Johnson Controls MG9S*MP Installation Manual

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EFFICIENCY RATING CERTIFIED

ISO 9001

Certified Quality

Management System

MANUFACTURED HOUSING OR MODULAR

INSTALLATION MANUAL

HOME GAS FURNACE

MODELS: MG9S*MP - 33” Models –

(95.5% AFUE Single Stage Multi-position)

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

CONDENSATE PIPING AND FURNACE

VENTING CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Duct Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Attachment to Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Combustible Floor Base Accessory . . . . . . . . . . . . . . . . . . . . . . . 6

Mobile Home Filter Frame Accessories . . . . . . . . . . . . . . . . . . . . 6

Blend Air Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Blend Air Installation (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Vertical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Coil Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

PC Series Upflow Coil Installation . . . . . . . . . . . . . . . . . . . . . . . . 8

Combustible Floor Base Accessory . . . . . . . . . . . . . . . . . . . . . . . 8

Downflow Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Dimensions (Upflow configuration shown) . . . . . . . . . . . . . . . . . 9

Side Return Cutout Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Upflow/Downflow Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Line Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Single Stage Heat Thermostat Connections . . . . . . . . . . . . . . . 12

Accessory Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Shipped in Downflow Configuration

LIST OF SECTIONS

LIST OF FIGURES

COMBUSTION AIR and VENT SYSTEM . . . . . . . . . . . . . . . . . 17

START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . 23

SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

NORMAL OPERATION AND DIAGNOSTICS . . . . . . . . . . . . . 29

REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . 31

REPLACEMENT PART CONTACT INFORMATION . . . . . . . . 31

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Typical. Condensate drain, vertical in stallation . . . . . . . . . . . . . 13

Typical. Combustion Pipe Drain Tee . . . . . . . . . . . . . . . . . . . . . 14

Upflow Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Downflow Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Home Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Termination Configuration - 2 Pipe . . . . . . . . . . . . . . . . . . . . . . 20

Termination Configuration - 2 Pipe Basement . . . . . . . . . . . . . 20

Double Horizontal Combustion Air Intake

and Vent Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Double Vertical Combustion Air Intake

and Vent Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Direct Vent Air Intake Connection and Vent Connection . . . . . . 21

Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . 22

Attic and Crawl Space Combustion Air Termination . . . . . . . . . 23

Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Furnace Control Event Schedule . . . . . . . . . . . . . . . . . . . . . . . 31

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

LIST OF TABLES

Unit Clearances to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . 4

Coil Projection Dimensions - PC Series Coils . . . . . . . . . . . . . . . 8

Cabinet and Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Recommended Filter Sizes (High Velocity 600 FPM) . . . . . . . . .9

Nominal Manifold Pressure - High Fire . . . . . . . . . . . . . . . . . . . 11

Ratings & Physical / Electrical Data . . . . . . . . . . . . . . . . . . . . . 12

Maximum Equivalent Pipe Length . . . . . . . . . . . . . . . . . . . . . . . 17

Elbow Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Equivalent Length of Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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 downflow applications and may be converted for upflow applications.

Combustion Air Intake and Vent Connection

Size at Furnace (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Unconfined Space Minimum Area in Square Inch . . . . . . . . . . . 21

Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Gas Rate (CU FT/HR) at Full Input . . . . . . . . . . . . . . . . . . . . . . 25

Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Blower Performance CFM - Any Position (Without Filter) . . . . . 28

These furnaces are designed for residential installation in a basement, closet, alcove, attic, recreation room or garage applications. All units are factory assembled, wired and tested to assure safe dependable and economical installation and operation.

These units are Category IV listed and may not be common vented with another gas appliance as allowed by the National Fuel Gas Code.

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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 resul t in minor 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 qualified cont ractor, installer or service agency should

install this product.

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, "COMBUSTION AIR and VENT SYSTEM" 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 may also be handled by duct(s) sealed to the furnace casing and terminating outside the space containing the furnace. The return air duct system is not required by the furnace manufacturer provided the combustion air and vent system have been installed and maintained as a Two Pipe Sealed Combustion Air System and provided a return air duct system and return air plenum are not required by state, local, or regional codes.

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;

It is also used to

• 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 Manufactured (Mobile) Home, 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.

12. When moving or handling this furnace prior to installation, always leave the doors on the furnace to provide support and to prevent damage or warping of the cabinet. When lifting the furnace by the cabinet, support the ends of the furnace rather than lifting by the cabinet flanges at the return air openings (bottom or sides) or supply air opening.

13. When lifting the furnace, it is acceptable to use the primary heat exchanger tubes as a lifting point provided that the tubes are lifted at the front of the heat exchangers where attached to the vestibule panel. Do not use the top return bend of the heat exchangers as lifting points as the tubes may shift out of position or their location brackets/baffles.

14. Manufactured (Mobile) Home Installation: This appliance must be installed in a two-pipe (direct vent) configuration. The combustion air pipe must terminate in the same atmospheric zone, external to the building.

15. Modular Home Installations: A (two pipe) direct vent configuration. This configuration has a combustion air pipe and the vent pipe that terminate in the same atmospheric zone, external to the building, Refer to Figures 26 or 27 for combustion air and vent terminations.

16. Modular Home Definition: Factory-built home constructed to the state, local, or regional code where the house will be located. The home is transported in one or more modules and joined at the home site.

17. Mobile Home Definition: Factory-built home constructed, transported and installed under the federal building code administered by the U.S. Department of Housing and Urban Development (HUD Code), rather than to building codes at their destination. The home is built, transported, installed on a non-removable chassis.

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.

• A manufactured (mobile) home installation must conform with Manufactured Home Construction and Safety Standard, Title 24 CFR, Part 3280, or when such standard is not applicable, the standard for Manufactured Home Installations (Manufactured Home Sites, Communities, and Set-ups) ANSI/NCS A225.1, and /or the Canadian Standard for CAN/CSA Z240 MH, Series M92 Mobile Homes. Furnaces have been certified to the latest edition of standard ANSI Z21-47 • CSA 2.3.

• 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 12. The plenum must be installed according to the instructions.

• Provide clearances from combustible materials as listed under Clearances to Combustibles in Table 1.

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• Provide clearances for servicing ensuring that service access is allowed for both the burners and blower.

• These models ARE

HUD Approved Modular Home 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.

• 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.

CSA listed or approved for installation into a

or a Manufactured (Mobile)

COMBUSTION AIR QUALITY (LIST OF CONTAMINANTS)

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.

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.

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

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.

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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 local 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 possible 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.

FURNACE LOCATION AND CLEARANCES

The furnace shall be located using the following guidelines:

1. Where a minimum amount of air intake/vent piping and elbows will be required.

2. As centralized with the air distribution as possible.

3. Where adequate combustion air will be available (particularly when the appliance is not using outdoor combustion air).

4. Where it will not interfere with proper air circulation in the confined space.

5. Where the outdoor vent terminal will not be blocked or restricted. Refer to “VENT CLEARANCES” located in SECTION VII of these instructions. These minimum clearances must be maintained in the installation.

6. Where the unit will be installed in a level position with no more than 1/4” (6.4 mm) slope side-to-side and front-to-back to provide proper condensate drainage.

Installation in freezing temperatures:

1. Furnace shall be installed in an area where ventilation facilities provide for safe limits of ambient temperature under normal operating conditions. Ambient temperatures must not fall below 32°F (0°C) unless the condensate system is protected from freezing.

Improper installation in an ambient below 32ºF (0.0° C) could create a hazard, resulting in damage, injury or death.

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.

3. If this furnace is installed in an unconditioned space and an extended power failure occurs, there will be potential damage to the internal components. Following a power failure situation, do not operate the unit until inspection and repairs are performed.

Liquid anti-freeze will cause damage to internal plastic parts of this furnace. D O NOT attempt to winterize the furnace using liquid

anti-freeze.

Clearances for access/service:

Ample clearances should be provided to permit easy access to the unit. The following minimum clearances are recommended:

1. Twenty-four (24) inches (61 cm) between the front of the furnace and an adjacent wall or another appliance, when access is required for servicing and cleaning.

2. Eighteen (18) inches (46 cm) at the side where access is required for passage to the front when servicing or for inspection or 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.

Table 1:

Unit Clearances to Combustibles

Application Upflow Downflow

Top 1" 0" Vent 0" 0" Rear 0" 0" Side 0" 0"

Front* 0" 0"

Floor Combustible

Closet Yes Yes

Line Contact No No

1. For combustible floors only when used with special sub-base. * - 24" clearance in front and 18" on side recommended for service access. All furnaces approved for alcove installation.

Combustible

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Factory installed

For duct attachment, if needed.

Tie down perforated strap

Attach to wall stud with a nail or screw

Attach to Furnace with screw

Vent Pipe

Vent Drain

WALL

SUPPLY AIR DUCT

Combustion Air Pipe

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. For Manufactured (Mobile) Home and Modular Home Return Duct System Installations: The return air duct and the return air plenum are not required by the furnace manufacturer provided the combustion air and vent system have been installed and maintained as a Two Pipe Sealed Combustion Air System and provided a return air duct and plenum are not required by state, local or regional codes.

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.

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.

On all installations without a coil, a removable access panel is recommended in the outlet duct such that smoke or reflected light would be observable inside the casing to indicate the presence of leaks in the heat exchanger. This access cover shall be attached in such a manner as to prevent leaks.

DUCT FLANGES

Four flanges are provided to attach ductwork to the furnace. These flanges are rotated down for shipment. In order to use the flanges, remove the screw holding an individual flange, rotate the flange so it is in the upward position and reinstall the screw then repeat this for all 4 flanges.

If the flanges are not used, they must remain in the rotated down position as shipped.

FIGURE 1: Duct Attachment

DUCTWORK INSTALLATION AND SUPPLY PLENUM CONNECTION - UPFLOW

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.

Attachment to Structure

A furnace for installation in a manufactured (mobile) home must be securely attached to the building structure. The perforated strap supplied with the furnace may be used for that purpose. Refer to Figure 2.

The duct system must be properly sized to obtain the correct airflow for the furnace size that is being installed.

Refer to T able 6 or the furnace rating plate for the correct rise range and static pressures. If the ducts are undersized, the result will be high duct static 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.

Johnson Controls Unitary Products 5

FIGURE 2: Attachment to Structure

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420705-UIM-C-0310

FURNACE

WARM AIR PLENUM WITH 1” FLANGES

FIBERGLASS INSULATION

FIBERGLASS TAPE UNDER FLANGE

COMBUSTIBLE FLOOR BASE ACCESSORY

FLOOR BASE AND DUCTWORK INSTALLATION DOWNFLOW

Installations on combustible material or directly on any floors must use a combustible floor base shown in Figure 3. 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.

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.

DOWNFLOW RETURN PLEN UM CONN ECTION

The return air duct and the return air plenum are not required by the furnace manufacturer provided the combustion air and vent system have been installed and maintained as a Two Pipe Sealed Combustion Air System and provided a return air duct and plenum are not required by state, local or regional codes.

• If a return air duct system and return plenum are required by state, local or regional codes then the return plenum may be connected to the furnace inlet and must terminate outside the space containing the furnace. The external air filter accessory shown in Figure 4 is designed and recommended for use inside the return plenum. Attach the return plenum to the furnace inlet duct flanges. This is typically through the use of S cleat material when a metal plenum is used. Installations where a return air duct system is utilized, the use of a listed flexible duct connector is recommended. The connection of the plenum to the furnace and all the ducts connecting to the plenum must 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. 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 must 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 and in Table 3.

• If the return air duct and plenum are not required by state, local or regional codes then the filter can be attached to the top of the furnace as shown in Figure 6.

When replacing an existing the furnace, if a return air plenum is used and 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 a return duct mounted filter rack or filter grille is being used, see the instructions provided with that accessory for proper hole cut size.

FIGURE 3: 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.

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.

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.

FIGURE 4: Mobile Home Filter Frame Accessories

6 Johnson Controls Unitary Products

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420705-UIM-C-0310

Screw x2

Blend Air Bracket

18” Max.

9155 Series Filter Kit

Gas Furnace

Blend Air Bracket (3500-5241) mounted to wall next to furnace

Blend Air Damper

Coil

Cabinet

Run flexible duct tubing as close to the wall as possible

UPFLOW

DOWNFLOW

Furnace

Alternate Flange Location (Used for downflow installations)

Factory Flange

Location(Used for

upflow installations)

BLEND AIR INSTALLATIONS

Upflow

This bracket is to be used only for Alcove application on the 90% Gas Furnaces. It helps in installation of Blend Air Damper Tube close to the furnace. It is recommended that the Blend Air be installed with the help of this bracket as close to the furnace as possible. The Blend Air Bracket Assembly should be installed no higher than 18 inches above the furnace. See Figure 6.

FIGURE 5: Blend Air Bracket

Downflow

This bracket is to be used only for Alcove application on the 95% Gas Furnaces. It helps in installation of Blend Air Damper Tube close to the furnace. It is recommended that the Blend Air be installed with the help of this bracket as close to the furnace as possible. The Blend Air Bracket Assembly should be installed as close to the return air grille as possible. See Figure 5.

COIL INSTALLATION

COIL/FURNACE ASSEMBLY - MC/FC/PC SERIES COILS

FIGURE 7: 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 7 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 8.

FIGURE 6: Blend Air Installation (Optional)

Johnson Controls Unitary Products 7

FIGURE 8: Coil Flange

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Flexible Duct Collar

Do not drill or Screw this flange

Field Fabricated Ductwork

Upflow Coil

Upflow Furnace

Secondary

Drain

Primary

Drain

(Min)

Alternate

Drain Location

FURNACE

WARM AIR PLENUM WITH 1” FLANGES

FIBERGLASS INSULATION

FIBERGLASS TAPE UNDER FLANGE

COMBUSTIBLE FLOOR BASE ACCESSORY

LEFT SIDE VENT RIGHT SIDE VENT

Rotate vent blower 90° either way

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 9.

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 9.

DOWNFLOW DUCT CONNECTORS

FIGURE 9: 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

Dimension “C” should be at least 2/3 of dimension “D”. See Figure 9.

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 6.

FIGURE 10: Combustible Floor Base Accessory

DOWNFLOW APPLICATION

Furnace is shipped in downflow configuration. It may be necessary to rotate the vent blower 180° left so that the vent pipe passes through the side of the furnace casing. See Figure 11.

FIGURE 11: Downflow Venting

8 Johnson Controls Unitary Products

Page 9

FIGURE 12: Dimensions (Upflow configuration shown)

FRONT

LEFT SIDE

Combustion Air Inlet

Condensate Drain (Downflow)

Vent Outlet

Thermostat Wiring

28.5”

Gas Pipe Entry

Electrical Entry

Condensate Drain

Thermostat Wiring

RIGHT SIDE

Vent Outlet

Condensate Drain (Downflow)

14”

1”

1.5”

23”

Combustion Air Inlet

Gas Pipe Entry

Electrical Entry

Condensate Drain

Optional Return Air Cutout (Either side)

29.5”

(For Cladded door add appoximately an additional .75”)

SUPPLY END

.56”

20”

3”

23.8”

.56”

Combustion Air Inlet

Vent Outlet

RETURN END

24.25”

NOTICE

Front of Furnace

Corner Markings

Side of Furnace

Table 3: Cabinet and Duct Dimensions

420705-UIM-C-0310

BTUH (kW)

Input

Nominal

CFM (m

/min)

Cabinet

60 (17.6) 1200 (34.0) B 17 1/2 44.4 16 3/8 41.6 13 1/4 33.7 122 80 (23.4) 1200 (34.0) B 17 1/2 44.4 16 3/8 41.6 14 3/4 37.5 126

80 (23.4) 1600 (45.3) C 21 53.3 19 7/8 50.5 16 1/2 41.9 136 100 (29.3) 1600 (45.3) C 21 53.3 19 7/8 50.5 18 1/4 46.4 142 100 (29.3) 2000 (56.6) C 21 53.3 19 7/8 50.5 18 1/4 46.4 145 120 (35.1) 2000 (56.6) D 24 1/2 62.2 23 3/8 59.4 21 3/4 55.2 156

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.

Single side return above 1800 CFM is approved as long as the filter velocity does not exceed filter manufacturer’s recommendation and a transition is used to allow use on a 20x25 filter.

Table 4: Recommended Filter Sizes (High Velocity 600 FPM)

CFM

Cabinet

(m³/min)

1200 (34.0) B 16 x 25 16 x 25 1600 (45.3) 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 2200 (62.3) C (2) 16 x 25 20 x 25

2000 (56.6) D (2) 16 x 25 22 x 25

1.Air velocity through throwaway type filters may not exceed 300 feet per min-

2.Do not exceed 1800 CFM using a single side return and a 16x25 filter. For

Johnson Controls Unitary Products 9

ute (91.4 m/min). All velocities over this require the use of high velocity filters.

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.

Size

Side

Size

(in)

Cabinet Dimensions (Inches)

Approximate

Operating Weights

AA (cm)BB (cm)CC (cm) Lbs

SIDE RETURN - UPFLOW ONLY

Locate the “L” shaped corner locators. These indicate the size of the cutout to be made in the furnace side panel. Refer to Figure 13.

Bottom

(in)

FIGURE 13: 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 12.

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420705-UIM-C-0310

INLET

WRENCH BOSS

INLET PRESSURE PORT

OFF

ON/OFF SWITCH (Shown in ON position)

MAIN REGULATOR ADJUSTMENT

OUTLET

OUTLET PRESSURE PORT

VENT PORT

Upflow

Configuration

Downflow

Configuration

External Manual Shut-off Valve

To Gas Supply

Drip Leg

Gas Pipe

Gas Valve

Gas Pipe

Gas Valve

Ground Union

NOTE: Ground Union maybe installed inside or outside unit.

SECTION IV: GAS PIPING

GAS SAFETY

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.

FIGURE 14: Gas Valve

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.

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 15.

FIGURE 15: Upflow/Downflow 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.

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 knockouts on both sides of the furnace. Refer to Figure 12.

10 Johnson Controls Unitary Products

GAS ORIFICE CONVERSION FOR PROPANE (LP)

This furnace is constructed at the factory for natural gas-fired operation, but may be converted to operate on propane (LP) gas by using a factory-supplied LP conversion kit.

The gas supply must be shut off prior to disconnecting the electrical power, before proceeding with the conversion.

SHOCK HAZARD - Turn off electrical supply to furnace.

1. Shut off gas supply at valve upstream from furnace or at meter as required.

2. Disconnect gas supply piping from gas valve on furnace.

3. Disconnect electrical wires from gas valve, noting which wires are connected to which terminals

4. Remove the screws that attach the gas manifold to the burner support box.

5. Remove and discard natural gas orifices.

Page 11

6. Remove LP (propane) orifices from the bag in the Customer Packet.

7. Install the LP (propane) gas orifices supplied with the furnace. Tighten to 15 - 25 inch - pounds of torque.

8. Reinstall the manifold in the assembly by reversing the removal process.

9. Reconnect the wires to the proper terminals on the gas valve.

10. Unscrew the gas valve regulator with the blue cap and turn it upside down so the letters “LP” are upright. Replace the blue cap on the regulator.

11. Remove the natural gas tag and replace with the propane gas tag supplied in the orifice bag.

12. Remove the blue conversion label on the furnace door after the furnace has been converted.

13. Reconnect the gas supply piping to the gas valve and insure that all gas connections are tight.

14. Remove pressure tap plugs from gas valve and connect water gauge to the pressure tap ports. See Figure 14 for location of the gas valve pressure taps and pressure regulator adjustment.

15. Turn on gas supply to furnace and check all gas connections with suitable leak detector.

Table 5: Nominal Manifold Pressure - High Fire

Manifold Pressures (in wc) Manifold Pressures (kpa)

Altitude (feet) Altitude (m)

0-7999 8000-8999 9000-9999 0-2437 2438-2742 2743-3048 800 3.5 3.5 3.5 850 3.5 3.5 3.5 31.70.870.870.87 900 3.5 3.5 3.5 33.50.870.870.87 950 3.5 3.5 3.3 35.40.870.870.81

1000 3.5 3.2 2.9 37.3 0.87 0.80 0.73

(BTU/cu ft.)

Gas Heating Value

1050 3.5 2.9 2.7 39.1 0.87 0.73 0.67 1100 3.2 2.7 2.4 41.0 0.80 0.66 0.61

2500 (LP) 9.8 8.2 7.5 93.2 (LP) 2.44 2.03 1.86

420705-UIM-C-0310

Never use an open flame to check for leaks. Fire or explosion could occur. Since some leak solutions including soap and water may cause corrosion or stress cracking, the piping must be rinsed with water after testing unless it has been determined that the leak test solution is non-corrosive.

HIGH ALTITUDE GAS ORIFICE CONVERSION

This furnace is constructed at the factory for natural gas-fired operation at 0 –7,999 feet (0-m – 2,438 m) above sea level.

The manifold pressure must be changed in order to maintain proper and safe operation when the furnace is installed in a location where the altitude is greater than 7,999 feet (2,438 m) above sea level. Refer to Table 5 for proper manifold pressure settings.

HIGH ALTITUDE PRESSURE SWITCH CONVERSION

For installation where the altitude is less than 5,000 feet (1,524m), it is not required that the pressure switch be changed unless you are in an area subject to low pressure inversions.

For altitudes above 5,000 feet, see kits below. S1-1PS3306 - 080

S1-1PS3307 - 060 S1-1PS3302 - 100, 120

29.80.870.870.87

(MJ/cu m)

Gas Heating Value

PROPANE AND HIGH ALTITUDE CONVERSION KITS

It is very important to choose the correct kit and/or gas orifices for the altitude and the type of gas for which the furnace is being installed. Only use natural gas in furnaces designed for natural gas. Only use propane (LP) gas for furnaces that have been properly converted to use pro-

pane (LP) gas. Do not use this furnace with butane gas. Incorrect gas orifices or a furnace that has been improperly converted will create an extremely dangerous condition resulting in premature heat

exchanger failure, excessive sooting, high levels of carbon monoxide, personal injury, property damage, a fire hazard and/or death. High altitude and propane (LP) conversions are required in order for the appliance to satisfactory meet the application. An authorized distributor or dealer must make all gas conversions. In Canada, a certified conversion station or other qualified agency, using factory specified and/or approved parts, must perform the conversion. The installer must take every precaution to insure that the furnace has been converted to the proper gas orifice size when the furnace is installed.

Do not attempt to drill out any orifices to obtain the proper orifice size. Drilling out a gas orifice will cause misalignment of the burner flames, 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 in these instructions for specific furnace electrical data.

Johnson Controls Unitary Products 11

Use copper conductors only.

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Electrical Entry

Junction Box

L1-Hot Neutral

Connect ground lead to screw

BLK

WHT

BLK

WHT

GRN

BLK (HOT)

WHT (NEUTRAL)

GRN

NOMINAL 115 VOLT

ROOM THERMOSTAT

FURNACE CONTROL

CONDENSING UNIT

TO AIR CONDITIONER CONTROLS

R W G Y C

R W G

COMMON T’STAT CONNECTION

Y/Y2

Table 6: Ratings & Physical / Electrical Data

Input Output

Nominal

MBH kW MBH kW CFM

Airflow

AFUE

/min

Air Temp.

Rise

°F °C °F °C HP Amps

60 17.6 57 16.7 1200 34.0 95.5 30-60 19-36 160 71.1 1/3 4.8 11 x 8 15 10.0 14 80 23.4 76 22.3 1200 34.0 95.5 35-65 19-36 165 73.9 1/3 4.8 11 x 8 15 10.0 14

80 23.4 76 22.3 1600 45.3 95.5 35-65 19-36 155 68.3 1/2 7.5 11 x 10 15 11.5 14 100 29.3 95 27.8 1600 45.3 95.5 35-65 19-36 165 73.9 1/2 7.5 11 x 10 15 11.5 14 100 29.3 95 27.8 2000 56.6 95.5 35-65 19-36 155 68.3 1 14.5 11 x 11 20 17.0 12 120 35.1 114 33.4 2000 56.6 95.5 35-65 19-36 160 71.1 1 14.5 11 x 11 20 17.0 12

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 code s. The furnace shall be installed so that the electrical components are protected from water.

Max. Outlet

Air Temp

Blower

Size

Max

Over-Current

Protect

Total Unit

Amps

Min. wire Size

(awg) @ 75 ft

one way

SUPPLY VOLTAGE CONNECTIONS

FIGURE 16: Electrical Wiring

1. Provide a power supply separate from all other circuits. Install overcurrent protection and disconnect switch per local/national electrical codes. The switch should be close to the unit for 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.

3. The furnace's control system requires correct polarity of the power supply and a proper ground connection. Refer to Figure 16.

The power connection leads and wiring box may be relocated to the left side of the furnace. Remove the screws and cut wire tie holding excess wiring. Reposition on the left side of the furnace and fasten using holes provided.

LOW VOLTAGE CONTROL WIRING CONNECTIONS

Install the field-supplied thermostat by following the instructions that come with the thermostat. With the thermostat set in the OFF position and the main electrical source disconnected, connect the thermostat wiring from the wiring connections on the thermostat to the terminal board on the ignition module, as shown in Figure 18. Electronic thermostats may require the common wire to be connected. Apply strain relief to thermostat wires passing through cabinet. If air conditioning equipment is installed, use thermostat wiring to connect the Y and C terminals on the furnace control board to the proper wires on the condensing unit (unit outside).

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.

FIGURE 17: Line Wiring Connections

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 ou tside 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 16.

12 Johnson Controls Unitary Products

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.

FIGURE 18: Single Stage Heat Thermostat Connections

Page 13

ACCESSORY CONNECTIONS

115 VOLT HUMIDIFER

115 VOLT ELECTRONIC AIR CLEANER

EAC HOT

HUM. HOT

BLK

WHT

EAC

HUM

NEUTRALS

SWITCHED CIRCUITS

BLK

WHT

NOTICE

To Open Or Vented Drain

Tee

5” Min.

Open Stand Pipe

(Anti-siphon air vent)

NOTICE

The furnace control will allow power-switching control of various accessories. Refer to Figure 19, for connection details.

420705-UIM-C-0310

The furnace, evaporator coil, and humidifier drains may be combined and drained together. The evaporator coil drain may have an external, field-supplied trap prior to the furnace drain connection to prevent conditioned air leakage. All drain connections (furnace, evaporator coil, or humidifier) must be terminated into an open or vented drain as close to the respective equipment as possible. Regular maintenance is required on condensate drainage system.

Condensate must be disposed of properly. Follow local plumbing or wastewater codes. The drain line must maintain a 1/4" per foot (20 mm/m) downward slope to the drain.

FIGURE 19: Accessory Connections

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.

SECTION VI: CONDENSATE PIPING AND FURNACE VENTING CONFIGURATION

CONDENSATE DRAIN LOCATION

As shipped from the factory:

• For all 040, 060, & 080K input furnaces the main drain is plumbed through the casing right-side opening when viewed from the front of the furnace.

• For all 100, 120, & 130K input furnaces the main drain is plumbed through the casing left-side opening when viewed from the front of the furnace.

If an external vent tee is being installed, then it must have its own condensate trap before it is disposed into an open or vented drain.

This is not to be considered as a second trap as referenced elsewhere in this document.

The Figures 22 - 23 show the condensate drain arrangement for the various possible furnace and vent blower positions.

The condensate hoses must slope downwards at all points.

The furnace condensate pan is self priming and contains an internal trap to prevent flue gas leaking. Do not install an external condensate trap.

When drain hose routing changes are required (shown in Figures 22-

23), be sure to cap all un-used openings. If rerouting hoses - excess length should be cut off so that no sagging

loops will collect and hold condensate - which will cause the furnace to

not operate. No hose clamps are needed for connecting to the condensate pan.

Johnson Controls Unitary Products 13

FIGURE 20: Typical. Condensate drain, vertical installation The condensate will flow to the drain better if an open stand pipe is

installed in the drain line. See Figure 20. If evaporator coil or humidifier drains are combined with the furnace

drain, then the open stand pipe could be raised higher, above the 5” minimum.

A loop has been added to the pressure switch vacuum hose. However, ensure that all pressure switch hoses are routed such that they prevent any condensate from entering the pressure switch.

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420705-UIM-C-0310

Connect to Drain

Trap

Combustion Air Pipe

Tee with Drain Trap

Exhaust Pipe

It is possible for condensation to form inside the combustion air (intake) pipe in the summer months if significant length of combustion air pipe passes through conditioned space. This problem can be averted by the addition of a simple drain tee, or a drain tee with a drain on the combustion air pipe as close to the furnace as possible, as shown in Figure 21. This is true for all long horizontal venting in any furnace configuration. This will prevent the condensate from entering the furnace.

CONDENSATE DRAIN TERMINATION

A condensate sump pump MUST be used if required by local codes, or if no indoor floor drain is available. The condensate sump pump must be approved for use with acidic condensate.

DO NOT terminate the condensate drain in a chimney, or where the drain line may freeze. If the drain line will be exposed to temperatures below freezing, adequate measures must be taken to prevent the drain line from freezing. Failure to provide proper protection from freezing can result in improper operation or damage to the equipment and possible property damage. When exposed to temperatures below freezing, use of a 3 to 6 watt per foot at 115 VAC, 40°F (4.4°C) self-regulating, shielded and waterproof heat tape is recommended on the drain line outside the furnace. DO NOT trap the drain line at any other location than at the condensate drain trap supplied with the furnace.

Liquid anti-freeze will cause damage to internal plastic parts of this furnace. DO NOT attempt to winterize the furnace using liquid

anti-freeze.

FIGURE 21: Typical. Combustion Pipe Drain Tee

14 Johnson Controls Unitary Products

Page 15

INDUCER ROTATED FOR

LEFT SIDE VENTING

UPFLOW

AS RECEIVED

INDUCER ROTATED FOR

RIGHT SIDE VENTING

When drain hose routing changes are required, be sure to cap all un-used openings.

If rerouting hoses - excess length should be cut off so that no sagging loops will collect

and hold condensate, which will cause the furnace to not operate.

Shorten

pressure

switch hose

Re-route and

shorten

pressure

switch hose

Shorten

rain gutter

hose

Move rain

gutter hose

to this position

For 100, 120 input furnaces, the condensate

drain is plumbed toward the left casing outlet from the factory.

For 060 & 080K input furnaces, the condensate drain is plumbed toward the right casing outlet from the factory.

Condensate drain may exit cabinet on either side.

420705-UIM-C-0310

FIGURE 22: Upflow Configuration

Johnson Controls Unitary Products 15

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AIRFLOW

Move rain

gutter hose

to this position

DOWNFLOW - INDUCER ROTATED

FOR LEFT SIDE VENTING

DOWNFLOW - INDUCER ROTATED

FOR RIGHT SIDE VENTING

Move pressure switch

hose to this position.

NOTE: May require

the longer hose that

is provided with

wider cabinets

Move condensate drain

hose to this position

(May exit either side

of the cabinet)

Move rain gutter

hose to this position

When drain hose routing changes are required, be sure to cap all un-used openings.

If rerouting hoses - excess length should be cut off so that no sagging loops will collect

and hold condensate, which will cause the furnace to not operate.

FIGURE 23: Downflow Configuration

16 Johnson Controls Unitary Products

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STANDARD ELBOW

LONG (SWEEP) ELBOW

SECTION VII: COMBUSTION AIR AND VENT SYSTEM

COMBUSTION AIR AND VENT SAFETY

This Category IV, dual certified direct vent furnace is designed for residential or MH application. It may be installed without modification to the condensate system in a basement, garage, equipment room, alcove, attic or any other indoor location where all required clearance to combustibles and other restrictions are met. The combustion air and the venting system must be installed in accordance with Section 5.3, Air for Combustion and Ventilation, of the National Fuel Gas Code Z223.1/ NFPA 54 (latest edition), or Sections 7.2, 7.3 or 7.4 of CSA B149.1, National Gas and Propane Codes (latest edition) or applicable provisions of the local building code and these instructions.

The “VENT SYSTEM” must be installed as specified in these instructions for Manufactured (Mobile) Home and Modular Homes. The sealed combustion air / vent system is the only configuration that can be installed in a Manufactured (Mobile) Home.

Vertical vent termination must be secured for transit.

This furnace may not be common vented with any other appliance, since it requires separate, properly sized air intake and vent lines. The furnace shall not be connected to any type of B, BW or L vent or vent connector, and not connected to any portion of a factorybuilt or masonry chimney The furnace shall not be connected to a chimney flue serving a separate appliance designed to burn solid fuel.

When combustion air pipe is installed above a suspended ceiling or when it passes through a warm and humid space, the pipe must be insulated with 1/2” Armaflex or other heat resistant type insulation if two feet or more of pipe is exposed. Vent piping must be insulated if it will be subjected to freezing temperatures such as routing through unheated areas or through an unused chimney.

3. Three vent terminal elbows (two for the vent and one for the combustion air intake) are already accounted for and need not be included in the equivalent length calculation.

4. All combustion air and vent pipe must conform to American National Standards Institute (ANSI) and American Society for Testing and Materials (ASTM) standards D1785 (Schedule 40 PVC), D2665 (PVC-DWV), F891 (PVC-DWV Cellular Core), D2261 (ABS-DWV) or F628 (Schedule 40 ABS). Pipe cement and primer must conform to ASTM Standard D2546 (PVC) or D2235 (ABS). If ABS pipe is to be used, any joint where ABS pipe is joined to PVC pipe must be glued with cement that is approved for use with BOTH materials. Metallic materials must not

be used for venting or

air intake.

5. If a flexible connector is used in the vent system, it must be made of a material that is resistant to acidic exposure and to at least 225° F temperature. Flexible connectors are also allowed in the combustion air pipe.

6. All models are supplied with 2" vent connections. When the pipe must be increased to 3" diameter, the transition from 2" to 3" must be done as close to the furnace as possible. For upflow models, the transition from 2" to 3" should be done immediately above the furnace. For downflow or horizontal models, the transition from 2" to 3" pipe should be done immediately after exiting the furnace.

7. In Canada, vents shall be certified to ULC S636, Standard for T ype BH Gas Venting Systems.

8. In Canada, the first three feet (900 mm) of the vent must be readily accessible for inspection.

9. For single pipe systems it is recommended to install the combustion air coupling provided and install approximately 18” of PVC pipe on the furnace.

10. Minimum vent length for all models is 5 feet.

TABLE 7:

Maximum Equivalent Pipe Length

Model Input

BTUH (kW)

Pipe Size

Inches (cm)

Maximum

Equivalent

length feet (m)

60,000 (17.6) 2 (5.1) 65 (19.8) 60,000 (17.6) 3 (7.6) 90 (27.4) 80,000 (23.4) 2 (5.1) 65 (19.8) 80,000 (23.4) 3 (7.6) 90 (27.4)

100,000 (29.3) 2 (5.1) 30 (9.2) 100,000 (29.3) 3 (7.6) 90 (27.4) 120,000 (35.1) 3 (7.6) 90 (27.4)

COMBUSTION AIR/VENT PIPE SIZING

The size of pipe required will be determined by the furnace model, the total length of pipe required and the number of elbows required.

Table 7 lists the maximum equivalent length of pipe allowed for each model of furnace. The equivalent length of elbows is shown in Table 9. The equivalent length of the vent system is the total length of straight pipe PLUS the equivalent length of all of the elbows.

The following rules must also be followed:

1. Long radius (sweep) elbows are recommended. Standard elbows may be used, but since they have a longer equivalent length, they will reduce the total length of pipe that will be allowed. Short radius (plumbing vent) elbows are not allowed. The standard dimensions of the acceptable elbows are shown below.

2. The maximum equivalent length listed in Table 7 is for the vent piping and the air intake piping separately. For example, if the table allows 65 equivalent feet for a particular model, then the vent can have 65 equivalent feet of pipe, AND the combustion air intake can have another 65 equivalent feet of pipe.

Johnson Controls Unitary Products 17

FIGURE 24: TABLE 8: Elbow

Dimensions

Elbow "A" Dimension

2" Standard 2-5/16" 3" Standard 3-1/16" 2" Sweep 3-1/4" 3" Sweep 4-1/16"

Dimensions are those required in Standard ASTM D-3311.

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420705-UIM-C-0310

TABLE 9:

Example: An 80,000 BTUH furnace requires 32 feet of pipe and five 90º elbows.

Using 2" pipe and standard elbows, the total equivalent length will be:

This exceeds the 65 foot maximum equivalent length of 2" pipe allowed for that model and is thus not

By using sweep elbows, the total equivalent length will be:

This is less than the 65 foot maximum equivalent length of 2" pipe allowed for that model and is thus acceptable.

Alternatively, using 3" pipe and standard elbows, the total equivalent length will be:

This is less than the 90 foot maximum equivalent length of 3" pipe allowed for that model and is thus acceptable.

TABLE 10:

Equivalent Length of Fittings

Fitting Equivalent Length

2" 90º sweep elbow 5 feet of 2" pipe

2" 45º sweep elbow 2-1/2 feet of 2" pipe 2" 90º standard elbow 7 feet of 2" pipe 2" 45º standard elbow 3-1/2 feet of 2" pipe

3" 90º sweep elbow 5 feet of 3" pipe

3" 45º sweep elbow 2-1/2 feet of 3" pipe 3" 90º standard elbow 7 feet of 3" pipe 3" 45º standard elbow 3-1/2 feet of 3" pipe

2" corrugated connector 10 feet of 2" pipe 3" corrugated connector 10 feet of 3" pipe

32 feet of 2" pipe = 32 equivalent feet 5 - 90º standard 2" elbows = (5 x 7) = 35 equivalent feet Total = 67 equivalent feet of 2" pipe

acceptable.

32 feet of 2" pipe = 32 equivalent feet 5 - 90º sweep 2" elbows = (5 x 5) = 25 equivalent feet Total = 57 equivalent feet of 2" pipe

32 feet of 3" pipe = 32 equivalent feet 5 - 90º standard 3" elbows = (5 x 7) = 35 equivalent feet Total = 67 equivalent feet of 3" pipe

Combustion Air Intake and Vent Connection Size at Furnace

(All Models)

FURNACE VENT CONNECTION SIZES

Furnace Input All

Intake Pipe Size 2” (5.1 cm)

Vent Pipe Size 2” (5.1 cm)

Furnace vent pipe connections are sized for 2” (5.1 cm). pipe. Any pipe size change must be made outside the furnace casing in a vertical pipe section to allow proper drainage of condensate. An offset using two 45º (degree) elbows will be required for plenum clearance when the vent is increased to 3” (7.6 cm).

Accessory concentric vent / intake termination kits 1CT0302 and 1CT0303, and for Canadian applications 1CT0302-636 and 1CT0303-636 are available and approved for use with these furnaces. Horizontal sidewall vent terminations kits 1HT0901 & 1HT0902 are also approved for use with these furnaces.

COMBUSTION AIR AND VENT PIPING ASSEMBLY

The final assembly procedure for the combustion air and vent piping is as follows:

1. Cut piping to the proper length beginning at the furnace.

2. Deburr the piping inside and outside.

3. Chamfer (bevel) the outer edges of the piping.

4. Dry-fit the vent piping assembly from the furnace to the outside termination checking for proper fit support and slope.

5. Dry-fit the combustion air piping assembly checking for proper fit, support and slope on the following systems:

a. Sealed combustion air systems from the furnace to the out-

side termination.

b. Ventilated combustion air systems from the furnace to the

attic or crawl space termination.

Solvent cements are flammable and must be used in well-ventilated areas only. Keep them away from heat, sparks and open flames. Do not breathe vapors and avoid contact with skin and eyes.

6. Disassemble the combustion air and vent piping, apply cement primer and the cement per the manufactures instructions. Primer and cement must conform to ASTM D2564 for PVC, or ASTM D2235 for ABS piping.

7. All joints must provide a permanent airtight and watertight seal.

8. Support the combustion air and vent piping such that it is angled a minimum of 1/4” per foot (21 mm/m) so that condensate will flow back towards the furnace. Piping should be supported with pipe hangers to prevent sagging.

9. Seal around the openings where the combustion air and / or vent piping pass through the roof or sidewalls.

COMBUSTION AIR / VENTING

18 Johnson Controls Unitary Products

The vent must be installed with the minimum required clearances, and must comply with local codes and requirements.

Page 19

VENT CLEARANCES

OPERABLE

FIXED CLOSED

VENT TERMINAL

AIR SUPPLY

AREA WHERE TERMINAL IS NOT PERMITTED

FIXED CLOSED

FIGURE 25: Home Layout

420705-UIM-C-0310

Direct Vent Terminal Clearances

A. Clearance above grade, veranda, porch, deck, or

balcony

B. Clearance to window or door that may be opened

Canadian Installations

1,3

US Installation

12” (30.5 cm) 12” (30.5 cm) 12” (30.5 cm) for models 100,000 BTUH (30 kW),

36” (91.4 cm) for models >100,000 BTUH (30 kW).

Two-pipe (direct vent) applic ations: 12” (30.5 cm)†† Single-pipe applications: 4 feet (1.2 m).

2,3

C. Clearance to permanently closed window 12” (30.5 cm) 12” (30.5 cm) D. Vertical clearance to ventilated soffit located

above the terminal within a horizontal distance of 2 feet (61 cm) from the center line of the terminal

E. Clearance to unventilated soffit

F. Clearance to outside corner

12” (30.5 cm) or in accordance with local installation codes and the requirements of the gas supplier.

G. Clearance to inside corner 3 feet (91.4 cm) 3 feet (91.4 cm)

H. Clearance to each side of center line

extended above meter/regulator assembly

Above a meter/regulator assembly within 3 feet (91.4 cm) horizontally of the vertical center-line of the regulator vent outlet to a maximum vertical distance of

15 feet (4.5 m) above the meter/regulator assembly. I. Clearance to service regulator vent outlet 3 feet (91.4 cm) J. Clearance to non-mechanical air supply inlet to

building or the combustion air inlet to any other appliance

12” (30.5 cm) for models 100,000 BTUH (30 kW),

36” (91 cm) for models >100,000 BTUH (30 kW).

K. Clearance to a mechanical supply inlet 6 feet (1.83 m) L. Clearance above paved sidewalk or paved

driveway located on public property

7 feet (2.13 m)†

M. Clearance under veranda, porch, deck, or balcony 12” (30.5 cm)‡

Above a meter/regulator assembly within 3 feet (91 cm) horizontally of the vertical center-line of the regulator vent outlet to a maximum vertical distance of 15 feet (4.5 m) above the meter/regulator assembly.

3 feet (91.4 cm) or in accordance with local installatio n codes and the requirements of the gas supplier.

Two-pipe (direct vent) applications: 12” (30.5 cm) Single-pipe applications: 4 feet (1.2 m).

3 feet (91.4 cm) above if within 10 feet (3 m) horizontally.

7 feet (2.13 m) or in accordance with local installation codes and the requirements of the gas supplier.

12” (30.5 cm) or in accordance with local installation codes and the requirements of the gas supplier

1. In accordance with the current CSA B149.1-00, Natural Gas and Propane Installation Code.

2. In accordance with the current ANSI Z223.1 / NFPA 54, National Gas Code.

3. In accordance with the current ANSI Z21.47 * CSA 2.3 American National Standard. † A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.

†† 12” (30.5 cm) up from the bottom edge of the structure for Two-pipe (direct vent) applications per ANSI Z223.1 / NFPA 54, Nat ional Gas Code. ‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides benea th the floor and the distance between th e top of the vent termina-

tion and the underside of the veranda, porch, or deck is greater than 12” (30.5 cm) as specified in CSA B149.1-00. A vent shall not terminate less than 12” (30.5 cm) above a grade level. Any fresh air or make up inlet for dryer or furnace area is considered to be forced air inlet. Avoid areas where condensate drippage may cause problems such as above planters, patios, or adjacent to windows where steam may cause fogging. A terminus of a vent shall be fitted with a cap in accordance with the vent manufacturer’s installation instructions, or in accordance with the installation instructions for a

special venting system. Responsibility for the provision of proper adequate venting and air supply for application shall rest with the installer. Vent shall extend high enough above build ing, or a neighboring obstruction, so that wind from any direction will not create a positive pressure in the vicinity of the vent.

Consideration must be given for degradation of building materials by flue gases. Sidewall termination may require sealing or shielding of building surfaces with a corrosion resistant material to protect against combustion product corrosion. Consideration must be given to wind direction in order to prevent flue products and/or condensate from being blown against the building surfaces. If a metal shield is used it must be a stainless steel material at a minimum dimension of 20 inches (51 cm). It is recommended that a retaining type collar be used that is attached to the building surface to prevent movement of the vent pipe.

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Maintain 12” minimum clearance above highest anticipated snow level.

12” vertical separation between combustion air intake and vent.

12” minimum below overhang

12” minimum separation between bottom of combustion air pipe and bottom of vent.

Maintain 12” minimum clearance above highest anticipated snow level or grade, whichever is higher.

12” MIN.

OVERHANG

12” Minimum below overhang

12” Minimum separation between bottom of combustion air intake and bottom of vent

Maintain 12” minimumclearance above highest anticipated snow level or grade, whichever is higher

VENT

2” MIN.

COMBUSTION AIR

MIN. 6”

VENT SYSTEM

This furnace is certified to be installed with one of two possible vent configurations.

1. Horizontal vent system. This vent system can be installed completely horizontal or combinations of horizontal, vertical, or offset using elbows.

2. Vertical vent system. This vent system can be installed completely vertical or a combination of horizontal, vertical, or offset using elbows.

VENT APPLICATIONS AND TERMINATION

When selecting the location for a combustion air / vent termination, the following should be considered:

1. Observe all clearances listed in vent clearances in these instructions.

2. Termination should be positioned where vent vapors will not damage plants or shrubs or air conditioning equipment.

3. Termination should be located where it will not be affected by wind gusts, light snow, airborne leaves or allow recirculation of flue gases.

4. Termination should be located where it will not be damaged or exposed to flying stones, balls, etc.

5. Termination should be positioned where vent vapors are not objectionable.

6. Horizontal portions of the vent system must slope upwards and be supported to prevent sagging.

7. Direct vent systems must be installed so the vent and the combustion air pipes terminate in the same atmospheric zone. Refer to Figures 26 or 27.

VENTING MULTIPLE UNITS

Multiple units can be installed in a space or structure as a two-pipe configuration.

The combustion air side of the two-pipe configuration shown in Figure 27 can be installed so the combustion air pipe terminates as described in outdoor combustion air or ventilated combustion air sections in these instructions. Follow the instructions for outdoor combustion air or ventilated combustion air and the instructions for installing the vent system with the vent terminating as shown in Figures 28 or 29. The two-pipe system must have a separate combustion air pipe and a separate vent pipe for each furnace. Under NO circumstances can the two combustion air or vent pipes be tied together. The combustion air and vent pipes must terminate in the same atmospheric zone.

FIGURE 28: Double Horizontal Combustion Air Intake and Vent

Termination

FIGURE 26: Termination Configuration - 2 Pipe

FIGURE 27: Termination Configuration - 2 Pipe Basement

20 Johnson Controls Unitary Products

FIGURE 29: Double Vertical Combustion Air Intake and Vent

Termination

COMBUSTION AIR SUPPLY

All installations must comply with Section 5.3, Air for Combustion and Ventilation of the National Fuel Gas Code, ANSI Z223.1 or Sections

7.2, 7.3 or 7.4 of CAN/CGA B149.1 or .2 Installation Code - latest editions.

This furnace is certified to be installed with one only possible combustion air intake configurations.

1. OUTDOOR COMBUSTION AIR: where the combustion air is supplied through a PVC or ABS pipe that is connected to the PVC coupling attached to the furnace and is terminated in the same atmospheric zone as the vent. This type of installation is approved on all models. Refer to Figure 20.

This is a direct vent configuration

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420705-UIM-C-0310

NOTICE

Connects to collar on top of burner box

Vent pipe cements into socket just above top panel

Or vent pipe may be clamped into outlet of drain coupling

Outdoor Combustion Air

Combustion Air Intake/Vent Connections

This installation requires combustion air to be brought in from outdoors. This requires a properly sized pipe (Shown in Figure 30) that will bring air in from the outdoors to the furnace combustion air intake collar on the burner box. The second pipe (Shown in Figure 30) is the furnace vent pipe.

FIGURE 30: Direct Vent Air Intake Connection and Vent Connection The combustion air intake pipe should be located either through the

wall (horizontal or side vent) or through the roof (vertical vent). Care should be taken to locate side vented systems where trees or shrubs will not block or restrict supply air from entering the terminal.

Also, the terminal assembly should be located as far as possible from a swimming pool or a location where swimming pool chemicals might be stored. Be sure the terminal assembly follows the outdoor clearances listed in Section #1 “Outdoor Air Contaminants.”

An unconfined space is not less than 50 cu.ft (1.42 m 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 doors.

A confined space is an area with less than 50 cu.ft (1.42 m 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.

An optional plastic birdscreen is shipped in the loose parts bag with every furnace. This may be installed in the intake collar to prevent any small objects from entering the furnace.

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.

) per 1,000 Btu/

) per 1,000

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 11, to estimate free area.

Table 11: 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 Grilles (Canada Only)

1. The free area of a supply air opening shall be calculated by sub-

tracting the blockage area of all fixed louvers grilles or screens from the gross area of the opening.

2. Apertures in a fixed louver, a grille, or screen shall have no dimen-

sion smaller than 0.25” (0.64 cm).

3. A manually operated damper or manually adjustable louvers are

not permitted for use.

4. 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.

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 12: Unconfined Space Minimum Area in Square Inch

BTUH Input Rating

60,000

80,000 100,000 120,000

Table 13: 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

Minimum Free Area in Square Feet

Required for Each Opening

60 in

(387 cm2)

80 in

(516 cm2)

100 in

(645 cm2)

120 in

(742 cm2)

Vertical Duct or

Opening to Outside

(4,000 BTUH)

(193 cm2) 15 in2 (97 cm2)

(258 cm2) 20 in2 (129 cm2)

(322 cm2) 25 in2 (161 cm2)

(387 cm2) 30 in2 (193 cm2)

Round Duct

(4,000 BTUH)

5” (13 cm) 5” (13 cm) 6” (15 cm) 7” (18 cm)

Johnson Controls Unitary Products 21

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Gable Vent

Gas Vent

Soffit Vent

Ventilated

Attic Top Above Insulation

Optional Inlet (a)

Outlet Air (a)

Ventilated

Crawl Space

Gas Water Heater

Furnace

Soffit Vent

Gas Water Heater

Inlet Air (a)

Inlet Air (b)

Furnace

Gas Vent

Outlet Air (a)

Outlet Air (b)

Inlet Air (a)

Inlet Air (b)

Gas Water Heater

Furnace

Ventilated

Attic

Top Above Insulation

Gable Vent

Gas Vent

FIGURE 31: Outside and Ambient Combustion Air

Air Supply Openings and Ducts

1. An opening may be used in lieu of a duct to provide to provide the outside air supply to an appliance unless otherwise permitted by the authority having jurisdiction. The opening shall be located within 12” (30.5 cm) horizontally from, the burner level of the appliance. Refer to “AIR SOURCE FROM OUTDOORS AND VENT AND SUPPLY AIR SAFETY CHECK” in these instructions for additional information and safety check procedure.

2. The duct shall be either metal, or a material meeting the class 1 requirements of CAN4-S110 Standard for Air Ducts.

3. The duct shall be least the same cross-sectional area as the free area of the air supply inlet opening to which it connects.

4. The duct shall terminate within 12 in (30.5 cm) above, and within 24 in (61 cm) horizontally from, the burner level of the appliance having the largest input.

5. A square or rectangular shaped duct shall only be used when the

required free area of the supply opening is 9 in

(58.06 cm2) or larger. When a square or rectangular duct is used, its small dimension shall not be less than 3 in (7.6 cm).

6. An air inlet supply from outdoors shall be equipped with a means to prevent the direct entry of rain and 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.

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 grille is not known. Refer to Table 11.

Ventilated Combustion Air (Modular Home Installations Only)

The ventilated attic space or a crawl space from which the combustion air is taken must comply with the requirements specified in “COMBUSTION AIR SOURCE FROM OUTDOORS” in this instruction or in Section 5.3, Air for Combustion and Ventilation of the National Fuel Gas Code, ANSI Z223.1 (latest edition). This type installation requires two properly sized pipes. One brings combustion air from a properly ventilated attic space or crawl space and a second pipe that extends from the furnace vent connection (top right of unit) to the exterior of the building. Refer to Table 7 for intake pipe sizing, allowable length and elbow usage. Follow all notes, procedures and required materials in the SEALED COMBUSTION AIR SUPPLY section in these instructions when installing the combustion air pipe from the unit and into a ventilated attic space or crawl space. DO NOT terminate vent pipe in an Attic or Crawl Space.

Ventilated Combustion Air Te rmination (Modular Home Installations Only

Refer to Figure 32 for required attic termination for the combustion air intake pipe. For attic termination, use two 90 elbows with the open end in a downward position. Be sure to maintain 12” (30.5 cm) clearance above any insulation, flooring or other material.

A crawl space combustion air installation consists of a straight pipe from the PVC coupling on the burner box that extends into the crawl space and terminates with a 1/4” (0.63 cm) mesh screen and no elbows.

22 Johnson Controls Unitary Products

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12” Min.

12” minimum between bottom of air intake and any material below.

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 accordance with the National Fuel Gas Code Z223.1 or CAN/CGA B149.1 Natural Gas and Propane Installation Code (latest editions). If the vent system must be resized, follow the appropriate tables in Appendix G of the above codes or for this appliance.

FIGURE 32: Attic and Crawl Space Combustion Air Termination Specially Engineered Installations

The above requirements shall be permitted to be waived where special engineering, approved by the authority having jurisdiction, provides an adequate supply of air for combustion and ventilation.

Be sure to instruct the owner not to block this intake pipe.

VENT BLOWER ROTATION

For ease of venting, the vent blower may be rotated 90° in either direction. For upflow installations the vent may exit through the top or either side of the cabinet. For downflow installations, the vent blower must be rotated so that the vent exits through either side of the cabinet. See Figures 22-23 for details.

SECTION VIII: START-UP AND ADJUSTMENTS

The initial start-up of the furnace requires the following additional procedures:

All electrical connections made in the field and in the factory should be checked for proper tightness.

When the gas supply is initially connected to the furnace, the gas piping may be full of air. In order to purge this air, it is recommended that the ground union be loosened until the odor of gas is detected. When gas is detected, immediately retighten the union and check for leaks. Allow five minutes for any gas to dissipate before continuing with the start-up procedure. Be sure proper ventilation is available to dilute and carry away any vented gas.

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.

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NOTICE

HOT SURFACE IGNITION SYSTEM Do not attempt to light this furnace by hand (with a match or any other means). There may be a potential shock hazard from the components of the hot surface ignition syst em. The furnace can only be lit automatically by its hot surface ignition system.

CALCULATING THE FURNACE INPUT (NATURAL GAS)

Burner orifices are sized to provide proper input rate using natural gas with a heating value of 1030 BTU/Ft

of your gas is significantly different, it may be necessary to replace the orifices.

DO NOT set manifold pressure less than 3.2” w.c. or more than 3.8” w.c. for natural gas at sea level. If manifold pressure is outside this range, change main burner orifices.

If orifice hole appears damaged or it is suspected to have been redrilled, check orifice hole with a numbered drill bit of correct size. Never redrill an orifice. A burr-free and squarely aligned orifice hole is essential for proper flame characteristics.

(38.4 MJ/m3). If the heating value

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 14 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.

24 Johnson Controls Unitary Products

Page 25

Table 14: 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

420705-UIM-C-0310

Size of Test Dial

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NOTICE

INLET

WRENCH BOSS

INLET PRESSURE PORT

OFF

ON/OFF SWITCH (Shown in ON position)

MAIN REGULATOR ADJUSTMENT

OUTLET

OUTLET PRESSURE PORT

VENT PORT

FLAME SENSOR

GAS VALVE

OUTLET PRESSURE TAP

GAS BURNERS

MAINIFOLD PIPE

1/4” TUBING

U-TUBE MANOMETER

3.5 IN WATER COLUMN GAS PRESSURE SHOWN

ADJUSTMENT OF MANIFOLD GAS PRESSURE & INPUT RATE

Inlet and manifold gas pressure may be measured by connecting the “U” tube manometer to the gas valve with a piece of tubing. Follow the appropriate section in the instructions below. Refer to Figure 33 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. Find the pressure ports on the gas valve marked Out P and In P.

1. The manifold pressure must be taken at the port marked OUT P.

2. The gas line pressure must be taken at the port marked IN P.

3. Using a 3/32” (2.4 mm) Allen wrench, loosen the set screw by turning it 1 turn counter clockwise. DO NOT REMOVE THE SET SCREW FROM THE PRESSURE PORT.

Read the inlet gas pressure

Connect the positive side of the manometer to the IN P Tap on the gas valve. Do not connect any tubing to the negative side of the manometer, as it will reference atmospheric pressure. Refer to Figure 34 for connection details.

1. Turn gas and electrical supplies on and follow the operating instructions to place the unit back in operation.

Table 15: Inlet Gas Pressure Range

INLET GAS PRESSURE RANGE

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 inlet gas pressure operating range table specifies what the minimum and maximum gas line pressures must be for the furnace to operate safely. The gas line pressure MUST BE

a minimum of:

• 7” W.C. (1.74 kPA) for Natural Gas

• 11” W.C. (2.74 kPA) for Propane (LP) Gas

in order to obtain the BTU input specified on the rating plate and/or the nominal manifold pressure specified in these instructions and on the rating plate.

2. Once the correct gas inlet pressure has been established, see Table 15, turn the gas valve to OFF and turn the electrical supply switch to OFF; then remove the flexible tubing from the gas valve pressure tap and tighten the pressure tap plug using the 3/32” (2.4 mm) allen wrench.

3. Turn the electrical and gas supplies back on, and with the burners in operation, check for gas leakage around the gas valve pressure port for leakage using an approved non-corrosive gas leak detection fluid, or other non-flammable leak detection methods.

Read the manifold gas pressure

Connect the positive side of the manometer to the adapter previously installed in the OUT P Tap on the gas valve. Do not connect any tubing to the negative side of the manometer, as it will reference atmospheric pressure. Refer to Figure 34 for connection details.

1. Refer to Figure 33 for location of pressure regulator adjustment cap and adjustment screws on main gas valve.

2. Turn gas and electrical supplies on and follow the operating instructions to place the unit back in operation.

3. Adjust manifold pressure by adjusting gas valve regulator screw for the appropriate gas per the following:

Table 16: Nominal Manifold Pressure

NOMINAL MANIFOLD PRESSURE

Natural Gas 3.5" w.c. (0.87 kPa)

Propane (LP) Gas 10.0" w.c. (2.488 kPa)

FIGURE 33: Gas Valve

If gas valve regulator is turned in (clockwise), manifold pressure is increased. If screw is turned out (counterclockwise), manifold pressure will decrease.

4. After the manifold pressure has been adjusted, re-calculate the furnace input to make sure you have not exceeded the specified input on the rating plate. Refer to “CALCULATING THE FURNACE INPUT (NATURAL GAS)”.

5. Once the correct BTU (kW) input has been established, turn the gas valve to OFF and turn the electrical supply switch to OFF; then remove the flexible tubing from the gas valve pressure tap and tighten the pressure tap plug using the 3/32” (2.4 mm) Allen wrench.

6. Turn the electrical and gas supplies back on, and with the burners in operation, check for gas leakage around the gas valve pressure port for leakage using an approved non-corrosive gas leak detection fluid, or other non-flammable leak detection methods.

MANIFOLD PRESSURE “U” TUBE CONNECTION

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.

The regulated outlet pressure has been calibrated at the factory. Additional pressure adjustment should not be necessary. If adjustment is necessary, set to the following specifications. After adjustment, check for gas leakage.

26 Johnson Controls Unitary Products

FIGURE 34: Reading Gas Pressure

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PARK

HI COOL

HEAT

EAC-H

XFMR

NEUTRALS

HUM

TWIN

120

180

BLOWER

OFF

DELAY

Y/Y2

Blower Off Delay Timer Adjustment Jumper (in seconds)

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.

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 readings of both the return air and the heated air in the ducts, about six feet (1.83 m) from the furnace where they will not be affected by radiant heat. Increase the blower speed to decrease the temperature rise; decrease the blower speed to increase the rise.

All direct-drive blowers have multi-speed motors. The blower motor speed taps are located on the furnace control board in the blower compartment. Refer to Figure 35, and the unit-wiring label to change the blower speed. To use the same speed tap for heating and cooling, the heat terminal and cool terminal must be connected using a jumper wire and connected to the desired motor lead. Place all unused motor leads on Park terminals. Two park terminals are provided.

Do not energize more than one motor speed at a time or damage to the motor will result.

ADJUSTMENT OF FAN CONTROL SETTINGS

This furnace is equipped with a time-on/time-off heating fan control. The fan on delay is fixed at 30 seconds. The fan off delay has 4 settings (60, 90, 120 and 180 seconds). The fan off delay is factory set to 120 seconds. The fan-off setting must be long enough to adequately cool the furnace, but not so long that cold air is blown into the heated space. The fan-off timing may be adjusted by positioning the jumper on two of the four pins as shown in Figure 35.

FIGURE 35: Furnace Control Board

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Blower Performance CFM - Any Position (Without Filter)

Bottom Airflow Data (SCFM)

Models

Input/Airflow/Cabinet

60/1200/B

80/1200/B

80/1600/C

1001600/C

100/2000/C

120/2000/D

Models

Input/Airflow/Cabinet

60/1200/B

80/1200/B

80/1600/C

1001600/C

100/2000/C

120/2000/D

NOTES:

1.Airflow expressed in standard cubic feet per minute (CFM).

2.Return air is through side opposite motor (left side).

3.Motor voltage at 115 V.

Speed

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

High 1492 1442 1378 1325 1243 1176 1075 966 849 655 Medium High 1236 1201 1161 1139 1082 1011 919 830 715 590 Medium Low 986 950 961 916 872 831 757 703 600 510

Low 824 795 783 744 713 659 624 554 489 389

High 1597 1537 1484 1435 1370 1286 1230 1155 1075 925 Medium High 1338 1307 1273 1223 1179 1123 1065 998 928 812 Medium Low 1113 1094 1077 1043 1008 972 924 868 803 798

Low 937 916 900 877 854 817 775 718 639 560

High 1919 1865 1802 1738 1671 1600 1517 1414 1322 1201 Medium High 1532 1533 1513 1499 1465 1416 1352 1283 1198 1084 Medium Low 1232 1313 1291 1280 1250 1209 1207 1148 1055 937

Low 826 821 853 858 838 817 794 776 760 711

High 1909 1880 1823 1776 1706 1637 1562 1474 1375 1252 Medium High 1465 1463 1469 1485 1477 1416 1386 1324 1250 1114

Medium 1190 1222 1216 1215 1224 1189 1158 1145 1087 996

Low 787 834 819 836 819 810 790 761 690 707

High 2284 2205 2114 2021 1934 1848 1752 1653 1505 1397 Medium High 1967 1905 1824 1763 1712 1628 1551 1473 1379 1213 Medium Low 1610 1563 1513 1480 1430 1367 1319 1261 1101 1012

Low 1326 1304 1267 1232 1183 1143 1080 1003 871 798

High 2341 2245 2153 2072 1977 1876 1769 1642 1506 1306 Medium High 2002 1952 1878 1823 1739 1657 1563 1458 1322 1185 Medium Low 1615 1579 1533 1473 1430 1368 1282 1186 1091 953

Low 1352 1295 1259 1245 1190 1141 1076 998 938 820

Left Side Airflow Data (SCFM)

Speed

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

High 1470 1406 1361 1309 1241 1155 1060 920 775 628 Medium High 1211 1186 1139 1101 1042 980 896 796 681 545 Medium Low 970 957 927 889 853 796 745 660 568 450

Low 793 781 756 724 694 653 585 530 469 382

High 1605 1562 1514 1454 1393 1330 1251 1169 1073 940 Medium High 1372 1318 1280 1255 1205 1161 1093 1023 943 849 Medium Low 1087 1073 1052 1003 993 953 897 843 775 709

Low 916 896 881 854 831 802 757 708 642 574

High 1956 1907 1846 1778 1717 1647 1573 1483 1353 1209 Medium High 1543 1543 1516 1504 1477 1446 1382 1309 1202 1099 Medium Low 1238 1241 1243 1241 1252 1242 1201 1140 1074 967

Low 906 902 903 910 888 866 859 829 795 743

High 1828 1829 1789 1768 1727 1671 1601 1505 1390 1272 Medium High 1422 1444 1437 1424 1396 1326 1301 1253 1200 1100

Medium 1224 1229 1243 1234 1219 1193 1168 1135 1088 977

Low 813 819 818 814 783 762 756 732 690 642

High 2391 2286 2165 2079 2004 1934 1839 1692 1560 1366 Medium High 1945 1878 1838 1782 1694 1642 1565 1451 1334 1163 Medium Low 1549 1530 1495 1430 1431 1365 1284 1192 1097 1022

Low 1256 1229 1189 1159 1089 1033 1008 950 871 784

High 2343 2253 2167 2071 1979 1881 1785 1668 1473 1351 Medium High 1954 1892 1846 1781 1714 1637 1548 1429 1238 1171 Medium Low 1596 1539 1511 1458 1399 1341 1254 1180 942 988

Low 1299 1261 1229 1177 1111 1053 993 937 882 782

Ext. Static Pressure (in. H2O)

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SECTION IX: SAFETY CONTROLS

CONTROL CIRCUIT FUSE

A 3-amp fuse is provided on the control circuit board to protect 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

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.

This unit is equipped with an electrical interlock switch mounted in the burner compartment. This switch interrupts all power at the unit when the panel covering the blower compartment is removed.

Electrical supply to this unit is dependent upon the panel that covers the blower compartment being in place and properly positioned.

ROLLOUT SWITCH CONTROLS

These controls are mounted on the burner assembly. If the temperature in the area surrounding burner exceeds its set point, the gas valve is de-energized. The operation of this control indicates a malfunction in the combustion air blower, heat exchanger or a blocked vent pipe connection. Corrective action is required. These are manual reset controls that must be reset before operation can continue.

PRESSURE SWITCHES

This furnace is supplied with two pressure switches, which monitor the flow through the combustion air/vent piping and condensate drain system. These switches de-energize the gas valve if any of the following conditions are present. Refer to "CONDENSATE PIPING AND FURNACE VENTING CONFIGURATION" for tubing connections.

1. Blockage of vent piping or terminal.

2. Failure of combustion air blower motor.

3. Blockage of combustion air piping or terminals.

4. Blockage of condensate drain piping.

LIMIT CONTROLS

There is a high temperature limit control located on the furnace vestibule panel near the gas valve. This is an automatic reset control that provides over temperature protection due to reduced airflow. This may be caused by:

1. A dirty filter.

2. If the indoor fan motor should fail.

3. Too many supply or return registers closed or blocked off. The control module will lockout if the limit trips 5 consecutive times. If

this occurs, control will reset & try ignition again after 1 hour.

SECTION X: NORMAL OPERATION AND DIAGNOSTICS

NORMAL OPERATION SEQUENCE

The following describes the sequence of operation of the furnace. Refer to Owners Manual for component location.

Continuous Blower

Cooling/heating thermostats have a fan switch that has an ON and AUTO position. In the ON position the thermostat circuit is completed between terminals R and G. The motor will operate continuously on the speed tap wire that is connected to the “HI COOL” cooling terminal on the control board. To obtain a constant air circulation at lower flow rate, change the high-speed wire to another low speed wire.

Intermittent Blower - Cooling

Cooling/heating thermostats have a fan switch that has an ON and AUTO position. In the AUTO position the thermostat circuit is completed between terminals R and G when there is a call for cooling. The motor will operate on the speed tap wire that is connected to the “HI COOL” cooling terminal on the control board. The fan off setting is fixed at 60 seconds to improve cooling efficiency.

Heating Cycle

When the thermostat switch is set on HEAT and the fan is set on AUTO, and there is a call for heat, a circuit is completed between terminals R and W of the thermostat. When the proper amount of combustion air is being provided, the pressure switch will close, the ignition control provides a 17-second ignitor warm-up period, the gas valve then opens, the gas starts to flow, ignition occurs and the flame sensor begins its sensing function. The blower motor will energize 30 seconds after the gas valve opens, if a flame is detected. Normal furnace operation will continue until the thermostat circuit between R and W is opened, which causes the ignition system and gas valve to de-energize and the burner flames to be extinguished. The vent motor will operate for 15 seconds and the blower motor will operate for the amount of time set by the fanoff delay jumper located on the control board. See Table ?. The heating cycle is now complete, and ready for the start of the next heating cycle.

If the flame is not detected within 7 seconds of the gas valve opening, the gas valve is shut off and a retry operation begins. Also, if the flame is lost for 2 seconds during the 10-second stabilization period, the gas valve is shut off and a retry operation begins. During a retry operation, the vent motor starts a 15 second inter-purge and the ignitor warm-up time is extended to 27 seconds. If the flame is established for more than 10 seconds after ignition during a retry, the control will clear the ignition attempt (retry) counter. If three retries occur during a call for heat, the furnace will shut down for one hour. If at the end of the one hour shut down there is a call for heat, the furnace will initiate a normal start cycle. If the problem has not been corrected the furnace will again lockout after three retries.

A momentary loss of gas supply, flame blowout, or a faulty flame probe circuit will result in a disruption in the flame and be sensed within 1.0 seconds. The gas valve will de-energize and the control will begin a recycle operation. A normal ignition sequence will begin after a 15 second inter-purge. If during the five recycles the gas supply does not return, or the fault condition is not corrected the ignition control will lockout for 60 minutes.

During burner operation, a momentary loss of power for 50 milliseconds or longer will de-energize the gas valve. When the power is restored, the gas valve will remain de-energized and the ignition sequence will immediately restart.

IGNITION SYSTEM SEQUENCE

1. Turn the gas supply ON at external valve and main gas valve.

2. Set the thermostat above room temperature to call for heat.

3. System start-up will occur as follows: a. The induced draft blower motor will start and come up to

speed. Shortly after inducer start-up, the hot surface igniter will glow for about 17 seconds.

b. After this warm up, the ignition module will energize (open)

the main gas valve.

c. After flame is established, the supply air blower will start in

about 30 seconds.

TROUBLESHOOTING

The following visual checks should be made before troubleshooting:

1. Check to see that the power to the furnace and the ignition control module is ON.

2. The manual shut-off valves in the gas line to the furnace must be open.

3. Make sure all wiring connections are secure.

4. Review the sequence of operation. Start the system by setting the thermostat above the room temperature. Observe the system’s response. Then use the troubleshooting section in this manual to check the system’s operation.

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NOTICE

Never bypass any safety control to allow furnace operation. To do so will allow furnace to operate under potentially hazardous conditions. Do not try to repair controls. Replace defective controls with UPG Source 1 Parts.

Never adjust pressure switch to allow furnace operation.

FURNACE CONTROL DIAGNOSTICS

The furnace has built-in, self-diagnostic capability. If a system problem occurs, a blinking LED can flash red, green or amber to indicate various conditions.

The control continuously monitors its own operation and the operation of the system. If a failure occurs, the LED will indicate the failure code. If the failure is internal to the control, the light will stay on continuously. In this case, the entire control should be replaced, as the control is not field repairable.

Flash sequence codes 1 through 11 are as follows: LED will turn “on” for 1/4 second and “off” for 1/4 second. This pattern will be repeated the number of times equal to the code. For example, six “on” flashes equals a number 6 fault code. All flash code sequences are broken by a 2 second “off” period.

SLOW GREEN FLASH: Normal operation. SLOW AMBER FLASH: Normal operation with call for heat. RAPID RED FLASH: Twinning error, incorrect 24V phasing. Check

twinning wiring. RAPID AMBER FLASH: Flame sense current is below 1.5 microamps.

Check and clean flame sensor. Check for proper gas flow. Verify that current is greater than 1.5 microamps at flame current test pad.

4 AMBER FLASHES: The control is receiving a “Y” signal from the thermostat without a “G” signal, indicating improper thermostat wiring.

1 RED FLASH: This indicates that flame was sensed when there was not a call for heat. The control will turn on both the inducer motor and supply air blower. A gas valve that leaks or is slow closing would typically cause this fault.

2 RED FLASHES: This indicates that the normally open pressure switch contacts are stuck in the closed position. The control confirms these contacts are open at the beginning of each heat cycle. This would indicate a faulty pressure switch or miswiring.

3 RED FLASHES: This indicates the normally open pressure switch contact did not close after the inducer was energized. This could be caused by a number of problems: faulty inducer, blocked vent pipe, broken pressure switch hose or faulty pressure switch.

4 RED FLASHES: This indicates that the main limit switch has opened its normally closed contacts. The control will operate the supply air blower and inducer. This condition may be caused by: dirty filter, improperly sized duct system, incorrect blower speed setting, incorrect firing rate or faulty blower motor. Also, this fault code could be caused by a blown fuse located on the control board.

5 RED FLASHES: This fault is indicated if the normally closed contacts in the rollout switch opens. The rollout control is manually reset. If it has opened, check for proper combustion air, proper inducer operation, and primary heat exchanger failure or burner problem. Be sure to reset the switch and cycle power (24 VAC) to the control after correcting the failure condition. Also, this fault code could be caused by a blown fuse located on the control board.

6 RED FLASHES: This indicates that after the unit was operating, the pressure switch opened 4 times during the call for heat. If the main blower is in a “Delay on” mode, it will complete it, and any subsequent delay off period. The furnace will lock out for one hour and then restart.

7 RED FLASHES: This fault code indicates that the flame could not be established. This no-light condition occurred 3 times (2 retries) during the call for heat before locking out. Low gas pressure, faulty gas valve, dirty or faulty flame sensor, faulty hot surface ignitor or burner problem may cause this. The furnace will lock out for one hour and then restart.

8 RED FLASHES: This fault is indicated if the flame is lost 5 times (4 recycles) during the heating cycle. This could be caused by low gas pressure, dirty or faulty flame sensor or faulty gas valve. The furnace will lock out for one hour and then restart.

9 RED FLASHES: Indicates reversed line voltage polarity or grounding problem. Both heating and cooling operations will be affected. Check polarity at furnace and branch. Check furnace grounding. Check that flame probe is not shorted to chassis.

10 RED FLASHES: Flame sensed with no call for heat. Check gas valve and gas valve wiring.

11 RED FLA SHES: This indicates that a primary or auxiliary limit switch has opened its normally-closed contacts and has remained open for more than five minutes. This condition is usually caused by a failed blower motor or blower wheel. Cycle power (24 VAC) to the control to reset the hard lockout condition after correcting the failure condition.

12 RED FLASHES: This code indicates an open igniter circuit, which could be a disconnected or loose wire or a cracked or broken igniter.

STEADY ON RED: Control failure. Replace control board. 60-MINUTE AUTOMATIC RESET FROM LOCKOUT: This control

includes a “watchdog” type circuit that will reset from a lockout condition after 60 minutes. Operational faults 6,7,8 will be reset. This provides protection to an unoccupied structure if a temporary condition exists causing a furnace malfunction. An example would be a low incoming gas supply pressure preventing unit operation. When the gas pressure is restored, at some point the “watchdog” would restart the unit and provide heat for the house.

If a flame is detected the control flashes the LED for 1/8 of a second and then enters a flame stabilization period.

IGNITION CONTROL FLAME SENSE LEVELS

Normal flame sense current is approximately

3.7 microamps DC (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. This feature should only be used by a qualified service tech-

nician.

If more than five error codes have occurred since the last reset, only the five most recent will be retained. The furnace control board has a 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.

To retrieve the error codes, push the LAST ERROR button. The LED on the control will then flash the error codes that are in memory, starting with the most recent. There will be a two-second pause between each flash code. After the error codes have all been displayed, the LED will resume the normal slow green flash after a five second pause. To repeat the series of error codes, push the button again.

If there are no error codes in memory, the LED will flash two green flashes. To clear the memory, push the LAST ERROR button and hold it for more than five seconds. The LED will flash three green flashes when the memory has been cleared, then will resume the normal slow green flash after a five-second pause.

30 Johnson Controls Unitary Products

Page 31

FIGURE 36: Furnace Control Event Schedule

Thermostat Calling for Heat

Thermostat Satisfied

(Seconds)

THERMOSTAT

INDUCER

IGNITOR

MAIN VALVE

HUMIDIFIER

ELECTRONIC AIR CLEANER

CIRCULATING BLOWER

OFF

15 Sec. Post Purge

Fan on Delay 30 Seconds

17 22

60, 90, 120, 180 SEC. Selectable Fan Off Delay

SECTION XI: REPLACEMENT PARTS LIST

DESCRIPTION

MOTOR

MOTOR, DIRECT DRIVE BLOWER BLOWER, COMBUSTION

ELECTRICAL

CAPACITOR, RUN SWITCH, LIMIT CONTROL, FURNACE IGNITER SENSOR, FLAME SWITCHES, PRESSURE SWITCH, DOOR TRANSFORMER VALVE, GAS CONTROL, TEMPERATURE

AIR MOVING

HOUSING, BLOWER WHEEL, BLOWER

FABRICATED PARTS

RESTRICTOR, COMBUSTION BLOWER BURNER, MAIN GAS BRACKET, IGNITER SHELF, BLOWER RAIL, BLOWER (2 Req’d) BRACKET, BLOWER TRACK (2 Req’d) HEAT EXCHANGER ASS’Y

420705-UIM-C-0310

DESCRIPTION

FABRICATED PARTS Continued

MANIFOLD, GAS PAN, BOTTOM PANEL, TOP PANEL, DOOR (2 Req’d)

PANEL, BLOCKOFF

MISCELLANEOUS

ORIFICE, BURNER (Natural #45) SIGHT GLASS, OVAL (2 Req’d) GASKET, FOAM (Door) (1.5 ft req’d) PAN, CONDENSATE BRACKET, DOOR HARNESS, WIRING FERRULE (3 Req’d) GROMMET (3 Req’d)

MOTOR MOUNT

TUBING, SILICON HOSE, RAIN GUTTER HOSE, CONDENSATE PLUG, SEAL, 7/8” PLUG, SEAL, 2-3/8” PLUG, VENT PIPE BAG, PARTS

KNOB, QUARTER TURN (4 Req’d)

DIAGRAM, WIRING

REPLACEMENT PART CONTACT INFORMATION

This is a generic parts list. To request a complete parts list, refer to the contact information below:

Johnson Controls Unitary Products 31

• 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

Page 32

SECTION XII: WIRING DIAGRAM

FIGURE 37: Wiring Diagram

Johnson Controls Unitar y Prod uc ts

P.O. Box 19014

Wichita, KS 67204-9014

Johnson Controls MG9S*MP Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual