Johnson Controls TM9VMP User Manual

EFFICIENCY
RATING
CERTIFIED

ISO 9001

Certified Quality

Management System

RESIDENTIAL GAS FURNACE MODELS

INSTALLATION MANUAL

TM9V*MP

(96% AFUE Two Stage Variable Speed Multi-position)

LIST OF SECTIONS

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

CONDENSATE PIPING AND FURNACE

VENTING CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

LIST OF FIGURES

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

Vertical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Coil Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Horizontal Right Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Horizontal Left Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

PC Series Upflow Coil Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Horizontal Left or Right application (Right Shown) . . . . . . . . . . . . . . 6

Combustible Floor Base Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Horizontal Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Typical Attic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Typical Suspended Furnace / Crawl Space Installation . . . . . . . . . . . 7

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Side Return Cutout Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Upflow/Downflow Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Horizontal Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Thermostat Chart - Single Stage Air Conditioners

with Two Stage Variable Speed Furnaces . . . . . . . . . . . . . . . . . . . . 12

Thermostat Chart - Single Stage Heat Pump with Two Stage

Variable Speed Furnace (Hot Heat Pump or Conventional) . . . . . . 13

Thermostat Chart - Two Stage AC with

Two Stage Variable Speed Furnace . . . . . . . . . . . . . . . . . . . . . . . . 14

COMBUSTION AIR and VENT SYSTEM . . . . . . . . . . . . . . . . . . . .22

START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . .29

SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

REPLACEMENT PART CONTACT INFORMATION . . . . . . . . . . . . 36

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Thermostat Chart - Two Stage HP with Two Stage

Variable Speed Furnace (Hot Heat Pump or Conventional) . . . . . . .15

Typical. Condensate drain, vertical installation. . . . . . . . . . . . . . . . .16

Typical. Combustion Pipe Drain Tee. . . . . . . . . . . . . . . . . . . . . . . . .17

Upflow Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Downflow Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Horizontal Left Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Horizontal Right Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Home Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Termination Configuration - 1 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . .25

Termination Configuration - 2 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . .25

Termination Configuration - 2 Pipe Basement . . . . . . . . . . . . . . . . .25

Double Horizontal Combustion Air Intake and Vent Termination . . .25

Double Vertical Combustion Air Intake and Vent Termination . . . . . 25

Direct Vent Air Intake Connection and Vent Connection . . . . . . . . .26

Combustion Airflow Path Through The Furnace Casing . . . . . . . . .26

Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . .27

Attic and Crawl Space Combustion Air Termination . . . . . . . . . . . . .28

Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Furnace Control Event Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

LIST OF TABLES

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

Coil Projection Dimensions - PC Series Coils . . . . . . . . . . . . . . . . . . 6

Cabinet and Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Recommended Filter Sizes (High Velocity 600 FPM) . . . . . . . . . . . . 8

Nominal Manifold Pressure - High Fire . . . . . . . . . . . . . . . . . . . . . . 10

Nominal Manifold Pressure - Low Fire . . . . . . . . . . . . . . . . . . . . . . . 10

Ratings & Physical / Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . 11

Maximum Equivalent Pipe Length . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Elbow Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

These high efficiency, compact units employ induced combustion, reli­able hot surface ignition and high heat transfer aluminized tubular heat
exchangers. The units are factory shipped for installation in upflow or
horizontal applications and may be converted for downflow applica­tions.
These furnaces are designed for residential installation in a basement,
closet, alcove, attic, recreation room or garage and are also ideal fo r
commercial applications. All units are factory assembled, wired and
tested to assure safe dependable and economical installation and oper­ation.
These units are Category IV listed and may not be common vented with
another gas appliance as allowed by the National Fuel Gas Code.

Equivalent Length of Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Combustion Air Intake and Vent Connection Size at

Furnace (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Unconfined Space Minimum Area in Square Inch . . . . . . . . . . . . . . 27

Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Gas Rate (CU FT/HR) at Full Input . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

SECTION I: SAFETY

This is a safety alert symbol. When you see this symbol on
labels or in manuals, be alert to the potential for personal
injury.

Understand and pay particular attention to the signal words DANGER,

WARNING, or CAUTION.
DANGER indicates an imminently hazardous situation, which, if not

avoided, will result in death or serious injury
WARNING indicates a potentially hazardous situation, which, if not

avoided, could result in death or serious injury
CAUTION indicates a potentially hazardous situation, which, if not

avoided may result in minor or moderate injury.
alert against unsafe practices and hazards involving only property dam­age.

.

.

It is also used to

438335-UIM-B-0509

438335-UIM-B-0509

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 contractor, 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 shall also be handled by duct(s) sealed to the fur­nace casing and terminating outside the space containing the fur­nace.

9. It is permitted to use the furnace for heating of buildings or struc­tures under construction where the application and use must com­ply with all manufacturer’s installation instructions including:

• Proper vent installation;

• Furnace operating under thermostatic control;

• Return air duct sealed to the furnace;

• Air filters in place;

• Set furnace input rate and temperature rise per rating plate

marking;

• Means for providing outdoor air required for combustion;

• Return air temperature maintained between 55ºF (13ºC) and

80ºF (27ºC);

• The air filter must be replaced upon substantial completion of

the construction process;

• Clean furnace, duct work and components upon substantial

completion of the construction process, and verify furnace­operating conditions including ignition, input rate, temperature
rise and venting, according to the manufacturer’s instructions.

10. When installed in a non-HUD-Approved Modular Home or building
constructed on-site, combustion air shall not be supplied from
occupied spaces.

11. The size of the unit should be based on an acceptable heat loss
calculation for the structure. ACCA, Manual J or other approved
methods may be used.

SAFETY REQUIREMENTS

This product must be installed in strict compliance with the installa­tion instructions and any applicable local, state, and national codes
including, but not limited to building, electrical, and mechanical
codes.

• Refer to the unit rating plate for the furnace model number, and
then see the dimensions page of this instruction for return air ple­num dimensions in Figures 12. The plenum must be installed
according to the instructions.

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

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

• These models ARE NOT
into a HUD Approved Modular Home
(Mobile) Home.

• This furnace is not approved for installation in trailers or recre­ational vehicles.

• Furnaces for installation on combustible flooring shall not be
installed directly on carpeting, tile or other combustible material
other than wood flooring.

• Check the rating plate and power supply to be sure that the elec­trical characteristics match. All models use nominal 115 VAC, 1
Phase, 60-Hz power supply. DO NOT CONNECT THIS APPLI­ANCE TO A 50-Hz POWER SUPPLY OR A VOLTAGE ABOVE
130 VOLTS.

• Furnace shall be installed so the electrical components are pro­tected from water.

• Installing and servicing heating equipment can be hazardous due
to the electrical components and the gas fired components. Only
trained and qualified personnel should install, repair, or service
gas heating equipment. Untrained service personnel can perform
basic maintenance functions such as cleaning and replacing the
air filters. When working on heating equipment, observe precau­tions in the manuals and on the labels attached to the unit and
other safety precautions that may apply.

CSA listed or approved for installation

or a Manufactured

COMBUSTION AIR QUALITY
(LIST OF CONTAMINANTS)

The furnace requires OUTDOOR AIR for combustion when the furnace
is located in any of the following environments.

• Buildings with indoor pools

• Chemical exposure

• Commercial buildings

• Furnaces installed in hobby or craft rooms

• Furnaces installed in laundry rooms

• Furnaces installed near chemical storage areas

• Restricted Environments

The furnace requires OUTDOOR AIR for combustion when the furnace
is located in an area where the furnace is being exposed to the follow­ing substances and / or chemicals.

• Antistatic fabric softeners for clothes dryers

• Carbon tetrachloride

• Cements and glues

• Chlorinated waxes and cleaners

• Chlorine-based swimming pool chemicals

• Cleaning solvents (such as perchloroethylene)

• De-icing salts or chemicals

• Halogen type refrigerants

• Hydrochloric acid

• Masonry acid washing materials

• Permanent wave solutions

• Printing inks, paint removers, varnishes, etc.

• Water softening chemicals

When outdoor air is used for combustion, the combustion air intake duct
system termination must be located external to the building and in an
area where there will be no exposure to the substances listed above.

2 Johnson Controls Unitary Products

The furnace area must not be used as a broom closet or for any
other storage purposes, as a fire hazard may be created. Never
store items such as the following on, near or in contact with the fur­nace.

1. Spray or aerosol cans, rags, brooms, dust mops, vacuum
cleaners or other cleaning tools.

2. Soap powders, bleaches, waxes or other cleaning com­pounds; plastic items or containers; gasoline, kerosene, ciga­rette lighter fluid, dry cleaning fluids or other volatile fluid.

3. Paint thinners and other painting compounds.

4. Paper bags, boxes or other paper products

Never operate the furnace with the blower door removed. To
do so could result in serious personal injury and/or equipment
damage.

CODES AND STANDARDS

Follow all national, local codes and standards in addition to this installa­tion manual. The installation must comply with regulations of the serv­ing gas supplier, local building, heating, plumbing, and other codes. In
absence of local codes, the installation must comply with the national
codes listed below and all authorities having jurisdiction.

In the United States and Canada, follow all codes and standards for the
following, using the latest edition available:

STEP 1 -Safety

• US: National Fuel Gas Code (NFGC) NFPA 54/ANSI Z223.1 and
the Installation Standards, Warm Air Heating and Air Conditioning
Systems ANSI/NFPA 90B

• CANADA: CAN/CGA-B149.1 National Standard of Canada. Natu­ral Gas and Propane Installation Codes (NSCNGPIC)

STEP 2 -General Installation

• US: Current edition of the NFGC and NFPA 90B. For copies, con­tact the

National Fire Protection Association Inc.
Batterymarch Park
Quincy, MA 02269

or for only the NFGC, contact the

American Gas Association,
400 N. Capital, N.W.
Washington DC 20001

or www.NFPA.org

• CANADA: NSCNGPIC. For a copy contact:

Standard Sales, CSA International
178 Rexdale Boulevard
Etobicoke, (Toronto) Ontario Canada M9W 1RS

STEP 3 -Combustion and Ventilation Air

• US: Section 5.3 of the NFGC, air for Combustion and Ventilation

• CANADA: Part 7 of NSCNGPIC, Venting Systems and Air Supply
for Appliances

STEP 4 -Duct Systems

• US and CANADA: Air Conditioning Contractors Association
(ACCA) Manual D, Sheet Metal and Air Conditioning Contractors
Association National Association (SMACNA), or American Soci­ety of Heating, Refrigeration, and Air Conditioning Engineers
(ASHRAE) 1997 Fundamentals Handbook Chapter 32.

STEP 5 -Acoustical Lining and Fibrous Glass Duct

• US and CANADA: Current edition of SMACNA and NFPA 90B as
tested by UL Standard 181 for Class I Rigid Air Ducts

STEP 6 -Gas Piping and Gas Pipe Pressure Testing

• US: NFGC; chapters 2, 3, 4, & 9 and National Plumbing Codes

• CANADA: NSCNGPIC Part 5

STEP 7 -Electrical Connections

• US: National Electrical Code (NEC) ANSI/NFPA 70

• CANADA: Canadian Electrical Code CSA C22.1

438335-UIM-B-0509

These instructions cover minimum requirements and conform to exist­ing national standards and safety codes. In some instances these
instructions exceed certain local codes and ordinances, especially
those who have not kept up with changing residential and non-HUD
modular home construction practices. These instructions are required
as a minimum for a safe installation.

FOR FURNACES INSTALLED IN THE COMMON­WEALTH OF MASSACHUSETTS ONLY

For all side wall horizontally vented gas fueled equipment installed in
every dwelling, building or structure used in whole or in part for resi­dential purposes, including those owned or operated by the Com­monwealth and where the side wall exhaust vent termination is less
than seven (7) feet above finished grade in the area of the venting,
including but not limited to decks and porches, the following require­ments shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At
the time of installation of the side wall horizontal vented gas
fueled equipment, the installing plumber or gasfitter shall
observe that a hard wired carbon monoxide detector with an
alarm and battery back-up is installed on the floor level where
the gas equipment is to be installed. In addition, the installing
plumber or gasfitter shall observe that a battery operated or
hard wired carbon monoxide detector with an alarm is installed
on each additional level of the dwelling, building or structure
served by the side wall horizontal vented gas fueled equipment.
It shall be the responsibility of the property owner to secure the
services of qualified licensed professionals for the installation of
hard wired carbon monoxide detectors

a. In the event that the side wall horizontally vented gas

fueled equipment is installed in a crawl space or an attic,
the hard wired carbon monoxide detector with alarm and
battery back-up may be installed on the next adjacent floor
level.

b. In the event that the requirements of this subdivision can

not be met at the time of completion of installation, the
owner shall have a period of thirty (30) days to comply with
the above requirements; provided, however, that during
said thirty (30) day period, a battery operated carbon mon­oxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each car­bon monoxide detector as required in accordance with the
above provisions shall comply with NFPA 720 and be ANSI/UL
2034 listed and IAS certified.

3. SIGNAGE. A metal or plastic identification plate shall be perma­nently mounted to the exterior of the building at a minimum
height of eight (8) feet above grade directly in line with the
exhaust vent terminal for the horizontally vented gas fueled
heating appliance or equipment. The sign shall read, in print
size no less than one-half (1/2) inch in size, "GAS VENT

DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUC­TIONS".

4. INSPECTION. The state or lo cal gas inspector of the side wall
horizontally vented gas fueled equipment shall not approve the
installation unless, upon inspection, the inspector observes car­bon monoxide detectors and signage installed in accordance
with the provisions of 248 CMR 5.08(2)(a)1 through 4.

INSPECTION

As soon as a unit is received, it should be inspected for possib le dam­age during transit. If damage is evident, the extent of the damage
should be noted on the carrier’s freight bill. A separate request for
inspection by the carrier’s agent should be made in writing. Also, before
installation, the unit should be checked for screws or bolts which may
have loosened in transit. There are no shipping or spacer brackets
which need to be removed from the interior of this unit.

Johnson Controls Unitary Products 3

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FURNACE LOCATION AND CLEARANCES

The furnace shall be located using the following guidelines:

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

2. As centralized with the air distribution as possible.

3. Where adequate combustion air will be available (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.

4. Special precautions MUST be made if installing furnace in an area
which may drop below freezing. This can cause improper opera­tion or damage to the equipment. If the furnace is installed in an
area that has the potential of freezing, the drain line must be pro­tected. Use a 3 to 6 watt per foot at 115 vac, 40º F (4.4°C) self-reg­ulating, shielded and waterproof heat tape. Wrap the drain line
outside of the furnace with the heat tape and secure with ties. Fol­low the heat tape manufacturer's recommendations.

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

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” (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

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

Front* 0" 0" 0"

Floor Combustible

Closet Yes Yes Yes

Line Contact No No Yes

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

Upflow Downflow Horizontal

1

Combustible

Combustible

SECTION II: DUCTWORK

DUCTWORK GENERAL INFORMATION

The duct system’s design and installation must:

1. Handle an air volume appropriate for the served space and within
the operating parameters of the furnace specifications.

2. Be installed in accordance of National Fire Protection Association
as outlined in NFPA standard 90B (latest editions) or applicable
national, provincial, state, and local fire and safety codes.

3. Create a closed duct system. For residential and non-HUD Modu­lar Home installations, when a furnace is installed so that the sup­ply ducts carry air circulated by the furnace to areas outside the
space containing the furnace, the return air shall also be handled
by a duct(s) sealed to the furnace casing and terminating outside
the space containing the furnace.

4. Complete a path for heated or cooled air to circulate through the
air conditioning and heating equipment and to and from the condi­tioned space.

The cooling coil must be installed in the supply air duct, down­stream of the furnace. Cooled air may not be passed over the heat
exchanger.

When the furnace is used with a cooling coil, the coil must be installed
parallel with, or in the supply air side of the furnace to avoid condensa­tion in the primary heat exchanger. When a parallel flow arrangement is
used, dampers or other means used to control airflow must be ade­quate to prevent chilled air from entering the furnace. If manually oper­ated, the damper must be equipped with means to prevent the furnace
or the air conditioner from operating unless the damper is in full heat or
cool position.

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” (10.2 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” (5.1 cm) minimum spacing may be needed to ensure
against drain pan distortion.

4 Johnson Controls Unitary Products

438335-UIM-B-0509

Factory
installed

For duct attachment,
if needed.

UPFLOW

DOWNFLOW

Furnace

Furnace

ALTERNATE
FLANGE LOCATION
(Used for downflow or
horizontal left installations)

FACTORY

FLANGE

LOCATION

(Used for upflow

or horizontal

right installations)

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

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

Refer to T able7 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.

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.

Attach the air conditioning coil cabinet to the duct connector, and then
position the furnace on top of the coil cabinet. The connection to the fur­nace, air conditioning coil cabinet, duct connector, and supply air duct
must be sealed to prevent air leakage.

COIL INSTALLATION

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.

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

FIGURE 1: Duct Attachment

DUCTWORK INSTALLATION AND SUPPLY PLENUM
CONNECTION - UPFLOW/HORIZONTAL

FLOOR BASE AND DUCTWORK INSTALLATION ­DOWNFLOW

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.

Johnson Controls Unitary Products 5

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.

Installations on combustible material or directly on any
floors must use a combustible floor base shown in Figures

8. Follow the instructions supplied with the combustible
floor base accessory. This combustible floor base can be
replaced with a matching cooling coil, properly sealed to
prevent leaks. Follow the instructions supplied with the
cooling coil cabinet for installing the cabinet to the duct con­nector. Plug intake and vent pipe holes in bottom panel and
move grommet to desired vent side exit.

Downflow Air Conditioning Coil Cabinet

FIGURE 2: Vertical Applications

FURNACE ASSEMBLY - MC & FC SERIES COILS

These coils are factory shipped for installation in either upflow or down­flow applications with no conversion.

Position the coil casing over or under the furnace opening as shown in
Figures 2 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 Figures 3.

FIGURE 3: Coil Flange

438335-UIM-B-0509

Furnace

Mounting Plate

Furnace

Mounting Plate

Flexible
Duct Collar

Do not drill
or Screw
this flange

Field
Fabricated
Ductwork

Upflow
Coil

Upflow
Furnace

Secondary

Drain

Primary

Drain

D

C

(Min)

Alternate

Drain Location

Use tie plate
supplied with coil

Air flow

Gas Furnace

FURNACE ASSEMBLY - MC SERIES COILS ONLY

MC coils are supplied ready to be installed in a horizontal position. A
horizontal pan is factory installed. MC coils should be installed in all hor­izontal applications with the horizontal drain pan side down.

FIGURE 4: Horizontal Right Application
For horizontal left hand applications no conversion is required to an MC

coil when used with a downflow/horizontal furnace. A mounting plate,
supplied with every coil should always be installed on the side desig­nated as top side. See Figures 4 & 5.

FIGURE 5: Horizontal Left Application

FURNACE ASSEMBLY - PC SERIES COILS

These upflow coils are designed for installation on top of upflow fur­naces only.

If the coil is used with a furnace of a different size, use a 45° transition
to allow proper air distribution through the coil.

1. Position the coil casing over the furnace opening as shown in
Figures 6.

2. Place the ductwork over the coil casing flange and secure.

3. Check for air leakage between the furnace and coil casing and
seal appropriately.

Do not drill any holes or drive any screws into the front duct
flange on the coil in order to prevent damaging coil tubing. See
Figures 6

FIGURE 6: PC Series Upflow Coil Installation

Table 2: Coil Projection Dimensions - PC Series Coils

COIL SIZE DIMENSION “C” INCH

PC18 3-1/2
PC24 4-1/2

PC30, PC32, PC35 4-1/2

PC42, PC43, PC36, PC37 5-1/2

PC48 6-1/2
PC60 9

NOTE: Dimension “C” should be at least 2/3 of dimension “D”.
See Figures 6

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.

COIL / FURNACE ASSEMBLY - HC SERIES COILS

These coils are supplied ready to be installed in a right hand position or
a left hand position. When used in conjunction with a horizontal furnace
(blow through) application, the coil should be oriented with the opening
of the “A” coil closest to the furnace. See Figure 6.

NOTE: Each coil is shipped with an external tie plate that should be
used to secure the coil to the furnace. It should be installed on the back
side of the coil using the dimpled pilot holes. See Figure 6.

6 Johnson Controls Unitary Products

FIGURE 7: Horizontal Left or Right application (Right Shown)

438335-UIM-B-0509

FURNACE

WARM AIR PLENUM
WITH 1” FLANGES

FIBERGLASS
INSULATION

FIBERGLASS TAPE
UNDER FLANGE

COMBUSTIBLE FLOOR
BASE ACCESSORY

Return
Air

Sediment

Trap

Gas Piping

Supply
Air

Vent (Maintain
required
clearances to
combustibles)

Line contact only permissible
between lines formed by the
intersection of furnace top
and two sides and building
joists, studs or framing

12”

30” MIN.
Work Area

Filter rack
must be a minimum
distance
of 18” (45.7 cm)
from the
furnace

12”

Sheet metal in
front of furnace
combustion air
Openings is
Recommended

Support
Rod

Support
Angle (x3)

Maintain 6” minimum
clearance between support
rods and front of furnace

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.

ATTIC INSTALLATION

FIGURE 10: Typical Attic Installation

This appliance is certified for line contact when the furnace is installed
in the horizontal left or right position. The line contact is only permissible
between lines that are formed by the intersection of the top and two
sides of the furnace and the building joists, studs or framing. This line
may be in contact with combustible material. Refer to Figures 10.

When a furnace is installed in an attic or other insulated space,
keep all insulating materials at least 12” (30.5 cm) away from fur­nace and burner combustion air openings.

FIGURE 8: Combustible Floor Base Accessory

RESIDENTIAL AND MODULAR HOME UPFLOW
RETURN PLENUM CONNECTION

Return air may enter the furnace through the side(s) or bottom depend­ing on the type of application. Return air may not be connected into the
rear panel of the unit.

BOTTOM RETURN AND ATTIC INSTALLATIONS

Bottom return applications normally pull return air through a base plat­form or return air plenum. Be sure the return platform structure or return
air plenum is suitable to support the weight of the furnace.

The internal bottom panel must be removed for this application.
Attic installations must meet all minimum clearances to combustibles

and have floor support with required service accessibility.

HORIZONTAL APPLICATION

FIGURE 9: Horizontal Application

This furnace may be installed in a horizontal position on either side
as shown above. It must not be installed on its back.

Johnson Controls Unitary Products 7

SUSPENDED FURNACE / CRAWL SPACE
INSTALLATION

The furnace can be hung from floor joists or installed on suitable blocks
or pad. Blocks or pad installations shall provide adequate height to
ensure the unit will not be subject to water damage. Units may also be
suspended from rafters or floor joists using rods, pipe angle supports or
straps. Angle supports should be placed at the supply air end and near
the blower deck. Do not support at return air end of unit. All four sus­pension points must be level to ensure quite furnace operation. When
suspending the furnace use a secure platform constructed of plywood
or other building material secured to the floor joists. Refer to for typical
crawl space installation.

FIGURE 11: Typical Suspended Furnace / Crawl Space Installation

438335-UIM-B-0509

FRONT

33

A

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”)

C

SUPPLY END

.56”

.56”

20”

B

3”

23.8”

.56”

Combustion
Air Inlet

Vent
Outlet

RETURN END

B

24.25”

Front of
Furnace

Corner
Markings

Side of
Furnace

FIGURE 12: Dimensions

Table 3: Cabinet and Duct Dimensions

BTUH (kW)

Input

Nominal

CFM (m

3

/min)

Cabinet

Size

Cabinet Dimensions (Inches)

A (in) A (cm) B (in) B (cm) C (in) C (cm) Lbs (kg)

Approximate

Operating Weights

60 (17.6) 1200 (34.0) B 17 1/2 44.4 16 3/8 41.6 13 1/4 33.7 122 (55.3)
80 (23.4) 1200 (34.0) B 17 1/2 44.4 16 3/8 41.6 14 3/4 37.5 126 (57.1)

80 (23.4) 1600 (45.3) C 21 53.3 19 7/8 50.5 16 1/2 41.9 136 (61.7)
100 (29.3) 1600 (45.3) C 21 53.3 19 7/8 50.5 18 1/4 46.4 142 (64.4)
100 (29.3) 2000 (56.6) C 21 53.3 19 7/8 50.5 18 1/4 46.4 145 (65.8)
120 (35.1) 2000 (56.6) D 24 1/2 62.2 23 3/8 59.4 21 3/4 55.2 156 (70.7)

SECTION III: FILTERS

FILTER INSTALLATION

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.
NOTE: 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)

NOTES:

CFM

(m³/min)

Cabinet

Size

Side

(in)

1200 (34.0) B 16 x 25 16 x 25
1600 (45.3) C 16 x 25 20 x 25
2000 (56.6) C (2) 16 x 25 20 x 25
2000 (56.6) D (2) 16 x 25 22 x 25

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

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

minute (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.

Bottom

(in)

SIDE RETURN

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

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 Figures 12.

8 Johnson Controls Unitary Products

HORIZONTAL APPLICATION

INLET

WRENCH
BOSS

INLET
PRESSURE
PORT

ON OFF
SWITCH

LOW STAGE REGULATOR
ADJUSTMENT

OUTLET

OUTLET
PRESSURE
PORT

VENT
PORT

HIGH STAGE REGULATOR
ADJUSTMENT

External Manual
Shutoff Valve

To Gas
Supply

To Gas

Supply

Grounded Joint Union

may be Installed

Inside or Outside Unit.

Drip Leg

Manual
Shut-off
Valve

Gas
Pipe

Gas
Pipe

Drip
Leg

Manual
Shut-off Valve

Gas Valve

Gas Burners

Drip
Leg

Horizontal Filters

All filters and mounting provision must be field supplied. All installa­tions must have a filter installed.

Any branch duct (rectangular or round duct) attached to the plenum
must attach to the vertical plenum before the filter. The use of straps
and/or supports is required to support the weight of the external filter
box.

Downflow Filters

Downflow furnaces typically are installed with the filters located above
the furnace, extending into the return air plenum or duct. Any branch
duct (rectangular or round duct) attached to the plenum must attach to
the vertical plenum above the filter height.

Filter(s) may be located in the duct system external to the furnace using
an external duct filter box attached to the furnace plenum or at the end
of the duct in a return filter grille(s). The use of straps and/or supports is
required to support the weight of the external filter box.

SECTION IV: GAS PIPING

GAS SAFETY

438335-UIM-B-0509

FIGURE 15: Upflow/Downflow Gas Piping

An overpressure protection device, such as a pressure regulator,

FIGURE 16: Horizontal Gas Piping

must be installed in the gas piping system upstream of the furnace
and must act to limit the downstream pressure to the gas valve so it
does not exceed 0.5 psig [14" w.c. (3.48 kPa)]. Pressures exceed­ing 0.5 psig [14” w.c. (3.48 kPa)] at the gas valve will cause damage
to the gas valve, resulting in a fire or explosion or cause damage to

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 or some of its components that will result in property
damage and loss of life.

The furnace must be isolated from the gas supply piping system by
closing its individual external manual shutoff valve during any pressure
testing of the gas supply piping system at pressures equal to or less
than 0.5 psig (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 octa-

gon 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 14: Gas Valve

Figures 12.

GAS ORIFICE CONVERSION FOR PROPANE (LP)

This furnace is constructed at the factory for natural gas-fired operation,

Plan your gas supply before determining the correct gas pipe entry.
Use 90-degree service elbow(s), or short nipples and conventional
90-degree elbow(s) to enter through the cabinet access holes.

GAS PIPING INSTALLATION

Properly sized wrought iron, approved flexible or steel pipe must be
used when making gas connections to the unit. 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 Figures 15.

Johnson Controls Unitary Products 9

but may be converted to operate on propane (LP) gas by using a
factory-supplied LP conversion kit. Follow the instructions supplied with
the LP kit.

HIGH ALTITUDE GAS ORIFICE CONVERSION

This furnace is constructed at the factory for natural gas-fired operation
at 0 –5,000 feet (0 – 1,524 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 5,000 feet (1,524 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.

438335-UIM-B-0509

Table 5: Nominal Manifold Pressure - High Fire

Manifold Pressures (in. w.c.) 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 31.7 0.87 0.87 0.87
900 3.5 3.5 3.5 33.5 0.87 0.87 0.87
950 3.5 3.5 3.3 35.4 0.87 0.87 0.81

1000 3.5 3.2 2.9 37.3 0.87 0.80 0.73

(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

29.8 0.87 0.87 0.87

(MJ/cu m)

Gas Heating Value

TABLE 6:

Nominal Manifold Pressure - Low Fire

First Stage Manifold Pressures (in. w.c.) First Stage Manifold Pressures (kPa)

Altitude (feet) Altitude (m)

0-7999 8000-8999 9000-9999 0-2437 2438-2742 2743-3048
800 1.7 1.7 1.7
850 1.7 1.7 1.7 31.7 0.42 0.42 0.42
900 1.7 1.7 1.7 33.5 0.42 0.42 0.42
950 1.7 1.7 1.5 35.4 0.42 0.42 0.38

1000 1.6 1.5 1.4 37.3 0.41 0.37 0.34

(BTU/cu ft.)

Gas Heating Value

1050 1.5 1.4 1.3 39.1 0.37 0.34 0.31
1100 1.3 1.2 1.1 41.0 0.34 0.31 0.28

2500 (LP) 4.1 3.8 3.5 93.2 (LP) 1.03 0.95 0.87

(MJ/cu m)

Gas Heating Value

29.8 0.42 0.42 0.42

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 T able7 in
these instructions for specific furnace electrical data.

Use copper conductors only.

10 Johnson Controls Unitary Products

438335-UIM-B-0509

Electrical Entry

Junction
Box

L1-Hot

Neutral

Connect ground
lead to screw

BLK

WHT

Table 7: Ratings & Physical / Electrical Data

Input

High/Low

MBH kW MBH kW CFM
60/39 18/11 58/3 7 17/11 1200 34 17-1/2 44.4 9 96 35 - 65 1.6 - 18.3 35 - 65 1.6 - 18.3
80/52 23/15 77/5 0 22/14 1200 34 17-1/2 44.4 9 96 35 - 65 1.6 - 18.3 30 - 60 -1 - 15.5
80/52 23/15 77/5 0 22/14 1600 45.3 21 53.3 12 96 35 - 65 1.6 - 18.3 35 - 65 1.6 - 18.3

100/65 29/19 96/62 28/18 1600 45.3 21 53.3 12 96 35 - 65 1.6 - 18.3 30 - 60 -1 - 15.5
100/65 29/19 96/62 28/18 2000 56.6 21 53.3 14 96 35 - 65 1.6 - 18.3 35 - 65 1.6 - 18.3
120/78 35/23 115/75 33/22 2000 56.6 24-1/2 62.2 14 96 35 - 65 1.6 - 18.3 35 - 65 1.6 - 18.3

Input

High/Low

MBH kW °F °C HP Amps in. cm Lbs. Kg.
60/39 18/11 170 76.7 1/2 7 11 x 8 27.9 x 20.3 15 14 122 55.3
80/52 23/15 175 79.4 1/2 7 11 x 8 27.9 x 20.3 15 14 126 57.1
80/52 23/15 175 79.4 3/4 10.2 11 x 10 27.9 x 25.4 15 14 136 61.7

100/65 23/15 175 79.4 3/4 10.2 11 x 10 27.9 x 25.4 15 14 142 64.4
100/65 29/19 175 79.4 1 12.7 11 x 11 27.9 x 27.9 20 12 145 65.7
120/78 35/23 170 76.7 1 12.7 11 x 11 27.9 x 27.9 20 12 156 70.7

Annual Fuel Utilization Efficiency (AFUE) numbers are determined in accordance with DOE test procedures.
Wire size and over current protection must comply with the National Electrical Code (NFPA-70-latest edition) and all local codes.
The furnace shall be installed so that the electrical components are protected from water.

Output

High/Low

Max. Outlet

Air Temp.

Nominal

Airflow

m3/min

Blower Blower Size

Cabinet Width

in. cm % °F °C °F °C

Over-current

Total Unit

Amps

Max.

Protect

AFUE

Min. Wire Size
(awg) @ 75 ft.

One Way

High Fire

Air Temp. Rise

Operating

Weight

Low Fire

Air Temp. Rise

SUPPLY VOLTAGE CONNECTIONS

FIGURE 17: Electrical Wiring

1. Provide a power supply separate from all other circuits. Install

2. Remove the wiring box cover screws. Route all power wiring

3. The furnace's control system requires correct polarity of the power

Johnson Controls Unitary Products 11

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.

through a conduit connector or other proper bushing that has been
installed into the unit opening and the junction box. In the junction
box there is a black wire, a white wire and a green ground screw.
Connect the power supply as shown on the unit’s wiring label
located on the inside of the blower compartment door, or the wiring
schematic in this section. Connect the black wire to L1 (hot) from
the power supply. Connect the white wire to neutral. Connect the
ground wire (installer-supplied) to the green (equipment ground)
screw. An alternate wiring method is to use a field-provided 2”
(5.1 cm) x 4” (10.2 cm) box and cover on the outside of the fur­nace. Route the furnace leads into the box using a protective
bushing where the wires pass through the furnace panel. After
making the wiring connections replace the wiring box cover and
screws. Refer to Figures 17.

supply and a proper ground connection. Refer to Figures 17.

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

LOW VOLTAGE CONTROL WIRING CONNECTIONS

Install the field-supplied thermostat by following the instructions that
come with the thermostat. With the thermostat set in the OFF position
and the main electrical source disconnected, connect the thermostat
wiring from the wiring connections on the thermostat to the terminal
board on the ignition module, as shown in Figures 18. 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 wir es 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.

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.

438335-UIM-B-0509

AC 9A Single Stage Air Conditioner – Two Stage Variable Speed Furnace

Connection of the “C”

terminal, 24-Volt common

is optional when used with

batteries

C

24 – Volt Common

R

24 – Volt Hot

Y

First Stage Compressor

Y2

Second Stage

Compressor

G

Fan

*DN22C00124

THERMOSTAT

W2

Second Stage Heat

C

24 – Volt Common

R

24 – Volt Hot

Y1

First Stage Compressor

Y2

Second Stage

Compressor

G

Fan

*DP22U70124

THERMOSTAT

W2

Second Stage Heat

Step 1 of Thermostat User

Configuration Menu must

be set to MS 2

W

First Stage Heat

E/W1

First Stage Heat

Connection of the “C”

terminal, 24-Volt common

is optional when used with

batteries

Part Number:

S1-2HU16700124

External Humidistat

(Optional)

Open on Humidity Rise

C

24 – Volt Common

Y

Compressor

Y

Compressor Contactor

SINGLE STAGE

AIR

CONDITIONER

Part Numbers:

SAP = Legacy
265904 = 031-09169
449572

1

C

24 – Volt Common

R

24 – Volt Hot

Y1
Single Stage
Compressor

TWO STAGE

VARIABLE SPEED

FURNACE CONTROL

G

Fan

TWO STAGE

VARIABLE SPEED

FURNACE

W/W1

First Stage Heat

Y/Y2

Second or Full

Stage Compressor

W2

Second Stage Heat

O

Reversing Valve

X/L

Malfunction Light

DHUM

Dehumidification

1

Move DHUM

jumper to “YES”

if humidistat is to be used.

PV(8/9)

ID MODELS

(F/L)*(8/9)V
(G/L)*(8/9)V

C

24 – Volt Common

Y

First Stage Compressor

Y2

Second Stage

Compressor

G

Fan

*PP32U70124

THERMOSTAT

W2

Second Stage Heat

R
24 – Volt Hot
(Heat XFMR)

RC
24 – Volt Hot
(Cool XFMR)

Connection of the “C”

terminal, 24-Volt common

is optional when used with

batteries

Thermostat Installer Setup

0170-System Type-must

be set to 9-2 Heat/1 Cool

Multistage Conventional

C

24 – Volt Common

Y

First Stage Compressor

Y2

Second Stage

Compressor

G

Fan

*DN22U00124

THERMOSTAT

W2

Second Stage Heat

R
24 – Volt Hot
(Heat XFMR)

RC
24 – Volt Hot
(Cool XFMR)

W

First Stage Heat

W

First Stage Heat

Connection of the “C”

terminal, 24-volt common

is optional when used with

batteries

Thermostat Installer Setup

1-System Type-must

be set to 7-2 Heat/1 Cool

Multistage Conventional

Thermostat Installer Setup
15-Compressor Protection

-must be set to 5
2

2

TM(8/9)V

For additional connection diagrams for all UPG equipment refer to “Low Voltage System Wiring” document available on-line at www.upgnet.com in
the Product Catalog Section.

FIGURE 18: Thermostat Chart - Single Stage Air Conditioners with Two Stage Variable Speed Furnaces

12 Johnson Controls Unitary Products