Johnson Controls Furnace 356486 UUM H 0609 User Manual

EFFICIENCY  
RATING  
CERTIFIED  
USER’S INFORMATION  
MANUAL  
MODELS:  
ISO 9001  
Certified Quality  
Management System  
All Residential Multi-position Gas Furnaces  
(33” Models)  
TABLE OF CONTENTS  
CONTACT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
How to Clean your Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5  
BLOWER CARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5  
MOTOR LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5  
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
INSTRUCTIONS FOR EXAMINING THE  
FURNACE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
START-UP AND SHUTDOWN INSTRUCTIONS . . . . . . . . . . . . . . . . 3  
HOW YOUR GAS FURNACE WORKS . . . . . . . . . . . . . . . . . . . . . . 3  
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
TO TURN OFF THE APPLIANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5  
TROUBLESHOOTING PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . .5  
FURNACE CONTROL DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . .5  
FURNACE MAINTENANCE - DEALER/CONTRACTOR . . . . . . . . .5  
REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5  
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5  
LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6  
FURNACE MAINTENANCE - USER INFORMATION . . . . . . . . . . . . 4  
EXTERNAL AIR FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
CONTACT INFORMATION  
Contact us by mail:  
Johnson Controls Unitary Products  
Consumer Relations  
5005 York Drive  
Norman, OK 73069  
1. The furnace area must be kept clear and free of combustible mate-  
rials, gasoline and other flammable vapors and liquids.  
We recommend that the user read all sections of this  
manual and keep the manual for future reference.  
2. Insulating materials may be combustible. The furnace must be  
kept free and clear of insulating materials. The furnace area must  
be examined when installed in an attic or other insulated space or  
when insulation is added to be sure that the insulation material has  
been kept away from the furnace.  
FIRE OR EXPLOSION HAZARD - Failure to follow safety warnings  
exactly could result in serious injury, death, or property damage.  
3. The furnace needs air for combustion in order to operate properly  
and safely. Do not block or obstruct air openings on the furnace,  
air openings to the area where the furnace is installed, or spaces  
around the furnace.  
Do not store or use gasoline or other flammable vapors and  
liquids in the vicinity of this or any other appliance.  
WHAT TO DO IF YOU SMELL GAS:  
Do not try to light any appliance.  
4. Follow the instructions exactly as shown on the OPERATING  
INSTRUCTION LABEL on the furnace or the “START-UP AND  
SHUTDOWN INSTRUCTIONS” section of this manual when light-  
ing the furnace or turning the furnace off.  
Do not touch any electrical switch; do not use any phone (includ-  
ing cell phone) in your building.  
Leave the building immediately.  
Immediately call your gas supplier from a neighbor’s phone. Fol-  
low the gas supplier’s instructions.  
5. Should the gas supply fail to shut off or if overheating occurs, shut  
off the gas valve to the furnace before shutting off the electrical  
supply.  
If you cannot reach your gas supplier, call the fire department.  
Installation and service must be performed by a qualified  
installer, service agency or the gas supplier.  
6. Do not use this furnace if any part has been under water. A flood-  
damaged furnace is extremely dangerous. Attempts to use the fur-  
nace can result in fire or explosion. A qualified service agency  
should be contacted to inspect the furnace and replace all gas  
controls, control system parts, electrical parts that have been wet  
or the furnace if deemed necessary.  
SECTION I: SAFETY  
This is a safety alert symbol. When you see this symbol on  
labels or in manuals, be alert to the potential for personal  
injury.  
7. NEVER . . .Store flammable materials of any kind near your fur-  
nace. Gasoline, solvents, and other volatile liquids should be  
stored only in approved containers outside your home. These  
materials vaporize easily and are extremely dangerous.  
Understand and pay particular attention to the signal words DANGER,  
WARNING, or CAUTION.  
DANGER indicates an imminently hazardous situation, which, if not  
avoided, will result in death or serious injury.  
8. NEVER . . .Store cleaning materials near your furnace. Materials  
such as bleaches, detergents, powdered cleansers, etc., can  
cause corrosion of the heat exchangers.  
WARNING indicates a potentially hazardous situation, which, if not  
avoided, could result in death or serious injury.  
CAUTION indicates a potentially hazardous situation, which, if not  
avoided may result in minor or moderate injury. It is also used to  
alert against unsafe practices and hazards involving only property dam-  
age.  
9. NEVER . . . Use the area around your furnace as a storage area  
for items which could block the normal flow of air. This flow of air is  
required for ventilation of the various furnace components.  
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356486-UUM-H-0609  
Rollout  
Safety Switch  
Rollout  
Safety Switch  
Flame Sensor  
Manifold  
Pipe  
Manifold  
Pipe  
Flame Sensor  
Gas Valve  
Ignitor  
Ignitor  
Gas Valve  
Limit Switch  
(Behind gas valve)  
Limit Switch  
(Behind gas valve)  
Vent Pipe  
Vent Pipe  
Draft Inducer  
Assembly  
Draft Inducer  
Assembly  
Electrical  
Junction Box  
Electrical  
Junction Box  
Pressure  
Switch  
Pressure  
Switch  
Silicone Tube  
Silicone Tube  
Condensate  
Pan  
Condensate  
Pan  
Safety  
Door Switch  
Safety  
Door Switch  
Control  
Board  
Control  
Board  
Transformer  
Blower  
Transformer  
Blower  
Power Factor  
Choke (Not  
used on all  
models)  
Capacitor  
ECM MOTOR  
PSC MOTOR  
FIGURE 5: Component Location - 97% Modulating PSC Models  
FIGURE 6: Component Location - 97% Modulating ECM Models  
1. Examine the heat exchanger, vent pipe, combustion air passages,  
vent connectors and chimney to be sure they are clear and free of  
obstructions.  
SECTION III: START-UP AND SHUTDOWN  
INSTRUCTIONS  
Read the Instructions Below Before Trying to Start the  
Furnace!  
2. Examine the vent pipe making sure it is firmly in place, that it  
slopes slightly upward and is physically sound without holes and  
all of the connections are secure.  
3. Examine the return-air duct connections to make sure they are  
physically sound, sealed to the furnace casing, and the ducts ter-  
minate outside the space containing the furnace.  
If you do not follow these instructions exactly, a fire or explo-  
sion may result causing property damage, personal injury,  
and/or loss of life.  
4. Examine the furnace casing making sure the physical support is  
sound without sagging, cracks or gaps. Examine the furnace base  
making sure it is physically sound without cracks, gaps or sagging  
and has a good seal.  
HOW YOUR GAS FURNACE WORKS  
Your furnace is a very easy appliance to take for granted. Season after  
season, it sits there in your home, keeping you warm and comfortable.  
For this reason, you may never have given much thought to the way  
your furnace operates. In order to get the safest and most efficient oper-  
ation from your furnace, you should understand how your furnace does  
its job.  
5. Examine the furnace casing for obvious signs of deterioration.  
6. Examine the burner flames to make sure they are in good adjust-  
ment. Refer to the pictorial sketch shown in Figure 7 as a compar-  
ison to the actual flame.  
Blue Cone Portion of Flame Should  
Enter Heat Exchanger Tube  
When you set your thermostat to provide more heat in your home, you  
are starting the heating cycle of the furnace. First, the inducer motor  
starts to purge the heat exchanger of any remaining gases. Next, the  
hot surface ignitor glows and after a warm-up period the gas valve  
opens and ignition occurs. A short time later, the blower starts and dis-  
tributes the warm air throughout the home. When the temperature set-  
ting on your thermostat is reached, the gas valve closes, the main  
burners are turned off, and the blower continues to run until the remain-  
ing warm air in the system is distributed. When the blower stops, the  
heating cycle has ended.  
1. This appliance does not have a pilot. It is equipped with an ignition  
device which automatically lights the burner. Do not try to light the  
burner by hand.  
FIGURE 7: Burner Flame Drawing (Upflow Configuration Shown)  
2. BEFORE OPERATING; smell all around the appliance area for  
gas. Be sure to smell next to the floor because some gas is  
heavier than air and will settle on the floor.  
7. Examine and replace external air filters as needed to make sure  
they are not blocked, and proper airflow is provided to the furnace.  
8. Examine any installed accessories or system components such as  
evaporator coils to insure proper operation, drainage of conden-  
sate, and that there is no water leakage or damage to the furnace  
or any components.  
3. Use only your hand to push the gas control switch to the ON posi-  
tion. Never use tools. If the switch will not operate by hand, don’t  
try to repair it, call a qualified service technician. Force or  
attempted repair may result in a fire or explosion.  
4. Do not use this appliance if any part has been under water. Imme-  
diately call a qualified service technician to inspect the appliance  
and to replace any part of the control system and any gas control,  
which has been under water.  
Johnson Controls Unitary Products  
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356486-UUM-H-0609  
OPERATING INSTRUCTIONS  
HIGH STAGE REGULATOR  
ADJUSTMENT  
1. STOP! Read the safety information above for your protection.  
2. Set the thermostat to the lowest setting in the heat mode.  
3. Turn off all electric power to the appliance.  
OUTLET  
PRESSURE  
PORT  
VENT  
PORT  
4. Remove furnace burner access panel/door.  
5. Move gas control switch to the OFF position. Do not force. See  
Figures 9-11.  
INLET  
OUTLET  
6. Wait five (5) minutes to clear out any gas. If you then smell gas,  
STOP! Follow “B” in the safety information above. If you don’t  
smell gas, go to next step.  
WRENCH  
BOSS  
INLET  
PRESSURE  
PORT  
7. Move gas control switch to the ON position. Do not force. See Fig-  
ures 9-11.  
LOW STAGE REGULATOR  
ADJUSTMENT  
ON OFF  
SWITCH  
8. Replace furnace burner access panel/door.  
9. Turn on all electric power to the appliance.  
FIGURE 10: Two-Stage Gas Valve  
10. Set thermostat to the desired setting. Burner will light, which may  
take 30-60 seconds.  
11. After three (3) trials for ignition, if the appliance will not operate fol-  
low the instructions, “TO TURN OFF THE APPLIANCE” and call  
your service technician or gas supplier.  
TO TURN OFF THE APPLIANCE  
1. Set the thermostat to lowest setting in heating mode.  
Main  
Regulator  
Adjustment  
2. Turn off all electric power to the appliance if service is to be per-  
formed.  
On/Off  
Knob  
3. Remove furnace burner access panel/door.  
Outlet  
Pressure  
Tap  
Inlet  
Pressure  
Tap  
4. Move gas control switch to the “OFF” position. See Figures 9-11.  
5. Replace furnace burner access panel/door.  
FIGURE 11: Modulating Gas Valve  
SECTION IV: FURNACE MAINTENANCE -  
USER INFORMATION  
Should overheating occur, or the gas valve fail to shut off, turn  
the external manual gas valve in the gas supply line to the fur-  
nace to the “off” position and let the furnace cool off before  
shutting off the electrical power supply.  
Before proceeding, be sure the area is well ventilated. Turn the  
thermostat OFF. If the blower is running, wait until it stops auto-  
matically. Turn OFF the gas and electrical power supplies to the  
furnace. Check all metal parts and surfaces to be sure they  
have cooled to room temperature before you begin.  
External Manual  
Shutoff Valve  
To Gas  
Supply  
To Gas  
Supply  
EXTERNAL AIR FILTERS  
Filters used with this furnace must be installed external to the furnace  
casing. DO NOT attempt to install filters inside the furnace cabinet.  
Grounded Joint Union  
may be Installed  
Inside or Outside Unit.  
Some installations may have the air filter in a rack attached to the cas-  
ing of the furnace or placed in the return air duct. If the filter location or  
replacement process is not obvious, contact your installer or service  
technician for assistance.  
Drip Leg  
FIGURE 8: Gas Piping  
Every time the external air filters are changed the following items should  
be visually inspected:  
Outlet  
Pressure  
Port  
Vent Port  
Outlet  
Check combustion air and vent pipe for blockage or leakage.  
Check all components to be sure they are in good condition and  
that there are no obvious signs of deterioration.  
Inlet  
Check the drain lines to make sure there are no cracks or leaks.  
Check for dirt or lint on any surfaces or on components. Do not try  
to clean any of the surfaces or components. Cleaning of the fur-  
nace and its components must be done by a qualified service pro-  
fessional.  
Wrench  
Boss  
Inlet  
Main Regulator  
Adjustment  
Pressure  
Port  
On/Off Switch  
(Shown in ON position)  
FIGURE 9: Single Stage Gas Valve  
4
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FURNACE CONTROL DIAGNOSTICS  
The furnace has built-in, self-diagnostic capability. If a system problem  
occurs, a blinking LED shows a fault code. The LED can flash red,  
green or amber to indicate various conditions. It is located behind a  
clear view port in the blower compartment door.  
If during the inspection of your furnace, you find any of the following  
conditions:  
Excessive amounts of dust and lint on components.  
Damaged or deteriorated components or surfaces.  
Leaks or blockage in the vent pipe passages.  
Water on any surface inside or outside of the furnace.  
The control continuously monitors its own operation and the operation  
of the system. If a failure occurs, the LED will indicate the failure code. If  
the failure is internal to the control, the light will stay on continuously. In  
this case, the entire control should be replaced, as the control is not  
field repairable.  
Do not operate the furnace, call a certified dealer or servicing contractor  
to check or clean your furnace, or for more information if you have  
questions about the operation of your furnace.  
If all components appear to be in good operating condition, replace the  
furnace access panels/doors. Turn ON the gas and electrical power  
supplies to the furnace, and set thermostat to the desired temperature.  
Flash sequence codes 1 through 10 are as follows: LED will turn ON for  
1/4 second and OFF for 1/4 second. This pattern will be repeated the  
number of times equal to the code. For example, six ON flashes equals  
a number 6 fault code. All flash code sequences are broken by a 2 sec-  
ond OFF period.  
How to Clean your Filter  
High-velocity filters may be cleaned with a vacuum cleaner or washed  
with a garden hose. Be sure to shake off excess water and allow filter to  
completely dry before re-installing the filter.  
SLOW GREEN FLASH: Normal operation.  
DOUBLE AMBER FLASH: Normal heating operation - Modulating Fur-  
nace Models Only  
Replace throw away filter(s) with the same size new filter(s). Throw  
away filter(s) may be replaced with cleanable filter(s) at this time.  
SLOW AMBER FLASH: Normal operation with call for heat.  
BLOWER CARE  
RAPID RED FLASHES: There is a problem with the operation of this  
furnace. Contact your local dealer, contractor or service provider.  
Even with good filters properly in place, blower wheels and motors will  
become dust laden after months of operation. The entire blower assem-  
bly should be inspected annually. This service must be performed by a  
qualified service agency.  
FURNACE MAINTENANCE - DEALER/CONTRACTOR  
The furnace should be cleaned and adjusted by a certified dealer or  
qualified service contractor once a year or before the start of every  
heating season. The following items must be cleaned and serviced or  
replaced if there are signs of deterioration.  
NOTE: The spring-loaded safety cut-off switch, mounted at the blower  
deck will automatically cut off the electrical power supply to the furnace  
when the furnace blower access panel/door is removed. As a safety  
precaution, all electrical power and the gas supply to the furnace should  
be turned off before servicing.  
1. The vent terminal.  
2. The furnace vent and combustion air intake passageways. Should  
it be necessary to service the vent/air intake system, the manufac-  
turer recommends this service be conducted by a qualified service  
agency. The operation of this appliance requires the reassembly  
and resealing of the vent/air intake system.  
Make sure you DO NOT move the clip on weight on the  
indoor fan wheel when cleaning the wheel. This weight is  
used to balance the wheel. Moving the weight will cause the  
fan wheel to vibrate.  
3. The furnace burners, ignitor and flame sensor.  
4. The condensate collection and disposal system. If any disassem-  
bly of components containing flue or vent gases is required, a  
qualified service agency must perform the service.  
MOTOR LUBRICATION  
5. Heat exchanger assembly.  
The motors in these furnaces are permanently lubricated, and do not  
require periodic oiling.  
6. Induced draft motor assembly.  
REPLACEMENT PARTS LIST  
SECTION V: SERVICE INFORMATION  
All components, assemblies, accessories, and replacement parts for  
this furnace are available through qualified service agencies. It is not  
recommended that the user purchase, install, or replace any compo-  
nents of this furnace. Contact your local contactor, dealer, or service  
provider for additional information.  
TROUBLESHOOTING PROBLEMS  
If your furnace is not operating correctly, the following visual checks  
should be made before contacting your local contractor, dealer, or ser-  
vice provider.  
1. Check that electrical power to the furnace is turned on.  
2. Check that the manual gas shut-off valve in the gas piping supply  
is turned to the ON position. Refer to Figure 9.  
WIRING DIAGRAM  
The unit wiring diagram may be found on the inside of one of the access  
panels on the furnace. It is intended for reference only. If service is  
required, contact your local contactor, dealer, or service provider.  
3. Check that the ON/OFF switch on the gas valve is turned to the  
ON position. Refer to Figures 9, 7 or 8.  
4. Check that the furnace blower access panel/door is correctly posi-  
tioned. The electrical power supply will be cut off if this door is  
removed.  
Johnson Controls Unitary Products  
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Limited Warranty  
Johnson Controls Unitary Products (hereinafter “Company”) warrants this product to be free from defects in factory workmanship and material under normal  
use and service and will, at its option, repair or replace any parts, without charge, subject to the exclusions below, that prove to have such defects according to  
the terms outlined on this warranty. This warranty covers only the equipment described by the Product Model Number and Serial Number on the equipment or  
listed on the Warranty Registration Card and applies only to products installed in the United States or Canada.  
FOR WARRANTY SERVICE OR REPAIR:  
Contact the installer or a Company dealer. You may find the installer’s name on this page or on the equipment. You can also find a Company dealer online at  
73069. Or, by phone 877-874-7378. All warranty service or repair will be performed during regular business hours, Monday through Friday 9:00am-5:00pm.  
Product Model No.__________________________________  
Unit Serial No._____________________________________  
Installation Date_________________________________________  
Installing Dealer_________________________________________  
FOR PRODUCT REGISTRATION: For your benefit and protection, return the Warranty Registration Card to Company promptly after installation. This will ini-  
tiate the warranty period and allow us to contact you, should it become necessary. For this warranty to apply, the product must be installed according to Com-  
pany recommendations and specifications, and in accordance with all local, state, and national codes; and the product must not be removed from its place of  
original installation. The warranty period for repair or replacement parts provided hereunder shall not extend beyond the warranty period stated below. In the  
absence of a recorded Warranty Registration Card, the warranty period will begin upon product shipment from Company. If you are unaware of the date the  
ductregistration.com or by returning the Warranty Registration Card on the back page of this packet.  
HEAT EXCHANGER WARRANTY ADDITIONAL TERMS: Company warrants the heat exchangers (primary and/or secondary, if applicable) in this product to  
be free from defects in factory workmanship and material under normal use and service and will at its option, repair or furnish a replacement heat exchanger,  
either new or reconditioned that meets the intended fit, use and function of the original heat exchanger. Alternatively, Company may, at its option, extend a  
replacement allowance to be applied toward the purchase of a new furnace marketed by Company. The exact amount of the allowance will be determined at  
the discretion of Company, based upon current market conditions, but in no case shall this allowance exceed thirty (30) percent of the original consumer pur-  
chase price of the furnace, excluding such items as ductwork, wiring, piping, and installation costs. Company shall have no responsibility hereunder for instal-  
lation, shipping, handling or other charges except as specifically provided herein.  
The warranty period in years, depending on the part and the claimant, is as shown in the chart below.  
HEAT EXCHANGER  
Residential Applications  
FURNACE TYPE  
PARTS  
Non-Residential  
Applications  
Subsequent  
Owner  
Original Owner  
20  
20  
N/A  
N/A  
20  
10  
10  
10  
5
5 or 10†  
5
GG8S,GGLS  
TM8X,TMLX,TM8T,TMLT,TM8V,TMLV,TG8S,TGLS  
GG9S  
Lifetime  
TM9V,TM9T,TM9X,TG9S  
TP9C,TP8C,TPLC,TM9M,TM8M,TMLM,YP9C,YP8C,YPLC,YM9M,YM8M,YMLM  
CP9C,CP8C,CPLC,CM9M,CM8M,CMLM,LP9C,LP8C,LPLC,LM9M,LM8M,LMLM  
Lifetime  
20  
10  
5 or 10†  
or 90 days of closing for new home construction. In some states, registration is not required, but proof of installation may is required to qualify for the 10-year parts  
warranty. Guardian Brand products have a 5-year compressor and 5-year parts warranty and are not eligible for the 10-year parts warranty.  
Company strongly recommends regular periodic preventative maintenance on this equipment. The person most familiar with the equipment in your HVAC sys-  
tem is a Company dealer. The Company dealer can ensure your maintenance program meets the conditions of the "Company Warranty", maximize the effi-  
ciency of the equipment, and service your unit within the mandated guidelines with regard to unlawful discharge of refrigerants into the atmosphere.  
EXCLUSIONS:  
This warranty does not cover any:  
1.  
2.  
Shipping, labor, or material charges or damages resulting from transportation, installation, or servicing.  
Damages resulting from accident, abuse, fire, flood, alteration, or acts of God (tampering, altering, defacing or removing the product serial number will  
serve to void this warranty).  
3.  
4.  
5.  
6.  
7.  
Damages resulting from use of the product in a corrosive atmosphere.  
Damages resulting from inadequacy or interruption of electrical service or fuel supply, improper voltage conditions, blown fuses, or other like damages.  
Cleaning or replacement of filters or damages resulting from operation with inadequate supply of air or water.  
Damages resulting from failure to properly and regularly clean air and/or water side of condenser and evaporator.  
Damages resulting from: (I) freezing of condenser water or condensate; (II) inadequate or interrupted water supply; (III) use of corrosive water; (IV) fouling  
or restriction of the water circuit by foreign material or like causes.  
8.  
9.  
Damages resulting from use of components or accessories not approved by Company (vent dampers, etc.).  
Increase in fuel or electric cost.  
This warranty is in lieu of all other warranties, expressed or implied, including the implied warranties of merchantability and fitness for a particular  
purpose.  
Some states do not allow the disclaimer of implied warranty, so that the above disclaimer may not apply to you. Some states only allow a partial  
limitation on implied warranties to limit the duration of implied warranties to the duration of the express warranty. In such states, the duration of  
implied warranties is hereby expressly limited to the duration of the express warranty on the face hereof. Some states do not allow limitations on  
how long an implied warranty lasts, so the above limitation may not apply to you.  
In no event, whether as a result of breach of warranty or contract, tort (including negligence), strict liability, or otherwise, shall Company be liable  
for special, incidental, or consequential damages, including but not limited to loss of use of the equipment or associated equipment, lost revenues  
or profits, cost of substitute equipment or cost of fuel or electricity. The above limitations shall inure to the benefit of Company’s suppliers and  
subcontractors. The above limitation on consequential damages shall not apply to injuries to persons in the case of consumer goods.  
Company does not assume, or authorize any other person to assume for Company, any other liability for the sale of this product. Some states do  
not allow the exclusion or limitation of incidental or consequently damages, so the above limitation may not apply to you.  
This warranty gives you specific legal rights. You may also have other rights which vary from state to state.  
Subject to change without notice. Printed in U.S.A.  
356486-UUM-H-0609  
Copyright © 2009 by Johnson Controls, Inc. All rights reserved.  
Supersedes: 356486-UUM-G-0409  
Johnson Controls Unitary Products  
5005 York Drive  
Norman, OK 73069  
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