Thermo Pride TP9C User Manual

When paired with a

York heat pump

MODULATING ECM

INSTALLATION MANUAL

RESIDENTIAL GAS FURNACES

MODELS: TP9C, YP9C, CP9C, and LP9C Series

(Up to 98% AFUE Multi-position)

LIST OF SECTIONS

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

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

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

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

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

CONDENSATE PIPING AND FURNACE

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

COMBUSTION AIR AND VENT SYSTEM . . . . . . . . . . . . . . . . 27

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 Cabinet Attachment Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . 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

Terminal Screw Wire Connection. . . . . . . . . . . . . . . . . . . . . . . 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 Modulati ng Furnace . . . . . 17

START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . 35

SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

NORMAL OPERATION AND DIAGNOSTICS . . . . . . . . . . . . . 40

REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . 42

REPLACEMENT PART CONTACT INFORMATION . . . . . . . . 42

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

START UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Thermostat Chart - Single Stage Heat Pump –

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 Installation . . . . . . . . . . . . . 22

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

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

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

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

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Home Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Termination Configuration - 1 Pipe . . . . . . . . . . . . . . . . . . . . . . 31

Termination Configuration - 2 Pipe . . . . . . . . . . . . . . . . . . . . . . 31

Termination Configuration - 2 Pipe Basement . . . . . . . . . . . . . 31

Double Horizontal Combustion Air Intake and

Vent Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Double Vertical Combustion Air Intake and

Vent Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Downward Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Direct Vent Air Intake Connection and Vent Connection . . . . . . 32

Combustion Airflow Path Through The Furnace Casing . . . . . . 33

Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Attic and Crawl Space Combustion Air Termination . . . . . . . . . 35

Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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 . . . . . . . . . . . . . . . . . . . . . . . 28

Elbow Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Equivalent Length of Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Combustion Air Intake and Vent Connection

Size at Furnace (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Unconfined Space Minimum Area . . . . . . . . . . . . . . . . . . . . . . . 33

Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Gas Rate (CU FT/HR) at Full Input . . . . . . . . . . . . . . . . . . . . . . 36

Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Blower Performance CFM - Any Position . . . . . . . . . . . . . . . . . 39

1083292-UIM-A-0114

The York YP9C is part 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

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• Furnaces for upflow 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.

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FOR FURNACES INSTALLED IN THE COMMONWEALTH OF MASSACHUSETTS ONLY

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

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

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

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

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

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

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

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

DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".

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

INSPECTION

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

FURNACE LOCATION AND CLEARANCES

The furnace shall be located using the following guidelines:

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

2. As centralized with the air distribution as possible.

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

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

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

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

Installation in freezing temperatures:

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

Improper installation in an ambient below 32ºF (0°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"

Front

Floor Combustible

0" 0" 0"

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

When the furnace is used with an indoor coil, the coil must be installed parallel with, or in the supply air side of the furnace to avoid 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 the furnace rating plate for the correct rise range and static pressures or to Table 6 for the correct rise range.

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 indoor coil is used, it may be placed directly on the furnace outlet and sealed to prevent leakage. If an uncased indoor coil with a thermoplastic drain pan is to be installed in the upflow/horizontal configuration, then extra 2” (5.1 cm) minimum spacing may be needed to ensure against drain pan distortion.

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 indoor coil, properly sealed to prevent leaks. Follow the instructions supplied with the indoor coil cabinet for installing the cabinet to the duct connector. Plug intake and vent pipe holes in bottom panel and move grommet to desired vent side exit.

Downflow Air - Indoor Coil Cabinet

The furnace should be installed with coil cabinet part number specifically intended for downflow application. If a matching indoor 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 indoor coil cabinet to the duct connector, and then position the furnace on top of the coil cabinet. The connection to the furnace, air conditioning coil cabinet, duct connector, and supply air duct must be 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.

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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

ATTACHMENT FLANGES

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

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

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COIL INSTALLATION

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 coil cabinet includes four removable flanges to allow proper fit up with furnaces having inlet and outlet configurations. The flanges are attached to the inside top of the coil cabinet in the factory during production. The 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. Repeat the procedure for all 4 flanges. See Figure 8.

FIGURE 6: Downflow Venting

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FIGURE 8: Coil Cabinet Attachment Flanges

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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

(Min)

Alternate

Drain Location

NOTICE

Gas Furnace

Use tie plate supplied with coil

Air flow

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.

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 - HD SERIES COILS

Horizontal duct coils are referred to as HD series coils. This coil must be connected using a supply duct transition. This coil is direction sensitive. Refer to the HD coil installation instructions for more information.

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.

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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.

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

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FRONT

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”)

SUPPLY END

.56”

20”

3”

23.8”

.56”

Combustion Air Inlet

RETURN END

24.25”

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

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)

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CFM

(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

(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 .

Nominal

CFM (m

Cabinet

Size

/min)

Cabinet

Side

(in)

Size

Cabinet Dimensions (Illustrated in Figure 13)

A (in) A (cm) B (in) B (cm) C (in) C (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.

Bottom

(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 for the “Optional Return Air Cutout” shown in Figure 13.

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Inlet Pressure Ta p

Outlet Pressure Ta p

On/Off Switch

Main Regulator Adjustment

Upflow

Configuration

Downflow

Configuration

Horizontal

Configuration

External Manual Shut-off Valve

To Gas Supply

Drip Leg

Gas Pipe

Gas Valve

Gas Pipe

Gas Valve

Gas Pipe

Gas Valve

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.

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 Figures 13 and 16.

FIGURE 16: Gas Piping

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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 pro-

pane (LP) gas. Do not use this furnace with butane gas. Incorrect gas orifices or a furnace that has been improperly converted will create an extremely dangerous condition resulting in premature heat exchanger failure, excessive sooting, high levels of carbon monoxide, personal injury, property damage, a fire hazard and/or death. High altitude and propane (LP) conversions are required in order for the appliance to satisfactory meet the application. An authorized distributor or dealer must make all gas conversions. In Canada, a certified conversion station or other qualified agency, using factory specified and/or approved parts, must perform the conversion. The installer must take every precaution to insure that the furnace has been converted to the proper gas orifice size when the furnace is installed. Do not attempt to drill out any orifices to obtain the proper orifice size. Drilling out a gas orifice will cause misalignment of the burner flames, causing premature heat exchanger burnout, high levels of carbon monoxide, excessive sooting, a fire hazard, personal injury, property damage and/or death.

SECTION V: ELECTRICAL POWER

ELECTRICAL POWER CONNECTIONS

Field wiring to the unit must be grounded. Electric wires that are field installed shall conform to the temperature limitation for 63°F (35°C) rise wire when installed in accordance with instructions. Refer to Table 6 in these instructions for specific furnace electrical data.

Use copper conductors only.

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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

/min

AFUE

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 opposite side of the furnace. Remove the screws and cut wire tie holding excess wiring. Reposition on the opposite side of the furnace and fasten using holes provided.

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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 (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

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.

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A+

B-

A+

GND or C

B-

A+

GND

B-

COMP

DHUM

Y/Y2

Touch Screen

Communicating control

Modulating Furnace

Communicating control

Air Conditioner/Heat Pump

Communicating control

A+

B-

A+

B-

COMP

DHUM

Y/Y2

Touch Screen

Communicating control

Modulating Furnace

Communicating control

Non-

Air Conditioner

Communicating

GND or C

A+

B-

A+

B-

NOTE

ENSURE ONLY ONE WIRE UNDER TERMINAL SCREW.

TO CONNECT MORE THAN ONE WIRE:

1. CONNECT ONLY TERMINAL END OF 6” WIRE PIGTAIL,

2. USE WIRE CONNECTOR TO CONNECT OTHER END OF PIGTAIL TO OTHER WIRES.

WIRE

CONNECTOR

TERMINAL

SCREW

THERMOSTAT

OUTDOOR UNIT

MODULATING FURNACE

COMMUNICATING

CONTROL

INDOOR UNIT

FIGURE 19: Modulating Furnace with Communicating AC or HP

FIGURE 21: Terminal Screw Wire Connection

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 22-27. 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 thermo-

FIGURE 20: Modulating Furnace with Communicating Thermostat and

Do not place more than one wire under any single communication terminal screw (there are four communication terminal screws). If more than one wire must be connected to a terminal screw, attach only the terminal end of a one wire pigtail no longer than 6“, and use a wire connector to connect the other end of the pigtail to the other wires. Failure to do this will result in nuisance communication error faults. See Figure 21.

14 Johnson Controls Unitary Products

Non-Communicating AC

stat manufacturer's instructions.

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

AIR CONDITIONER CONNECTIONS

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

For Single-Stage A/C - Connect the low voltage wiring as shown in Figure 22.

For Two-Stage A/C - Use a two-stage thermostat, connect the low voltage wiring as shown in Figure 23.

For Two-Stage A/C using a Single-Stage Thermostat - connect the low voltage wiring as shown in Figure 24.

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.

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Thermo Pride TP9C User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual