Winchester B2332496, B2332493, B2332491, B2332492, B2332490 User Manual
INSTALLATION MANUAL
SINGLE STAGE ECM
RESIDENTIAL GAS FURNACES
MODELS: TM8E, TMLE
(80% Multi-Position/Standard & Low NOx)
LIST OF SECTIONS
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
VENT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
LIST OF FIGURES
Duct Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Furnace and Coil Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Combustible Floor Base Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Horizontal Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Typical Attic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Typical Suspended Furnace / Crawl Space Installation . . . . . . . . . . . 7
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Side Return Cutout Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . 16
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . 25
REPLACEMENT PART CONTACT INFORMATION . . . . . . . . 25
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
START UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Thermostat Chart - Single Stage AC with
Single Stage Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Thermostat Chart - Single Stage HP with
Single Stage Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Combustion Air Inducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Combustion Airflow Path Through The Furnace Casing to the Burner
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . 15
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
LIST OF TABLES
Unit Clearances to Combustibles (All Dimensions in
Inches and cm, and All Surfaces Identified with the
Unit in an Upflow Configuration) . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cabinet and Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Recommended Filter Sizes (High Velocity 600 FPM) . . . . . . . . . 8
Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Ratings & Physical / Electrical Data . . . . . . . . . . . . . . . . . . . . . 11
Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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 for
commercial applications. All units are factory assembled, wired and
tested to assure safe dependable and economical installation and operation.
These units are Category I listed and may be common vented with
another gas appliance as allowed by the National Fuel Gas Code.
SECTION I: SAFETY
This is a safety alert symbol. When you see this symbol on
labels or in manuals, be alert to the potential for personal
injury.
Understand and pay particular attention to the signal words DANGER,
WARNING, or CAUTION.
Unconfined Space Minimum Area . . . . . . . . . . . . . . . . . . . . . . . 14
Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Gas Rate (CU FT/HR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Default Blower Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Blower Performance CFM - Any Position (without filter) . . . . . . 21
DANGER indicates an imminently hazardous situation, which, if not
avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation, which, if not
avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation, which, if not
avoided may result in minor or moderate injury. It is also used to
alert against unsafe practices and hazards involving only property damage.
!
WARNING
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.
Johnson Controls Ducted Systems 5594752-UIM-B-0419
5594752-UIM-B-0419
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
VI of these instructions.
6. Test for gas leaks as specified in these instructions.
!
WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warnings exactly could result in serious
injury, death or property damage.
Never test for gas leaks with an open flame. Use a commercially
available soap solution made specifically for detection of leaks to
check all connections. A fire or explosion may result causing property
damage, personal injury or loss of life.
7. Always install the furnace to operate within the furnace’s intended
temperature rise range. Only connect the furnace to a duct system
which has an external static pressure within the allowable range, as
specified on the furnace rating plate.
8. When a furnace is installed so that supply ducts carry air circulated
by the furnace to areas outside the space containing the furnace,
the return air shall also be handled by duct(s) sealed to the furnace
casing and terminating outside the space containing the furnace.
9. It is permitted to use the furnace for heating of buildings or structures under construction where the application and use must comply with all manufacturer’s installation instructions including:
• Proper vent installation;
• Furnace operating under thermostatic control;
• Return air duct sealed to the furnace;
• Air filters in place;
• Set furnace input rate and temperature rise per rating plate mark-
ing;
• 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 com-
pletion of the construction process, and verify furnace-operating
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.
IMPORTANT: During installation, doors should remain on the
furnace when moving or lifting.
SAFETY REQUIREMENTS
!
CAUTION
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 7. 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 CSA listed or approved for installation
into a HUD Approved Modular Home or a Manufactured
(Mobile) Home.
• This furnace is not approved for installation in trailers or recreational vehicles.
• Furnaces for installation on combustible flooring shall not be
installed directly on carpeting, tile or other combustible material
other than wood flooring.
• Check the rating plate and power supply to be sure that the electrical characteristics match. All models use nominal 115 VAC, 1
Phase, 60 Hz power supply. DO NOT CONNECT THIS APPLIANCE TO A 50 Hz POWER SUPPLY OR A VOLTAGE ABOVE
130 VOLTS.
• Furnace shall be installed so the electrical components are protected from water.
• Installing and servicing heating equipment can be hazardous due
to the electrical components and the gas fired components. Only
trained and qualified personnel should install, repair, or service
gas heating equipment. Untrained service personnel can perform
basic maintenance functions such as cleaning and replacing the
air filters. When working on heating equipment, observe precautions in the manuals and on the labels attached to the unit and
other safety precautions that may apply.
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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.
!
WARNING
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 backup 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 perma-
nently 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.
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.
!
WARNING
Improper installation in an ambient below 32ºF (0ºC) could create a
hazard, resulting in damage, injury or death.
2. Do not allow return air temperature to be below 55ºF (13ºC) for
extended periods. To do so may cause condensation to occur in the
main heat exchanger, leading to premature heat exchanger failure.
Clearances for access/service:
Ample clearances should be provided to permit easy access to the unit.
The following minimum clearances are recommended:
1. Twenty-four (24) inches (61 cm) between the front of the furnace
and an adjacent wall or another appliance, when access is required
for servicing and cleaning.
2. Eighteen (18) inches (46 cm) at the side where access is required
for passage to the front when servicing or for inspection or replacement of flue/vent connections.
In all cases, accessibility clearances shall take precedence over clearances for combustible materials where accessibility clearances are
greater.
Installation in a residential garage:
A gas-fired furnace for installation in a residential garage must be
installed so the burner(s) and the ignition source are located not less
than 18” (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 (All Dimensions in Inches and cm, and All Surfaces Identified with the Unit in an Upflow Configuration)
Application
Upflow 1 (2.5) 1 (2.5) 0 (0.0) 0 (0.0) 0 (0.0) 6 (15.2) Combustible Yes Yes Yes No
Upflow B-Vent 1 (2.5) 1 (2.5) 0 (0.0) 0 (0.0) 0 (0.0) 1 (2.5) Combustible Yes Yes Yes No
Downflow 1 (2.5) 1 (2.5) 0 (0.0) 0 (0.0) 0 (0.0) 6 (15.2)
Downflow B-Vent 1 (2.5) 1 (2.5) 0 (0.0) 0 (0.0) 0 (0.0) 1 (2.5)
Horizontal 1 (2.5) 1 (2.5) 0 (0.0) 0 (0.0) 0 (0.0) 6 (15.2) Combustible No Yes Yes
Horizontal B-Vent 1 (2.5) 1 (2.5) 0 (0.0) 0 (0.0) 0 (0.0) 1 (2.5) Combustible No Yes Yes
1. Special floor base or air conditioning coil required for use on combustible floor.
2. Line contact only permitted between lines formed by the intersection of the rear panel and side panel (top in horizontal position) of the furnace jacket and building
joists, studs or framing.
Top Front Rear
In. (cm) In. (cm) In. (cm) In. (cm) In. (cm) In. (cm)
Left
Side
Right
Side
Flue
Floor/
Bottom
1 (25.4)
1 (25.4)
Closet Alcove Attic
1
Yes Ye s Ye s No
1
Yes Ye s Ye s No
Line
Contact
2
Yes
2
Yes
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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.
!
CAUTION
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.
IMPORTANT: 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” (10.1 cm) attached
to the plenum.
!
WARNING
The duct system must be properly sized to obtain the correct airflow
for the furnace size that is being installed.
Refer to Table 5 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 cased 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/horizontalconfiguration, then extra 2” minimum spacing may be needed to ensure
against drain pan distortion.
On all installations without an indoor 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.
)RUGXFWDWWDFKPHQW
LIQHHGHG
FIGURE 1: Duct Attachment
)DFWRU\
LQVWDOOHG
$
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 3.
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 Conditioning 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,
indoor coil cabinet, duct connector, and supply air duct must be sealed
to prevent air leakage.
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COIL INSTALLATION
IMPORTANT: 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.
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The indoor coil must be mounted on the supply side of the furnace as
shown in Figure 2. Refer to the Installation Instructions provided with
each indoor coil.
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FIGURE 2: Furnace and Coil Attachment
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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FIGURE 3: Combustible Floor Base Accessory
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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.
SIDE RETURN APPLICATION
Side return applications pull return air through an opening cut in the
side of the furnace casing. This furnace is supplied with a bottom blockoff panel that should be left in place if a side return is to be used. If the
furnace is to be installed on a flat, solid surface, this bottom panel will
provide an adequate seal to prevent air leakage through the unused
bottom opening. However, if the furnace is to be installed on a surface
that is uneven, or if it is to be installed on blocks or otherwise raised off
the floor, it will be necessary to seal the edges of the bottom panel
to the casing using tape or other appropriate gasket material to
prevent air leakage.
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.
6 Johnson Controls Ducted Systems
5594752-UIM-B-0419
DOWNFLOW APPLICATION
For downflow applications, the furnace must be turned upside-down so
that the circulating air enters at the top and exits the furnace at the bottom. The combustion air inducer must be rotated 90° as shown in Figure 14. DO NOT BLOCK COMBUSTION AIR INLET OPENINGS.
HORIZONTAL APPLICATION
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FIGURE 4: Horizontal Application
IMPORTANT: 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
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FIGURE 5: 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 5.
When moving or handling this furnace prior to installation, always leave
the doors on the furnace to provide support and to prevent damage or
warping of the cabinet. When lifting the furnace, 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 6 for details and additional information.
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FIGURE 6: Typical Suspended Furnace / Crawl Space Installation
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IMPORTANT: During installation, doors should remain on the
furnace when moving or lifting.
IMPORTANT: During installation, doors should remain on the
furnace when moving or lifting.
When moving or handling this furnace prior to installation it is recom-
!
WARNING
When a furnace is installed in an attic or other insulated space, keep
all insulating materials at least 12 inches (30.5 cm) away from furnace
and burner combustion air openings.
mended 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.
Johnson Controls Ducted Systems 7
5594752-UIM-B-0419
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FIGURE 7: Dimensions
Table 2: Cabinet and Duct Dimensions
BTUH (kW)
Input
Nominal
CFM (m
3
/min)
Cabinet
Size
A A (cm) B B (cm) C C (cm) Lbs
Cabinet Dimensions (Inches)
40 (11.7) 1200 (34.0) A 14 1/2 36.8 13 3/8 34.0 10.3 26.2 89
60 (17.6) 1200 (34.0) A 14 1/2 36.8 13 3/8 34.0 10.3 26.2 94
80 (23.4) 1200 (34.0) B 17 1/2 44.4 16 3/8 41.6 11.8 29.9 103
80 (23.4) 1600 (45.3) C 21 53.3 19 7/8 50.5 13.6 34.5 116
80 (23.4) 2000 (56.6) C 21 53.3 19 7/8 50.5 13.6 34.5 121
100 (29.3) 1200 (34.0) B 17 1/2 44.4 16 3/8 41.6 11.8 29.9 108
100 (29.3) 1600 (45.3) C 21 53.3 19 7/8 50.5 13.6 34.5 120
100 (29.3) 2000 (56.6) C 21 53.3 19 7/8 50.5 13.6 34.5 124
120 (35.1) 1600 (45.3) C 21 53.3 19 7/8 50.5 15.8 40.1 125
120 (35.1) 2000 (56.6) C 21 53.3 19 7/8 50.5 15.8 40.1 131
130 (38.1) 2000 (56.6) D 24.5 62.2 23 3/8 59.4 17.5 44.4 137
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Approximate
Operating Weights
SECTION III: FILTERS
FILTER INSTALLATION
!
CAUTION
All filters and mounting provision must be field supplied. All installations must have a filter installed.
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.
NOTICE
Single side return above 1800 CFM is approved as long as the filter
Table 3: Recommended Filter Sizes (High Velocity 600 FPM)
CFM
(m³/min)
Cabinet
Size
Side
(in)
Bottom
(in)
1200 (34.0) A 16 x 25 14 x 25
1200 (34.0) B 16 x 25 16 x 25
1600 (45.3) C 16 x 25 20 x 25
2000 (56.6) C (2) 16 x 25 20 x 25
2000 (56.6) D (2) 16 x 25 22 x 25
1. Air velocity through throwaway type filters may not exceed 300 feet per
minute (91.4 m/min). All velocities over this require the use of high velocity
filters.
2. Do not exceed 1800 CFM using a single side return and a 16x25 filter. For
CFM greater than 1800, you may use two side returns or one side and the
bottom or one return with a transition to allow use of a 20x25 filter.
velocity does not exceed filter manufacturer’s recommendation.
8 Johnson Controls Ducted Systems
5594752-UIM-B-0419
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 8.
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FIGURE 8: Side Return Cutout Markings
Install the side filter rack following the instructions provided with that
accessory. If a filter(s) is provided at another location in the return air
system, the ductwork may be directly attached to the furnace side
panel.
IMPORTANT: 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 7.
HORIZONTAL FILTERS
Any branch duct (rectangular or round duct) attached to the plenum
must attach to the vertical plenum before the filter. Use of straps and/or
supports is required to support the weight of the external filter box.
DOWNFLOW FILTERS
!
CAUTION
In downflow furnace arrangement, the filter must be located a minimum of 12” from the return air inlet of furnace.
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
!
DANGER
An overpressure protection device, such as a pressure regulator,
must be installed in the gas piping system upstream of the furnace
and must act to limit the downstream pressure to the gas valve so it
does not exceed 0.5 PSI (14" w.c., 3.48 kPa). Pressures exceeding
0.5 PSI (14” w.c., 3.48 kPa) at the gas valve will cause damage to the
gas valve, resulting in a fire or explosion or cause damage to the furnace or some of its components that will result in property damage
and loss of life.
OUTLET
PRESSURE
PORT
INLET
WRENCH
BOSS
INLET
PRESSURE
PORT
ON/OFF SWITCH
(Shown in ON position)
OFF
ON
FIGURE 9: Gas Valve
IMPORTANT: Plan your gas supply before determining the correct
gas pipe entry. Use 90-degree service elbow(s), or short nipples and
conventional 90-degree elbow(s) to enter through the cabinet access
holes.
GAS PIPING INSTALLATION
Properly sized wrought iron, approved flexible or steel pipe must be
used when making gas connections to the unit. If local codes allow the
use of a flexible gas appliance connection, always use a new listed connector. Do not use a connector that has previously serviced another gas
appliance.
Some utility companies or local codes require pipe sizes larger than the
minimum sizes listed in these instructions and in the codes. The furnace
rating plate and the instructions in this section specify the type of gas
approved for this furnace - only use those approved gases. The installation of a drip leg and ground union is required. Refer to Figure 10.
VENT PORT
OUTLET
MAIN REGULATOR
ADJUSTMENT
A0226-001
NOTE: Ground Union maybe installed inside or outside unit.
Ground
Union
To Gas
Supply
Drip
Leg
External
Manual
Shut-off
Valve
Upflow
Configuration
To Gas
Supply
Drip
Leg
Ground
Union
Gas
Pipe
Gas
Valve
To Gas
Supply
Drip
Leg
External
Manual
Shut-off
Valve
Downflow
Configuration
To Gas
Supply
Drip
Leg
Ground
Union
Gas
Valve
Horizontal
Configuration
Gas Pipe
Gas
Valve
Ground
Union
Drip Leg
Drip Leg
Ground
Union
External
Manual
Shut-off
Valve
To Gas
Supp
To Gas
Supply
ly
FIGURE 10: Gas Piping
Johnson Controls Ducted Systems 9
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