Johnson Controls TP9C C, YP9C C, CP9C C, LP9C C Installation Manual

EFFICIENCY
RATING
CERTIFIED

When paired with a

York heat pump

RESIDENTIAL GAS FURNACE

INSTALLATION MANUAL

WITH ECM MOTOR

MODELS:
TP9C*C, YP9C*C, CP9C*C, LP9C*C

(Up to 98% Modulating Multi-position)

LIST OF SECTIONS

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

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

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

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

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

CONDENSATE PIPING AND FURNACE

VENTING CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . 21

LIST OF FIGURES

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

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

Horizontal Application (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Typical Attic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

Downflow Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Vertical Applications (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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

Horizontal Right Application (Typical) . . . . . . . . . . . . . . . . . . . . . 8

Horizontal Left Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

Horizontal Left or Right application (Right Shown) . . . . . . . . . . . 8

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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

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

Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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

Furnace Control Board – Communications Connections . . . . . 13

Modulating Furnace with Communicating AC or HP . . . . . . . . . 14

Modulating Furnace with Communicating Thermostat and

Non-Communicating AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Thermostat Chart - Single Stage Air Conditioner –

Variable Speed Modulating Furnace . . . . . . . . . . . . . . . . . . . . . 15

Thermostat Chart - Two Stage Air Conditioner –

Variable Speed Modulating Furnace . . . . . . . . . . . . . . . . . . . . . 16

Thermostat Chart - Two Stage Air Conditioner with Single Stage

Thermostat – Variable Speed Modulating Furnace . . . . . . . . . .17

Thermostat Chart - Single Stage Heat Pump –

COMBUSTION AIR and VENT SYSTEM . . . . . . . . . . . . . . . . . 27

START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . 34

SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

NORMAL OPERATION AND DIAGNOSTICS . . . . . . . . . . . . . 39

REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . 41

REPLACEMENT PART CONTACT INFORMATION . . . . . . . . 41

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Variable Speed Modulating Furnace . . . . . . . . . . . . . . . . . . . . . 18

Thermostat Chart - Single Stage Heat Pump –

Variable Speed Modulating Furnace . . . . . . . . . . . . . . . . . . . . . 19

Thermostat Chart - Two Stage Heat Pump –

Variable Speed Modulating Furnace . . . . . . . . . . . . . . . . . . . . . 20

Typical Condensate drain, vertical instal lation . . . . . . . . . . . . . 22

Typical Combustion Pipe Drain Tee . . . . . . . . . . . . . . . . . . . . . 22

Upflow Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Downflow Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Horizontal Left Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Horizontal Right Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 26

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Home Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Termination Configuration - 1 Pipe . . . . . . . . . . . . . . . . . . . . . . 30

Termination Configuration - 2 Pipe . . . . . . . . . . . . . . . . . . . . . . 30

Termination Configuration - 2 Pipe Basement . . . . . . . . . . . . . 30

Double Horizontal Combustion Air Intake

and Vent Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Double Vertical Combustion Air Intake

and Vent Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Downward Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Direct Vent Air Intake Connection and Vent Connection . . . . . . 31

Combustion Airflow Path Through The Furnace Casing . . . . . . 31

Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . 32

Attic and Crawl Space Combustion Air Termination . . . . . . . . . 33

Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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

High Altitude Orifices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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

Maximum Equivalent Pipe Length . . . . . . . . . . . . . . . . . . . . . . . 27

Elbow Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Equivalent Length of Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Combustion Air Intake and Vent Connection Size at Furnace (All

Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Unconfined Space Minimum Area . . . . . . . . . . . . . . . . . . . . . . . 32

Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Gas Rate (CU FT/HR) at Full Input . . . . . . . . . . . . . . . . . . . . . . 35

Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Blower Performance CFM - Any Position . . . . . . . . . . . . . . . . . 38

681292-UIM-A-0211

681292-UIM-A-0211

The Y ork YP9C is p art of a "Hybrid Comfort System" when paired with a
York Heat pump.

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.

SECTION I: SAFETY

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

Understand and pay particular attention to the signal words DANGER,

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

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

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

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

Improper installation may create a condition where the operation of
the product could cause personal injury or property damage.

Improper installation, adjustment, alteration, service or mainte­nance can cause injury or property damage. Failure to carefully

read and follow all instructions in this manual can result in fur­nace malfunction, death, personal injury and/or property dam­age. Only a 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 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

.

.

It is also used to

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.

12. When moving or handling this furnace prior to installation it is rec­ommended to 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.

During installation, doors should remain on the furnace when
moving or lifting.

SAFETY REQUIREMENTS

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

• Refer to the unit rating plate for the furnace model number, and
then see the dimensions page of this instruction for return air ple­num dimensions in Figure 13. 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.

CSA listed or approved for installation

or a Manufactured

2 Johnson Controls Unitary Products

681292-UIM-A-0211

• 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.

COMBUSTION AIR QUALITY
(LIST OF CONTAMINANTS)

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

• Restricted Environments

• Commercial buildings

• Buildings with indoor pools

• Furnaces installed in laundry rooms

• Furnaces installed in hobby or craft rooms

• Furnaces installed near chemical storage areas

• Chemical exposure

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

• Permanent wave solutions

• Chlorinated waxes and cleaners

• Chlorine based swimming pool chemicals

• Water softening chemicals

• De-icing salts or chemicals

• Carbon tetrachloride

• Halogen type refrigerants

• Cleaning solvents (such as perchloroethylene)

• Printing inks, paint removers, varnishes, etc.

• Hydrochloric acid

• Cements and glues

• Antistatic fabric softeners for clothes dryers

• Masonry acid washing materials

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

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

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.

Johnson Controls Unitary Products 3

681292-UIM-A-0211

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°C) could create a
hazard, resulting in damage, injury or death.

2. Do not allow return air temperature to be below 55ºF (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” (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 Horizontal

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

1

Front

Floor Combustible

0" 0" 0"

2

Combustible

Combustible

Closet Yes Yes Yes

Line Contact No No Yes

1.Line contact only permitted between lines formed by the intersection of the
rear panel and side panel (top in horizontal position) of the furnace jacket
and building joists, studs or framing.

2. For combustible floors only when used with special sub-base.

All furnaces approved for alcove and attic installation.

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681292-UIM-A-0211

Factory Installed

For duct attachment,
if needed

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.

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.

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.

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/HORIZONTAL

Attach the supply plenum to the furnace outlet. The use of
an approved flexible duct connector is recommended on all
installations. This connection should be sealed to prevent
air leakage. The sheet metal should be crosshatched to
eliminate any popping of the sheet metal when the indoor
fan is energized.

FLOOR BASE AND DUCTWORK INSTALLATION ­DOWNFLOW

Installations on combustible material or directly on any
floors must use a combustible floor base shown in Figure 2.
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.

Johnson Controls Unitary Products 5

681292-UIM-A-0211

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

30” MIN.
Work Area

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

FIGURE 2: Combustible Floor Base Accessory

FIGURE 4: Typical Attic Installation

This appliance is certified for line contact when the furnace is installed
in the horizontal left or right position. The line contact is only permissible
between lines that are formed by the intersection of the top and two
sides of the furnace and the building joists, studs or framing. This line
may be in contact with combustible material. Refer to Figure 4.

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 3: Horizontal Application (Typical)

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

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 the two
sides of the furnace and the building joists, studs, or framing. This line
may be in contact with combustible material. Refer to Figure 4 for
details and additional information.

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.

During installation, doors should remain on the furnace when
moving or lifting.

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

It is acceptable to use the primary heat exchanger tubes as a lifting
point provided that the tubes are lifted at the front of the heat 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.

SUSPENDED FURNACE / CRAWL SPACE
INSTALLATION

The furnace can be hung from floor joists or installed on suitable blocks
or pads. Blocks or pad installations shall provide adequate height to
ensure that 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. In all cases, the furnace should be supported
with rods, straps, or angle supports at three locations to properly sup­port the furnace. Place one support at the supply end of the furnace,
one support located approximately in the center of the furnace near the
blower shelf, and the third support should be at the return end of the fur­nace. Maintain a 6” (15.2 cm) minimum clearance between the front of
the furnace and the support rods or straps.

All six suspension points must be level to ensure proper and quiet fur­nace operation. When suspending the furnace, use a secure platform
constructed of plywood or other building materials secured to the floor
or ceiling joists. Refer to Figure 5 for details and additional information.

6 Johnson Controls Unitary Products

FIGURE 5: Typical Suspended Furnace / Crawl Space Installation

Support
Rod

Support
Angle (x3)

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

LEFT SIDE VENT

RIGHT SIDE VENT

Rotate vent
blower 90°
either way

UPFLOW

DOWNFLOW

Furnace

Furnace

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

FACTORY

FLANGE

LOCATION

(Used for upflow

or horizontal

right installations)

During installation, doors should remain on the furnace whe n
moving or lifting.

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

It is acceptable to use the primary heat exchanger tubes as a lifting
point provided that the tubes are lifted at the front of the heat 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.

DOWNFLOW APPLICATION

To apply the furnace in a downflow position, it will be necessary to
rotate the vent blower 90° left or right so that the vent pipe passes
through the side of the furnace casing rather than the end. See Figure

6.

681292-UIM-A-0211

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 7: Vertical Applications (Typical)

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: Downflow Venting

Johnson Controls Unitary Products 7

FIGURE 8: Coil Flange

681292-UIM-A-0211

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

NOTICE

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 9: Horizontal Right Application (Typical)
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 9 & 10.

FIGURE 10: Horizontal Left Application

FURNACE ASSEMBLY - PC SERIES COILS

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

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

1. Position the coil casing over the furnace opening as shown in Fig­ure 11.

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 11.

FIGURE 11: 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 11.

CRITICAL COIL PROJECTION

The coil assembly must be located in the duct such that a minimum dis­tance is maintained between the top of the coil and the top of the duct.
Refer to Table 2.

COIL / 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 12.

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 12.

8 Johnson Controls Unitary Products

FIGURE 12: Horizontal Left or Right application (Right Shown)

681292-UIM-A-0211

FRONT

33

A

LEFT SIDE

Combustion Air Inlet

Condensate Drain
(Downflow)

Thermostat
Wiring

28.5”

Gas Pipe
Entry

Electrical
Entry

Condensate
Drain

Thermostat
Wiring

RIGHT SIDE

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

RETURN END

B

24.25”

2” Vent
Connection
Outlet

2” Vent
Connection
Outlet

2” Vent
Connection
Outlet

NOTICE

Front of
Furnace

Corner
Markings

Side of
Furnace

FIGURE 13: Dimensions
Table 3: Cabinet and Duct Dimensions

BTUH (kW)

Input

Nominal

CFM (m

3

/min)

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

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

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) 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 30 0 f eet pe r min ute

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

Johnson Controls Unitary Products 9

(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

Cabinet

Size

(in)

Bottom

Cabinet Dimensions (Inches)

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

SIDE RETURN

Locate the “L” shaped corner locators. These indicate the size of the cut­out to be made in the furnace side panel. Refer to Figure 14.

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.

(in)

FIGURE 14: Side Return Cutout Markings

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 13.

681292-UIM-A-0211

Inlet
Pressure
Ta p

Outlet
Pressure
Ta p

On/Off
Switch

Main
Regulator
Adjustment

Upflow

Downflow

Horizontal

External
Manual
Shut-off
Valve

External
Manual
Shut-off
Valve

External Manual
Shut-off Valve

To Gas
Supply

To Gas
Supply

To Gas
Supply

To Gas
Supply

To Gas
Supply

To Gas
Supply

Drip
Leg

Drip
Leg

Drip
Leg

Drip
Leg

Drip Leg

Drip

Gas
Pipe

Gas
Valve

Gas
Pipe

Gas
Valve

Gas
Pipe

Gas
Valve

Ground
Union

Ground
Union

Ground
Union

Ground
Union

Ground
Union

Ground
Union

NOTE: Ground Union maybe installed inside or outside unit.

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

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 psig [14" w.c. (3.48 kPa)]. Pressures exceed­ing 0.5 psig [14” w.c. (3.48 kPa)] at the gas valve will cause damage
to the gas valve, resulting in a fire or explosion or cause damage to
the furnace or some of its components that will result in property
damage and loss of life.

FIGURE 15: Gas Valve

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

16.

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 0.5 psig (3.5 kPa).

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

FIGURE 16: Gas Piping

10 Johnson Controls Unitary Products

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 16.

681292-UIM-A-0211

GAS CONVERSION FOR PROPANE (LP)

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

HIGH ALTITUDE NATURAL GAS ORIFICE
CONVERSION

The National Fuel Gas Code requires that gas appliances installed
above 2,000 feet elevation have their inputs de-rated by 4% per 1,000
feet above sea level. The modulating furnaces automatically de-rate for
altitude by measuring the inducer blower pressure and using that to
determine if there is adequate air to support good combustion. If there
is not enough combustion air to properly support 100% of the furnace
nameplate input rate, the control will reduce the input to the point that
there will be good combustion.

The factory gas orifice sizes are based on a gas h eating value of
1030 BTU/cu.ft., so if your gas value is significantly higher or lower
than that, it may be necessary to change to smaller or larger gas
orifices.

The chart below shows recommended gas orifice sizes to use at vari­ous altitudes and at various de-ration levels. To use the chart, follow
these instructions:

1. Clock the gas meter and calculate the actual input rate using your
local gas heating value. See "CALCULATING THE FURNACE
INPUT (NAT. GAS)" in this manual.

2. Divide that input rate by the input rate shown on the furnace rating
plate to get the actual de-ration percent.

3. Read down the left-hand “Actual Rate” column to find the closest
number to your actual de-ration percent.

4. Read across that row to the column for the elevation at your loca­tion. The number listed there is the orifice size that is proper for
your unit.

Example – You have a 100,000 BTU/H furnace installed at an elevation
of 6,000 feet. You clock the gas meter and find that the furnace is actu­ally fired at 64,000 BTU/H. Divide 64,000 by 100,000, which gives 0.64
(64%). The closest number to 64% in the left-hand “Actual Rate” col­umn is 65. Read across that row to the column for 6,000 feet elevation,
which shows “#43”. You should change from the factory #45 orifices to
larger #43 orifices, which will bring the input rate back up to approxi­mately 76,000 BTU/H, which is what it should be for that furnace at
6,000 feet.

Table 5: High Altitude Orifices

Actual Rate

(percent of

nameplate)

100 48 49 49 50 51 51 52

95 47 48 49 50 50 50 51
90 46 47 48 49 49 49 50
85 45 46 47 48 49 49 50
80 45 45 46 47 48 48 49
75 44 45 45 45 47 47 49
70 43 44 44 45 45 45 48
65 42 43 43 44 45 45 47
60 41 42 42 43 44 45 46
55 40 41 41 32 43 43 44
50 39 40 40 40 43 42 42

4,000 5,000 6,000 7,000 8,000 9,000 10,000

84% 80% 76% 72% 68% 64% 60%

Elevation in Feet Above Sea Level

Orifice Drill Size

PROPANE KITS

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

Use copper conductors only.

Johnson Controls Unitary Products 11

681292-UIM-A-0211

Electrical Entry

Junction
Box

L1-Hot

Neutral

Connect ground
lead to screw

BLK
WHT

Table 6: Ratings & Physical / Electrical Data

BTUH/

Cabinet/CFM

Input

Max/Min

MBH kW MBH kW CFM

60B12 60/21 17.6/6.2 58/20 17.0/5.9 1200 34.0 40-70 22-39 20-50 11-28
80B12 80/28 23.4/8.2 77/27 22.6/7.9 1200 34.0 40-70 22-39 20-50 11-28

80C16 80/28 23.4/8.2 78/27 22.8/7.9 1600 45.3 40-70 22-39 20-50 11-28
100C16 100/35 29.3/10.2 97/34 28.4/10.0 1600 45.3 40-70 22-39 20-50 11-28
100C20 100/35 29.3/10.2 97/34 28.4/10.0 2000 56.6 45-75 25-42 25-55 13-31
120D20 120/42 35.1/12.3 116/40 34.0/11.7 2000 56.6 45-75 25-42 25-55 13-31

BTUH

Cabinet/CFM

Max. Outlet

Air Temp

°F °C HP Amps % Lbs (kg)

60B12 170 76.7 1/2 4.8 11 x 8 97.5 15 7.0 14 113 (51)

80B12 175 79.4 1/2 4.8 11 x 8 97.5 15 7.5 14 119 (54)

80C16 175 79.4 3/4 7.5 11 x 10 97.7 15 10.0 14 134 (61)
100C16 175 79.4 3/4 7.5 11 x 10 97.7 15 10.0 14 140 (64)
100C20 180 82.2 1 14.5 11 x 11 97.7 20 12.0 12 143 (65)
120D20 180 82.2 1 14.5 11 x 11 98.0 20 12.0 12 152 (69)

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

Max/Min

Blower

Nominal

Blower

Wheel

Size

Airflow

3

m

/min

AFUE

Air Temp. Rise

Air Temp. Rise

Max Input

°F °C °F °C

Max

Over-Current

Protect

Total Unit

Amps

Min. wire Size

(awg) @ 75 ft

one way

Min Input

Approximate

Operating Wgt.

SUPPLY VOLTAGE CONNECTIONS

FIGURE 17: Electrical Wiring

1. Provide a power supply separate from all other circuits. Install
overcurrent protection and disconnect switch per local/national
electrical codes. The switch should be close to the unit for conve­nience in servicing. With the disconnect or fused switch in the OFF
position, check all wiring against the unit wiring label. Refer to the
wiring diagram in this instruction.

2. Remove the screws retaining the wiring box cover. Route the
power wiring through the opening in the unit into the junction box
with a conduit connector or other proper connection. In the junc­tion box there will be 3 wires, a Black Wire, a White Wire. Connect
the power supply as shown on the unit-wiring label on the inside of
the blower compartment door or the wiring schematic in this sec­tion. The black furnace lead must be connected to the L1 (hot)
wire from the power supply. The white furnace screw must be con­nected to neutral. Connect the power supply ground to the green
screw (equipment ground) An alternate wiring method is to use a
field provided 2” (5.1 cm) x 4” (10.2 cm) box and cover on the out­side of the furnace. Route the furnace leads into the box using a
protective bushing where the wires pass through the furnace
panel. After making the wiring connections replace the wiring box
cover and screws. Refer to Figure 17.

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

12 Johnson Controls Unitary Products

681292-UIM-A-0211

Diagnostic Light

CFM Light

CONTROL WIRING

This furnace can be connected to the wall thermostat and outdoor A/C
or heat pump using either conventional low voltage (24 VAC) thermo­stat wiring OR using four-wire digital communications wiring. To use
conventional low voltage wiring, see the section below entitled “Con­ventional Low Voltage Control Wiring”. To use four-wire communica­tions control wiring, see the section below entitled “Control Wiring using
Communicating Controls”.

The Communicating System consists of several intelligent communicat­ing components including the Communicating Thermostat Control
(touch-screen wall thermostat), modulating variable speed furnace, air
conditioner (15 and 18 SEER premium air conditioners) or heat pump
(13, 15 and 18 SEER premium heat pumps), which continually commu­nicate with each other via a four-wire connection called the A-R-C-B.
Commands, operating conditions, and other data are passed continu­ally between components over the A-R-C-B. See Figure 18. The result
is a new level of comfort, versatility, and simplicity.

In order to use this furnace in full communications (COMM) mode, it
MUST be installed with the matching touch-screen Communicating
Control (wall thermostat) and an outdoor air conditioner or heat pump
with a fully communicating control.

This furnace may also be used along with the Communicating Thermo­stat Control and a non-communicating outdoor air conditioner through
the addition of a communicating Outdoor Aux Control board to the out­door unit. This system allows full communication between the furnace
and thermostat and limited communication to the outdoor unit. See Fig­ure 19.

This furnace may also be used along with the Communicating Thermo­stat Control and a non-communicating outdoor air conditioner or heat
pump using COMM between the furnace and thermostat and conven­tional 24V wiring to the outdoor unit. This system allows full communi­cation between the furnace and thermostat but no digital
communication with the outdoor unit.

FIGURE 18: Furnace Control Board – Communications Connections

Johnson Controls Unitary Products 13

681292-UIM-A-0211

A+

R

C

B-

A+

R

GND or C

B-

A+

R

GND

B-

LO

COMP

HI

COMP

O

DHUM

Y1

Y/Y2

W

R

G

C

Touch Screen

Communicating control

Modulating Furnace

Communicating control

Air Conditioner/Heat Pump

Communicating control

A+

R

C

B-

A+

R

B-

LO

COMP

HI

COMP

O

DHUM

Y1

Y/Y2

W

R

G

C

Touch Screen

Communicating control

Modulating Furnace

Communicating control

Non-

Air Conditioner

Communicating

Y

Y2

R

C

GND or C

CONTROL WIRING USING COMMUNICATING
CONTROLS

Use the wiring diagram below to connect the furnace control, Communi­cating Control (wall thermostat) and communicating outdoor unit. Be
sure that all of the “A” terminals are connected together, all of the “B”
terminals are connected together, all of the “GND” or “C” terminals are
connected together and all of the “R” terminals are connected together.
See Figure 19. When using a fully communicating system, the large
screw terminals (C, G, R, etc.) on the furnace control are not used. The
four small screw terminals in the terminal block on the end of the fur­nace control should be used.

When connecting the Communicating Control (wall thermostat) and fur­nace control to a non-communicating outdoor A/C or heat pump, use
the wiring diagram in Figure 20. The thermostat and furnace will be con­nected exactly as shown above, but the conventional 24 volt R, C and
Y/Y2 terminals will be used to control the outdoor unit.

CONVENTIONAL 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 21-26. 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 0.1 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.

FIGURE 19: Modulating Furnace with Communicating AC or HP

FIGURE 20: Modulating Furnace with Communicating Thermostat and

14 Johnson Controls Unitary Products

Non-Communicating AC

The 24-volt, 40 VA transformer is sized for the furnace components
only, and should not be connected to power auxiliary devices such as
humidifiers, air cleaners, etc. The transformer may provide power for an
air conditioning unit contactor.

AIR CONDITIONER CONNECTIONS

This furnace may be used with single-stage or two-stage air condition­ing units.

For Single-Stage A/C - Connect the low voltage wiring as shown in
Figure 21.

For Two-Stage A/C - Use a two-stage thermostat, connect the low volt­age wiring as shown in Figure 22.

For Two-Stage A/C usin g a Single-Stage Thermostat - connect the
low voltage wiring as shown in Figure 23.

This furnace control board can control a two-stage A/C using only a sin­gle-stage thermostat. In this case, the furnace control switches between
high cool and low cool based on the calculated cooling load.

681292-UIM-A-0211

HM1

Humidistat

Y

Full Stage Compressor

G

Fan

*PP11C70224

THERMOSTAT

RH

24 – Volt Hot

(Heat XFMR)

RC
24 – Volt Hot
(Cool XFMR)

W

Full Stage Heat

Clipping Jumper W914 for

electric heat on thermostat

is not necessary

C

24 – Volt Common

Y

Compressor

SINGLE STAGE

AIR CONDITIONER

Y

Compressor Contactor

SINGLE STAGE

AIR

CONDITIONER

C

24 – Volt Common

R

24 – Volt Hot

Y1

Single

Stage Compressor

MODULATING

FURNACE CONTROL

G

Fan

MODULATING

FURNACE

Y/Y2

Second or Full

Stage Compressor

DHUM

Dehumidification-

Open on Humidity Rise

W

Modulating Heat

Part Numbers:

SAP = Legacy

1

1

Move HUMIDISTAT

jumper to “YES”

if humidistat is to be used.

ID MODELS

LO COMP

Single Stage

Compressor (OUT)

O

Reversing Valve

Energized in Cool

HI COMP

Second Stage

Compressor (OUT)

Part Number:

S1-2HU16700124

2

External Humidistat

(Optional)

Open on Humidity Rise

2

TP9C
YP9C
CP9C
LP9C

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

FIGURE 21: Thermostat Chart - Single Stage Air Conditioner – Variable Speed Modulating Furnace

Johnson Controls Unitary Products 15

681292-UIM-A-0211

C

24 – Volt Common

Y1

First Stage Compressor

Y2

Second Stage

Compressor

G

Fan

*PP32U70124

THERMOSTAT

AUX

Auxiliary Heat

R
24 – Volt Hot
(Heat XFMR)

R
24 – Volt Hot
(Cool XFMR)

C

24 – Volt Common

Y1

First Stage Compressor

Y2

Second Stage

Compressor

G

Fan

*DN22U00124

THERMOSTAT

W2

Second Stage Heat

R

24 – Volt Hot

(Heat XFMR)

R
24 – Volt Hot
(Cool XFMR)

E/W1

Emergency Heat

E/W1

First Stage Heat

TWO STAGE

AIR

CONDITIONER

C

24 – Volt Common

R

24 – Volt Hot

Y1

First Stage Compressor

Y2

Second Stage

Compressor

C

24 – Volt Common

R

24 – Volt Hot

Y1

Single

Stage Compressor

MODULATING

FURNACE CONTROL

G

Fan

MODULATING

FURNACE

Y/Y2

Second or Full

Stage Compressor

DHUM

Dehumidification-

Open on Humidity Rise

W

Modulating Heat

Part Numbers:

SAP = Legacy

1

1

Move HUMIDISTAT

jumper to “YES”

if humidistat is to be used.

ID MODELS

LO COMP

Single Stage

Compressor (OUT)

O

Reversing Valve

Energized in Cool

HI COMP

Second Stage

Compressor (OUT)

External Humidistat

(Optional)

Open on Humidity Rise

2

Part Number:

S1-2HU16700124

2

TP9C

YP9C

CP9C

LP9C

Thermostat Installer Setup
1-System Type-must
be set to 8-1 Heat/2 Cool
Conventional

Connection of the "C"
terminal, 24-volt common
is optional when used with
batteries

Connection of the "C"
terminal, 24-volt common
is optional when used with
batteries

Thermostat Installer Setup
0170-System Type-must
be set to 10-1 Heat/2 Cool
Multistage Conventional

Thermostat Installer Setup
15-Compressor Protection
must be set to 5

FIGURE 22: Thermostat Chart - Two Stage Air Conditioner – Variable Speed Modulating Furnace

16 Johnson Controls Unitary Products

HM1

Humidistat

Y

Full Stage Compressor

G

Fan

*PP11C70224

THERMOSTAT

RH

24 – Volt Hot

(Heat XFMR)

RC
24 – Volt Hot
(Cool XFMR)

W

Full Stage Heat

Clipping Jumper W914 for

electric heat on thermostat

is not necessary

C

24 – Volt Common

R

24 – Volt Hot

Y1

Single

Stage Compressor

MODULATING

FURNACE CONTROL

G

Fan

MODULATING

FURNACE

Y/Y2

Second or Full

Stage Compressor

DHUM

Dehumidification-

Open on Humidity Rise

W

Modulating Heat

Part Numbers:

SAP = Legacy

1

1

Move HUMIDISTAT

jumper to “YES”

if humidistat is to be used.

ID MODELS

LO COMP

Single Stage

Compressor (OUT)

O

Reversing Valve

Energized in Cool

HI COMP

Second Stage

Compressor (OUT)

TWO STAGE

AIR

CONDITIONER

C

24 – Volt Common

R

24 – Volt Hot

Y1

First Stage Compressor

Y2

Second Stage

Compressor

External Humidistat

(Optional)

Open on Humidity Rise

2

Part Number:

S1-2HU16700124

2

TP9C
YP9C
CP9C
LP9C

681292-UIM-A-0211

FIGURE 23: Thermostat Chart - Two Stage Air Conditioner with Single Stage Thermostat – Variable Speed Modulating Furnace

Johnson Controls Unitary Products 17

681292-UIM-A-0211

C

24 – Volt Common

R

24 – Volt Hot

Y1

First Stage Compressor

O

Reversing Valve

Energized in Cool

L

Malfunction Light

G

Fan

*DP32H70124

THERMOSTAT

W1

Second Stage Aux. Heat

E

Emergency Heat

W2

Third Stage Heat

N/A

*BP21H50124
*BN21H00124
*DP21H40124

*DN21H00124

THERMOSTAT

N/A

*DN22U00124

THERMOSTAT

Part Numbers:

SAP = Legacy

67297 = 031-01975

O

Reversing Valve

Energized in Cool

C

24 – Volt Common

R

24 – Volt Hot

W1/66(out)

Heat

Y

Compressor

DEMAND DEFROST

CONTROL

X/L

Malfunction Light

W

Auxiliary Heat

SINGLE STAGE

HEAT PUMP

1

1

Part Number:

S1-2HU16700124

3

Y2

Second Stage Compressor

Step 9 of Thermostat

Installer / Configuration

Menu must be set to

Pump OFF

Step 1 of Thermostat

Installer / Configuration

Menu must be set to

Heat Pump 1

E*B*

E*ZD

E*R*

OD MODELS

*HGD

HP*

*RHS

C

24 – Volt Common

R

24 – Volt Hot

Y1

Single

Stage Compressor

MODULATING

FURNACE CONTROL

G

Fan

MODULATING

FURNACE

Y/Y2

Second or Full

Stage Compressor

DHUM

Dehumidification-

Open on Humidity Rise

W

Modulating Heat

Part Numbers:

SAP = Legacy

2

2

Move HUMIDISTAT

jumper to “YES”

if humidistat is to be used.

ID MODELS

LO COMP

Single Stage

Compressor (OUT)

O

Reversing Valve

Energized in Cool

HI COMP

Second Stage

Compressor (OUT)

External Humidistat

(Optional)

Open on Humidity Rise

3

TP9C
YP9C
CP9C
LP9C

FIGURE 24: Thermostat Chart - Single Stage Heat Pump – Variable Speed Modulating Furnace

18 Johnson Controls Unitary Products

681292-UIM-A-0211

C

24 – Volt Common

R

24 – Volt Hot

Y1

First Stage Compressor

O

Reversing Valve

Energized in Cool

L

Malfunction Light

G

Fan

*DP32H70124

THERMOSTAT

W1

Second Stage Aux. Heat

E

Emergency Heat

W2

Third Stage Heat

Step 1 of Thermostat

Installer / Configuration

Menu must be set to

Heat Pump 1

C

24 – Volt Common

R

24 – Volt Hot

Y1

First Stage Compressor

O

Reversing Valve

Energized in Cool

L

Malfunction Light

Y2

Second

Stage Compressor

G

Fan

*BP21H50124
*BN21H00124
*DP21H40124

*DN21H00124

THERMOSTAT

E

Emergency Heat

W2

Second Stage Heat

B/O Switch on Thermostat

must be in the O position

C

24 – Volt Common

Y1

First Stage Compressor

O/B

Reversing Valve

L

Malfunction Light

Y2

Second

Stage Compressor

G

Fan

*DN22U00124

THERMOSTAT

E

Emergency Heat

AUX

Auxiliary Heat

R
24 – Volt Hot
(Heat XFMR)

R

24 – Volt Hot
(Cool XFMR)

O

Reversing Valve

Energized in Cool

C

24 – Volt Common

R

24 – Volt Hot

W1 OUT

First Stage Heat

W2 OUT

Second Stage Heat

Y2 OUT

Second

Stage Compressor

Y1

Single

Stage Compressor

X/L

Malfunction Light

Y2

Second

Stage Compressor

W

Auxiliary Heat

BS

Bonnet Sensor

BSG

Bonnet Sensor

YORKGUARD VI

CONTROL

SINGLE STAGE

HEAT PUMP

Bonnet Sensor

(Optional)

Change FFuel jumper

on the heat pump control

to “ON”

1

H*3

YMB

YZB

OD MODELS

Y2

Second

Stage Compressor

Thermostat Installer Setup
1-System Type-must be set
to 5 – 2 Heat/1 Heat Pump

Thermostat Installer Setup

2-Changeover Valve-must

be set to 0 – O/B terminal

Energized in Cooling

C

24 – Volt Common

R

24 – Volt Hot

Y1

Single

Stage Compressor

MODULATING

FURNACE CONTROL

G

Fan

MODULATING

FURNACE

Y/Y2

Second or Full

Stage Compressor

DHUM

Dehumidification-

Open on Humidity Rise

W

Modulating Heat

Part Numbers:

SAP = Legacy

2

2

Move HUMIDISTAT

jumper to “YES”

if humidistat is to be used.

ID MODELS

LO COMP

Single Stage

Compressor (OUT)

O

Reversing Valve

Energized in Cool

HI COMP

Second Stage

Compressor (OUT)

Change Hot Heat Pump

jumper on the heat

pump control to “ON” if

Hot Heat Pump

Operation is desired.

Part Number:

S1-2HU16700124

3

External Humidistat

(Optional)

Open on Humidity Rise

3

Part Numbers:

SAP = Legacy

126768 = 031-09137
18395 = 031-01996
340512 = 031-09178

1

TP9C
YP9C

CP9C

LP9C

FIGURE 25: Thermostat Chart - Single Stage Heat Pump – Variable Speed Modulating Furnace

Johnson Controls Unitary Products 19

681292-UIM-A-0211

O

Reversing Valve

Energized in Cool

C

24 – Volt Common

R

24 – Volt Hot

W1 OUT

First Stage Heat

W2 OUT

Second Stage Heat

Y2 OUT
Second

Stage Compressor

Y1

Single

Stage Compressor

X/L

Malfunction Light

Y2

Second

Stage Compressor

W

Auxiliary Heat

BS

Bonnet Sensor

BSG

Bonnet Sensor

YORKGUARD VI

CONTROL

TWO STAGE

HEAT PUMP

Bonnet Sensor

(Optional)

Change FFuel jumper

on the heat pump control

to “ON”

1

Part Numbers:

SAP = Legacy
126768 = 031-09137
18395 = 031-01996
340512 = 031-09178

1

YZE

OD MODELS

YZH

H*5
H*8

C

24 – Volt Common

R

24 – Volt Hot

Y1

First Stage Compressor

O

Reversing Valve

Energized in Cool

L

Malfunction Light

Y2

Second

Stage Compressor

G

Fan

*DN22H00124
*DP22U70124

THERMOSTAT

E/W1

First Stage Aux. Heat

W2

Second Stage Aux. Heat

C

24 – Volt Common

Y

First Stage Compressor

O/B

Reversing Valve

L

Malfunction Light

Y2

Second

Stage Compressor

G

Fan

*PP32U70124

THERMOSTAT

E

Emergency Heat

R

24 – Volt Hot

(Heat XFMR)

RC
24 – Volt Hot
(Cool XFMR)

AUX

Auxiliary Heat

Step 1 of Thermostat

Installer/Configuration

Menu must be set to “HP2”

Selection of GAS/ELEC

switch on thermostat

not necessary

Thermostat Installer Setup

0170-System Type-

must be set to 12

3 Heat/2 Heat Pump

Thermostat Installer Setup

0190-Changeover Valve-

must be set to 0

O/B terminal

Energized in Cooling

Thermostat Installer Setup

0200-Backup Heat Source-

must be set to 1

Heat Pump Backup Heat

Source is Fossil Fuel

Thermostat Installer Setup

0210-External Fossil Fuel

Kit- must be set to 1

Heat Pump Control

is Controlling Heat Pump

Backup Heat

C

24 – Volt Common

R

24 – Volt Hot

Y1

Single

Stage Compressor

MODULATING

FURNACE CONTROL

G

Fan

MODULATING

FURNACE

Y/Y2

Second or Full

Stage Compressor

DHUM

Dehumidification-

Open on Humidity Rise

W

Modulating Heat

Part Numbers:

SAP = Legacy

2

2

Move HUMIDISTAT

jumper to “YES”

if humidistat is to be used.

ID MODELS

LO COMP

Single Stage

Compressor (OUT)

O

Reversing Valve

Energized in Cool

HI COMP

Second Stage

Compressor (OUT)

Change Hot Heat Pump

jumper on the heat

pump control to “ON” if

Hot Heat Pump

Operation is desired.

External Humidistat

(Optional)

Open on Humidity Rise

3

TP9C
YP9C
CP9C
LP9C

FIGURE 26: Thermostat Chart - Two Stage Heat Pump – Variable Speed Modulating Furnace

20 Johnson Controls Unitary Products

681292-UIM-A-0211

ACCESSORY CONNECTIONS

The furnace control will allow power-switching control of various acces­sories.

ELECTRONIC AIR CLEANER CONNECTION

Two 1/4” (6.4 mm) 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” (6.4 mm) 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 read.

HUMIDISTAT CONNECTION

For better humidity control during cooling operation, an external humidi­stat may be used. When using a external humidistat, put the HUMIDI­STAT jumper in the YES position. Connect the low voltage wiring as
shown in Figures 21-26.

ZONING OPERATION

This furnace may be used in zoning systems, using a separate after­market zoning control. For use in zoned systems, put the ZONE CON­TROL jumper on the furnace control board in the “YES” position.

If the Zone jumper is put in the “Yes” position , the heating load logic
switches to a special algorithm for multi-zone homes.

1. This algorithm operates at the “low demand” firing rate for 10 min­utes and then ramps to high fire within 20 minutes (30 minutes
maximum to get to 100% firing rate).

2. The special zoning algorithm does not
the burners will stop firing as soon as there is no call for heating.

have the Run 2 function, so

HEAT PUMP OPERATION

This furnace may be used in conjunction with a heat pump in dual fuel
applications. For heat pump applications, put the HEAT PUMP jumper
on the furnace control board in the “YES” position. Connect the low volt­age wiring as shown in Figures 24-26, Thermostat Charts. If a two­stage heat pump is to be used, a two-stage thermostat is required.

If the Heat Pump jumper is in the “YES” position, it indicates that there
is a heat pump present and the furnace is used as a secondary heat
source. In addition, the “YES” Heat Pump jumper allows the system to
read the presence of the “O” terminal signal. In heat pump operation,
the following special algorithm logic applies:

1. Supplemental Heating - When both a “W” signal and a “Y1” signal
are present, the modulating firing rate will operate as normal,
except there will be no Run 2 function, so the burners will stop fir­ing as soon as the “W” signal is removed.

2. Defrost Cycle - When both a “W” signal and a “Y2” signal are pres­ent, the modulating firing rate will operate at a constant 80% firing
rate and there will be no Run 2 function, so the burners will stop fir­ing as soon as the “W” signal is removed.

3. Hot Heat Pump - The “hot” heat pump feature will work when the
control is wired to a 2-stage thermostat and a 2-stage heat pump.

4. Hot Heat Pump - The “hot” heat pump feature will not
the control is wired to a single-stage
pump.

thermostat and a 2-stage heat

work when

TWINNING

These furnaces are not to be twinned. If more than one furnace is
needed in an application, each furnace must have its own complete
duct system and its own wall thermostat.

SECTION VI: CONDENSATE PIPING AND
FURNACE VENTING CONFIGURATION

CONDENSATE DRAIN LOCATION

As shipped from the factory:

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

The Figures 29-32 show the condensate drain arrangement for the var­ious possible furnace and vent blower positions.

The condensate hoses must slope downwards at all points.
The condensate water will flow to the drain better if an open tee, or

short length of pipe is installed in the drain line.

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 29-

32), 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 the condensate pan.

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
(21 mm/m) downward slope to the drain.

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.

Johnson Controls Unitary Products 21

681292-UIM-A-0211

To Open Or
Vented Drain

Tee

5” Min.

Open Stand Pipe

(Anti-siphon air vent)

NOTICE

Connect to Drain

Trap

Combustion Air Pipe

Tee with Drain Trap

Exhaust Pipe

FIGURE 27: 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 27.
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.

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 28. This is true for all long horizontal vent­ing in any furnace configuration. This will prevent the condensate
from entering the furnace.

FIGURE 28: Typical Combustion Pipe Drain Tee

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 liqu id

anti-freeze.

22 Johnson Controls Unitary Products

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, 120K 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.

1

2

1

2

681292-UIM-A-0211

FIGURE 29: Upflow Configuration

Johnson Controls Unitary Products 23

681292-UIM-A-0211

AIRFLOW

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.

1

2

4

3

FIGURE 30: Downflow Configuration

24 Johnson Controls Unitary Products

HORIZONTAL - LEFT

INDUCER ROTATED

HORIZONTAL - LEFT

INDUCER AS RECEIVED

AIRFLOW

AIRFLOW

Move pressure switch hose

to this position.

NOTE: May require the longer

hose that is provided with

wider cabinets

Move rain gutter hose to this position

NOTE: May require hose extension

that is provided with wider cabinets

Move rain gutter

hose to this position

Move pressure switch

hose to this position.

NOTE: May requirethe longer

hose thatis provided with

wider cabinets

Change condensate drain

connection to the 90° fitting provided

Move condensate

drain hose to this position

Move rain gutter hose to this

position NOTE: May require hose

extension that is provided with

wider cabinets

Move

condensate

drain hose to this position

Change condensate

drain connection to

the 90° fitting provided

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

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

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

1

2

3

4

5

3

4

2

1

681292-UIM-A-0211

FIGURE 31: Horizontal Left Configuration

Johnson Controls Unitary Products 25

681292-UIM-A-0211

AIRFLOW

HORIZONTAL - RIGHT

INDUCER ROTATED

HORIZONTAL - RIGHT

INDUCER AS RECEIVED

Move rain gutter

hose to this position

Move pressure

switch hose to

this position.

Change condensate

drain connection to

the 90° fitting

provided

Move condensate

drain hose to

this position

Move rain gutter

hose to this position

Change condensate drain

connection to the 90°

fitting provided

Move condensate

drain hose to this position

AIRFLOW

Move pressure

switch 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.

2

3

4

1

1

2

3

4

FIGURE 32: Horizontal Right Configuration

26 Johnson Controls Unitary Products

681292-UIM-A-0211

SECTION VII: COMBUSTION AIR AND
VENT SYSTEM

COMBUSTION AIR AND VENT SAFETY

This Category IV, dual certified dir ect vent furnace is desig ned for resi­dential 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/NFP A 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 Residential and non-HUD Modular Homes. The
direct vent system is the only configuration that can be installed in a
non-HUD Modular Home.

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

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. Fo r example, if the table
allows 65 equivalent feet for a particular model, then the vent can
have 65 equivalent feet of pipe, AND the combustion air intake can
have another 65 equivalent feet of pipe.

3. Three vent terminal elbows (two for the vent and one for the 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
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" (5.1 cm) vent connections. When
the pipe must be increased to 3" (7.6 cm) diameter, the transition
from 2" to 3" must be done as close to the furnace as possible. 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 (914 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 is five feet for all models.

TABLE 7:

Maximum Equivalent Pipe Length

Model Input

BTUH (kW)

60,000 2 (5.1) 65 (19.8)
60,000 3 (7.6) 90 (27.4)
60,000 4 (10.2) 150 (45.7)
80,000 2 (5.1) 65 (19.8)
80,000 3 (7.6) 90 (27.4)

80,000 4 (10.2) 150 (45.7)
100,000 2 (5.1) 30 (9.1)
100,000 3 (7.6) 90 (27.4)
100,000 4 (10.2) 150 (45.7)
120,000 3 (7.6) 90 (27.4)
120,000 4 (10.2) 150 (45.7)

Pipe Size

Inches (cm)

be used for venting or

Maximum

Equivalent

length feet (m)

Johnson Controls Unitary Products 27

681292-UIM-A-0211

A

A

A

A

STANDARD ELBOW

LONG (SWEEP) ELBOW

FIGURE 33:
TABLE 8: Elbow

Dimensions

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.

TABLE 9:

Equivalent Length of Fittings

Fitting Equivalent Length

2" 90° sweep elbow 5 feet of 2" pipe

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

3" 90° sweep elbow 5 feet of 3" pipe

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

4" 90° elbow (sweep or standard) 5 feet of 4" pipe
4" 45° elbow (sweep or standard) 2-1/2 feet of 4" pipe

2" corrugated connector 10 feet of 2" pipe
3" corrugated connector 10 feet of 3" pipe
4" corrugated connector 10 feet of 4" pipe

TABLE 10:

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” (51 mm). 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” (76 mm).

Accessory concentric vent / intake termination kits 1CT0302 and
1CT0303, and for Canadian applications ICT0302-636 and
ICT0303-636 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.

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:

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

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

acceptable.

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

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

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

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

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

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

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

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

28 Johnson Controls Unitary Products

VENT CLEARANCES

L

E

D

B

V

V

V

X

V

B

V

J

X

B

B

B

V

V

F

V

C

B

X

V

I

V

G

H

A

M

K

OPERABLE

FIXED
CLOSED

VENT TERMINAL

AIR SUPPLY

AREA WHERE TERMINAL IS NOT PERMITTED

FIXED
CLOSED

FIGURE 34: Home Layout

681292-UIM-A-0211

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.

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

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

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

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

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, National Gas Code.
‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor and the distance bet ween the top of the ve nt termina -

tion and the underside of the veranda, porch, or deck is greater than 12” (30.5 cm) as specified in CSA B149.1-00.
A vent shall not terminate less than 12” (30.5 cm) above a grade level.
Any fresh air or make up inlet for dryer or furnace area is considered to be forced air inlet.
Avoid areas where condensate drippage may cause problems such as above planters, patios, or adjacent to windows where steam may cause fogging.
A terminus of a vent shall be fitted with a cap in accordance with the vent manufacturer’s installation instructions, or in accordance with the installation instructions for a
special venting system.
Responsibility for the provision of proper adequate venting and air supply for application shall rest with the installer.
Vent shall extend high enough above building, or a neighboring obstruction, so that wind from any direction will not create a positive pressure in the vicinity of t he 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 t hat is attached to the build­ing surface to prevent movement of the vent pipe.

Johnson Controls Unitary Products 29

681292-UIM-A-0211

12” Min.

12” Min.

Maintain 12” minimum clearance
above highest anticipated snow level.
Maximum 24” above roof.

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.

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 horizontal 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 n ot 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 36 or 37.

FIGURE 37: Termination Configuration - 2 Pipe Basement

VENTING MULTIPLE UNITS

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

The combustion air side of the single pipe configuration shown in Figure
35 is referred to in these instructions as ambient combustion air supply.
Follow the instructions for ambient combustion air installations, paying
particular attention to the section on air source from inside the building.
The vent for a single pipe system must be installed as specified in the
venting section of these instructions with the vent terminating as shown
in Figure 35. Each furnace must have a separate vent pipe. Under NO
circumstances can the two vent pipes be tied together.

The combustion air side of the two-pipe configuration shown in Figure
36 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 38 or 39. 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 35: Termination Configuration - 1 Pipe

FIGURE 36: Termination Configuration - 2 Pipe

30 Johnson Controls Unitary Products

FIGURE 38: Double Horizontal Combustion Air Intake and Vent

Termination

FIGURE 39: Double Vertical Combustion Air Intake and Vent

Termination

DOWNWARD VENTING

16’ MAX

6” MIN.

6” MIN.

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

Vent pipe cements
into socket just
above top panel

COMBUSTION AIR

Or vent pipe may be
clamped into outlet
of drain coupling

In some applications, it may be necessary to run the vent pipe and air
intake downwards. If this is to be done, the following rules must be fol­lowed.

• A condensate trap hose must be connected to both the air intake
pipe and the vent pipe at the lowest part of the horizontal run.

• The condensate drain trap must have a trap of a minimum of six
inches.

• The total vertical downward distance must not exceed sixteen
feet.

• The condensate drain hose must be connected to a condensate
drain pump, a open or vented drain or into the condensate drain
line from the furnace.

• The condensate drain lines must not pass through unconditioned
spaces where the temperature may fall below freezing.

• The condensate drain line must be primed at the initial start-up
prior to the start of heating season.

FIGURE 40: Downward Venting

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 of three possible com­bustion air intake configurations.

1. OUTDOOR COMBUSTION AIR:

2. AMBIENT COMBUSTION AIR:

3. VENTILATED COMBUSTION AIR:

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 40) 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 40) is the furnace
vent pipe.

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 40.

the area surrounding the furnace through openings in the furnace
casing. The combustion air and the vent pipes are not terminated
in the same atmospheric zone. Refer to Figure 33 for vent termina­tions. Refer to "Ambient Combustion Air Supply" for proper instal­lation. Refer to Figure 41.

through a PVC or ABS pipe that is connected to the PVC coupling
attached to the burner box and is terminated in a ventilated attic or
crawl space. The combustion air and the vent pipes are not termi­nated in the same atmospheric zone. Refer to Figure 43 for attic
and crawl space termination. Only the combustion air intake may
terminate in the attic. The vent must terminate outside.

This is a direct vent configuration

Combustion air is supplied from

Combustion air is supplied

Johnson Controls Unitary Products 31

681292-UIM-A-0211

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.

FIGURE 41: Direct Vent Air Intake Connection and Vent Connection
The combustion air intake pipe should be located either through the

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

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

Ambient Combustion Air Supply

This type installation will draw the air required for combustion from
within the space surrounding the appliance and from areas or rooms
adjacent to the space surrounding the appliance. This may be from
within the space in a non-confined location or it may be brought into the
furnace area from outdoors through permanent openings or ducts. It is
not piped directly into the furnace. A single, properly sized pipe from the
furnace vent connector to the outdoors must be provided. It is recom­mended that the supplied intake coupling and 18” of pipe be attached to
the furnace to prevent accidental blockage or combustion air intake.

FIGURE 42: Combustion Airflow Path Through The Furnace Casing

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.

681292-UIM-A-0211

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

An unconfined space is not less than 50 ft3 (1.42 m3) per 1,000 BTU/
hr (0.2928 kW) input rating for all of the appliances installed in that
area.

Rooms communicating directly with the space containing the appli­ances are considered part of the unconfined space, if doors are fur­nished with openings or louvers.

3

A confined space is an area with less than 50 ft

(1.42 m3) per 1,000
BTU/hr (0.2928 kW) input rating for all of the appliances installed in that
area. The following must be considered to obtain proper air for combus­tion and ventilation in confined spaces.

Combustion Air Source From Outdoors

The blocking effects of louvers, grilles and screens must be given con­sideration in calculating free area. If the free area of a specific louver or
grille is not known, refer to Table 11, to estimate free area.

Table 11: Estimated Free Area

Wood or Metal

Louvers or Grilles

Screens+

* Do not use less than 1/4” (6.4 mm) 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” (6.4 mm)

mesh or larger 100%

Dampers, Louvers and Grille s (C anada Only)

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

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

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

sion smaller than 1/4” (6.4 mm).

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

BTUH Input Rating

60,000

80,000
100,000
120,000

Minimum Free Area

Required for Each Opening

2

(387 cm2)

60 in

2

80 in

(516 cm2)

2

100 in

(645 cm2)

2

120 in

(742 cm2)

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)

2

(193 cm2) 15 in2 (97 cm2)

30 in

2

(258 cm2) 20 in2 (129 cm2)

40 in

2

(322 cm2) 25 in2 (161 cm2)

50 in

2

(387 cm2) 30 in2 (193 cm2)

60 in

Vertical Duct or

Opening to Outside

(4,000 BTUH)

Round Duct

(4,000 BTUH)

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

EXAMPLE: Determining Free Area.
Appliance 1 Appliance 2 Total Input
100,000 + 30,000 = (130,000  4,000) = 32.5 Sq. In. Vertical
Appliance 1 Appliance 2 Total Input
100,000 + 30,000 = (130,000  2,000) = 65 Sq. In. Horizontal

FIGURE 43: 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

3. The duct shall be least the same cross-sectional area as the free

4. The duct shall terminate within 12” (30.5 cm) above, and within 24”

requirements of CAN4-S110 Standard for Air Ducts.

area of the air supply inlet opening to which it connects.

(61 cm) horizontally from, the burner level of the appliance having
the largest input.

32 Johnson Controls Unitary Products

5. A square or rectangular shaped duct shall only be used when the
required free area of the supply opening is 9 in

2

(58.06 cm2) or
larger. When a square or rectangular duct is used, its small dimen­sion shall not be less than 3” (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” (30.5 cm) of the top and
one within 12” (30.5 cm) 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.

681292-UIM-A-0211

12” Min.

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

2. One permanent openings, commencing within 12” (30.5 cm) of the
top of the enclosure shall be permitted where the equipment has
clearances of at least 1” (2.54 cm) from the sides and back and 6”
(15.2 cm) from the front of the appliance. The opening shall com­municate directly with the outdoors and shall have a minimum free
area of:

a. 1 square in. per 3000 BTU per hour (6.45 cm

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.

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 CO

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” 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 Fue l 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.

3

per 0.879 kW)

Ventilated Combustion Air

The ventilated attic space or a crawl space from which the combustion
air is taken must comply with the requirements specified in “AIR
SOURCE FROM OUTDOORS” in this instruction or in Section 5.3, Air
for Combustion and Ventilation of the National Fuel Gas Code, ANSI
Z223.1 (latest edition). This type installation requires two properly sized
pipes. One brings combustion air from a properly ventilated attic space
or crawl space and a second pipe that extends from the furnace vent
connection (top right of unit) to the exterior of the building. Refer to
Table 7 for intake pipe sizing, allowable length and elbow usage. Follow
all notes, procedures and required materials in the "COMBUSTION
AIR/VENT PIPE SIZING" 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 Termination

Refer to Figure 43 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” (6.4 mm) mesh screen and no elbows.

and CO levels of each appliance. Use a draft gauge to check for a

2

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.

FIGURE 44: Attic and Crawl Space Combustion Air Termination

Johnson Controls Unitary Products 33

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

VENT BLOWER ROTA TION

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 29-32 for details.

681292-UIM-A-0211

NOTICE

NOTICE

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 0.5 psig (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.

HOT SURFACE IGNITION SYSTEM
Do not attempt to light this furnace by hand (with a match or

any other means). There may be a potential shock hazard from
the components of the hot surface ignition system. The fur­nace can only be lit automatically by its hot surface ignition
system.

SETUP TEST MODE

During normal operation, the furnace input rate can vary between 35%
and 100% of full nameplate input, making it difficult to check for proper
operation. To help with th e furnace startup process, the control has a

TEST MODE available that allows the furnace input rate to stay at a
constant input rate. To access this TEST MODE perform the following
sequence:

1. With power to the board on and with no thermostat calls (no call for
heating, cooling or continuous fan), push and hold the TEST but­ton on the board for one second. The LED on the board will glow
red.

2. Release the TEST button. The LED on the board will flash a rapid

green signal, indicating that TEST MODE is activated.

3. Turn the thermostat to call for heat (R & W signal).

4. The furnace will light and operate at high (100%) firing rate. The
furnace firing rate should be checked at this level to confirm that
the furnace is not overfired or underfired.

5. To run the furnace at minimum rate (35%) , press the ERROR but­ton once. The LED will flash one green flash to confirm.

6. To run the furnace at a middle rate (70% ), press the ERROR but­ton twice within a five-second period. The LED will flash green two
times to confirm.

7. To again oper ate the furnace at maximum (100%) rate, press the
ERROR button three times within a five-second period. The LED
will flash green three times to confirm.

8. If the thermostat call for heat is removed, the LED will flash a rapid
green signal, indicating that the furnace is still in TEST MODE.

9. When startup tests are completed, turning off power to the board
will take the furnace out of TEST MODE and will restore normal
operation. The furnace will automatically return to normal opera­tion after 150 minutes if power is not cycled.

CALCULATING THE FURNACE INPUT (NAT. 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.

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/ft

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.

3

(38.4 MJ/m3). If the heating value

3

) to obtain

34 Johnson Controls Unitary Products

Be sure to relight any gas appliances that were turned off at the
start of this input check.

Table 14: Gas Rate (CU FT/HR) at Full Input

Seconds For
1 Revolution

10 360 720 1800 50 72 144 360
11 327 655 1636 51 71 141 355
12 300 600 1500 52 69 138 346
13 277 555 1385 53 68 136 340
14 257 514 1286 54 67 133 333
15 240 480 1200 55 65 131 327
16 225 450 1125 56 64 129 321
17 212 424 1059 57 63 126 316
18 200 400 1000 58 62 124 310
19 189 379 947 59 61 122 305
20 180 360 900 60 60 120 300
21 171 343 857 62 58 116 290
22 164 327 818 64 56 112 281
23 157 313 783 66 54 109 273
24 150 300 750 68 53 106 265
25 144 288 720 70 51 103 257
26 138 277 692 72 50 100 250
27 133 267 667 74 48 97 243
28 129 257 643 76 47 95 237
29 124 248 621 78 46 92 231
30 120 240 600 80 45 90 225
31 116 232 581 82 44 88 220
32 113 225 563 84 43 86 214
33 109 218 545 86 42 84 209
34 106 212 529 88 41 82 205
35 103 206 514 90 40 80 200
36 100 200 500 92 39 78 196
37 97 195 486 94 38 76 192
38 95 189 474 96 38 75 188
39 92 185 462 98 37 74 184
40 90 180 450 100 36 72 180
41 88 176 439 102 35 71 178
42 86 172 429 104 35 69 173
43 84 167 419 106 34 68 170
44 82 164 409 108 33 67 167
45 80 160 400 110 33 65 164
46 78 157 391 112 32 64 161
47 76 153 383 116 31 62 155
48 75 150 375 120 30 60 150
49 73 147 367

1 Cu Ft 2 Cu Ft 5 Cu Ft 1 Cu Ft 2 Cu Ft 5 Cu Ft

Size of Test Dial

681292-UIM-A-0211

HIGH ALTITUDE NATURAL GAS ORIFICE
CONVERSION

The National Fuel Gas Code requires that gas appliances installed
above 2,000 feet elevation have their inputs de-rated by 4% per 1,000
feet above sea level. The modulating furnaces automatically de-rate for
altitude by measuring the inducer blower pressure and using that to
determine if there is adequate air to support good combustion. If there
is not enough combustion air to properly support 100% of the furnace
nameplate input rate, the control will reduce the input to the point that
there will be good combustion.

Seconds For
1 Revolution

Size of Test Dial

Johnson Controls Unitary Products 35

NOTICE

Inlet
Pressure
Ta p

Outlet
Pressure
Ta p

On/Off
Switch

Main
Regulator
Adjustment

681292-UIM-A-0211

ADJUSTMENT OF MANIFOLD GAS PRESSURE

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 44 for a
drawing of the locations of the pressure ports on the gas valve.

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” w.c. (3.24 kPa)

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

• 7” w.c. (1.74 kPA) for Natural Gas

• 11” w.c. (2.74 kPA) for Propane (LP) Gas

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

The cap for the pressure regulator must be removed to gain access
to the adjustment screw.

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.

TABLE 16:

Nominal Manifold Pressure

NOMINAL MANIFOLD PRESSURE

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

Natural Gas (Min) 0.5" w.c. (0.15 kPa)

Propane (LP) Gas (Max) 10.0" w.c. (2.49 kPa)

Propane (LP) Gas (Min) 1.6" w.c. (0.40 kPa)

a minimum of:

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

3. Using a 3/16” allen wrench, remove the plugs from the inlet and
outlet pressure ports. Connect a 1/8” UPT barbed hose fitting to
each pressure port.

4. Refer to Figure 44 for location of pressure regulator adjustment
cap and adjustment screws on main gas valve.

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

6. Remove the small plastic cap to gain access to the regulator
adjustment screw.

7. Use a small slotted screwdriver to turn the regulator adjustment
screw. Adjust the pressure by turning the screw one click at a time
until desired pressure is reached. Wait a few seconds after each
adjustment to allow the pressure to stabilize before making addi­tional adjustments. This is an electronic adjustment screw that
does not require very much force. Application of excessive force to
the adjustment screw will damage the gas valve.

FIGURE 45: Gas Valve

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

The adjustment screw has a range of 16 clicks (about ±0.5” mani­fold pressure). There is not a hard stop at the ends of the adjust­ment range. When the limit of the adjustment range is reached, the
next click will start over at the other end of the range. For instance,
if you are increasing pressure and reach the upper limit of adjust­ment the next click will drop the pressure to the lower limit.

8. 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 (NAT. GAS)".

9. Once the correct BTU (kW) input has been established, turn the
gas valve to OFF and turn the electrical supply switch to OFF; then
remove the flexible tubing and fittings from the gas valve pressure
tap replace the pressure tap plugs.

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

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 temperature readings of both the return air and the heated air
in the ducts about six feet away from the furnace, where they will not be
affected by radiant heat. Increase or decrease the temperature rise by
changing the ATR jumper on the furnace control board. The jumper is
factory-set to deliver an air temperature rise near the midpoint of the
nameplate temperature rise range. If more air is desired (lower temper­ature rise), move the jumper to the -10 position. If less air is desired
(higher temperature rise), move the jumper to the +10 position.

36 Johnson Controls Unitary Products

681292-UIM-A-0211

Low
Voltage
Terminals

Humidistat
Jumper

Last
Error Button

Test
Button

Continuous
Fan Speed
Jumper

Cooling Speed
Jumper

Heat Pump
Jumper

Zoning
Jumper

EAC
Terminals

Humidifier
Terminals

Diagnostic
Light

ADJUSTMENT OF FAN CONTROL SETTINGS

Cooling - The airflow delivered by the furnace during cooling operation
can be adjusted to match the cooling capacity of the A/C condensing
unit. This is done by moving the COOL and ADJ jumper on the control
board to give the desired airflow.

The COOL jumper has four positions, which will deliver the airflow in
cooling mode shown in Table 17.

The ADJ jumper has three positions which can be used to make further
adjustments to the cooling blower airflow.

Continuous Fan Operation - The airflow delivered by the furn ace dur­ing continuous fan operation can be adjusted as desired. This is done
my moving the control fan jumper on the control board to give the
desired airflow.

The jumper has three positions. The "H" position delivers maximum air­flow, 100% of the blower capacity. Position "M" delivers approximately
70% of the blower capacity. And Position "L" delivers minimum airflow,
approximately 40% of the blower capacity.

Delay Taps Selection

The set of jumper pins on the control board labeled "DELAY" are used
to set the delay profiles for the furnace. These can be chosen so as to
maximize the comfort and sound levels for various regions of the coun­try.

Tap A is the default profile. It provides a 30-second ramp-up from zero
airflow to full capacity and a 30-second ramp-down from full capacity
back to zero airflow. Whenever there is a change in airflow mode, such
as from low heat to high heat, the motor will take 30 seconds to ramp
from one speed to the other.

Tap B is the humid p rofile. This profile is best-suited for installations
where the humidity is frequently very high during cooling season, such
as in the southern part of the country. On a call for cooling, the blower
will ramp up to 50% of full capacity and will stay there for two minutes,
then will ramp up to 82% of full capacity and will stay there for five min­utes, and then will ramp up to full capacity, where it will stay until the
wall thermostat is satisfied. In every case, it will take the motor 30 sec­onds to ramp from one speed to another.

Tap C is the dry profile. This profile is best suited to parts of the country
where excessive humidity is not generally a problem, where the sum­mer months are usually dry. On a call for cooling the motor will ramp up
to full capacity and will stay there until the thermostat is satisfied. At the
end of the cooling cycle, the blower will ramp down to 50% of full capac­ity where it will stay for 60 seconds. Then it will ramp down to zero. In
every case, it will take the motor 30 seconds to ramp from one speed to
another.

Tap D is the normal profile, best suited for most of the country, where
neither excessive humidity nor extremely dry conditions are the norm.
On a call for cooling, the motor will ramp up to 63% of full capacity and
will stay there for 90 seconds, then will ramp up to full capacity. At the
end of the cooling cycle, the motor will ramp down to 63% of full capac­ity and will stay there for 30 seconds, then will ramp down to zero. In
every case, it will take the motor 30 seconds to ramp from one speed to
another.

Humidistat

When a humidistat is installed in the system, the “Humidistat con­nected?” jumper on the control board should be moved to the “YES”
position. The cooling airflow will then be reduced by 15% whenever the
humidistat indicates high humidity.

FIGURE 46: Furnace Control Board

Johnson Controls Unitary Products 37

681292-UIM-A-0211

Table 17: Blower Performance CFM - Any Position

High / Low Speed Cooling CFM

060B12 080B12 Jumper Settings

Hi Cool Lo Cool Hi Cool Lo Cool COOL Jumper ADJ Jumper

1305 850 1290 840 H B
1100 715 1090 710 MH B
1065 690 1015 660 H A
1000 650 1000 650 MH A

960 625 960 625 H C
760 495 760 495 ML B
900 585 900 585 MH C
660 430 660 430 L B
690 450 680 445 ML A
600 400 600 400 L A
620 400 620 400 ML C
550 400 540 400 L C

High / Low Speed Cooling CFM

080C16 100C16 Jumper Settings

Hi Cool Lo Cool Hi Cool Lo Cool COOL Jumper ADJ Jumper

1670 1085 1655 1075 H B
1295 840 1275 820 MH B
1385 900 1345 875 H A
1175 765 1160 755 MH A
1245 810 1210 785 H C

995 645 1000 650 ML B

1055 685 1045 680 MH C

935 605 955 620 L B
905 590 910 590 ML A
850 550 870 565 L A
815 530 815 530 ML C
765 500 785 510 L C

High / Low Speed Cooling CFM

100C20 120D20 Jumper Settings

Hi Cool Lo Cool Hi Cool Lo Cool COOL Jumper ADJ Jumper

2215 1440 2180 1415 H B
1765 1145 1760 1140 MH B
1820 1180 1800 1170 H A
1605 1040 1595 1035 MH A
1635 1060 1620 1050 H C
1270 825 1255 815 ML B
1445 940 1435 935 MH C
1055 685 1050 680 L B
1155 750 1160 755 ML A

960 620 960 615 L A

1040 675 1035 670 ML C

860 560 840 545 L C

All CFM’s are shown at 0.5” w.c. external static pressure.These units have variable speed motors that automatically adjust to provide constant CFM from 0.0”
to 0.6” w.c. static pressure. From 0.6” to 1.0” static pressure, CFM is reduced by 2% per 0.1” increase in static. Operation on duct systems with greater than

1.0” w.c. external static pressure is not recommended.
NOTE: At some settings, LOW COOL airflow may be lower that what is required to operate an airflow switch on certai n models of electronic air cleaners.

Consult the instructions for the electronic air cleaner for further details.

38 Johnson Controls Unitary Products

681292-UIM-A-0211

SECTION IX: SAFETY CONTROLS

CONTROL CIRCUIT FUSE

A 3-amp fuse is provided on the control circuit board to pr otect the 24­volt transformer from overload caused by control circuit wiring errors.
This is an ATO 3, automotive type fuse and is located on the control
board.

BLOWER DOOR SAFETY SWITCH

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

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

Main power to the unit must still be interrupted at the main power
disconnect switch before any service or repair work is to be done to
the unit. Do not rely upon the interlock switch as a main power dis­connect. Blower and burner must never be operated without the
blower panel in place.

ROLLOUT SWITCH CONTROLS

These controls are mounted on the burner assembly. If the temperature
in the 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 CONTROLS

Pressure Sensor - This furnace is equipped with a pressure sensor in
the burner compartment near the combustion blower. This sensor mon­itors combustion airflow through furnace and piping systems. If any of
the conditions listed below are detected by the pressure sensor, the
control board will prevent a hazardous condition from occurring by
speeding up the combustion blower motor in order to maintain ade­quate combustion airflow. If the combustion blower is already turning at
full speed, the furnace control will then start reducing the input to the
furnace in order to maintain proper combustion with the amount of com­bustion airflow available. If there is not enough combustion air available
to give proper combustion even at the minimum input rate (35%), the
control will close the gas valve and shut off the burners. The sensor will
detect the following conditions.

1. Blockage of vent piping or vent terminal

2. Failure of combustion air blower motor or blower wheel.

3. Blockage of combustion air piping or terminals.
Pressure Switch - This furnace is equipped with a pressure switch

mounted on the draft inducer. This switch monitors the flow through the
vent system. The switch will close at the beginning of each cycle when
adequate combustion airflow is established. However, this switch may
be open under certain conditions when the burners are lit. The pressure
sensor is the primary flow sensor.

Condensate Pressure Switch - This furnace is equipped with a pres­sure switch that will shut the furnace burners off if the condensate drain
line is blocked so that the water does not drain properly from the fur­nace.

LIMIT CONTROLS

Limit Switch - This furnace is equipped with a high temperature limit
control mounted to the left side of the furnace vestibule panel. This limit
switch will open and shut off gas to the burners if it detects excessive air
temperature in the furnace, which can be caused by any of the following
conditions:

1. Dirty filter

2. Failure of the circulating blower motor or wheel

3. Too many supply or return registers closed or blocked.
Temperature Sensor - This furnace is also equipped with a tempera-

ture sensor mounted to the vestibule panel, near the limit switch. This
sensor monitors the temperature of the air being supplied to the home.
If the sensor detects air temperature higher than normal, the furnace
control will speed up the circulating blower motor in order to try to
increase the amount of airflow being delivered, thereby reducing the air
temperature.

SECTION X: NORMAL OPERATION AND
DIAGNOSTICS

NORMAL OPERATION SEQUENCE

The furnace control calculates the optimum firing rate each time the
wall thermostat R and W contacts close or open (at the beginning and
at the end of each call for heat) based on information from the thermo­stat and past demand. UNLIKE CONVENTIONAL SYSTEMS, THE
WALL THERMOSTAT DOES NOT SIMPLY TURN THE FURNACE ON
AND OFF. THE FU RNACE CONTROL CALCULATES THE DEMAND
AND MAY CONTINUE TO FIRE THE FURNACE DURING PORTIONS
OF THE THERMOSTAT "OFF" CYCLE.

When the wall thermostat R and W contacts close, indicating a call for
heat, the following sequence occurs:

1. The inducer is energized and ramps up its speed until airflow is

proven by the pressure switch and by the pressure sensor on the
control board.

2. The hot surface ignitor is energized.

3. After a 17-20 second igniter heat-up, the gas valve opens and the

burners light.

4. When the control senses that flame is present, the circulating

blower starts at low speed.

5. The furnace fires at 70% of full rate for 30-45 seconds, then drops

to the minimum (35%) firing rate.

6. The firing rate is automatically adjusted to meet demand, increas-

ing gradually to maximum (100%) firing rate if the thermostat is not
satisfied within a defined time.

7. When the thermostat R and W contacts open (thermostat is satis-

fied) the furnace control recalculates the demand and a new firing
rate.

a. If demand exceeds the minimum firing rate, the burners will

continue to fire at a recalculated reduced firing rate, decreas­ing if the thermostat remains off for a defined time.

b. If demand does not exceed the minimum firing rate, the burn-

ers will shut off immediately.

8. After the burners shut off, the circulating blower will continue to run

until the temperature sensor detects that the supply air tempera­ture has dropped to the desired level, which should take from 30 to
90 seconds.

Johnson Controls Unitary Products 39

681292-UIM-A-0211

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.

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

This furnace has built-in self-diagnostic capability. If a system problem
occurs, a flashing LED shows a fault code. The LED can flash red,
green or amber to indicate various conditions. The LED is located on
the furnace control board and can be seen through the clear view po rt
in the lower door of the furnace. To indicate an error condition, the LED
will turn on for 1/4 second and off for 1/4 second. The pattern will be
repeated the number of times equal to the flash code. For instance, a
"six flash code" will be indicated by the LED turning on and off six times.
There will be a two second off period between each set of flashes. The
flash codes and an indication of their likely causes are listed below:

STEADY OFF - No 24V power to board. Check the 24 volt control cir­cuit fuse on the board. Check the circuit breaker or fuse on the 115 volt
supply power to the furnace. Check that the 24 volt transformer.

One Green Flash - Normal Operation with no call for heat.
Two Green Flashes - Indicator for "No error codes in memory". See

Diagnostic Fault Code Storage and Retrieval section below.
Three Green Flashes - Indicator for "Error codes cleared from mem-

ory". See Diagnostic Fault Code Storage and Retrieval section below.
Rapid Green Flash - Control is in "Factory Speed-up" mode. This

mode is used only during factory run-testing of the furnace. To stop this
mode, cycle power to the furnace off and then back on.

One Amber Flash - Normal operation with call for cooling.
Two Amber Flashes - Normal operation with call for heat.
Three Amber flashes - Normal operation, burner is on at end of heat-

ing cycle after wall thermostat has been satisfied.
Four Amber Flashes - Heating capacity is reduced due to restriction in

the circulating air system. Check for dirty filter or closed registers.
Five Amber Flashes - Heating capacity is reduced due to restriction in

the combustion air or vent system. Check for blocked vent/air pipe or
clogged condensate drain. Above 4,000 feet altitude, this may also indi­cate automatic, normal derating for altitude. See page 7 for additional
high altitude information.

Six Amber Flashes - (Heat Pump applications only) Normal operation
with call for heat pump heating.

Rapid Amber Flash - Low flame sense current. Check for dirty or mis­located flame sensor rod.

One Red Flash - Flame is present with no power being supplied to gas
valve. This can be caused by a gas valve that is slow to close or that
leaks gas through to the burners.

Two Red Flashes - Pressure switch closed with inducer pressure
below pressure switch setpoint (switch is closed when it should be
open). Check pressure switch.

Three Red Flashes - Pressure switch open with inducer pressure
above pressure switch setpoint (switch is open when it should be
closed). Check pressure switch.

Four Red Flashes - High limit switch open or defective temperature
sensor or 24 volt fuse is open. This may be caused by a dirty air filter,
improperly sized duct system, faulty blower motor, restricted circulating
airflow an open fuse on the control board.

Five Red Flashes - Rollout switch or condensate pressure switch
open. Check the rollout switch(es) on the burner assembly. It is a man­ual reset switch. To reset, push the small button in the center of the
switch. If it cannot be reset or if the switch trips again, contact a quali­fied serviceman.

Six Red Flashes - Gas valve communication error.
Seven Red Flashes - Lockout due to no ignition. The control will try

three times for ignition. If flame cannot be established in three tries, the
control will lockout for one hour and then will try again to light. Check
gas supply, ignitor, gas valve, flame sensor.

Eight Red Flashes - Lockout due to too many flame recycles. This
flash code occurs if flame is lost five times during a single heating cycle.
This could be caused by a faulty gas valve, low gas pressure, or dirty
flame sensor. The control will lock out for one hour and then will try
again.

Nine Red Flashes - Reversed line polarity or improper grounding.
Check polarity of the incoming power to the furnace. Check the ground­ing of the furnace, including the transformer ground and the L1 and
neutral connections.

Ten Red Flashes - Gas valve circuit shorted. Che
correct, replace gas valve.

Eleven Red Flashes - Main blower failure - This flash code occurs
when the main limit opens and fails to reclose within five minutes, indi­cating that the blower motor or blower wheel has failed.

Twelve Red Flashes - ID plug is not present or not connected properly,
check for loose plug or loose wires in plug.

Steady On Red - Control fault has been detected or there is 24 volts
present without 115 volts. Check that there is 24 volts and 115 volts
being supplied to the board. If so, then the board should be replaced.

IGNITION CONTROL FLAME SENSE LEVELS

Normal flame sense current is approximately

3.7 microamps DC (µa)

Low flame signal warning starts at 1.5 microamps.

Low flame signal control lockout point is

0.1 microamps DC (µa)

ck gas valve wiring. If

DIAGNOSTIC FAULT CODE STORAGE AND
RETRIEVAL

The control in this furnace is equipped with memory that will store up to
five error codes to allow a service technician to diagnose problems
more easily. This memory will be retained even if power to the furnace
is lost. Only a qualified service technician should use this feature.

The control stores up to five separate error codes. If more than five
error codes have occurred since the last reset, only the five most recent
will be retained. The furnace control board has a button, labeled "LAST
ERROR" that is used to retrieve error codes. This function will only
work if there are no active thermostat signals. So any call for heating,
cooling or continuous fan must be terminated before attempting to
retrieve error codes.

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

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

40 Johnson Controls Unitary Products

SECTION XI: REPLACEMENT PARTS LIST

DESCRIPTION

MOTOR

MOTOR, DIRECT DRIVE BLOWER
BLOWER, COMBUSTION

ELECTRICAL

CAPACITOR, RUN
SWITCH, LIMIT
CONTROL, FURNACE

IGNITER
SENSOR, FLAME
SWITCH, PRESSURE
SWITCH, DOOR

TRANSFORMER
VALVE, GAS
CONTROL, TEMPERATURE

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

681292-UIM-A-0211

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:

• Visit our website at www.source1parts.com for the following information:

1. Search for a part or browse the catalog.

2. Find a dealer or distributor.

3. Customer Service contact information.
a. Click on the “Brand Links” button

b. Click on the “Customer Service” button

• You can contact us by mail. Just send a written request to:

Johnson Controls Unitary Products

Consumer Relations

5005 York Drive

Norman, OK 73069

Johnson Controls Unitary Products 41

SECTION XII: WIRING DIAGRAM

FIGURE 47: Wiring Diagram

Subject to change without notice. Published in U.S.A. 681292-UIM-A-0211
Copyright © 2011 by Johnson Controls, Inc. All rights reserved. Supersedes: 531518-UIM-C-0110

Johnson Controls Unitary Products

5005 York Drive

Norman, OK 73069