capacity of the A/C condensing unit. This is done by moving the COOL jumper on the control board to give the desired airflow.
Do not move the motor wires to different positions on the furnace control board!
The jumper has four positions, which will deliver sufficient airflow in cooling mode for the cooling capacities shown in the table below. The CFM delivery on each jumper position is shown in Table13.
TABLE 13:
Cooling Airflow - A/C Capacity in Tons
Models
ABCD
Jumper Position
60/1200 3 2-1/2 2 1-1/2 80/1200 3 2-1/2 2 1-1/2
80/1600 4 3-1/2 3 2-1/2 100/1600 4 3-1/2 3 2-1/2 100/2000 5 4 3-1/2 3 120/2000 5 4 3-1/2 3
HUMIDIFIER TERMINALS
BLUE
120VAC 120VAC
BLACK
XFORMER
BLOWER
NEUTRAL
NEUTRAL
BLOWER
WHITE
XFORMER
GROUND
BLOWER
BLOWER
YELLOW
RED
BLOWER
HOT
HUMIDIFIER
NEUTRAL
Continuous Fan Operation - The airflow delivered by the furnace dur­ing continuous fan operation can be adjusted as desired. This is done my moving the FAN jumper on the control board to give the desired air­flow.
Do not move the motor wires to different positions on the furnace control board!
The jumper has three positions. The "A" position delivers maximum air­flow, 100% of the blower capacity. Position "B" delivers approximately 70% of the blower capacity. And Position "C" delivers minimum airflow, approximately 40% of the blower capacity.
HOT
INDUCER
NEUTRAL
IGNITER
HOT
NEUTRAL
EAC TERMINALS
FLAME ROD
HOT
EAC
EAC
NEUTRAL
ZONE
CONTROL
ZONING JUMPER
FLAME VOLTAGE
EXT
YES
NO
PRESSURE
SENSOR
HEAT PUMP JUMPER
24VAC
MODULATE COIL
GAS VALVE
PRIMARY LIMIT
AUX LIMIT
AIR
DIAGNOSTIC LIGHT
TEMP
SW
SENSOR
LOW VOLTAGE TERMINALS
FIGURE 30: Furnace Control Board
SECTION IX: SAFETY CONTROLS
CONTROL CIRCUIT FUSE
A 3-amp fuse is provided on the control circuit board to pr otect the 24­volt transformer from overload caused by control circuit wiring errors. This is an ATO 3, automotive type fuse and is located on the control board.
BLOWER DOOR SAFETY SWITCH
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.
A-COIL
TEMP
H
MH
COOL
ML L
LMH
CONT FAN
ATR
C
G
LAST ERROR BUTTON
SENSOR
COOLING SPEED JUMPER
CONTINUOUS
+10F
FAN SPEED
NOM
-10F
JUMPER
TEST
TEST
BUTTON
BUTTON
ERROR
BUTTON
LO COMP
HI COMP
ID PLUG
Y1
O
DHUM
HUMIDISTAT JUMPER
HUMIDISTAT
Y/Y2
W
HEAT PUMP
YES NO
YES NO
R
Main power to the unit must still be interrupted at the main power disconnect switch before any service or repair work is to be done to the unit. Do not rely upon the interlock switch as a main power dis­connect. Blower and burner must never be operated without the blower panel in place.
ROLLOUT SWITCH CONTROLS
These controls are mounted on the burner assembly. If the temperature in the burner area exceeds its set point, the ignition control and the gas valve are de-energized. The operation of this control indicates a mal­function in the combustion air blower, heat exchanger or a blocked vent pipe connection. Corrective action is required. These are manual reset controls that must be reset before operation can continue.
24 Johnson Controls Unitary Products
368261-UIM-A-0508
PRESSURE CONTROLS
Pressure Sensor - This furnace is equipped with a pressure sensor in the burner compartment near the combustion blower. This sensor mon­itors combustion airflow through furnace and piping systems. If any of the conditions listed below are detected by the pressure sensor, the control board will prevent a hazardous condition from occurring by speeding up the combustion blower motor in order to maintain ade­quate combustion airflow. If the combustion blower is already turning at full speed, the furnace control will then start reducing the input to the furnace in order to maintain proper combustion with the amount of com­bustion airflow available. If there is not enough combustion air available to give proper combustion even at the minimum input rate (50%), the control will close the gas valve and shut off the burners. The sensor will detect the following conditions.
1. Blockage of vent piping or vent terminal
2. Failure of combustion air blower motor or blower wheel. Pressure Switch - This furnace is equipped with a pressure switch
mounted on the furnace vestibule panel. This switch monitors the flow through the vent system. The switch will close at the beginning of each cycle when adequate combustion airflow is established. However, this switch may be open under certain conditions when the burners are lit. The pressure sensor is the primary flow sensor.
LIMIT CONTROLS
Limit Switch - This furnace is equipped with a high temperature limit control mounted to the left side of the furnace vestibule panel. This limit switch will open and shut off gas to the burners if it detects excessive air temperature in the furnace, which can be caused by any of the following conditions:
1. Dirty filter
2. Failure of the circulating blower motor or wheel
3. Too many supply or return registers closed or blocked. Temperature Sensor - This furnace is also equipped with a tempera-
ture sensor mounted to the left side of the vestibule panel, near the limit switch. This sensor monitors the temperature of the air being supplied to the home. If the sensor detects air temperature higher than normal, the furnace control will first speed up the circulating blower motor in order to try to increase the amount of airflow being delivered, thereby reducing the air temperature. If the blower motor is already turning at full speed, the control will then start reducing the input to the furnace to try to reduce the air temperature. If the supply air temperature is too high even at the minimum input rate (50%), the control will close the gas valve and shut off the furnace.
SECTION X: NORMAL OPERATION AND DIAGNOSTICS
NORMAL OPERATION SEQUENCE
The furnace control calculates the optimum firing rate each time the wall thermostat R and W contacts close or open (at the beginning and at the end of each call for heat) based on information from the thermo­stat and past demand. UNLIKE CONVENTIONAL SYSTEMS, THE WALL THERMOSTAT DOES NOT SIMPLY TURN THE FURNACE ON AND OFF. THE FURNACE CONTROL CALCULATES THE DEMAND AND MAY CONTINUE TO FIRE THE FURNACE DURING PORTIONS OF THE THERMOSTAT "OFF" CYCLE.
When the wall thermostat R and W contacts close, indicating a call for heat, the following sequence occurs:
1. The inducer is energized and ramps up its speed until airflow is proven by the pressure switch and by the pressure sensor on the control board.
2. The hot surface ignitor is energized.
3. After a 17-20 second igniter heatup, the gas valve opens and the burners light.
4. When the control senses that flame is present, the circulating
blower starts at low speed.
5. The furnace fires at 70% of full rate for 30-45 seconds, then drops to the minimum (50%) firing rate.
6. The firing rate is automatically adjusted to meet demand, increas­ing gradually to maximum (100%) firing rate if the thermostat is not satisfied within a defined time.
7. When the thermostat R and W contacts open (thermostat is satis­fied) the furnace control recalculates the demand and a new firing rate.
A. If demand exceeds the minimum firing rate, the burners will
continue to fire at a recalculated reduced firing rate, decreas­ing if the thermostat remains off for a defined time.
b. If demand does not exceed the minimum firing rate, the burn-
ers will shut off immediately.
8. After the burners shut off, the circulating blower will continue to run until the temperature sensor detects that the supply air tempera­ture has dropped to the desired level, which should take from 30 to 90 seconds.
FURNACE CONTROL DIAGNOSTICS
This furnace has built-in self-diagnostic capability. If a system problem occurs, a flashing LED shows a fault code. The LED can flash red, green or amber to indicate various conditions. The LED is located on the furnace control board and can be seen through the clear view port in the lower door of the furnace. To indicate an error condition, the LED will turn on for 1/4 second and off for 1/4 second. The pattern will be repeated the number of times equal to the flash code. For instance, a "six flash code" will be indicated by the LED turning on and off six times. There will be a two second off period between each set of flashes. The flash codes and an indication of their likely causes are listed below:
STEADY OFF - No 24V power to board. Check the 24 volt control cir­cuit fuse on the board. Check the circuit breaker or fuse on the 115 volt supply power to the furnace. Check that the 24 volt transformer.
One Green Flash - Normal Operation with no call for heat. Two Green Flashes - Indicator for "No error codes in memory". See
Diagnostic Fault Code Storage and Retrieval section below. Three Green Flashes - Indicator for "Error codes cleared from mem-
ory". See Diagnostic Fault Code Storage and Retrieval section below. Rapid Green Flash - Control is in "Factory Speedup" mode. This mode
is used only during factory run-testing of the furnace. To stop this mode, cycle power to the furnace off and then back on.
One Amber Flash - Normal operation with call for cooling. Two Amber Flashes - Normal operation with call for heat. Three Amber flashes - Normal operation, burner is on at end of heat-
ing cycle after wall thermostat has been satisfied. Four Amber Flashes - Heating capacity is reduced due to restriction in
the circulating air system. Check for dirty filter or closed registers. Five Amber Flashes - Heating capacity is reduced due to restriction in
the combustion air or vent system. Check for blocked vent/air pipe or clogged condensate drain. Above 4,000 feet altitude, this may also indi­cate automatic, normal derating for altitude. See page 7 for additional high altitude information.
Six Amber Flashes - (Heat Pump applications only) Normal operation with call for heat pump heating.
Rapid Amber Flash - Low flame sense current. Check for dirty or mis­located flame sensor rod.
One Red Flash - Flame is present with no power being supplied to gas valve. This can be caused by a gas valve that is slow to close or that leaks gas through to the burners.
Two Red Flashes - Stuck closed pressure switch. The con trol conf irm s that the pressure switch contacts are open at the beginning of each cycle. This could be caused by a faulty pressure switch or by mis-wiring of the pressure switch.
Johnson Controls Unitary Products 25
368261-UIM-A-0508
Three Red Flashes - Stuck open pressure switch. This indicates that the pressure switch is open when it should be closed. This could be caused by a faulty combustion air blower, blocked vent pipe, blocked air intake pipe, blocked condensate drain, faulty pressure switch hose or a faulty pressure switch.
Four Red Flashes - High limit switch open or 24 volt fuse is open. This may be caused by a dirty air filter, improperly sized duct system, faulty blower motor, restricted circulating airflow or an open fuse on the con­trol board.
Five Red Flashes - Rollout switch or auxiliary limit switch open. Check the rollout switch on the side of the burner box. It is a manual reset switch. To reset, push the small button in the center of the switch. If it cannot be reset or if the switch trips again, contact a qualified service­man. Check the limit switch mounted in the combustion air blower hous­ing.
Six Red Flashes - Current failure on modulating gas valve. Seven Red Flashes - Lockout due to no ignition. The control will try
three times for ignition. If flame cannot be established in three tries, the control will lockout for one hour and then will try again to light. Check gas supply, ignitor, gas valve, flame sensor.
Eight Red Flashes - Lockout due to too many flame recycles. This flash code occurs if flame is lost five times during a single heating cycle. This could be caused by a faulty gas valve, low gas pressure, or dirty flame sensor. The control will lock out for one hour and then will try again.
Nine Red Flashes - Reversed line polarity or improper grounding. Check polarity of the incoming power to the furnace. Check the ground­ing of the furnace, including the transformer ground and the L1 and neutral connections.
Ten Red Flashes - Gas valve circuit shorted. Check gas valve wiring. If correct, replace gas valve.
Eleven Red Flashes - Main blower failure - This flash code occurs when the main limit opens and fails to reclose within five minutes, indi­cating that the blower motor or blower wheel has failed.
Twelve Red Flashes - ID plug is not present or not connected properly, check for loose plug or loose wires in plug.
Steady On Red - Control fault has been detected or there is 24 volts present without 115 volts. Check that there is 24 volts and 115 volts being supplied to the board. If so, then the board should be replaced.
IGNITION CONTROL FLAME SENSE LEVELS
Normal flame sense current is approximately
3.7 microamps DC (µa)
Low flame signal warning starts at 1.5 microamps.
Low flame signal control lockout point is
0.1 microamps DC (µa)
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. Only a qualified service technician should use this feature.
The control stores up to five separate error codes. 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 button, 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.
T o 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. T o clear the memory , push the LAST ERROR button and hold it for more than five seconds. The LED will flash three green flashes when the memory has been cleared, then will resume the normal slow green flash after a five-second pause.
26 Johnson Controls Unitary Products
SECTION XI: REPLACEMENT PARTS LIST
DESCRIPTION
MOTOR
MOTOR, DIRECT DRIVE BLOWER BLOWER, COMBUSTION
ELECTRICAL
CAPACITOR, RUN SWITCH, LIMIT CONTROL, FURNACE
IGNITER SENSOR, FLAME SWITCH, PRESSURE SWITCH, DOOR
TRANSFORMER VALVE, GAS CONTROL, TEMPERATURE SENSOR, PRESSURE SENSOR, THERMISTOR
AIR MOVING
HOUSING, BLOWER WHEEL, BLOWER
FABRICATED PARTS
BAFFLE, FLUE BURNER, MAIN GAS BRACKET, IGNITER SHELF, BLOWER RAIL, BLOWER (2 Req’d)
368261-UIM-A-0508
DESCRIPTION
FABRICATED PARTS Continued
BRACKET, BLOWER TRACK (2 Req’d) HEAT EXCHANGER ASS’Y MANIFOLD, GAS PAN, BOTTOM PANEL, TOP PANEL, DOOR (2 Req’d)
VENT PAN, COMBUSTION (w/Gasket) PANEL, BLOCKOFF
LO-NOX SCREEN (L-Models Only)
MISCELLANEOUS
ORIFICE, BURNER (Natural #45) SIGHT GLASS, OVAL (2 Req’d) GASKET, FOAM (Door) (1.5 ft req’d) GASKET, INTAKE PAN PLUG, VENT HOLE BRACKET, DOOR WIRING HARNESS FERRULE (3 Req’d) GROMMET (3 Req’d)
MOTOR MOUNT
HOSE ASSY, VACUUM PLUG, ID (Control Board) KNOB, QUARTER TURN (4 Req’d) UNION DIAGRAM, WIRING
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 www.source1parts.com for the following information:
1. Search for a part or browse the catalog.
2. Find a dealer or distributor.
3. Customer Service contact information. a. Click on the “Brand Links” button
b. Click on the “Customer Service” button
• You can contact us by mail. Just send a written request to:
Johnson Controls Unitary Products
Consumer Relations
5005 York Drive
Norman, OK 73069
Johnson Controls Unitary Products 27
SECTION XII: WIRING DIAGRAM
FIGURE 31: Wiring Diagram Subject to change without notice. Printed in U.S.A. 368261-UIM-A-0508
Copyright © 2008 by Johnson Controls, Inc. All rights reserved. Supersedes: Nothing
Johnson Controls Unitary Products
5005 York Drive
Norman, OK 73069
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