Johnson Controls Burner TM9TMP User Manual

INSTALLATION MANUAL

RESIDENTIAL GAS FURNACE

EFFICIENCY

RATING

CERTIFIED

MODELS: TM9T*MP

ISO 9001

Certified Quality

Management System

(96% AFUE Two Stage Multi-position)

LIST OF SECTIONS

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

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

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

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

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

TWINNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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

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

SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

NORMAL OPERATION AND DIAGNOSTICS . . . . . . . . . . . . . . . . .34

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

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

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

CONDENSATE PIPING AND FURNACE

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

LIST OF FIGURES

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

Vertical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Coil Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

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

PC Series Upflow Coil Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Horizontal Left or Right application (Right Shown) . . . . . . . . . . . . . . 7

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

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

Typical Attic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Typical Suspended Furnace / Crawl Space Installation . . . . . . . . . . . 8

Downflow Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

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

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

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

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

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

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

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

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

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

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

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

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

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

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

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

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

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

Downward Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

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

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

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

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

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

Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

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

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

Thermostat Chart - Single Stage AC with

Single Stage PSC Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Thermostat Chart - Two Stage HP with

Two Stage PSC Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Typical Twinned Furnace Application . . . . . . . . . . . . . . . . . . . . . . . 15

Twinning Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

LIST OF TABLES

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

Coil Projection Dimensions - PC Series Coils . . . . . . . . . . . . . . . . . . 7

Cabinet and Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Recommended Filter Sizes (High Velocity 600 FPM) . . . . . . . . . . . . 9

Nominal Manifold Pressure - High Fire . . . . . . . . . . . . . . . . . . . . . . 11

Nominal Manifold Pressure - Low Fire . . . . . . . . . . . . . . . . . . . . . . . 11

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

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

Elbow Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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

Combustion Air Intake and Vent Connection

Size at Furnace (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

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

Unconfined Space Minimum Area . . . . . . . . . . . . . . . . . . . . . . . . . .27

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

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

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

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

Blower Performance CFM - Any Position (without filter) . . . . . . . . . .33

505309-UIM-D-0511

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

• This furnace is not approved for installation in trailers or recre-

ational vehicles.

• Furnaces for installation on combustible flooring shall not be

installed directly on carpeting, tile or other combustible material

other than wood flooring.

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.

CODES AND STANDARDS

• Check the rating plate and power supply to be sure that the electri-

cal characteristics match. All models use nominal 115 VAC, 1

Phase, 60-Hz power supply. DO NOT CONNECT THIS APPLI-

ANCE TO A 50-Hz POWER SUPPLY OR A VOLTAGE ABOVE

130 VOLTS.

Follow all national, local codes and standards in addition to this installa-

tion manual. The installation must comply with regulations of the serv-

ing 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.

• Furnace shall be installed so the electrical components are pro-

tected from water.

In the United States and Canada, follow all codes and standards for the

following, using the latest edition available:

• 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 precau-

tions in the manuals and on the labels attached to the unit and

other safety precautions that may apply.

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. Natu-

ral Gas and Propane Installation Codes (NSCNGPIC)

STEP 2 - General Installation

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

tact the

COMBUSTION AIR QUALITY

(LIST OF CONTAMINANTS)

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.

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.

Washington DC 20001

or www.NFPA.org

2. Soap powders, bleaches, waxes or other cleaning com-

pounds; plastic items or containers; gasoline, kerosene, ciga-

rette lighter fluid, dry cleaning fluids or other volatile fluid.

3. Paint thinners and other painting compounds.

• CANADA: NSCNGPIC. For a copy contact:

Standard Sales, CSA International

178 Rexdale Boulevard

Etobicoke, (Toronto) Ontario Canada M9W 1RS

4. Paper bags, boxes or other paper products

STEP 3 - Combustion and Ventilation Air

Never operate the furnace with the blower door removed. To do

so could result in serious personal injury and/or equipment

damage.

• 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

The furnace requires OUTDOOR AIR for combustion when the furnace

• 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.

is located in any of the following environments.

• Buildings with indoor pools

• Chemical exposure

• Commercial buildings

• Furnaces installed in hobby or craft rooms

• Furnaces installed in laundry rooms

• Furnaces installed near chemical storage areas

• Restricted Environments

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

The furnace requires OUTDOOR AIR for combustion when the furnace

is located in an area where the furnace is being exposed to the follow-

ing substances and / or chemicals.

STEP 7 - Electrical Connections

• Antistatic fabric softeners for clothes dryers

• Carbon tetrachloride

• Cements and glues

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

• CANADA: Canadian Electrical Code CSA C22.1

These instructions cover minimum requirements and conform to exist-

ing 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.

• Chlorine based swimming pool chemicals

• Chlorinated waxes and cleaners

• Cleaning solvents (such as perchloroethylene)

• De-icing salts or chemicals

• Halogen type refrigerants

• Hydrochloric acid

• Masonry acid washing materials

• Permanent wave solutions

• Printing inks, paint removers, varnishes, etc.

• Water softening chemicals

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

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.

FOR FURNACES INSTALLED IN THE COMMON-

WEALTH 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 resi-

dential purposes, including those owned or operated by the Com-

monwealth 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 require-

ments shall be satisfied:

Installation in freezing temperatures:

1. Furnace shall be installed in an area where ventilation facilities pro-

vide 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.

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 pro-

fessionals for the installation of hard wired carbon monoxide

detectors

Improper installation in an ambient below 32ºF (0.0° C) could create a

hazard, resulting in damage, injury or death.

2. Do not allow return air temperature to be below 55º F (13°C) for

extended periods. To do so may cause condensation to occur in the

main heat exchanger, leading to premature heat exchanger failure.

3. If this furnace is installed in an unconditioned space and an

extended power failure occurs, there will be potential damage to the

internal components. Following a power failure situation, do not

operate the unit until inspection and repairs are performed.

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.

Liquid anti-freeze will cause damage to internal plastic parts of this

furnace. DO NOT attempt to winterize the furnace using liquid

anti-freeze.

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon

monoxide detector as required in accordance with the above pro-

visions shall comply with NFPA 720 and be ANSI/UL 2034 listed

and IAS certified.

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.

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 heat-

ing 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".

2. Eighteen (18) inches (46 cm) at the side where access is required

for passage to the front when servicing or for inspection or replace-

ment of flue/vent connections.

In all cases, accessibility clearances shall take precedence over clear-

ances for combustible materials where accessibility clearances are

greater.

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 car-

bon monoxide detectors and signage installed in accordance

with the provisions of 248 CMR 5.08(2)(a)1 through 4.

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.

INSPECTION

As soon as a unit is received, it should be inspected for possible dam-

age 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.

Table 1: Unit Clearances to Combustibles

Application

Top

Upflow

Downflow

Horizontal

Vent

Rear

Side

FURNACE LOCATION AND CLEARANCES

The furnace shall be located using the following guidelines:

Front*

Floor

Combustible

Yes

Combustible¹

Combustible

Yes

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).

Closet

Line Contact

Yes

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

24" clearance in front and 18" on side recommended for service access.

All furnaces approved for alcove and attic installation.

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

SECTION II: DUCTWORK

DUCTWORK GENERAL INFORMATION

The duct system’s design and installation must:

The duct system must be properly sized to obtain the correct airflow

for the furnace size that is being installed.

Refer to Table 7 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 pres-

sures 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.

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.

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.

4. Complete a path for heated or cooled air to circulate through the air

conditioning and heating equipment and to and from the condi-

tioned space.

If the flanges are not used, they must remain in the rotated down posi-

tion as shipped.

The cooling coil must be installed in the supply air duct, downstream

of the furnace. Cooled air may not be passed over the heat

exchanger.

Factory

installed

For duct attachment,

if needed.

When the furnace is used with a cooling coil, the coil must be installed

parallel with, or in the supply air side of the furnace to avoid condensa-

tion in the primary heat exchanger. When a parallel flow arrangement is

used, dampers or other means used to control airflow must be ade-

quate to prevent chilled air from entering the furnace. If manually oper-

ated, 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 con-

trols may not operate at all.

FIGURE 1: Duct Attachment

DUCTWORK INSTALLATION AND SUPPLY PLENUM

CONNECTION - UPFLOW/HORIZONTAL

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.

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

The minimum plenum height is 12” (30.5 cm). The furnace will not

operate properly on a shorter plenum height. The minimum recom-

mended rectangular duct height is 4” (10.2 cm) attached to the ple-

num.

Installations on combustible material or directly on any

floors must use a combustible floor base shown in Figure 8.

Follow the instructions supplied with the combustible floor

base accessory. This combustible floor base can be

replaced with a matching cooling coil, properly sealed to

prevent leaks. Follow the instructions supplied with the

cooling coil cabinet for installing the cabinet to the duct con-

nector. Plug intake and vent pipe holes in bottom panel and

move grommet to desired vent side exit.

If a matching cooling coil is used, it may be placed directly on the fur-

nace outlet and sealed to prevent leakage. If thermoplastic evaporator

‘A’ coil drain pans are to be installed in the upflow/horizontal configura-

tion, 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 recom-

mended 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.

Downflow Air Conditioning Coil Cabinet

The furnace should be installed with coil cabinet part number specifi-

cally intended for downflow application. If a matching cooling coil is

used, it may be placed directly on the furnace outlet and sealed to pre-

vent leakage. For details of the coil cabinet dimensions and installation

requirements, refer to the installation instructions supplied with the coil

cabinet.

Attach the air conditioning coil cabinet to the duct connector, and then

position the furnace on top of the coil cabinet. The connection to the fur-

nace, air conditioning coil cabinet, duct connector, and supply air duct

must be sealed to prevent air leakage.

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

COIL INSTALLATION

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 hor-

izontal applications with the horizontal drain pan side down.

On all installations without a coil, a removable access panel is recom-

mended 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 man-

ner as to prevent leaks.

Mounting Plate

COIL/FURNACE ASSEMBLY - MC/FC/PC SERIES

COILS

Furnace

FIGURE 4: Horizontal Right Application

For horizontal left hand applications no conversion is required to an MC

coil when used with a downflow/horizontal furnace. A mounting plate,

supplied with every coil should always be installed on the side desig-

nated as top side. See Figures 4 & 5.

Mounting Plate

Furnace

UPFLOW

DOWNFLOW

FIGURE 2: Vertical Applications

FIGURE 5: Horizontal Left Application

FURNACE ASSEMBLY - MC & FC SERIES COILS

These coils are factory shipped for installation in either upflow or down-

flow applications with no conversion.

FURNACE ASSEMBLY - PC SERIES COILS

These upflow coils are designed for installation on top of upflow fur-

naces only.

Position the coil casing over or under the furnace opening as shown in

Figure 2 after configuring coil flanges as required see “Coil Flange” sec-

tion below.

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

COIL FLANGE INSTALLATION

The coils include removable flanges to allow proper fit up with furnaces

having various inlet and outlet flange configurations. The two flanges

are attached to the top of the coil in the factory during production. For

proper configuration of flanges refer to Figure 3.

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

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

appropriately.

Do not drill any holes or drive any screws into the front duct flange on

the coil in order to prevent damaging coil tubing. See Figure 6.

FACTORY

FLANGE

LOCATION

(Used for upflow

or horizontal

right installations)

ALTERNATE

FLANGE LOCATION

(Used for downflow or

horizontal left installations)

FIGURE 3: Coil Flange

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

DOWNFLOW DUCT CONNECTORS

All downflow installations must use a suitable duct connector approved

by the furnace manufacturer for use with this furnace. The duct connec-

tors are designed to be connected to the rectangular duct under the

floor and sealed. Refer to the instructions supplied with the duct con-

nector for proper installation. Refer to the separate accessory parts list

at the end of these instructions for the approved accessory duct con-

nectors.

(Min)

Flexible

Duct Collar

Field

Fabricated

Ductwork

Do not drill

or Screw

this flange

FURNACE

Upflow

Coil

WARM AIR PLENUM

WITH 1” FLANGES

Upflow

Furnace

FIBERGLASS

INSULATION

Alternate

Drain Location

Primary

Drain

Secondary

Drain

FIBERGLASS TAPE

UNDER FLANGE

FIGURE 6: PC Series Upflow Coil Installation

Table 2: Coil Projection Dimensions - PC Series Coils

COIL SIZE

DIMENSION “C” INCH

PC18

PC24

3-1/2

4-1/2

5-1/2

6-1/2

COMBUSTIBLE FLOOR

BASE ACCESSORY

PC30, PC32, PC35

PC42, PC43, PC36, PC37

PC48

FIGURE 8: Combustible Floor Base Accessory

RESIDENTIAL AND MODULAR HOME UPFLOW

RETURN PLENUM CONNECTION

PC60

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

Return air may enter the furnace through the side(s) or bottom depend-

ing on the type of application. Return air may not be connected into the

rear panel of the unit.

CRITICAL COIL PROJECTION

The coil assembly must be located in the duct such that a minimum dis-

tance is maintained between the top of the coil and the top of the duct.

Refer to Table 2.

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 block-

off 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.

COIL / FURNACE ASSEMBLY - HC SERIES COILS

These coils are supplied ready to be installed in a right hand position or

a left hand position. When used in conjunction with a horizontal furnace

(blow through) application, the coil should be oriented with the opening

of the “A” coil closest to the furnace. See Figure 7.

NOTICE

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 7.

BOTTOM RETURN AND ATTIC INSTALLATIONS

Bottom return applications normally pull return air through a base plat-

form or return air plenum. Be sure the return platform structure or return

air plenum is suitable to support the weight of the furnace.

Use tie plate

supplied with coil

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.

Gas Furnace

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

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

HORIZONTAL APPLICATION

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 sup-

port 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 fur-

nace. Maintain a 6” (15.2 cm) minimum clearance between the front of

the furnace and the support rods or straps.

FIGURE 9: Horizontal Application

This furnace may be installed in a horizontal position on either side as

shown above. It must not be installed on its back.

All six suspension points must be level to ensure proper and quiet fur-

nace 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 11 for details and additional information.

ATTIC INSTALLATION

Line contact only permissible

between lines formed by the

intersection of furnace top

and two sides and building

joists, studs or framing

Supply

Air

Vent (Maintain

required

clearances to

combustibles)

Filter rack

must be a minimum

distance

Gas Piping

of 18” (45.7 cm)

from the

furnace

Support

Rod

30” MIN.

Work Area

Support

Angle (x3)

Return

Air

Sediment

Trap

Maintain 6” minimum

clearance between support

rods and front of furnace

FIGURE 10: Typical Attic Installation

FIGURE 11: Typical Suspended Furnace / Crawl Space 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 10.

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. See Figure 12.

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.

Rotate vent

blower 90°

either way

When moving or handling this furnace prior to installation it is recom-

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.

LEFT SIDE VENT

RIGHT SIDE VENT

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 exchang-

ers 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.

FIGURE 12: Downflow Venting

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

RIGHT SIDE

Combustion Air Inlet

LEFT SIDE

Combustion Air Inlet

FRONT

Condensate Drain

(Downflow)

Gas Pipe

Entry

Gas Pipe

Entry

Condensate Drain

(Downflow)

Vent Outlet

Electrical

Entry

Electrical

Entry

Vent Outlet

23”

Condensate

Drain

Condensate

Drain

Thermostat

Wiring

Thermostat

Wiring

Optional Return Air

Cutout (Either side)

14”

1”

28.5”

29.5”

(For Cladded door add appoximately an additional .75”)

1.5”

.56”

23.8”

3”

Vent

Outlet

Combustion

Air Inlet

.56”

24.25”

.56”

20”

SUPPLY END

FIGURE 13: Dimensions

RETURN END

Table 3: Cabinet and Duct Dimensions

Approximate

Operating Weights

Cabinet Dimensions (Inches)

Nominal

CFM (m³/min)

BTUH (kW)

Input

Cabinet

Size

A (in)

17 1/2

A (cm)

44.4

53.3

62.2

B (in)

16 3/8

19 7/8

23 3/8

B (cm)

41.6

50.5

59.4

C (in)

13 1/4

14 3/4

16 1/2

18 1/4

21 3/4

C (cm)

33.7

37.5

41.9

46.4

55.2

Lbs (kg)

122

60 (17.6)

80 (23.4)

100 (29.3)

120 (35.1)

1200 (34.0)

1600 (45.3)

2000 (56.6)

126

136

142

145

24 1/2

156

SIDE RETURN

Locate the “L” shaped corner locators. These indicate the size of the cut-

out to be made in the furnace side panel. Refer to Figure 14.

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.

Front of

Furnace

Side of

Furnace

NOTICE

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.

Corner

Markings

Table 4: Recommended Filter Sizes (High Velocity 600 FPM)

FIGURE 14: Side Return Cutout Markings

CFM (m³/min)

1200 (34.0)

1600 (45.3)

2000 (56.6)

Cabinet Size

Side (in)

16 x 25

Bottom (in)

16 x 25

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.

16 x 25

20 x 25

(2) 16 x 25

20 x 25

22 x 25

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

ute (91.4 m/min). All velocities over this require the use of high velocity fil-

ters.

Some accessories such as electronic air cleaners and pleated media

may require a larger side opening. Follow the instructions supplied

with that accessory for side opening requirements. Do not cut the

opening larger than the dimensions shown in Figure 13.

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 side return with a transition to allow use of a 20x25 filter.

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

HORIZONTAL APPLICATION

Horizontal Filters

HIGH STAGE REGULATOR

ADJUSTMENT

OUTLET

PRESSURE

PORT

VENT

PORT

All filters and mounting provision must be field supplied. All installa-

tions must have a filter installed.

INLET

OUTLET

WRENCH

BOSS

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.

INLET

PRESSURE

PORT

LOW STAGE REGULATOR

ADJUSTMENT

ON OFF

SWITCH

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.

FIGURE 15: Gas Valve

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.

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

SECTION IV: GAS PIPING

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 con-

nector. Do not use a connector that has previously serviced another gas

appliance.

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 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.

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 instal-

lation of a drip leg and ground union is required. Refer to Figure 16.

To Gas

Supply

NOTE: Ground Union maybe installed inside or outside unit.

To Gas

Supply

External

Manual

Shut-off

Valve

Ground

Union

To Gas

Supply

External

Manual

Shut-off

Valve

Ground

Union

To Gas

Supply

To Gas

Supply

Ground

Union

Drip Leg

Gas

Valve

External Manual

Shut-off Valve

Gas

Pipe

Ground

Union

Drip

Leg

Gas

Valve

Drip

Leg

Ground

Union

Gas

Valve

To Gas

Supply

Gas

Pipe

Drip

Leg

Gas

Pipe

Ground

Union

Drip

Leg

Downflow

Upflow

Horizontal

Drip

FIGURE 16: Gas Piping

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 gas valve body is a very thin casting that cannot take any exter-

nal 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 opera-

tion and/or the valve to leak.

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).

Gas piping may be connected from either side of the furnace using any

of the gas pipe entry knockouts on both sides of the furnace. Refer to

Figure 13.

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

The manifold pressure must be changed in order to maintain proper

and safe operation when the furnace is installed in a location where the

altitude is greater than 7,999 feet (2,438 m) above sea level. Refer to

Table 5 for proper manifold pressure settings.

GAS ORIFICE 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 PRESSURE SWITCH CONVERSION

HIGH ALTITUDE GAS ORIFICE CONVERSION

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

at 0 –7,999 feet (0 – 2,438 m) above sea level.

For installation where the altitude is less than 5,000 feet (1,524m), it is

not required that the pressure switch be changed unless you are in an

area subject to low pressure inversions.

Table 5: Nominal Manifold Pressure - High Fire

Manifold Pressures (in. w.c.)

Manifold Pressures (kPa)

Altitude (feet)

Altitude (m)

0-7999

3.5

8000-8999

3.5

9000-9999

3.5

0-2437

0.87

0.80

2.44

2438-2742

0.87

2743-3048

0.87

800

850

29.8

31.7

3.5

0.87

900

3.5

33.5

0.87

950

3.5

3.3

35.4

0.87

0.81

1000

1050

1100

3.5

3.2

2.9

37.3

0.80

0.73

3.5

2.9

2.7

39.1

0.73

0.67

3.2

2.7

2.4

41.0

0.66

0.61

2500 (LP)

9.8

8.2

7.5

93.2 (LP)

2.03

1.86

TABLE 6: Nominal Manifold Pressure - Low Fire

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

First Stage Manifold Pressures (kPa)

Altitude (feet)

Altitude (m)

0-7999

1.7

8000-8999

1.7

9000-9999

1.7

0-2437

0.42

0.41

0.37

0.34

1.03

2438-2742

0.42

2743-3048

0.42

800

850

29.8

31.7

1.7

0.42

900

1.7

33.5

0.42

950

1.7

1.5

35.4

0.42

0.38

1000

1050

1100

1.6

1.5

1.4

37.3

0.37

0.34

1.5

1.4

1.3

39.1

0.34

0.31

1.3

1.2

1.1

41.0

0.31

0.28

2500 (LP)

4.1

3.8

3.5

93.2 (LP)

0.95

0.87

DANGER

PROPANE AND HIGH ALTITUDE CONVERSION KITS

It is very important to choose the correct kit and/or gas orifices for the altitude and the type of gas for which the furnace is being installed.

Only use natural gas in furnaces designed for natural gas. Only use propane (LP) gas for furnaces that have been properly converted to use pro-

pane (LP) gas. Do not use this furnace with butane gas.

Incorrect gas orifices or a furnace that has been improperly converted will create an extremely dangerous condition resulting in premature heat

exchanger failure, excessive sooting, high levels of carbon monoxide, personal injury, property damage, a fire hazard and/or death.

High altitude and propane (LP) conversions are required in order for the appliance to satisfactory meet the application.

An authorized distributor or dealer must make all gas conversions.

In Canada, a certified conversion station or other qualified agency, using factory specified and/or approved parts, must perform the conversion.

The installer must take every precaution to insure that the furnace has been converted to the proper gas orifice size when the furnace is installed.

Do not attempt to drill out any orifices to obtain the proper orifice size. Drilling out a gas orifice will cause misalignment of the burner flames, caus-

ing premature heat exchanger burnout, high levels of carbon monoxide, excessive sooting, a fire hazard, personal injury, property damage and/or

death.

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 7 in

SECTION V: ELECTRICAL POWER

ELECTRICAL POWER CONNECTIONS

these instructions for specific furnace electrical data.

Use copper conductors only.

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

Table 7: Ratings & Physical / Electrical Data

Input - HI/LOW

Output - HI/LOW

Nominal Air Flow

Total Unit AFUE

Hi Fire Air Temp Rise

Lo Fire Air Temp Rise

MBH

60/39

MBH

58/37

77/50

96/62

115/75

CFM

m3/min

Amps

°F

°C

°F

°C

18/11

23/15

29/19

35/23

17/11

22/14

28/18

33/22

1200

1600

2000

35 - 65

45 - 75

35 - 65

45 - 75

19.5 - 36

25 - 41.6

19.5 - 36

25 - 41.6

35 - 65

20 - 50

25 - 55

35 - 65

20 - 50

35 - 65

19.5 - 36

11.1 - 27.8

13.9 - 30.5

19.5 - 36

11.1 - 27.8

19.5 - 36

80/52

45.3

56.6

11.5

100/65

120/78

Max. Outlet Air Temp

Blower

Blower Size

Max. Over Current

Min. Wire Size

Operating Weight

°F

°C

1/2

3/4

Amps

in.

Protect

(awg) @ 75ft.one way

lbs.

122

126

136

142

145

156

kg.

170

175

180

76.7

79.4

76.7

11 x 8

11 x 10

11 x 11

27.9 x 20.3

27.9 x 25.4

27.9 x 27.9

55.3

57.1

61.7

64.4

65.7

70.7

8.8

14.5

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.

SUPPLY VOLTAGE CONNECTIONS

The power connection leads and wiring box may be relocated to the

left side of the furnace. Remove the screws and cut wire tie holding

excess wiring. Reposition on the left side of the furnace and fasten

using holes provided.

Junction

Box

Connect ground

lead to screw

LOW VOLTAGE CONTROL WIRING CONNECTIONS

Install the field-supplied thermostat by following the instructions that

come with the thermostat. With the thermostat set in the OFF position

and the main electrical source disconnected, connect the thermostat

wiring from the wiring connections on the thermostat to the terminal

board on the ignition module, as shown in Figures 18 or 19. Electronic

thermostats may require the common wire to be connected. Apply

strain relief to thermostat wires passing through cabinet. If air condition-

ing equipment is installed, use thermostat wiring to connect the Y and C

terminals on the furnace control board to the proper wires on the con-

densing unit (unit outside).

Electrical Entry

BLK

L1-Hot

Neutral

WHT

FIGURE 17: Electrical Wiring

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

current 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 dia-

gram in this instruction.

Set the heat anticipator in the room thermostat to 0.4 amps. Setting it

lower will cause short cycles. Setting it higher will cause the room

temperature to exceed the set points.

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

through a conduit connector or other proper bushing that has been

installed into the unit opening and the junction box. In the junction

box there is a black wire, a white wire and a green ground screw.

Connect the power supply as shown on the unit’s wiring label

located on the inside of the blower compartment door, or the wiring

schematic in this section. Connect the black wire to L1 (hot) from

the power supply. Connect the white wire to neutral. Connect the

ground wire (installer-supplied) to the green (equipment ground)

screw. An alternate wiring method is to use a field-provided 2” (5.1

cm) x 4” (10.2 cm) box and cover on the outside of the furnace.

Route the furnace leads into the box using a protective bushing

where the wires pass through the furnace panel. After making the

wiring connections replace the wiring box cover and screws. Refer

to Figure 17.

Some electronic thermostats do not have adjustable heat anticipa-

tors. They should be set to six cycles per hour. Follow the thermostat

manufacturer's instructions.

The 24-volt, 40 VA transformer is sized for the furnace components

only, and should not be connected to power auxiliary devices such as

humidifiers, air cleaners, etc. The transformer may provide power for an

air conditioning unit contactor.

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

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

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

For additional connection diagrams for all Johnson Controls Unitary Products’ equipment refer to “Low Voltage System Wiring” document available

on-line at www.upgnet.com in the Product Catalog Section.

AC 15A

Two Stage Air Conditioner - Two Stage PSC Furnace

ID MODELS

PT(8/9)

(F/L)*(8/9)T

(G/L)*(8/9)T

THERMOSTAT

*PP32U70124

THERMOSTAT

TM9*

TWO STAGE

AIR

CONDITIONER

*DN22H00124

*DP22U70124

TWO STAGE PSC

FURNACE

TWO STAGE PSC

FURNACE

24 – Volt Common

Single Stage

Compressor

Y Y1

First Stage Compressor First Stage Compressor

First Stage Compressor

24 – Volt Hot

(Heat XFMR)

Fan

W / W1

First Stage Heat

Second Stage

Aux. Heat

Second Stage Heat

24 – Volt Hot

(Cool XFMR)

Y / Y2

Second or Full

Stage Compressor

Second Stage

Compressor

Second Stage

Compressor

Second Stage

Compressor

First Stage Heat

E/W1

First Stage Aux. Heat

External Humidistat

(Optional)

Open on Humidity Rise

24VAC Humidifier

(Optional)

Connection of the “C”

terminal, 24-Volt common terminal, 24-Volt common

is optional when used with is optional when used with

batteries

Thermostat Installer Setup

0170-System Type-must

be set to 8-2 Heat/2 Cool

Multistage Conventional

Part Numbers:

Part Number:

S1-2HU16700124

SAP

Legacy

265903 = 031-09168

449573

FIGURE 18: Thermostat Chart - Single Stage AC with Single Stage PSC Furnaces

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

HP 22A

Two Stage Heat Pump - Two Stage PSC Furnace (Hot Heat Pump or Conventional)

ID MODELS

OD MODELS

PT(8/9)

YZE

YZH

H*5

H*8

(F/L)*(8/9)T

(G/L)*(8/9)T

TM9*

THERMOSTAT

*PP32U70124

THERMOSTAT

*DN22H00124

*DP22U70124

TWO STAGE PSC

FURNACE

TWO STAGE

HEAT PUMP

TWO STAGE PSC

FURNACE

YORKGUARD VI

CONTROL

24 – Volt Common

Single Stage

Compressor

Single Stage

Compressor

First Stage Compressor First Stage Compressor

24 – Volt Hot

(Heat XFMR)

Fan

Emergency Heat

W / W1

First Stage Heat

W1 OUT

First Stage Heat

Second Stage

Aux. Heat

Second Stage Heat

W2 OUT

Second Stage Heat

24 – Volt Hot

(Cool XFMR)

Y / Y2

Second or Full

Stage Compressor

Y2 OUT

Second Stage

Compressor

O/B

Reversing Valve

Energized in Cool

Reversing Valve

Energized in Cool

Malfunction Light

X/L

Malfunction Light

Second Stage

Compressor

Second Stage

Compressor

Second Stage

Compressor

AUX

Auxiliary Heat

E/W1

First Stage Aux. Heat

Auxiliary Heat

BSG

Bonnet Sensor

External Humidistat

(Optional)

Open on Humidity Rise

Bonnet Sensor

(Optional)

Bonnet Sensor

24VAC Humidifier

(Optional)

Thermostat Installer Setup

0170-System Type-

must be set to 12

Step 1 of Thermostat

Installer/Configuration

Menu must be set to “HP2”

Selection of GAS/ELEC

switch on thermostat

not necessary

Change FFuel jumper

on the heat pump control

to “ON”

3 Heat/2 Heat Pump

Thermostat Installer Setup

0190-Changeover Valve-

must be set to 0

Change Hot Heat Pump

jumper on the heat pump

control to “ON” if Hot Heat

Pump Operation is desired.

O/B terminal

Energized in Cooling

Thermostat Installer Setup

0200-Backup Heat Source-

must be set to 1

Part Numbers:

SAP

Legacy

Part Numbers:

126768 = 031-09137

18395 = 031-01996

340512 = 031-09178

Part Number:

S1-2HU16700124

SAP

Legacy

Heat Pump Backup Heat

Source is Fossil Fuel

Thermostat Installer Setup

0210-External Fossil Fuel

265903 = 031-09168

449573

FIGURE 19: Thermostat Chart - Two Stage HP with Two Stage PSC Furnace

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

If furnace staging is desired with two furnaces on a common duct,

where the gas burner on the first furnace operates on W1 and the gas

burner on the second furnace operates on W2, then the use of an air-

mixing device in the plenum to mix the air from both furnaces is strongly

recommended. The mixing device must be installed before any ducts

that supply air to occupied spaces. Twinning causes both indoor fans to

operate simultaneously. If a mixing device is not used, any ducts that

are connected down stream from the furnace that operates on W2, will

be supplying cold air in the Heating mode to the occupied spaces

unless W2 is energized.

ACCESSORY CONNECTIONS

The furnace control will allow power-switching control of various

accessories.

ELECTRONIC AIR CLEANER CONNECTION

Two 1/4” (6.4 mm) spade terminals (EAC and NEUTRAL) for electronic

air cleaner connections are located on the control board. The terminals

provide 115 VAC (1.0 amp maximum) during circulating blower

operation.

HUMIDIFIER CONNECTION

Two 1/4” (6.4 mm) spade terminals (HUM and NEUTRAL) for humidifier

connections are located on the control board. The terminals provide

115 VAC (1.0 amp maximum) during heating system operation.

Vent Pipe

A mounting hole is provided on the control panel next to the furnace

control board for mounting a humidifier transformer if required.

Gas Supply

Electrical

SINGLE STAGE THERMOSTAT

(Both sides)

Supply

If a single stage thermostat is used, the high/low input staging will be

controlled by the furnace control board, using the staging jumper. If the

staging jumper is set to the 10, 15, or 20 position, the furnace will switch

from low fire to high fire after 10, 15, or 20 minutes and will stay in high

fire until the thermostat is satisfied. If the staging jumper is left in the

OFF position and a single stage thermostat is used, the furnace will

only operate at low fire.

1 Coil for

Each Furnace

Supply

Air

SECTION VI: TWINNING

FIGURE 20: Typical Twinned Furnace Application

In applications where more heating capacity or more airflow capacity is

needed than what one furnace can deliver, twinning can be used to

make two furnaces operate in tandem. When two furnaces are installed

using the same duct system, it is very important that the two furnace cir-

culating air blowers operate in unison. If one blower starts before the

second blower, the duct system will become pressurized and the blower

on the second furnace will turn backwards causing the second furnace

to overheat, resulting in damage to the furnace. Twinning is used to

make two furnaces operate in tandem, using one duct system, one

room thermostat and causing both furnaces to turn on and off simulta-

neously.

When two furnaces are twinned, typical system total airflow will be

approximately 85% of additive individual furnaces, i.e., two 2000 CFM

units will yield a total 3400 CFM.

If a return duct is connected to only one furnace (with a connection

between the two furnaces) an imbalance in the airflow will occur and

the furnace furthest from the return plenum will overheat.

GAS PIPING

Before installing the relay and wiring, disconnect electrical power to

both furnaces. Failure to cut power could result in electrical shock or

equipment damage.

Furnace gas supplies must be provided as specified with these instruc-

tions. Since the furnaces are side by side, with no space between, gas

supplies must enter on the right and left respectively. All gas piping

must be in accordance with the national fuel gas code, ANSI Z223.1,

latest edition, and/or all local code or utility requirements.

TWINNING

The relay must not be installed in any location where it could be

exposed to water. If the relay has been exposed to water in any way,

it must not be used.

In applications where more heating capacity or more airflow capacity is

needed than what one furnace can deliver, twinning can be used to

make two furnaces operate in tandem, using one duct system and one

room thermostat. When one duct system is used for two furnaces, it is

necessary that the two blowers operate in unison. The twinning function

of the board in this furnace ensures that both blowers turn on and off

simultaneously, and operate on the same blower speed.

TWINNING DUCT SYSTEM

Twinned furnaces must only be applied on a common duct system. A

single air supply plenum must be used for both furnaces and coil(s).

Separate plenums and supply ducts systems cannot be utilized. A sin-

gle return air plenum, common to both furnaces must be used. It is sug-

gested that a return platform be utilized, with bottom air entrance into

each furnace. If a side entrance returns system is used, the common

return duct must be divided equally so as to supply each furnace with

an equal amount of return air.

The control in the furnace has the twinning feature. With this feature, a

wire is connected between the TWIN terminal on one furnace board to

the TWIN terminal on the second furnace board. The board then com-

municates the blower status from one furnace to the other along this

wire. This communication makes the second furnace blower come on at

the same time, and on the same speed, as the first furnace blower. To

ensure stable communication, the common terminal of each control

must be connected.

Both furnaces must be identical models in both heating capacity and

CFM capacity. Both furnaces must be operated on the same motor

speed tap. See typical application, Figure 20.

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

Twinning Instructions

Connect the control wiring as shown in Figure 21.

1. Connect the low voltage wiring from the wall thermostat to the termi-

nal strip on the control board of Furnace #1.

The furnace condensate pan is self priming and contains an internal

trap to prevent flue gas leaking. Do not install an external condensate

trap.

2. Connect a wire from the TWIN terminal of Furnace #1 to the TWIN

terminal of Furnace #2.

When drain hose routing changes are required (shown in Figures 24-

27), be sure to cap all un-used openings.

3. Install a separate 24V relay as shown in the diagram below. Use of

this relay is required, as it ensures that the transformers of the two

furnaces are isolated, thus preventing the possibility of any safety

devices being bypassed.

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

loops will collect and hold condensate - which will cause the furnace to

not operate.

4. Connect the 24V common wires of furnace #1 to the 24V common

terminal of furnace #2.

No hose clamps are needed for connecting to the condensate pan.

Twinning Operation

Heating - On a call for heat (W signal) from the wall thermostat, both

furnaces will start the ignition sequence and the burners on both fur-

naces will light. About thirty seconds after the burners light, the blowers

on both furnaces will come on in heating speed. When the thermostat is

satisfied, the burners will all shut off and, after the selected blower off

delay time, both blowers will shut off at the same time. The twinning

control ensures that both blowers come on and shut off at the same

time.

The furnace, evaporator coil, and humidifier drains may be combined

and drained together. The evaporator coil drain may have an exter-

nal, field-supplied trap prior to the furnace drain connection to prevent

conditioned air leakage. All drain connections (furnace, evaporator

coil, or humidifier) must be terminated into an open or vented drain as

close to the respective equipment as possible. Regular maintenance

is required on condensate drainage system.

Cooling - On a call for cooling (Y signal) from the wall thermostat, both

furnace blowers will come on at the same time in cooling speed. When

the thermostat is satisfied, both blowers will stay on for 60 seconds,

then will shut off at the same time.

Continuous Fan - On a thermostat call for continuous fan (G signal),

both furnace blowers will come on at the same time in cooling speed

and will stay on until the G signal is removed.

Condensate must be disposed of properly. Follow local plumbing

or wastewater codes. The drain line must maintain a 1/4" per foot (20

mm/m) downward slope to the drain.

FURNACE 1

CONTROL BOARD

FURNACE 2

CONTROL BOARD

If an external vent tee is being installed, then it must have its own

condensate trap before it is disposed into an open or vented drain.

This is not to be considered as a second trap as referenced else-

where in this document.

TWIN

R TWIN

ISOLATION

RELAY

TO A/C

WALL THERMOSTAT

FIGURE 21: Twinning Wiring Diagram

SECTION VII: CONDENSATE PIPING AND

FURNACE VENTING CONFIGURATION

CONDENSATE DRAIN LOCATION

Open

tand

(Anti-siphon

air vent)

Pipe

As shipped from the factory:

• For all 040, 060, & 080K input furnaces the main drain is plumbed

through the casing right-side opening when viewed from the front

of the furnace.

5” Min.

• For all 100, 120, & 130K input furnaces the main drain is plumbed

through the casing left-side opening when viewed from the front of

the furnace.

Tee

NOTICE

The Figures 24 - 27 show the condensate drain arrangement for the

various possible furnace and vent blower positions.

To Open Or

Vented Drain

The condensate hoses must slope downwards at all points.

FIGURE 22: Typical. Condensate drain, vertical installation

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

CONDENSATE DRAIN TERMINATION

A condensate sump pump MUST be used if required by local codes, or

if no indoor floor drain is available. The condensate sump pump must

be approved for use with acidic condensate.

The condensate will flow to the drain better if an open stand pipe is

installed in the drain line. See Figure 22.

If evaporator coil or humidifier drains are combined with the furnace

drain, then the open stand pipe could be raised higher, above the 5”

minimum.

NOTICE

DO NOT terminate the condensate drain in a chimney, or where the

drain line may freeze. If the drain line will be exposed to temperatures

below freezing, adequate measures must be taken to prevent the

drain line from freezing. Failure to provide proper protection from

freezing can result in improper operation or damage to the equipment

and possible property damage. When exposed to temperatures

below freezing, use of a 3 to 6 watt per foot at 115 VAC, 40°F (4.4°C)

self-regulating, shielded and waterproof heat tape is recommended

on the drain line outside the furnace.

A loop has been added to the pressure switch vacuum hose. How-

ever, ensure that all pressure switch hoses are routed such that they

prevent any condensate from entering the pressure switch.

It is possible for condensation to form inside the combustion air

(intake) pipe in the summer months if significant length of combustion

air pipe passes through conditioned space. This problem can be

averted by the addition of a simple drain tee, or a drain tee with a

drain on the combustion air pipe as close to the furnace as possible,

as shown in Figure 23. This is true for all long horizontal venting in

any furnace configuration. This will prevent the condensate from

entering the furnace.

DO NOT trap the drain line at any other location than at the conden-

sate drain trap supplied with the furnace.

Liquid anti-freeze will cause damage to internal plastic parts of this

furnace. DO NOT attempt to winterize the furnace using liquid

anti-freeze.

Exhaust Pipe

Combustion Air Pipe

Tee with Drain Trap

Trap

Connect to Drain

FIGURE 23: Typical. Combustion Pipe Drain Tee

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

For 060 & 080K input furnaces, the condensate drain

is plumbed toward the right casing outlet from the factory.

p l u m b e d t o w a r d t h e l e f t c a s i n

F o r 1 0 0 , 1 2 0 K i n p u t f u r n a c e

FIGURE 24: Upflow Configuration

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

FIGURE 25: Downflow Configuration

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

FIGURE 26: Horizontal Left Configuration

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

FIGURE 27: Horizontal Right Configuration

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

2. The maximum equivalent length listed in Table 8 is for the vent pip-

ing and the air intake piping separately. For example, if the table

allows 65 equivalent feet for a particular model, then the vent can

have 65 equivalent feet of pipe, AND the combustion air intake can

have another 65 equivalent feet of pipe.

SECTION VIII: COMBUSTION AIR AND

VENT SYSTEM

COMBUSTION AIR AND VENT SAFETY

This Category IV, dual certified direct vent furnace is designed for resi-

dential application. It may be installed without modification to the con-

densate system in a basement, garage, equipment room, alcove, attic

or any other indoor location where all required clearance to combusti-

bles and other restrictions are met. The combustion air and the venting

system must be installed in accordance with Section 5.3, Air for Com-

bustion and Ventilation, of the National Fuel Gas Code Z223.1/NFPA 54

(latest edition), or Sections 7.2, 7.3 or 7.4 of CSA B149.1, National Gas

and Propane Codes (latest edition) or applicable provisions of the local

building code and these instructions.

3. Three vent terminal elbows (two for the vent and one for the com-

bustion air intake) are already accounted for and need not be

included in the equivalent length calculation.

4. All combustion air and vent pipe must conform to American

National Standards Institute (ANSI) and American Society for Test-

ing and Materials (ASTM) standards D1785 (Schedule 40 PVC),

D2665 (PVC-DWV), F891 (PVC-DWV Cellular Core), D2261 (ABS-

DWV) or F628 (Schedule 40 ABS). Pipe cement and primer must

conform to ASTM Standard D2546 (PVC) or D2235 (ABS). If ABS

pipe is to be used, any joint where ABS pipe is joined to PVC pipe

must be glued with cement that is approved for use with BOTH

materials. Metallic materials must not be used for venting or air

intake.

The “VENT SYSTEM” must be installed as specified in these instruc-

tions for Residential and non-HUD Modular Homes. The direct vent

system is the only configuration that can be installed in a non-HUD

Modular Home.

5. If a flexible connector is used in the vent system, it must be made of

a material that is resistant to acidic exposure and to at least 225°F

(107°C) temperature. Flexible connectors are also allowed in the

combustion air pipe.

6. All models are supplied with 2" (5.1 cm) vent connections. When

the pipe must be increased to 3" (7.6 cm) diameter, the transition

from 2" to 3" must be done as close to the furnace as possible. For

upflow models, the transition from 2" to 3" should be done immedi-

ately above the furnace. For downflow or horizontal models, the

transition from 2" to 3" pipe should be done immediately after exit-

ing the furnace.

This furnace may not be common vented with any other appliance,

since it requires separate, properly sized air intake and vent lines.

The furnace shall not be connected to any type of B, BW or L vent or

vent connector, and not connected to any portion of a factory-built or

masonry chimney

7. In Canada, vents shall be certified to ULC S636, Standard for Type

BH Gas Venting Systems.

The furnace shall not be connected to a chimney flue serving a sepa-

rate appliance designed to burn solid fuel.

8. In Canada, the first three feet (91.4 cm) of the vent must be readily

accessible for inspection.

9. For single pipe systems it is recommended to install the combustion

air coupling provided and install approximately 18” (46 cm) of PVC

pipe on the furnace.

When combustion air pipe is installed above a suspended ceiling or

when it passes through a warm and humid space, the pipe must be

insulated with 1/2” Armaflex or other heat resistant type insulation if

two feet or more of pipe is exposed.

10. Minimum vent length for all models is 5 feet (1.5 m).

TABLE 8: Maximum Equivalent Pipe Length

Vent piping must be insulated if it will be subjected to freezing temper-

atures such as routing through unheated areas or through an unused

chimney.

Maximum

Equivalent

length feet (m)

Model Input

BTUH (kW)

Pipe Size

Inches (cm)

COMBUSTION AIR/VENT PIPE SIZING

The size of pipe required will be determined by the furnace model, the

total length of pipe required and the number of elbows required.

60,000

80,000

100,000

120,000

2 (5.1)

3 (7.6)

4 (10.2)

2 (5.1)

3 (7.6)

4 (10.2)

2 (5.1)

3 (7.6)

4 (10.2)

2 (5.1)

3 (7.6)

4 (10.2)

65 (19.8)

90 (27.4)

150 (45.7)

65 (19.8)

90 (27.4)

150 (45.7)

30 (9.1)

Table 8 lists the maximum equivalent length of pipe allowed for each

model of furnace. The equivalent length of elbows is shown in Table 9

The equivalent length of the vent system is the total length of straight

pipe PLUS the equivalent length of all of the elbows.

The following rules must also be followed:

90 (27.4)

150 (45.7)

30 (9.1)

1. Long radius (sweep) elbows are recommended. Standard elbows

may be used, but since they have a longer equivalent length, they

will reduce the total length of pipe that will be allowed. Short radius

(plumbing vent) elbows are not allowed. The standard dimensions

of the acceptable elbows are shown below.

90 (27.4)

150 (45.7)

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

This is less than the 90 foot maximum equivalent length of 3" pipe

allowed for that model and is thus acceptable.

TABLE 11: Combustion Air Intake and Vent Connection Size at Furnace

(All Models)

FURNACE VENT CONNECTION SIZES

Furnace Input

Intake Pipe Size

Vent Pipe Size

All

2” (5.1 cm)

STANDARD ELBOW

LONG (SWEEP) ELBOW

FIGURE 28: Dimensions

Furnace vent pipe connections are sized for 2” (5.1 cm). pipe. Any

pipe size change must be made outside the furnace casing in a verti-

cal pipe section to allow proper drainage of condensate. An offset

using two 45º (degree) elbows will be required for plenum clearance

when the vent is increased to 3” (7.6 cm).

TABLE 9: Elbow Dimensions

Elbow "A" Dimension

2" Standard

3" Standard

2" Sweep

2-5/16"

3-1/16"

3-1/4"

3" Sweep

4-1/16"

Dimensions are those required in Standard ASTM D-3311.

Accessory concentric vent / intake termination kits 1CT0302 and

1CT0303, and for Canadian applications 1CT0302-636 and

1CT0303-636 are available and approved for use with these fur-

TABLE 10: Equivalent Length of Fittings

naces. Horizontal sidewall vent terminations kits 1HT0901

1HT0902 are also approved for use with these furnaces.

Fitting

Equivalent Length

2" 90° sweep elbow

5 feet of 2" pipe

2-1/2 feet of 2" pipe

7 feet of 2" pipe

2" 45° sweep elbow

COMBUSTION AIR AND VENT PIPING ASSEMBLY

The final assembly procedure for the combustion air and vent piping is

as follows:

2" 90° standard elbow

2" 45° standard elbow

3" 90° sweep elbow

3-1/2 feet of 2" pipe

5 feet of 3" pipe

1. Cut piping to the proper length beginning at the furnace.

2. Deburr the piping inside and outside.

3" 45° sweep elbow

2-1/2 feet of 3" pipe

7 feet of 3" pipe

3" 90° standard elbow

3" 45° standard elbow

4" 90° elbow (sweep or standard)

4" 45° elbow (sweep or standard)

2" corrugated connector

3" corrugated connector

4" corrugated connector

3. Chamfer (bevel) the outer edges of the piping.

3-1/2 feet of 3" pipe

5 feet of 4" pipe

4. Dry-fit the vent piping assembly from the furnace to the outside ter-

mination checking for proper fit support and slope.

2-1/2 feet of 4" pipe

10 feet of 2" pipe

10 feet of 3" pipe

10 feet of 4" pipe

5. Dry-fit the combustion air piping assembly checking for proper fit,

support and slope on the following systems:

a. Sealed combustion air systems from the furnace to the outside

termination.

b. Ventilated combustion air systems from the furnace to the attic or

crawl space termination.

Example:

An 80,000 BTUH furnace requires 32 feet of pipe and five 90º elbows.

Using 2" pipe and standard elbows, the total equivalent length will be:

Solvent cements are flammable and must be used in well-ventilated

areas only. Keep them away from heat, sparks and open flames. Do

not breathe vapors and avoid contact with skin and eyes.

32 feet of 2" pipe =

5 - 90º standard 2" elbows = (5 x 7) =

Total =

32 equivalent feet

35 equivalent feet

67 equivalent feet of 2" pipe

6. Disassemble the combustion air and vent piping, apply cement

primer and the cement per the manufactures instructions. Primer

and cement must conform to ASTM D2564 for PVC, or ASTM

D2235 for ABS piping.

This exceeds the 65 foot maximum equivalent length of 2" pipe allowed

for that model and is thus not acceptable.

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

7. All joints must provide a permanent airtight and watertight seal.

32 feet of 2" pipe =

5 - 90º sweep 2" elbows = (5 x 5) =

Total =

32 equivalent feet

25 equivalent feet

57 equivalent feet of 2" pipe

8. Support the combustion air and vent piping such that it is angled a

minimum of 1/4” per foot (21 mm/m) so that condensate will flow

back towards the furnace. Piping should be supported with pipe

hangers to prevent sagging.

This is less than the 65 foot maximum equivalent length of 2" pipe

allowed for that model and is thus acceptable.

9. Seal around the openings where the combustion air and / or vent

piping pass through the roof or sidewalls.

Alternatively, using 3" pipe and standard elbows, the total equivalent

length will be:

COMBUSTION AIR / VENTING

32 feet of 3" pipe =

5 - 90º standard 3" elbows = (5 x 7) =

Total =

32 equivalent feet

35 equivalent feet

67 equivalent feet of 3" pipe

The vent must be installed with the minimum required clearances,

and must comply with local codes and requirements.

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

VENT CLEARANCES

VENT TERMINAL

FIXED

CLOSED

AIR SUPPLY

AREA WHERE TERMINAL IS NOT PERMITTED

FIXED

CLOSED

OPERABLE

FIGURE 29: Home Layout

Canadian Installations^1,3

US Installation^2,3

Direct Vent Terminal Clearances

A. Clearance above grade, veranda, porch, deck, or

balcony

12” (30.5 cm)

12” (30.5 cm) for models 100,000 BTUH (30 kW),

36” (91.4 cm) for models >100,000 BTUH (30 kW).

Two-pipe (direct vent) applications: 12” (30.5 cm)††

Single-pipe applications: 4 feet (1.2 m).

B. Clearance to window or door that may be opened

C. Clearance to permanently closed window

12” (30.5 cm)

D. Vertical clearance to ventilated soffit located

above the terminal within a horizontal distance

of 2 feet (61 cm) from the center line of the terminal

12” (30.5 cm) or in accordance with local installation

codes and the requirements of the gas supplier.

12” (30.5 cm) or in accordance with local installation

codes and the requirements of the gas supplier.

12” (30.5 cm) or in accordance with local installation

codes and the requirements of the gas supplier.

12” (30.5 cm) or in accordance with local installation

codes and the requirements of the gas supplier.

E. Clearance to unventilated soffit

12” (30.5 cm) or in accordance with local installation

codes and the requirements of the gas supplier.

12” (30.5 cm) or in accordance with local installation

codes and the requirements of the gas supplier.

F. Clearance to outside corner

G. Clearance to inside corner

3 feet (91.4 cm)

Above a meter/regulator assembly within 3 feet

(91.4 cm) horizontally of the vertical center-line of the

Above a meter/regulator assembly within 3 feet

(91 cm) horizontally of the vertical center-line of the

H. Clearance to each side of center line

extended above meter/regulator assembly

regulator vent outlet to a maximum vertical distance of regulator vent outlet to a maximum vertical distance of

15 feet (4.5 m) above the meter/regulator assembly.

3 feet (91.4 cm) or in accordance with local installation

codes and the requirements of the gas supplier.

I. Clearance to service regulator vent outlet

3 feet (91.4 cm)

J. Clearance to non-mechanical air supply inlet to

building or the combustion air inlet to any other

appliance

12” (30.5 cm) for models 100,000 BTUH (30 kW),

36” (91 cm) for models >100,000 BTUH (30 kW).

Two-pipe (direct vent) applications: 12” (30.5 cm)

Single-pipe applications: 4 feet (1.2 m).

3 feet (91.4 cm) above if within 10 feet (3 m)

horizontally.

K. Clearance to a mechanical supply inlet

6 feet (1.83 m)

7 feet (2.13 m)†

L. Clearance above paved sidewalk or paved

driveway located on public property

7 feet (2.13 m) or in accordance with local installation

codes and the requirements of the gas supplier.

12” (30.5 cm) or in accordance with local installation

codes and the requirements of the gas supplier.

M. Clearance under veranda, porch, deck, or balcony 12” (30.5 cm)‡

1. In accordance with the current CSA B149.1-00, Natural Gas and Propane Installation Code.

2. In accordance with the current ANSI Z223.1 / NFPA 54, National Gas Code.

3. In accordance with the current ANSI Z21.47 * CSA 2.3 American National Standard.

†

A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.

†† 12” (30.5 cm) up from the bottom edge of the structure for Two-pipe (direct vent) applications per ANSI Z223.1 / NFPA 54, National Gas Code.

Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor and the distance between the top of the vent termina-

‡

tion and the underside of the veranda, porch, or deck is greater than 12” (30.5 cm) as specified in CSA B149.1-00.

A vent shall not terminate less than 12” (30.5 cm) above a grade level.

Any fresh air or make up inlet for dryer or furnace area is considered to be forced air inlet.

Avoid areas where condensate drippage may cause problems such as above planters, patios, or adjacent to windows where steam may cause fogging.

A terminus of a vent shall be fitted with a cap in accordance with the vent manufacturer’s installation instructions, or in accordance with the installation instructions for a

special venting system.

Responsibility for the provision of proper adequate venting and air supply for application shall rest with the installer.

Vent shall extend high enough above building, or a neighboring obstruction, so that wind from any direction will not create a positive pressure in the vicinity of the vent.

Consideration must be given for degradation of building materials by flue gases. Sidewall termination may require sealing or shielding of building

surfaces with a corrosion resistant material to protect against combustion product corrosion. Consideration must be given to wind direction in order

to prevent flue products and/or condensate from being blown against the building surfaces. If a metal shield is used it must be a stainless steel

material at a minimum dimension of 20 inches (51 cm). It is recommended that a retaining type collar be used that is attached to the building sur-

face to prevent movement of the vent pipe.

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

VENT SYSTEM

This furnace is certified to be installed with one of two possible vent

configurations.

12” MIN.

1. Horizontal vent system. This vent system can be installed com-

pletely horizontal or combinations of horizontal, vertical, or offset

using elbows.

12” Minimum

below overhang

12” MIN.

12” Minimum

separation between

bottom of

combustion air

intake and

bottom of vent

2. Vertical vent system. This vent system can be installed completely

vertical or a combination of horizontal, vertical, or offset using

elbows.

VENT APPLICATIONS AND TERMINATION

When selecting the location for a combustion air / vent termination, the

following should be considered:

Maintain 12”

minimumclearance

above highest

anticipated snow

level or grade,

whichever is higher

1. Observe all clearances listed in vent clearances in these instruc-

tions.

2. Termination should be positioned where vent vapors will not dam-

age plants or shrubs or air conditioning equipment.

FIGURE 32: Termination Configuration - 2 Pipe Basement

3. Termination should be located where it will not be affected by wind

gusts, light snow, airborne leaves or allow recirculation of flue

gases.

VENTING MULTIPLE UNITS

Multiple units can be installed in a space or structure as either a single

pipe configuration or a two-pipe configuration.

4. Termination should be located where it will not be damaged or

exposed to flying stones, balls, etc.

The combustion air side of the single pipe configuration shown in Figure

30 is referred to in these instructions as ambient combustion air supply.

Follow the instructions for ambient combustion air installations, paying

particular attention to the section on air source from inside the building.

The vent for a single pipe system must be installed as specified in the

venting section of these instructions with the vent terminating as shown

in Figure 30. Each furnace must have a separate vent pipe. Under NO

circumstances can the two vent pipes be tied together.

5. Termination should be positioned where vent vapors are not objec-

tionable.

6. Horizontal portions of the vent system must slope upwards and be

supported to prevent sagging.

7. Direct vent systems must be installed so the vent and the combus-

tion air pipes terminate in the same atmospheric zone. Refer to Fig-

ures 30 or 31.

The combustion air side of the two-pipe configuration shown in Figure

31 can be installed so the combustion air pipe terminates as described

in outdoor combustion air or ventilated combustion air sections in these

instructions. Follow the instructions for outdoor combustion air or venti-

lated combustion air and the instructions for installing the vent system

with the vent terminating as shown in Figures 33 or 34. The two-pipe

system must have a separate combustion air pipe and a separate vent

pipe for each furnace. Under NO circumstances can the two combus-

tion air or vent pipes be tied together. The combustion air and vent

pipes must terminate in the same atmospheric zone.

Maintain 12” minimum clearance

above highest anticipated snow level.

Maximum 24” above roof.

12” Min.

VENT

FIGURE 30: Termination Configuration - 1 Pipe

12” vertical separation

between combustion air

intake and vent.

COMBUSTION AIR

Maintain 12” minimum

clearance above

highest anticipated

snow level.

12” minimum

below overhang

2”

MIN.

12” minimum

separation between

bottom of

combustion air pipe

and bottom of vent.

FIGURE 33: Double Horizontal Combustion Air Intake and Vent

Termination

Maintain 12”

minimum clearance

above highest

anticipated snow

level or grade,

whichever is higher.

MIN.

6”

FIGURE 31: Termination Configuration - 2 Pipe

FIGURE 34: Double Vertical Combustion Air Intake and Vent

Termination

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

DOWNWARD VENTING

In some applications, it may be necessary to run the vent pipe and air

intake downwards. If this is to be done, the following rules must be fol-

lowed.

Outdoor Combustion Air

Combustion Air Intake/Vent Connections

This installation requires combustion air to be brought in from outdoors.

This requires a properly sized pipe (Shown in Figure 35) that will bring

air in from the outdoors to the furnace combustion air intake collar on

the burner box. The second pipe (Shown in Figure 35) is the furnace

vent pipe.

• A condensate trap hose must be connected to both the air intake

pipe and the vent pipe at the lowest part of the horizontal run.

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

inches.

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

• The condensate drain hose must be connected to a condensate

drain pump, a open or vented drain or into the condensate drain

line from the furnace.

• The condensate drain lines must not pass through unconditioned

spaces where the temperature may fall below freezing.

• The condensate drain line must be primed at the initial start-up

prior to the start of heating season.

NOTICE

An optional plastic birdscreen is shipped in the loose parts bag with

every furnace. This may be installed in the intake collar to prevent any

small objects from entering the furnace.

The combustion air intake pipe should be located either through the

wall (horizontal or side vent) or through the roof (vertical vent). Care

should be taken to locate side vented systems where trees or shrubs

will not block or restrict supply air from entering the terminal.

Also, the terminal assembly should be located as far as possible from a

swimming pool or a location where swimming pool chemicals might be

stored. Be sure the terminal assembly follows the outdoor clearances

listed in Section #1 “Outdoor Air Contaminants.”

16’ MAX

Connects to

collar on top

of burner box

Vent pipe cements

into socket just

above top panel

Or vent pipe may be

clamped into outlet

of drain coupling

6” MIN.

FIGURE 35: Downward Venting

COMBUSTION AIR SUPPLY

All installations must comply with Section 5.3, Air for Combustion and

Ventilation of the National Fuel Gas Code, ANSI Z223.1 or Sections

7.2, 7.3 or 7.4 of CAN/CGA B149.1 or .2 Installation Code - latest edi-

tions.

FIGURE 36: Direct Vent Air Intake Connection and Vent Connection

Ambient Combustion Air Supply

This type installation will draw the air required for combustion from

within the space surrounding the appliance and from areas or rooms

adjacent to the space surrounding the appliance. This may be from

within the space in a non-confined location or it may be brought into the

furnace area from outdoors through permanent openings or ducts. It is

not piped directly into the furnace. A single, properly sized pipe from the

furnace vent connector to the outdoors must be provided. It is recom-

mended that the supplied intake coupling & 18” of pipe be attached to

the furnace to prevent accidental blockage of the combustion air intake.

This furnace is certified to be installed with one of three possible com-

bustion air intake configurations.

1. OUTDOOR COMBUSTION AIR: This is a direct vent configuration

where the combustion air is supplied through a PVC or ABS pipe

that is connected to the PVC coupling attached to the furnace and is

terminated in the same atmospheric zone as the vent. This type of

installation is approved on all models. Refer to Figure 35.

2. AMBIENT COMBUSTION AIR: Combustion air is supplied from

the area surrounding the furnace through openings in the furnace

casing. The combustion air and the vent pipes are not terminated in

the same atmospheric zone. Refer to Figure 21 for vent termina-

tions. Refer to "Ambient Combustion Air Supply" for proper installa-

tion. Refer to Figure 36.

Vent pipe cements

COMBUSTION AIR

into socket just

above top panel

3. VENTILATED COMBUSTION AIR: Combustion air is supplied

through a PVC or ABS pipe that is connected to the PVC coupling

attached to the burner box and is terminated in a ventilated attic or

crawl space. The combustion air and the vent pipes are not termi-

nated in the same atmospheric zone. Refer to Figure 38 for attic

and crawl space termination. Only the combustion air intake may

terminate in the attic. The vent must terminate outside.

Or vent pipe may be

clamped into outlet

of drain coupling

FIGURE 37: Combustion Airflow Path Through The Furnace Casing

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

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

sion smaller than 1/4” (6.4 mm).

3. A manually operated damper or manually adjustable louvers are

not permitted for use.

4. A automatically operated damper or automatically adjustable lou-

vers shall be interlocked so that the main burner cannot operate

unless either the damper or the louver is in the fully open position.

This type of installation requires that the supply air to the appliance(s)

be of a sufficient amount to support all of the appliance(s) in the area.

Operation of a mechanical exhaust, such as an exhaust fan, kitchen

ventilation system, clothes dryer or fireplace may create conditions

requiring special attention to avoid unsatisfactory operation of gas

appliances. A venting problem or a lack of supply air will result in a

hazardous condition, which can cause the appliance to soot and gen-

erate dangerous levels of CARBON MONOXIDE, which can lead to

serious injury, property damage and / or death.

When a Category I furnace is removed or replaced, the original vent-

ing system may no longer be correctly sized to properly vent the

attached appliances.

An unconfined space is not less than 50 cu.ft (1.42 m³) per 1,000 Btu/

hr (0.293 kW/h) input rating for all of the appliances installed in that

area.

An improperly sized vent system can cause CARBON MONOXIDE to

spill into the living space causing personal injury, and or death.

Rooms communicating directly with the space containing the appli-

ances are considered part of the unconfined space, if doors are fur-

nished with openings or louvers.

Table 13: Unconfined Space Minimum Area

BTUH Input Rating Minimum Free Area Required for Each Opening

A confined space is an area with less than 50 cu.ft (1.42 m³) per 1,000

Btu/hr (0.293 kW/h) input rating for all of the appliances installed in that

area. The following must be considered to obtain proper air for combus-

tion and ventilation in confined spaces.

60 in²(387 cm²)

60,000

80 in²(516 cm²)

80,000

100 in²(645 cm²)

100,000

120 in²(742 cm²)

120,000

Combustion Air Source From Outdoors

The blocking effects of louvers, grilles and screens must be given con-

sideration in calculating free area. If the free area of a specific louver or

grille is not known, refer to Table 12, to estimate free area.

Table 14: Free Area

Minimum Free Area Required for Each Opening

BTUH Input

Rating

Vertical Duct or

Opening to Outside

(4,000 BTUH)

15 in²(97 cm²)

20 in²(129 cm²)

25 in²(161 cm²)

30 in²(193 cm²)

Table 12: Estimated Free Area

Horizontal Duct

(2,000 BTUH)

Round Duct

(4,000 BTUH)

Wood or Metal

Louvers or Grilles

Wood 20-25%*

Metal 60-70% *

30 in²(193 cm²)

40 in²(258 cm²)

50 in²(322 cm²)

60 in²(387 cm²)

60,000

80,000

5” (13 cm)

6” (15 cm)

7” (18 cm)

1/4” (6.4 mm)

mesh or larger 100%

Screens+

100,000

120,000

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

+ Free area of louvers and grille varies widely; the installer should follow

louver or grille manufacturer’s instructions.

EXAMPLE: Determining Free Area.

Appliance 1 Appliance

Dampers, Louvers and Grilles (Canada Only)

2 Total Input

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

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

the gross area of the opening.

100,000 + 30,000 = (130,000  4,000) = 32.5 Sq. In. Vertical

Appliance 1 Appliance 2 Total Input

100,000 + 30,000 = (130,000  2,000) = 65 Sq. In. Horizontal

Gas

Vent

Gas

Vent

Gas

Vent

Gable

Vent

Gable

Vent

Ventilated

Attic

Top Above

Insulation

Ventilated

Attic

Optional

Inlet (a)

Top Above

Insulation

Outlet

Air (a)

Soffit

Vent

Soffit

Vent

Outlet

Air (b)

Outlet

Air (a)

Gas

Water

Heater

Gas

Water

Heater

Gas

Water

Heater

Inlet

Air (b)

Inlet

Air (b)

Inlet

Air (a)

Inlet

Air (a)

Ventilated

Crawl Space

FIGURE 38: Outside and Ambient Combustion Air

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

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

the largest input.

Air Supply Openings and Ducts

1. An opening may be used in lieu of a duct to provide to provide the

outside air supply to an appliance unless otherwise permitted by the

authority having jurisdiction. The opening shall be located within 12”

(30.5 cm) horizontally from, the burner level of the appliance. Refer

to “AIR SOURCE FROM OUTDOORS AND VENT AND SUPPLY

AIR SAFETY CHECK” in these instructions for additional informa-

tion and safety check procedure.

5. A square or rectangular shaped duct shall only be used when the

required free area of the supply opening is 9 in²(58.06 cm²) or

larger. When a square or rectangular duct is used, its small dimen-

sion shall not be less than 3” (7.6 cm).

6. An air inlet supply from outdoors shall be equipped with a means to

prevent the direct entry of rain and wind. Such means shall not

reduce the required free area of the air supply opening.

2. The duct shall be either metal, or a material meeting the class 1

requirements of CAN4-S110 Standard for Air Ducts.

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

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

7. An air supply inlet opening from the outdoors shall be located not

less than 12” (30.5 cm) above the outside grade level.

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

Combustion Air Source from Outdoors

Ventilated Combustion Air

1. Two permanent openings, one within 12” (30.5 cm) of the top and

one within 12” (30.5 cm) of bottom of the confined space, Two per-

manent openings, shall communicate directly or by means of ducts

with the outdoors, crawl spaces or attic spaces.

The ventilated attic space or a crawl space from which the combustion

air is taken must comply with the requirements specified in “AIR

SOURCE FROM OUTDOORS” in this instruction or in Section 5.3, Air

for Combustion and Ventilation of the National Fuel Gas Code, ANSI

Z223.1 (latest edition). This type installation requires two properly sized

pipes. One brings combustion air from a properly ventilated attic space

or crawl space and a second pipe that extends from the furnace vent

connection (top right of unit) to the exterior of the building. Refer to

Table 8 for intake pipe sizing, allowable length and elbow usage. Follow

all notes, procedures and required materials in the "COMBUSTION

AIR/VENT PIPE SIZING" section in these instructions when installing

the combustion air pipe from the unit and into a ventilated attic space or

crawl space. DO NOT terminate vent pipe in an Attic or Crawl Space.

2. One permanent openings, commencing within 12” (30.5 cm) of the

top of the enclosure shall be permitted where the equipment has

clearances of at least 1” (2.54 cm) from the sides and back and 6”

(15.2 cm) from the front of the appliance. The opening shall com-

municate directly with the outdoors and shall have a minimum free

area of:

a. 1 square inch per 3000 BTU per hour (322 cm²per 0.879 kW) of

the total input rating of all equipment located in the enclosure.

b. Not less than the sum of all vent connectors in the confined

space.

Ventilated Combustion Air Termination

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

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

Refer to Figure 38 for required attic termination for the combustion air

intake pipe. For attic termination, use two 90 elbows with the open end

in a downward position. Be sure to maintain 12” (30.5 cm) clearance

above any insulation, flooring or other material.

4. The blocking effects of louvers, grilles and screens must be given

consideration in calculating free area. If the free area of a specific

louver or grille is not known. Refer to Table 12.

A crawl space combustion air installation consists of a straight pipe from

the PVC coupling on the burner box that extends into the crawl space

and terminates with a 1/4” (6.4 mm) mesh screen and no elbows.

CARBON MONOXIDE POISONING HAZARD

Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon-

monxide poisoning or death.

The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances

connected to the venting system are not in operation:

1. Inspect the venting system for proper size and horizontal pitch. Determine that there is no blockage, restriction, leakage, corrosion or other

deficiencies, which could cause an unsafe condition

2. Close all building doors and windows and all doors.

3. Turn on clothes dryers and TURN ON any exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum

speed. Open the fireplace dampers. Do not operate a summer exhaust fan.

4. Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so the appliance shall operate contin-

uously.

5. Test each appliance (such as a water heater) equipped with a draft hood for spillage (down-draft or no draft) at the draft hood relief opening

after 5 minutes of main burner operation. Appliances that do not have draft hoods need to be checked at the vent pipe as close to the

appliance as possible. Use a combustion analyzer to check the CO₂and CO levels of each appliance. Use a draft gauge to check for a

downdraft or inadequate draft condition.

6. After it has been determined that each appliance properly vents when tested as outlined above, return doors, windows, exhaust fans, fire-

place dampers and any other gas burning appliance to their normal condition.

7. If improper venting is observed during any of the above tests, a problem exists with either the venting system or the appliance does not

have enough combustion air (Supply Air from outside) to complete combustion. This condition must be corrected before the appliance can

function safely.

NOTE: An unsafe condition exists when the CO reading exceeds 40 ppm and the draft reading is not in excess of - 0.1” w.c. (-25 kPa) with all

of the appliance(s) operating at the same time.

8. Any corrections to the venting system and / or to the supply (outside) air system must be in accordance with the National Fuel Gas Code

Z223.1 or CAN/CGA B149.1 Natural Gas and Propane Installation Code (latest editions). If the vent system must be resized, follow the

appropriate tables in Appendix G of the above codes or for this appliance.

Specially Engineered Installations

The above requirements shall be permitted to be waived where special

engineering, approved by the authority having jurisdiction, provides an

adequate supply of air for combustion and ventilation.

12” minimum

between bottom

of air intake and

any material below.

12” Min.

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

VENT BLOWER ROTATION

For ease of venting, the vent blower may be rotated 90° in either direc-

tion. For upflow installations the vent may exit through the top or either

side of the cabinet. For downflow installations, the vent blower must be

rotated so that the vent exits through either side of the cabinet. See Fig-

ures 24-27 for details.

FIGURE 39: Attic and Crawl Space Combustion Air Termination

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

3. System start-up will occur as follows:

SECTION IX: START-UP AND

ADJUSTMENTS

a. The induced draft blower motor will start and come up to speed.

Shortly after inducer start-up, the hot surface igniter will glow for

about 17 seconds.

The initial start-up of the furnace requires the following additional

procedures:

b. After this warm up, the ignition module will energize (open) the

main gas valve.

c. After flame is established, the supply air blower will start in about

30 seconds.

All electrical connections made in the field and in the factory should

be checked for proper tightness.

When the gas supply is initially connected to the furnace, the gas piping

may be full of air. In order to purge this air, it is recommended that the

ground union be loosened until the odor of gas is detected. When gas is

detected, immediately retighten the union and check for leaks. Allow

five minutes for any gas to dissipate before continuing with the start-up

procedure. Be sure proper ventilation is available to dilute and carry

away any vented gas.

HOT SURFACE IGNITION SYSTEM

Do not attempt to light this furnace by hand (with a match or any other

means). There may be a potential shock hazard from the components

of the hot surface ignition system. The furnace can only be lit auto-

matically by its hot surface ignition system.

CALCULATING THE FURNACE INPUT (NAT. GAS)

Burner orifices are sized to provide proper input rate using natural gas

GAS PIPING LEAK CHECK

with a heating value of 1030 BTU/Ft³(38.4 MJ/m³). If the heating value

of your gas is significantly different, it may be necessary to replace the

orifices.

FIRE OR EXPLOSION HAZARD

Failure to follow the safety warnings exactly could result in serious

injury, death or property damage.

Never test for gas leaks with an open flame. Use a commercially

available soap solution made specifically for the detection of leaks to

check all connections. A fire or explosion may result causing property

damage, personal injury or loss of life.

NOTICE

DO NOT set manifold pressure less than 3.2” w.c. or more than 3.8”

w.c. for natural gas at sea level. If manifold pressure is outside this

range, change main burner orifices.

NOTICE

If orifice hole appears damaged or it is suspected to have been

redrilled, check orifice hole with a numbered drill bit of correct size.

Never redrill an orifice. A burr-free and squarely aligned orifice hole is

essential for proper flame characteristics.

Burner ignition may not be satisfactory on first startup due to residual

air in the gas line or until gas manifold pressure is adjusted. The igni-

tion control will make three attempts to light before locking out.

It is recommended that when the gas supply is first connected to the

furnace, the ground union be loosened until the odor of gas is detected.

When gas is detected, immediately tighten the union and check for gas

leaks. Allow five minutes for any gas to dissipate before continuing with

the startup procedure. Be sure that proper ventilation is available to

dilute and carry away any vented gas.

DO NOT bottom out gas valve regulator adjusting screw. This can

result in unregulated manifold pressure and result in excess overfire

and heat exchanger failures.

With furnace in operation, check all of the pipe joints, gas valve connec-

tions and manual valve connections for leakage using an approved gas

detector, a non-corrosive leak detection fluid or other leak detection

methods. Take appropriate action to stop any leak. If a leak persists,

replace the faulty component.

Verify natural gas input rate by clocking meter.

1. Turn off all other gas appliances and pilots.

2. Run furnace for a minimum of 3 minutes in heating operation.

3. Measure time (in sec) for gas meter to complete 1 revolution and

note reading. The 2 cubic feet dial provides a more accurate mea-

surement of gas flow.

The furnace and its equipment shutoff valve must be disconnected from

the gas supply during any pressure testing of that system at test pres-

sures in excess of 0.5 psig (3.45 kPa).

4. Refer to Table 15 for cubic feet of gas per hour.

5. Multiply cubic feet per hour by heating valve (BTU/cu ft) to obtain

input.

The furnace must be isolated from the gas supply piping system by

closing the equipment shutoff valve during any pressure testing of the

gas supply system.

If clocked rate does not match the input rate from the unit nameplate.

follow steps in next section to adjust the manifold pressure. Repeat

steps 2 - 5 until correct input is achieved.

IGNITION SYSTEM SEQUENCE

1. Turn the gas supply ON at external valve and main gas valve.

2. Set the thermostat above room temperature to call for heat.

Be sure to relight any gas appliances that were turned off at the start

of this input check.

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

Table 15: Gas Rate (CU FT/HR) at Full Input

Size of Test Dial

Seconds For

1 Revolution

Seconds For

1 Revolution

1 Cu Ft

360

327

300

277

257

240

225

212

200

189

180

171

164

157

150

144

138

133

129

124

120

116

113

109

106

103

100

2 Cu Ft

720

655

600

555

514

480

450

424

400

379

360

343

327

313

300

288

277

267

257

248

240

232

225

218

212

206

200

195

189

185

180

176

172

167

164

160

157

153

150

147

144

141

138

136

133

5 Cu Ft

1800

1636

1500

1385

1286

1200

1125

1059

1000

947

900

857

818

783

750

720

692

667

643

621

600

581

563

545

529

514

500

486

474

462

450

439

429

419

409

400

391

383

375

367

360

355

346

340

333

1 Cu Ft

2 Cu Ft

131

129

126

124

122

120

116

112

109

106

103

100

5 Cu Ft

327

321

316

310

305

300

290

281

273

265

257

250

243

237

231

225

220

214

209

205

200

196

192

188

184

180

178

173

170

167

164

161

155

150

145

141

135

130

125

120

115

110

105

100

102

104

106

108

110

112

116

120

124

128

133

138

144

150

157

164

171

180

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

ADJUSTMENT OF MANIFOLD GAS PRESSURE &

INPUT RATE

Inlet and manifold gas pressure may be measured by connecting the

“U” tube manometer to the gas valve with a piece of tubing. Follow the

appropriate section in the instructions below. Refer to Figure 39 for a

drawing of the locations of the pressure ports on the gas valve.

NOTICE

The regulated outlet pressure has been calibrated at the factory.

Additional pressure adjustment should not be necessary. If adjust-

ment is necessary, set to the following specifications. After adjust-

ment, check for gas leakage.

Turn gas off at the ball valve or gas cock on gas supply line

before the gas valve. Find the pressure ports on the gas

valve marked Out P and In P.

This gas valve has separate regulator adjustment screws for high fire

and low fire, as shown in Figure 39. The procedure below is used to

adjust either the high fire manifold pressure or the low fire manifold

pressure.

1. The manifold pressure must be taken at the port marked OUT P.

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

1. Refer to Figure 39 for location of pressure regulator adjustment cap

and adjustment screws on main gas valve.

3. Using a 3/32” (2.4 mm) Allen wrench, loosen the set screw by turn-

ing it 1 turn counter clockwise. DO NOT REMOVE THE SET

SCREW FROM THE PRESSURE PORT.

2. Turn gas and electrical supplies on and follow the operating instruc-

tions to place the unit back in operation.

3. Adjust manifold pressure by adjusting gas valve regulator screw for

the appropriate gas per the following:

Read the inlet gas pressure

Connect the positive side of the manometer to the IN P Tap on the gas

valve. Do not connect any tubing to the negative side of the manometer,

as it will reference atmospheric pressure. Refer to Figure 40 for connec-

tion details.

Table 17: Nominal Manifold Pressure

NOMINAL MANIFOLD PRESSURE

Natural Gas (High Fire)

Natural Gas (Low Fire)

3.5" w.c. (0.87 kPa)

1.6" w.c. (0.40 kPa)

9.8" w.c. (2.488 kPa)

4.0" w.c. (0.99 kPa)

1. Turn gas and electrical supplies on and follow the operating instruc-

tions to place the unit back in operation.

Propane (LP) Gas (High Fire)

Propane (LP) Gas (Low Fire)

Table 16: Inlet Gas Pressure Range

INLET GAS PRESSURE RANGE

Natural Gas

Propane (LP)

HIGH STAGE REGULATOR

ADJUSTMENT

Minimum

Maximum

4.5” w.c. (1.12 kPa)

10.5” w.c. (2.61 kPa)

8.0” w.c. (1.99 kPa)

13.0” w.c. (3.24 kPa).

OUTLET

PRESSURE

PORT

VENT

PORT

INLET

OUTLET

The inlet gas pressure operating range table specifies what the mini-

mum and maximum gas line pressures must be for the furnace to

operate safely. The gas line pressure MUST BE a minimum of:

• 7” w.c. (1.74 kPA) for Natural Gas

WRENCH

BOSS

INLET

PRESSURE

PORT

LOW STAGE REGULATOR

ADJUSTMENT

ON OFF

SWITCH

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

in order to obtain the BTU input specified on the rating plate and/or

the nominal manifold pressure specified in these instructions and on

the rating plate.

FIGURE 40: Gas Valve

2. Once the correct gas inlet pressure has been established, see

Table 16, turn the gas valve to OFF and turn the electrical supply

switch to OFF; then remove the flexible tubing from the gas valve

pressure tap and tighten the pressure tap plug using the 3/32” (2.4

mm) Allen wrench.

If gas valve regulator is turned in (clockwise), manifold pressure is

increased. If screw is turned out (counterclockwise), manifold pres-

sure will decrease.

3. Turn the electrical and gas supplies back on, and with the burners

in operation, check for gas leakage around the gas valve pressure

port for leakage using an approved non-corrosive gas leak detec-

tion fluid, or other non-flammable leak detection methods.

4. After the manifold pressure has been adjusted, re-calculate the fur-

nace input to make sure you have not exceeded the specified input

on the rating plate. Refer to “CALCULATING THE FURNACE

INPUT (NATURAL GAS)”.

Read the manifold gas pressure

5. Once the correct BTU (kW) input has been established, turn the

gas valve to OFF and turn the electrical supply switch to OFF; then

remove the flexible tubing from the gas valve pressure tap and

tighten the pressure tap plug using the 3/32” (2.4 mm) Allen

wrench.

Connect the positive side of the manometer to the adapter previously

installed in the OUT P Tap on the gas valve. Do not connect any tubing

to the negative side of the manometer, as it will reference atmospheric

pressure. Refer to Figure 40 for connection details.

6. Turn the electrical and gas supplies back on, and with the burners

in operation, check for gas leakage around the gas valve pressure

port for leakage using an approved non-corrosive gas leak detec-

tion fluid, or other non-flammable leak detection methods.

The cap for the pressure regulator must be removed entirely to gain

access to the adjustment screw. Loosening or tightening the cap does

not adjust the flow of gas.

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

After about 5 minutes of operation, determine the furnace temperature

rise. Take readings of both the return air and the heated air in the ducts,

about six feet (1.83 m) from the furnace where they will not be affected

by radiant heat. Increase the blower speed to decrease the temperature

rise; decrease the blower speed to increase the rise.

MANIFOLD PRESSURE “U” TUBE CONNECTION

OUTLET

PRESSURE TAP

GAS VALVE

1/4” TUBING

MAINIFOLD

PIPE

All direct-drive blowers have multi-speed motors. The blower motor

speed taps are located on the furnace control board in the blower com-

partment. Refer to Figure 41, and the unit-wiring label to change the

blower speed. To use the same speed tap for heating and cooling, the

heat terminal and cool terminal must be connected using a jumper wire

and connected to the desired motor lead. Place all unused motor leads

on Park terminals. Two park terminals are provided.

FLAME

SENSOR

3.5 IN

WATER

COLUMN

GAS

PRESSURE

SHOWN

GAS

BURNERS

U-TUBE

MANOMETER

Do not energize more than one motor speed at a time or damage to

the motor will result.

FIGURE 41: Reading Gas Pressure

ADJUSTMENT OF FAN CONTROL SETTINGS

ADJUSTMENT OF TEMPERATURE RISE

This furnace is equipped with a time-on/time-off heating fan control. The

fan on delay is fixed at 30 seconds. The fan off delay has 4 settings (60,

90, 120 and 180 seconds). The fan off delay is factory set to 120 sec-

onds. The fan-off setting must be long enough to adequately cool the

furnace, but not so long that cold air is blown into the heated space. The

fan-off timing may be adjusted by positioning the jumper on two of the

four pins as shown in Figure 41.

DANGER

The temperature rise, or temperature difference between the return

air and the supply (heated) air from the furnace, must be within the

range shown on the furnace rating plate and within the application

limitations shown in Table 7.

The supply air temperature cannot exceed the “Maximum Supply

Air Temperature” specified in these instructions and on the furnace

rating plate. Under NO circumstances can the furnace be allowed to

operate above the Maximum Supply Air Temperature. Operating the

furnace above the Maximum Supply Air Temperature will cause pre-

mature heat exchanger failure, high levels of Carbon Monoxide, a fire

hazard, personal injury, property damage, and/or death.

CONTINUOUS FAN

SPEED JUMPER

BLOWER OFF

DELAY JUMPER

DIAGNOSTIC ERROR CODE

RETRIEVAL BUTTON

HUMIDIFIER

TERMINAL

ELECTRONIC AIR

CLEANER TERMINAL

FIGURE 42: Furnace Control Board

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

Blower Performance CFM - Any Position (without filter)

Bottom Airflow Data (SCFM)

Ext. Static Pressure (in. H2O)

Models

Speed

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1.0

655

High

Medium High

Medium Low

Low

1492

1236

986

1442

1201

950

1378

1161

961

1325

1139

916

1243

1082

872

1176

1011

831

1075

919

966

849

830

715

590

060B12MP11

757

703

600

510

824

795

783

744

713

659

624

554

489

389

High

1597

1338

1113

937

1537

1307

1094

916

1484

1273

1077

900

1435

1223

1043

877

1370

1179

1008

854

1286

1123

972

1230

1065

924

1155

998

1075

928

925

Medium High

Medium Low

Low

812

080B12MP11

080C16MP11

100C16MP11

100C20MP11

120D20MP11

868

803

798

817

775

718

639

560

High

1919

1532

1232

826

1865

1533

1313

821

1802

1513

1291

853

1738

1499

1280

858

1671

1465

1250

838

1600

1416

1209

817

1517

1352

1207

794

1414

1283

1148

776

1322

1198

1055

760

1201

1084

937

Medium High

Medium Low

Low

711

High

1909

1465

1190

787

1880

1463

1222

834

1823

1469

1216

819

1776

1485

1215

836

1706

1477

1224

819

1637

1416

1189

810

1562

1386

1158

790

1474

1324

1145

761

1375

1250

1087

690

1252

1114

996

Medium High

Medium

Low

707

High

2284

1967

1610

1326

2341

2002

1615

1352

2205

1905

1563

1304

2245

1952

1579

1295

2114

1824

1513

1267

2153

1878

1533

1259

2021

1763

1480

1232

2072

1823

1473

1245

1934

1712

1430

1183

1977

1739

1430

1190

1848

1628

1367

1143

1876

1657

1368

1141

1752

1551

1319

1080

1769

1563

1282

1076

1653

1473

1261

1003

1642

1458

1186

998

1505

1379

1101

871

1397

1213

1012

798

Medium High

Medium Low

Low

High

1506

1322

1091

938

1306

1185

953

Medium High

Medium Low

Low

820

Left Side Airflow Data (SCFM)

Ext. Static Pressure (in. H2O)

Models

Speed

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

775

1.0

628

High

Medium High

Medium Low

Low

1470

1211

970

1406

1186

957

1361

1139

927

1309

1101

889

1241

1042

853

1155

980

1060

896

920

796

681

545

060B12MP11

796

745

660

568

450

793

781

756

724

694

653

585

530

469

382

High

1605

1372

1087

916

1562

1318

1073

896

1514

1280

1052

881

1454

1255

1003

854

1393

1205

993

1330

1161

953

1251

1093

897

1169

1023

843

1073

943

940

Medium High

Medium Low

Low

849

080B12MP11

080C16MP11

100C16MP11

100C20MP11

120D20MP11

775

709

831

802

757

708

642

574

High

1956

1543

1238

906

1907

1543

1241

902

1846

1516

1243

903

1778

1504

1241

910

1717

1477

1252

888

1647

1446

1242

866

1573

1382

1201

859

1483

1309

1140

829

1353

1202

1074

795

1209

1099

967

Medium High

Medium Low

Low

743

High

1828

1422

1224

813

1829

1444

1229

819

1789

1437

1243

818

1768

1424

1234

814

1727

1396

1219

783

1671

1326

1193

762

1601

1301

1168

756

1505

1253

1135

732

1390

1200

1088

690

1272

1100

977

Medium High

Medium

Low

642

High

2391

1945

1549

1256

2343

1954

1596

1299

2286

1878

1530

1229

2253

1892

1539

1261

2165

1838

1495

1189

2167

1846

1511

1229

2079

1782

1430

1159

2071

1781

1458

1177

2004

1694

1431

1089

1979

1714

1399

1111

1934

1642

1365

1033

1881

1637

1341

1053

1839

1565

1284

1008

1785

1548

1254

993

1692

1451

1192

950

1560

1334

1097

871

1366

1163

1022

784

Medium High

Medium Low

Low

High

1668

1429

1180

937

1473

1238

942

1351

1171

988

Medium High

Medium Low

Low

882

782

NOTES:

1.Airflow expressed in standard cubic feet per minute (CFM).

2.Return air is through side opposite motor (left side).

3.Motor voltage at 115 V.

4.Airflow through across motor side (right side) may be slightly less than the data shown above.

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

Intermittent Blower - Cooling

SECTION X: SAFETY CONTROLS

Cooling/heating thermostats have a fan switch that has an ON and

AUTO position. In the AUTO position the thermostat circuit is completed

between terminals R and G when there is a call for cooling. The motor

will operate on the speed tap wire that is connected to the “HI COOL”

cooling terminal on the control board. The fan off setting is fixed at 60

seconds to improve cooling efficiency.

CONTROL CIRCUIT FUSE

A 3-amp fuse is provided on the control circuit board to protect the 24-

volt transformer from overload caused by control circuit wiring errors.

This is an ATO 3, automotive type fuse and is located on the control

board.

BLOWER DOOR SAFETY SWITCH

Heating Cycle

When the thermostat switch is set on HEAT and the fan is set on AUTO,

and there is a call for heat, a circuit is completed between terminals R

and W of the thermostat. When the proper amount of combustion air is

being provided, the pressure switch will close, the ignition control pro-

vides a 17-second ignitor warm-up period, the gas valve then opens,

the gas starts to flow, ignition occurs and the flame sensor begins its

sensing function. The blower motor will energize 30 seconds after the

gas valve opens, if a flame is detected. Normal furnace operation will

continue until the thermostat circuit between R and W is opened, which

causes the ignition system and gas valve to de-energize and the burner

flames to be extinguished. The vent motor will operate for 15 seconds

and the blower motor will operate for the amount of time set by the fan-

off delay jumper located on the control board. See Figure 41. The heat-

ing cycle is now complete, and ready for the start of the next heating

cycle.

Main power to the unit must still be interrupted at the main power dis-

connect switch before any service or repair work is to be done to the

unit. Do not rely upon the interlock switch as a main power discon-

nect.

Blower and burner must never be operated without the blower panel

in place.

This unit is equipped with an electrical interlock switch mounted in the

burner compartment. This switch interrupts all power at the unit when

the panel covering the blower compartment is removed.

Electrical supply to this unit is dependent upon the panel that covers the

blower compartment being in place and properly positioned.

ROLLOUT SWITCH CONTROLS

If the flame is not detected within 7 seconds of the gas valve opening,

the gas valve is shut off and a retry operation begins. Also, if the flame

is lost for 2 seconds during the 10-second stabilization period, the gas

valve is shut off and a retry operation begins. During a retry operation,

the vent motor starts a 15 second inter-purge and the ignitor warm-up

time is extended to 27 seconds. If the flame is established for more than

10 seconds after ignition during a retry, the control will clear the ignition

attempt (retry) counter. If three retries occur during a call for heat, the

furnace will shut down for one hour. If at the end of the one hour shut

down there is a call for heat, the furnace will initiate a normal start cycle.

If the problem has not been corrected the furnace will again lockout

after three retries.

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

in the area surrounding burner exceeds its set point, the gas valve is

de-energized. The operation of this control indicates a malfunction in

the combustion air blower, heat exchanger or a blocked vent pipe con-

nection. Corrective action is required. These are manual reset controls

that must be reset before operation can continue.

PRESSURE SWITCHES

This furnace is supplied with two pressure switches, which monitor the

flow through the combustion air/vent piping and condensate drain sys-

tem. These switches de-energize the gas valve if any of the following

conditions are present. Refer to SECTION VII, "CONDENSATE PIPING

AND FURNACE VENTING CONFIGURATION" for tubing connections.

A momentary loss of gas supply, flame blowout, or a faulty flame probe

circuit will result in a disruption in the flame and be sensed within 1.0

seconds. The gas valve will de-energize and the control will begin a

recycle operation. A normal ignition sequence will begin after a 15 sec-

ond inter-purge. If during the five recycles the gas supply does not

return, or the fault condition is not corrected the ignition control will lock-

out for 60 minutes.

1. Blockage of vent piping or terminal.

2. Failure of combustion air blower motor.

3. Blockage of combustion air piping or terminals.

4. Blockage of condensate drain piping.

LIMIT CONTROLS

During burner operation, a momentary loss of power for 50 milliseconds

or longer will de-energize the gas valve. When the power is restored,

the gas valve will remain de-energized and the ignition sequence will

immediately restart.

There is a high temperature limit control located on the furnace vesti-

bule panel near the gas valve. This is an automatic reset control that

provides over temperature protection due to reduced airflow. This may

be caused by:

TROUBLESHOOTING

The following visual checks should be made before troubleshooting:

1. A dirty filter.

2. If the indoor fan motor should fail.

3. Too many supply or return registers closed or blocked off.

1. Check to see that the power to the furnace and the ignition control

module is ON.

2. The manual shut-off valves in the gas line to the furnace must be

open.

The control module will lockout if the limit trips 5 consecutive times. If

this occurs, control will reset & try ignition again after 1 hour.

3. Make sure all wiring connections are secure.

4. Review the sequence of operation. Start the system by setting the

thermostat above the room temperature. Observe the system’s

response. Then use the troubleshooting section in this manual to

check the system’s operation.

SECTION XI: NORMAL OPERATION AND

DIAGNOSTICS

NORMAL OPERATION SEQUENCE

The following describes the sequence of operation of the furnace. Refer

to Owners Manual for component location.

Continuous Blower

Never bypass any safety control to allow furnace operation. To

do so will allow furnace to operate under potentially hazardous

conditions.

Do not try to repair controls. Replace defective controls with

Johnson Controls Unitary Products Source1 parts.

Never adjust pressure switch to allow furnace operation.

Cooling/heating thermostats have a fan switch that has an ON and

AUTO position. In the ON position the thermostat circuit is completed

between terminals R and G. The motor will operate continuously on the

speed tap wire that is selected with the BLOWER SPEED jumper on the

control board (HI COOL, LO COOL, HI HEAT, or LO HEAT).

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

5 RED FLASHES: This fault is indicated if the limit circuit is open for

more than fifteen minutes, usually indicating that a manual-reset rollout

switch has opened. Check for proper combustion air, proper inducer

operation, and primary heat exchanger failure or burner problem. The

control will enter a hard lockout and power will have to be cycled off and

on to reset the control after the problem has been corrected.

FURNACE CONTROL DIAGNOSTICS

The furnace has built-in, self-diagnostic capability. A blinking LED light

on the control board can flash red, green or amber to indicate various

conditions. The control continuously monitors its own operation and the

operation of the system. If a failure occurs, the LED light will indicate

the failure code.

6 RED FLASHES: This indicates that while the unit was operating, the

pressure switch opened four times during the call for heat. Check for

faulty inducer, blocked vent pipe or faulty pressure switch. The furnace

will lock out for one hour and then restart.

The SLOW flash speed is two seconds on and two seconds off.

The other flash codes listed below have the following timing: LED light

will turn on for 1/3 second and off for 1/3 second. This pattern will be

repeated the number of times equal to the code. There will be a two-

second pause between codes. For example, the six red flash code will

flash the LED light on and off six times, then will be off for two seconds.

This pattern will repeat as long as the fault condition remains. The con-

tinuous flash codes listed below will flash the LED light on and off con-

tinuously, with no breaks or longer pauses.

7 RED FLASHES: This fault code indicates that the flame could not be

established during three trials for ignition. Check that the gas valve

switch is in the ON position. Check for low or no gas pressure, faulty

gas valve, dirty or faulty flame sensor, faulty hot surface ignitor, loose

wires or a burner problem. The furnace will lock out for one hour and

then restart.

SLOW GREEN FLASH: Normal operation, no thermostat calls.

SLOW AMBER FLASH: Normal operation with call for heat.

8 RED FLASHES: This fault is indicated if the flame is lost five times

(four recycles) during the heating cycle. Check for low gas pressure,

dirty or faulty flame sensor or faulty gas valve. The furnace will lock out

for one hour and then restart.

LED STEADY OFF – If the LED light does not flash at all, check for

power to the board and check for a blown fuse on the board. If the

board is properly powered and the fuse is not blown, the control board

may need to be replaced.

9 RED FLASHES: Indicates reversed line voltage polarity, grounding

problem or reversed low voltage transformer wires. Both heating and

cooling operations will be affected. Check polarity at furnace and

branch. Check furnace grounding. Check that flame probe is not

shorted to chassis. The furnace will not start the ignition sequence until

this problem is corrected.

STEADY ON ANY COLOR: Control failure. Turn power to the furnace

off and back on. If the fault code returns, the control board must be

replaced. The control board is not field-repairable.

CONTINUOUS RED FLASH: Twinning error, incorrect 24V phasing or

no power to twinned unit. Check twinning wiring. Confirm that both

twinned units have power.

10 RED FLASHES: Gas valve energized with no call for heat. The main

blower and inducer blower will run and no ignition sequence will be

started as long as this condition exists. Check gas valve and gas valve

wiring.

CONTINUOUS AMBER FLASH: Flame sense current is below 1.5

microamps. Check and clean flame sensor. Check for proper gas flow.

Verify that current is greater than 1.5 microamps at flame current test

pad.

11 RED FLASHES: This indicates that the limit circuit has remained

open for more than five minutes and less than fifteen minutes. This con-

dition is usually caused by a failed blower motor or blower wheel. The

control will enter a hard lockout and power will have to be cycled off and

on to reset the control after the problem has been corrected.

1 RED FLASH: This indicates that flame was sensed when there was

not a call for heat. The control will turn on both the inducer motor and

supply air blower. Check for a leaking or slow-closing gas valve.

4 AMBER FLASHES: The control is receiving a “Y” signal from the

thermostat without a “G” signal. The furnace will operate normally in

both heating and cooling, but this fault code will be displayed in order to

alert the user that there is a wiring problem. Verify that the “G” wire from

the thermostat is connected properly.

2 RED FLASHES: This indicates that the pressure switch is closed

when it should be open. The control confirms that the pressure switch

contacts are open at the beginning of each heat cycle and will not let

the ignition sequence continue if the pressure switch contacts are

closed when they should be open. Check for a faulty pressure switch or

miswiring.

SOFT LOCKOUT: This control includes a soft lockout that will reset

automatically after one hour. This provides protection to an unoccupied

structure if a temporary condition exists causing a furnace malfunction.

An example of this is a temporary interruption in gas supply that would

prevent the furnace from lighting. The control will keep trying to light

each hour and will resume normal operation if the gas supply is

restored.

3 RED FLASHES: This indicates the pressure switch contacts are open

when they should be closed. Check for faulty inducer, blocked vent

pipe, broken pressure switch hose, disconnected pressure switch or

inducer wires or faulty pressure switch.

4 RED FLASHES: This indicates that the main limit switch has opened

its normally closed contacts. The control will turn on the supply air

blower and inducer. Check for a dirty filter, improperly sized duct sys-

tem, incorrect blower speed setting, incorrect firing rate, loose limit

switch wiring or faulty blower motor.

HARD LOCKOUT: Some fault conditions result in a hard lockout, which

requires power to the control to be turned off and then back on to reset

the control. The control will not automatically restart.

If the limit switch has not closed within five minutes, the control will

assume that the blower is not functioning, will start a hard lockout and

will begin to flash the 11 Red Flashes error code. If, after fifteen min-

utes, the main limit still has not closed, the control will assume that a

manual-reset rollout switch has opened and will begin to flash the 5 Red

Flash error code. See the description of “5 Red Flashes” and “11Red

Flashes” below.

IGNITION CONTROL FLAME SENSE LEVELS

Normal flame sense current is approximately

3.7 microamps DC (µa)

Low flame signal warning starts at 1.5 microamps.

Low flame signal control lockout point is

0.1 microamps DC (µa)

If the main limit switch opens five times within a single call for heat, the

control will indicate 4 Red Flashes and will enter a one-hour soft lock-

out.

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

To retrieve the error codes, push the LAST ERROR button. The LED on

the control will then flash the error codes that are in memory, starting

with the most recent. There will be a two-second pause between each

flash code. After the error codes have all been displayed, the LED will

resume the normal slow green flash after a five second pause. To

repeat the series of error codes, push the button again.

DIAGNOSTIC FAULT CODE STORAGE AND

RETRIEVAL

The control in this furnace is equipped with memory that will store up to

five error codes to allow a service technician to diagnose problems

more easily. This memory will be retained even if power to the furnace

is lost. This feature should only be used by a qualified service tech-

nician.

If there are no error codes in memory, the LED will flash two green

flashes. To clear the memory, push the LAST ERROR button and hold it

for more than five seconds. The LED will flash three green flashes when

the memory has been cleared, then will resume the normal slow green

flash after a five-second pause.

If more than five error codes have occurred since the last reset, only the

five most recent will be retained. The furnace control board has a but-

ton, labeled "LAST ERROR" that is used to retrieve error codes. This

function will only work if there are no active thermostat signals. So any

call for heating, cooling or continuous fan must be terminated before

attempting to retrieve error codes.

SECTION XII: REPLACEMENT PARTS LIST

DESCRIPTION

FABRICATED PARTS Continued

PANEL, TOP

DESCRIPTION

MOTOR

BLOWER, COMBUSTION

MOTOR, DIRECT DRIVE BLOWER

ELECTRICAL

RAIL, BLOWER (2 Req’d)

RESTRICTOR, COMBUSTION BLOWER

SHELF, BLOWER

CONTROL, FURNACE

CONTROL, TEMPERATURE

IGNITER

MISCELLANEOUS

BAG, PARTS

BRACKET, DOOR

SENSOR, FLAME

DIAGRAM, WIRING

SWITCH, DOOR

FERRULE (3 Req’d)

SWITCH, LIMIT

GASKET, FOAM (Door) (1.5 ft req’d)

GROMMET (3 Req’d)

HARNESS, WIRING

SWITCHES, PRESSURE

TRANSFORMER

VALVE, GAS

HOSE, CONDENSATE

HOSE, RAIN GUTTER

KNOB, QUARTER TURN (4 Req’d)

MOTOR MOUNT

AIR MOVING

HOUSING, BLOWER

WHEEL, BLOWER

FABRICATED PARTS

BRACKET, BLOWER TRACK (2 Req’d)

BRACKET, IGNITER

BURNER, MAIN GAS

HEAT EXCHANGER ASS’Y

MANIFOLD, GAS

ORIFICE, BURNER (Natural #45)

PAN, CONDENSATE

PLUG, SEAL, 7/8”

PLUG, SEAL, 2-3/8”

PLUG, VENT PIPE

SIGHT GLASS, OVAL (2 Req’d)

TUBING, SILICON

PANEL, BLOCKOFF

PAN, BOTTOM

PANEL, DOOR (2 Req’d)

REPLACEMENT PART CONTACT INFORMATION

This is a generic parts list. To request a complete parts list, refer to the contact information below:

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

1. Search for a part or browse the catalog.

2. Find a dealer or distributor.

3. Customer Service contact information.

a. Click on the “Brand Links” button

b. Click on the “Customer Service” button

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

Johnson Controls Unitary Products

Consumer Relations

5005 York Drive

Norman, OK 73069

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

505309-UIM-D-0511

SECTION XIII: WIRING DIAGRAM

FIGURE 43: Wiring Diagram

Johnson Controls Unitary Products

Download from Www.Somanuals.com. All Manuals Search And Download.

Subject to change without notice. Published in U.S.A.

505309-UIM-D-0511

Supersedes: 505309-UIM-C-0910

Johnson Controls Unitary Products

5005 York Drive

Download from Www.Somanuals.com. All Manuals Search And Download.

Norman, OK 73069

ION Turntable ION TTUSB User Manual
Jabra Marine Radio GN1000 User Manual
John Deere Automobile Parts CD4039DF008 User Manual
JVC DVD Player XV S400BK XV S402SL XV S300BK XV S302SL User Manual
JVC VCR HR A55U User Manual
Kaidan Camera Accessories KiWi Panoramic Tripod Head User Manual
Kenmore Vacuum Cleaner 11634728 User Manual
Kenwood Car Stereo System KDC 234SG User Manual
KitchenAid Oven KEBS207SSS03 User Manual
KitchenAid Slow Cooker KSC6222 User Manual