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CONTENTS
SAFETY INFORMATION . . . . . . . . . . . . . . . . 2
FOR YOUR SAFETY . . . . . . . . . . . . . . . . . . . . . . . 2
SYSTEM OPERATION . . . . . . . . . . . . . . . . . . 2
THERMOSTATS. . . . . . . . . . . . . . . . . . . . . . . . . . .2
INTERMITTENT IGNITION DEVICE . . . . . . . . . . . 2
INPUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATING INSTRUCTIONS. . . . . . . . . . . . . . . . 3
USER’S, MAINTENANCE
and
SERVICE INFORMATION
EXPLAIN UNIT FUNCTION . . . . . . . . . . . . . . 4
GENERAL MAINTENANCE . . . . . . . . . . . . . . 4
HEATING SYSTEM INSPECTION. . . . . . . . . . . . . 4
BURNER AND PILOT CHECK. . . . . . . . . . . . . . . . 4
CLEANING BURNERS. . . . . . . . . . . . . . . . . . . . . . 4
AIR FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BLOWER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 5
MOTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CONDENSER COIL . . . . . . . . . . . . . . . . . . . . . . . . 5
REGISTERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 6
BEFORE CALLING A SERVICE PERSON: . . . . . . 6
MANUAL
3 THRU 6 TON
SINGLE PACKAGE
AIR CONDITIONER
GAS/ELECTRIC
& ELECTRIC/ELECTRIC
The manufacturer recommends that the “User” read all sections of this manual and
keep the manual for future reference.
FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could
result in serious injury, death, or property damage.
- Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or
any other appliance.
- WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use
any phone in your building.
• Leave the building immediately.
• Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s
instructions.
• If you cannot reach your gas supplier, call the
fire department.
- Installation and service must be performed by
a qualified installer, service agency or the gas
supplier.
66358-YUM-D-0712
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66358-YUM-D-0712
SAFETY INFORMATION
FOR YOUR SAFETY
• Make sure that the furnace area is clear and free
of combustible materials, gasoline and other flammable vapors and liquids.
• Be sure the furnace is free and clear of insulating
material. Examine the furnace area after installation of the furnace or the installation of additional
insulation. Some types of insulation are combustible.
• For proper operation of this furnace, air for combustion and ventilation is required. Make sure that
these openings are not obstructed.
• For lighting or shutting down this furnace, refer to
the lighting instructions provided adjacent to the
burners and also located in this manual.
• A blocked vent roll-out switch is provided in the
burner compartment. This switch is a manual
reset. If the furnace fails to operate, contact a
qualified service technician.
• Should the gas supply fail to shut off or if overheating occurs, shut off the gas valve to the furnace
before shutting off the electrical supply . Then call a
qualified service technician.
SYSTEM OPERATION
THERMOSTATS
Set your thermostat for either heating or cooling then set it for
the desired temperature. DO NOT MOVE THE THERMOSTAT RAPIDLY ON AND OFF, OR BACK AND FORTH
FROM HEAT TO COOL. THIS COULD DAMAGE YOUR
EQUIPMENT.
Always allow at least 5 minutes between changes. Find the
temperature that is most comfortable to you, and then LEA VE
YOUR THERMOSTAT ALONE. (Exception is for night or
vacation “set back” to conserve energy).
Manually moving the thermostat up or down will not speed up
temperature changes in your rooms. This only causes the
thermostat switch to function at your command rather than
responding to room temperature.
Heat generated by devices other than the furnace may interfere with thermostat performance. Therefore, lamps, radios,
television sets, etc. should not be placed near the thermostat.
• Do not use this furnace if any part has been under
water. A flood-damaged furnace is extremely dangerous. Attempts to use the furnace can result in
fire or explosion. A qualified service technician
should be contacted to inspect the furnace and to
replace all gas controls, control system parts, electrical parts that have been wet or the furnace if
deemed necessary.
• Determine the integrity of the installation regarding
the flue gas vent, the return and supply air duct.
Confirm the equipment is well supported and there
are no signs of deterioration. The manufacturer
recommends that main burner, ignition device and
controls are inspected by a qualified service technician before each heating season.
FIGURE 1 - TYPICAL THERMOSTAT
INTERMITTENT IGNITION DEVICE
Your unit is equipped with a cycling pilot burner. It has a Pilot
Relight control designed to automatically light the pilot burner
each time the thermostat “calls” for heat.
This furnace is equipped with an intermittent pilot
and automatic re-ignition system. Do Not attempt
to manually relight the pilot. Personal injury could
result.
When the thermostat calls for heat, pilot gas is supplied and
at the same time, sparking occurs to light the pilot gas. With
the pilot lit, the flame sensor rod closes a circuit to the ignitor
control which then opens the gas valve to admit main burner
gas.
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66358-YUM-D-0712
When the room thermostat is satisfied, the electrical circuit to
the gas valve is opened, closing off both main burner and
pilot gas simultaneously. If the pilot burner should fail to light,
contact your heating contractor or gas utility for service to
insure that proper operating conditions are restored.
INPUT
The correct heat capacity of the furnace is regulated by the
burner orifices and the gas pressure. The proper orifices are
furnished but the gas pressure regulator must be adjusted by
the installer or gas utility service technician.
OPERATING INSTRUCTIONS
TO SHUT DOWN THE FURNACE:
1. Close the main gas shutoff valve(s).
2. Turn off the electric power supply.
TO LIGHT THE FURNACE:
1. Do not attempt to light manually.
2. Open the main gas shutoff valve(s).
3. Adjust the set point of the room thermostat above the
temperature in the space.
4. Turn on the electric power supply.
5. The draft fan will operate. After an adequate purge time,
the electric spark igniter will light the burners.
6. The burners will extinguish and relight automatically
upon the demand of the room thermostat.
VENT SAFETY SYSTEM:
This gas furnace is equipped with an automatic reset high
temperature sensor or rollout switch which in the unlikely
event of a sustained main burner flame rollout will shut off the
flow of gas by closing the main gas valve. The ignition modules will also be disabled, preventing the flow of gas to the
valves. The switch is located inside the gas heat access
panel above the burner inlet. Flame rollout can be caused by
blockage of the power vent system, improper gas pressure or
adjustment. If this event occurs the furnace will not operate
properly, gas supply to the furnace should be shut off and no
attempt should be made to place the furnace in operation.
The system should be inspected by a qualified service technician. Refer to Figure 2 for a typical installation.
100% SHUT OFF:
The ignition modules are designed for 100% shut-off. If the
furnace fails to ignite within 85 seconds after a call for heat,
the flow of gas (including pilot) will be shut off and the ignition
module will lock out. The module can be reset by:
A. Turning the system switch on the room thermostat to the
“OFF” position and back to the “HEAT” position.
B. Decreasing the set point of the room thermostat below
the temperature in the conditioned space and returning it
to its original setting.
C. Opening and closing the unit's main disconnect switch.
FIGURE 2 - TYPICAL INSTALLATION
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66358-YUM-D-0712
If the furnace continues to lock out, a qualified service technician should be called to determine the cause of the problem.
ELECTRICAL SHOCK, FIRE OR EXPLOSION
HAZARD
Failure to follow safety warnings exactly could
result in dangerous operation, serious injury,
death or property damage.
Improper servicing could result in dangerous operation, serious injury, death or property damage.
• Before servicing, disconnect all electrical power
to furnace.
• When servicing controls, label all wires prior to
disconnecting. Reconnect wires correctly.
• Verify proper operation after servicing.
Prior to any of the following maintenance procedures, shut off all power to the unit, to avoid personal injury.
EXPLAIN UNIT FUNCTION
When the system is functioning properly, show the owner the
location of all disconnect switches and the thermostat.
Explain how to start and stop the unit and how to adjust temperature settings within the limitations of the system. Advise
that the flue exhaust hood surface and the immediate area
will experience high temperatures during the heating cycle,
and that all unauthorized personnel and debris must be kept
away from this area.
HEATING SYSTEM INSPECTION
It is the owner's responsibility to insure that an annual inspection of the entire heating portion of the unit is made by a qualified service technician. This should include inspection of the
burner, heating element and flue for any corrosion or soot
accumulation which may require cleaning and also checking
of burner and controls for proper operation.
In addition, at least once during the heating season, the
owner shall make a visual inspection of the flue outlet for evidence of black soot or blockage of flue outlet by leaves or
other debris. If any soot is found, it is recommended a qualified service technician be called immediately. If any blockage
is found, it must be cleared immediately.
Check for obvious signs of deterioration of the unit. Check
that the return and supply ducts attached to the unit are
sound and air tight. Check that the unit's physical support,
concrete slab or roof curb, is sound and not in need of repair.
Make sure there are no gaps between the roof curb and the
unit where rain could leak into the building.
Start the furnace. The vent motor should start, the igniter will
start to spark and ignite the pilot flame. After a short delay the
main burner should ignite. If it does not, contact a qualified
service technician for assistance. Check the appearance of
the main burner flame. Adjust burner shutters so no yellow
flame is observed in the heat exchanger tubes. (See Figure
3.) If flame adjustment cannot be made, obtain the assistance
of a qualified service technician and refer to the PILOT
CHECKOUT and BURNER AIR SHUTTER ADJUSTMENT
sections in the UNIT INSTALLATION INSTRUCTION.
GENERAL MAINTENANCE
FIGURE 3 - TYPICAL FLAME APPEARANCE
In order to insure long and trouble free service from your system, we recommend periodic inspection, cleaning, lubrication
and adjustment by your installing Dealer/Contractor. Be sure
to ask about this service. For those who prefer to do-it-yourself, please follow the instructions listed below to care for
your system.
Snow or debris should not be allowed to accumulate in or
around the unit. Do not permit overhanging structures or
shrubs to obstruct outdoor air discharge, combustion air
inlets or vent outlets on your unit. These provide air for combustion and ventilation. Adequate air is important to the safe
and proper operation of the unit.
4 Johnson Controls Unitary Products
BURNER AND PILOT CHECK
Periodically (at least annually at the beginning of each heating season) make a visual check of the pilot and main burner
flame. If necessary , adjust main burner primary air shutters to
give a distinct, sharp blue flame as explained under BURNER
AIR SHUTTER ADJUSTMENT. If it is not possible to adjust
for the proper flame, the burners may need cleaning.
CLEANING BURNERS
Remove them from the furnace as explained in BURNER
INSTRUCTIONS section in the Unit Installation Instructions.
Clean burners with wire brush and vacuum as needed.
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66358-YUM-D-0712
AIR FILTERS
Units up through 125 MBH input (3-6 Ton) are shipped with 1"
throwaway type air filters. The filter racks on 3-6 ton units will
receive 1" or 2" filters. Filters can also be installed in the
building at a suitable return air location if an economizer or
outside air accessory is not used. Filters must always be
used. They should be inspected once a month and thoroughly cleaned or replaced if it appears they are beginning to
accumulate excessive dirt. Filter sizes and quantities are
shown in the following table.
THROWAWAY
FILTER
SIZES
(Inches)
14 x 20 2
14 x 25 1
To install the filters, remove the filter access panel located to
the left of the condensate drain connection as shown in Figure 5.
NOTE: Filters must be installed with “Air Flow” arrows point-
ing inward -- toward the indoor coil. In the event the
spacers in the filter section are removed, they must
be reinstalled in their original position.
Slide filters all the way into the filter racks provided. When
more than one filter in a filter rack is required, they must butt
each other when sliding into position. Replace the filter
access panel.
QUANTITY
PER
UNIT
(Nom, Tons)
3 - 6 TON
ally. If the motor and wheel are heavily coated with dust, they
can be brushed and cleaned with a vacuum cleaner.
These units are supplied with blower shaft bearings that do
not require maintenance but may be relubricated if desired.
Every three years, using a low pressure grease gun, pump
grease into the bearing grease fitting until grease just begins
to show at the seals. Do not over lubricate. Use any lithium
base grease recommended for ball bearing service.
Perform all maintenance operations on the blower
motor with electric power disconnected from the
unit. Do not attempt to lubricate bearings with the
unit in operation.
MOTORS
Outdoor fan motors are permanently lubricated and require
no maintenance.
Ventor motor is factory lubricated for an estimated 10 year
life.
Indoor Blower Motor and Drive - The indoor blower motor features ball bearings that do not require periodic lubrication.
Periodic lubrication of the motor and bearings can extend the
life of components but is optional.
If desired, every three years, using a low pressure grease
gun, pump grease into the bearing grease fitting until grease
just begins to show at the seals. Do not over lubricate. Use
any lithium base grease recommended for ball bearing service.
CONDENSER COIL
(2) 14" X 20"
FILTERS
(1) 14" X 25"
FILTERS
3 - 6 TON
An annual check and cleaning, if necessary, of the outdoor
coil should be done. Cleaning should be as often as necessary to keep the coil clean. Clean any debris and dirt from the
outside coil face with a brush being careful not to damage the
fins. If extremely dirty, a hose can be used to wash the coil
from the inside out while brushing a soapy solution on the
outside.
FIGURE 4 - END VIEW LESS FILTER ACCESS
PANEL
Damage can occur if the bearings are overlubricated. Use grease sparingly.
BLOWER ASSEMBL Y
Even with good filters properly in place, blower wheels and
motors will become dust laden after many months of operation. The entire blower assembly should be inspected annu-
Johnson Controls Unitary Products 5
REGISTERS
Supply and return air registers must be open when the unit is
in operation. Obstructions must not be allowed to block airflow in or out of the registers.
Page 6
TROUBLESHOOTING
B. Check thermostat for lint, etc.
BEFORE CALLING A SERVICE PERSON:
A. Check thermostat setting and insure thermostat is calling
for heat or cooling.
C. Check fuses or circuit breakers.
D. Check filters for excessive dust accumulation.
Subject to change without notice. Printed in U.S.A. 66358-YUM-D-0712
Copyright © 2007 by Johnson Controls, Inc. All rights reserved. Supersedes: 66358-YUM-C-1011
Johnson Controls Unitary Products
5005 York Drive
Norman, OK 73069
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