SGAC Installation, Operation
Contents
1. x 21 Adjusting Manifold x Cabinet Clearances x 22 Checking Gas Input x Venting Requirements x 23 Orifice SIZE a A uu u sisa x 6 Wall Opening x 24 Derating For High Altitudes x Sleeve x 25 System Balance x 8 Unit to Sleeve Attachment X 26 Measuring Air Temperature X 9 Installing Duct Work x 27 Maintaining Furnace in Good Working Order x 10 Return Air Duct amp Filter Arrangement X 28 Getting Information amp Publications X 11 Combustion Air Supply X 29 Refrigerant Charges X 12 Filter Rack Installation X 30 Wiring Conection X 13 Installing Gas X 31 Schematic Connection X 14 Condensate Drain X 32 Ignition System Troubleshooting X 15 Electrical Connections x 33 Direct Vent Clearances2. 2 Remove outlet pressure tap plug from gas con trol 3 Make sure shut off valve is in OFF position then install 1 8 pipe manual shut off valve in hole va cated by plug 4 Attach U tube water manometer to 1 8 pipe manual shut off valve just installed 5 Turn on all gas appliances attached to gas supply line 6 Open manual shut off valve in gas supply line just ahead of furnace Start furnace following Operat ing Instructions on front door 7 Open 1 8 pipe manual shut off valve leading to manometer 8 Read manifold pressure on manometer 9 Make small changes in manifold pressure within allowable range 3 2 inches W C to 3 8 inches W C for natural gas 9 2 inches W C to 9 8 inches W C for propane by turning gas control regulator adjusting screw clockwise to increase pressure turn counter clockwise to decrease pressure Major changes in flow rate can only be made by changing main burner orifice size See Section 24 10 Shut OFF furnace Turn OFF gas at manual shut off valve in gas supply line just ahead of furnace Install outlet pressure tap plug in gas control Turn ON gas 16 FORM 145 24 IOM1 908 11 Check regulator adjustment cover screw and gas control plug for gas leaks Use a commercial soap solution made for leak detection 22 CHECKING GAS INPUT Natural gas heating values BTU cu ft can vary significantly Therefore it is the installers responsibility to see that
3. Gas Propane LP gas installations do not have gas meters to double check input rate Measure manifold pressure adjust ments with an accurate U tube water manometer Failure to accurately adjust pressure could cause heat exchanger failure asphyxiation fire or explosion resulting in damage injury or death For furnace operation at elevations above 2 000 feet follow instructions in Section 24 NOTE 1 Make sure you have correct pilot orifice and main burner orifices Be sure that gas piping is large enough for all appliances connected to it to operate at once without lowering the main line pressure Failure to do so could cause lighting or burning problems on any of the appliances 2 Gas control inlet pressure must be between 11 inches and 13 inches for propane LP gas See Section 20A to check gas supply line for pres sure 17 3 Turn off all other gas appliances Pilots may be left on Start furnace following Operating Instructions on front door or in Users Information Manual 4 As furnace warms up watch gas supply line gas control inlet pressure using U tube water ma nometer in gas control inlet pressure tap See Section 20A Supply line pressure must still be between 11 inches and 13 inches W C for propane LP gas 5 After verifying correct gas control inlet pressure close shut off valve in gas control inlet pressure tap Move manometer to gas control outlet pres sure tap See Section
4. fire or explosion may result causing property damage personal injury or loss of life A Preparation Gas piping must meet requirements of current National Fuel Gas Code ANSE 2223 1 or CAN CGA B149 and lo cal codes Size of pipe running to furnace depends on e Length of pipe Number of fittings Specific gravity of gas Input requirements Btuh of all gas fired appliances attached to same main supply line Plan furnace gas supply piping so it will not interfere with removal of burner assembly front door or blower door for servicing Always use a pipe thread sealant that is resistant to propane LP gas solvent action Sparingly apply sealant to all joints on male threads only starting two threads back from end B Furnace Gas Entry Piping A hole and a rubber grommet are provided in the side of the cabinet for connecting 1 2 inch gas pipe to the gas control The gas piping connection is always on the op posite side of the cabinet to the furnace and return air connection If there is not enough room to run gas piping down the side of the unit it is possible to have the gas pipe entry through the top of the cabinet Knockouts are provided in the top panel for this purpose C Installation 1 Install A G A C G A listed manual shut off valve gas supply line immediately upstream of furnace Install 1 8 NPT plugged tapping immediately upstream of furnace Omit separate plugged tap ping if l
5. 3 7 V VENT BES TFRVINAL WALL SLEEVE PARTITION 4 III L 15 7 8 UNIT A 63 125 NOTE LEFT HAND UNT RGAC 55 875 OT HAND MIRROR WAGE LD13592 Fig 1 VENT TERMINAL 7 WALL OPENING A finished opening through an outside wall is re quired for exhausting flue products and condenser airflow The wall opening required is 16 wide by 56 high for R models and 16 wide by 63 high for S models The wall opening must be flush with the finished floor Consult local ordinances for framing requirements of the building wall opening JOHNSON CONTROLS FORM 145 24 10 1 908 RECOMMEND LINTEL WHERE REQUIRED ON WALL OPENING CAULK GRILLE FLUSH OR RECESSED OF WALL THE UNITS INSTALLED WITHOUT WALL SLEEV EEVE MUST HAVE PARTITION 4 TWEEN INLET AND 2 DISCHARGE AIR UNIT FLANGE BOTTOM OF WALL OPENING FLUSH WITH D BRICK VENEER INSTALLATION WITH WALL SLEEVE AND EXTERIOR GRILLE LD13378 Fig 2 INSTALLATION W WALL SLEEVE AND EXTERIOR GRILL 8 WALL SLEEVE Awall sleeve is required to finish the wall opening A factory made wall sleeve is available as an optional accessory for new construction When replacing a FEDDERS unit with a retrofit model R the R unit will mate with the existing FEDDERS wall sleeve
6. BLACK 24V BLUE RED YELLOW BLUE COMPRESSOR CONTACTOR 1 RED ROLL OUT PILOT 55 SWITCH MANUAL C W_HOT SURFACE RESET IGNITION CONDENSER MOTOR BLK YEL HIGH LIMIT CONTROL VALVE IGNITION CONTROL BRN BRN CAP RUN IGNITER ITI ORANGE COOL THERMOSTAT JOHNSON CONTROLS COMPRESSOR PURPLE YELLOW VENTOR FAN TIMER BOARD COMPRESSOR VACUUM 579120 2032 CONTACTOR SWITCH COIL DELAY YELLOW Bul NOTES Sw IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE FURNACE MUST REPLACED WIRING MATERIAL HAVING A TEMPERATURE RATING AT LEAST 105 DEGREES C MUST BE USED DEPENDING ON FURNACE SIZE THE HEAT TERMINAL SPEED TAP COULD BE HIGH MED OR LOW 5 03 1013593 23 31 SCHEMATIC WIRING DIAGRAM CABINET MUST BE GROUNDED 230V 208V RED ORANGE WHITE TRANSFORMER HEAT RED _ BLACK SKYPAK GAS FURNACE SCHEMATIC WIRING DIAGRAM 208 230V 12 RED RED OO O CONDENSER_FAN YELLOW COMPRESSOR EVAPORATOR BLOWER MOTOR LO N i YELLOW CAP BLACK DRA
7. TERMINALS ARE NOT DAMAGED M17143 1013595 25 FORM 145 24 IOM1 908 33 DIRECT VENT FURNACES VENT TERMINAL CLEARANCES Canadian Installations Installations 0 USInstallation Installations above grade veranda 12 inches 30 cm 12 inches 30 cm porch deck or balcony 9 inches 30 cm for appliances gt 10 000 3 kW and lt 50 000 Btuh 15 kW 12 inches 91 cm for appliances gt 50 000 Btuh 15 kW Clearance to permanently closed window 12 inches 30 cm for appliances gt 10 000 au 3 kW and lt 100 000 Btuh 30 kW Clearance to window or door that may be opened 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 Clearance to unventilated soffit Clearance to outside corner Clearance to inside corner Clearance to each side of center line 3 feet 91 cm within a height 15 feet extended above meter regulator 4 5 m above the meter regulator assembly assembly Clearance to service regulator vent outlet 3 feet 91 cm Clearance to nonmechanical air sup 12 inches 30 cm for appliances gt ply inlet to building or the combustion 10 000 Btuh 3 kW and lt 100 000 air inlet to any other appliance Btuh 30 kW 4 feet 1 2m below or to side of open ing 1 foot 30 cm above opening Clearance to a mechanical air supply inlet 3 feet 91 cm ab
8. Use a spirit level or plumb line to make sure that the wall sleeve vertical flanges which must mate with the back of the unit are perfectly vertical If the flanges are not vertical the unit will not seal properly against the wall sleeve Completely seal any gaps or openings around the wall sleeve and the wall opening use exterior grade caulking or expanding foam sealant to prevent air and weather penetration into the build ing envelope EXTERIOR GRILLE Finish the sleeve exterior with a factory grille The sleeve grille and vent terminal should be factory supplied UNIT TO SLEEVE ATTACHMENT amp INSTALLA TION OF VENT PIPE EXTENSION Before the unit is moved into final position and attached to the wall sleeve the ventor pipe exten sion must be installed The vent pipe extension is shipped loose in the blower compartment at the bottom of the unit The vent pipe extension must be cut to length depending on the depth of the wall sleeve used When installed the outlet end of the pipe must be 1 to 1 inches from the back of the exterior wall grille The required length of the pipe extension is gt inch less than the depth of the wall sleeve used Measure the required length from the end that has pre drilled screw holes and cut the surplus off the other end The pipe extension must be installed before the furnace is in final position and attached to the wall sleeve Secure the pipe extension to the ventor discharge pipe wi
9. carryover alignment They should touch but not overlap adjacent burner Replace screws Move gas control slide switch to ON position Open manual shut off valve in gas supply line just ahead of furnace Set room thermostat to its highest setting Turn on electricity at electrical disconnect switch located next to furnace Check for gas leaks using commercial soap solu tion made for leak detection Check gas input as per instructions in Section 22 JOHNSON CONTROLS FORM 145 24 IOM1 908 25 SYSTEM BALANCE A CAUTION Preparing to measure ductwork static pres 4 5 a High duct work static pressure may cause low airflow resulting in poor heating performance and reduced heat exchanger life Low airflow may also cause poor cooling performance sure Open supply air registers and return air grilles Make sure the registers and grilles are free of ob struction from rugs carpets drapes or furniture Set balancing dampers in supply duct system Check ductwork for obstructions or leaks Make sure filters are clean and in place See Sec tion 15 for filter information Blower speed taps are set for proper heating and cooling speed i Measure ductwork static pressure with circulat ing air blower on heating Follow instructions in below ii Measure heating air temperature rise Air Conditioning Measure ductwork static pressure with circulating air blower on air conditioning F
10. gas control from gas supply line Failure to isolate gas control test pressure could damage it causing gas leak resulting in fire or explosion 6 Use a commercial soap solution made to detect leaks and check all gas piping 14 CONDENSATE DRAIN PIPING The condensate drain pan is fitted with 34 NPT female pipe fitting which protrudes through the unit casing The 34 drain piping should be run horizontally from this fitting until the piping is past the side of the unit casing and not passing in front of any of the access doors Once the piping is clear of the unit casing a trap should be installed to prevent conditioned air from being blown out of the drain line The trap should be at least 2 inches deep with the outlet a minimum of 1 2 inch below the inlet The drain piping on the outlet side of the trap JOHNSON CONTROLS FORM 145 24 IOM1 908 should be pitched inch per foot down towards open drain Unions should be installed between the unit and the trap and on the outlet side of the trap to allow for disconnecting the piping and the trap for cleaning out 15 ELECTRICAL CONNECTIONS Check the voltage and phase listed on the unit rating plate before installation to be sure the power supply is correct If the compressor fails as the result of improper voltage the compressor is not replaceable under war ranty and the manufacturer will not be responsible for the cost of replacement The minimum and maxim
11. ignite 6 When the room thermostat is satisfied terminal W on the module is de energized 7 The main and pilot valves in the gas control are de energized 8 The ventor motor is de energized after a 5 second post purge period 9 The air circulating fan is de energized after the off delay timing which is factory set at 60 seconds The off delay is adjustable between 60 amp 180 seconds Increasing the off delay will cause cold drafts and is not recommended SEQUENCE OF OPERATION ON COOLING CYCLE 1 Room thermostat calls for cooling connecting R to Y terminals on fan timer control module T9120G2032 2 The compressor and condenser fan start immedi ately on a call for cooling 3 Air circulating fan starts after a four second de lay 4 When the room thermostat is satisfied terminal Y on the module is de energized 5 The compressor and condenser fan stop immedi ately when the thermostat is satisfied 6 The air circulating fan continues to run for an off delay period of 100 seconds The off delay is not adjustable on the cooling cycle JOHNSON CONTROLS FORM 145 24 IOM1 908 HEATING SEQUENCE OF OPERATION DIAGRAM CAUTION 1 Do not apply a jumper across or short the thermostat 24V hot or 24V common terminal in the SV9501 wiring harness Doing so can burn out the heat anticipator in the thermostat or damage the system transformer 2 After servicing verify proper system operation Sequence of Operation 1 Ma
12. knowledgeable with regard to electrical lock out tag out procedures The individual performing this work should be aware of and comply with all national state and local safety and environ mental regulations while carrying out this work Before attempting to work on any equipment the individual should be thoroughly familiar with the equipment by reading and understanding the associated service literature applicable to the equipment If you do not have this literature you may obtain it by contacting a Johnson Controls Service Office Should there be any question concerning any aspect of the tasks outlined in this instruction please consult a Johnson Controls Service Office prior to attempting the work Please be aware that this information may be time sensitive and that Johnson Controls reserves the right to revise this information at any time Be certain you are working with the latest information JOHNSON CONTROLS FORM 145 24 IOM1 908 TABLE OF CONTENTS 1 Preparing to Install Furnace x 18 Furnace Section Start Up Checklist x 2 Important Safety X 19 Checking Controls X 3 Meeting Codes 2 2 2 x 20 Checking inlet Gas Pressure 4 NSD AC KUNG annaran X amp Pilot Adjustment x 5 Installation Location
13. the BTU input does not exceed the rating of the furnace Failure to do so could cause heat exchanger failure asphyxi ation fire or explosion resulting in dam age injury or death Under firing could cause inadequate heat excessive condensation or ignition problems Over firing could cause sooting flame impingement or overheating of heat exchanger A Natural Gas For furnace operation above 2 000 feet elevation follow instructions in Section 24 NOTE Before starting natural gas input check obtain gas heat value at standard conditions from local supplier 1 Make sure gas piping is large enough for all appli ances connected to it to operate at once without lowering main line pressure Failure to do so could cause lighting or burning problems on any of the appliances 2 Make sure gas control inlet pressure does not exceed 10 5 inches W C Use method in section 20A to check gas supply line pressure 3 Make sure all other gas appliances are off You may leave pilots on Start furnace following Operating Instructions on front door or in Users Information Manual 4 As furnace warms up watch gas supply line gas control inlet pressure using U tube water manometer installed in gas control inlet pressure tap Natural gas supply line pressure must still not exceed 10 5 inches W C 5 After verifying correct gas control inlet pressure close shut off valve in gas control inlet pressure tap Move manometer con
14. 2 Adjust the thermostat several degrees above room temperature 3 Using ac voltmeter check for 24V at the ignition system control as shown in the troubleshooting guide JOHNSON CONTROLS 13 18 FURNACE SECTION START UP CHECKLIST Before starting furnace for the first time be sure you can answer Yes to each of these questions Is furnace properly equipped to operate with avail able fuel Is the furnace level Have you cleared away all loose construction and insulation materials Is furnace installed within proper clearances to combustible materials See Section 6A Did you completely check gas pipe and controls for gas leaks See Section 13 6 Does electrical wiring follow current National Elec trical Code ANSI or CSA C22 1 C E C Part 1 as well as local codes See Section 16 Is furnace electrically grounded See Section 16 Is room thermostat properly installed See Section 16 Is ductwork system correctly sized and sealed See Section 10 Are air filters in place and correctly sized See Section 12 On furnace installations above a 2000 foot eleva tion is furnace derated properly See Section 24 19 CHECKING CONTROLS 14 Before leaving the work site check to see that all controls are functioning properly Follow these steps Turn off electricity at electrical disconnect switch next to furnace Move gas control slide switch to OFF position Connect a U t
15. 2 Medium Medium Low High 6 0401212 Low 6 0401812 Medium Medium 6 0601812 High Medium 6 0402412 Low Medium 6 0602412 Meduim Medium 6 0603012 Low High GAD803612 Medium High If the blower speed is changed from the above factory settings the temperature rise must be checked to make sure it is still within the range shown above and CAUTION on the unit data label A Preparing to measure air temperature rise Follow steps 1 through 5 in Section 25A of this manual under System Balance B Measuring air temperature rise Air temperature rise warm air supply temperature minus cold air return temperature must be within allowable air temperature rise range specified on furnace rating plate 20 FORM 145 24 1 1 908 1 Place thermometer in supply air approximately 2 feet from plenum Position thermometer so that it is not affected by radiant heat from the heat exchanger 2 Place thermometer in return air duct approxi mately 2 feet from furnace Locate thermometer tip in center of duct to ensure proper temperature measurement 3 Set room thermostat on highest temperature set ting Operate furnace 6 minutes Record supply air and return air temperature 4 Calculate air temperature rise by subtracting return air temperature from supply air temperature 5 a If air temperature rise is below maximum tem perature rise heating system
16. 24 Open shut off valve in gas control outlet pressure tap Let furnace warm up for approximately 6 minutes 6 Manifold pressure should be 9 5 inches W C 0 3 inches W C Adjust by removing regulator cover screw on gas control Save cover screw for reinstallation Turn inner adjustment screw counter clockwise to decrease manifold pressure turn clockwise to increase manifold pressure Set correct manifold pressure Install cover screw and tighten to torque of 5 inch pounds to prevent gas leakage Many installers set propane LP mani fold pressure at 11 0 inches W C DO NOT DO THIS It could cause heat ex changer failure or nuisance callbacks CAUTION 7 Turn off gas before removing the 1 8 pipe manual shut off valves Install 1 8 pipe plugs in gas con trol inlet and outlet pressure taps Tighten to torque of 50 inch pounds Turn on gas Check both pipe plugs for gas leaks Use commercial soap solution made for leak detection 23 ORIFICE SIZE See Figure 7 for initial gas orifice sizes as shipped from factory Check with your local gas supplier to determine heat value BTU CU FT of gas in your area Depending on your local heat value and elevation you may need to adjust manifold pressure or change orifices to get proper gas input rate See Section 24 INITIAL ORIFICE SIZE Input Natural Gas Propane BTU Hr Orifice Size Orifice Size All Size Units 2 15 mm 1 35 mm 2 000 4 500 Above Sea Level See furn
17. 7 Turn on all gas appliances attached to gas supply line 8 With furnace operating read gas supply line pres sure on manometer a Gas supply line pressure must be between 5 7 in W C for natural gas b Gas supply line pressure must be between 11 13 in W C for propane LP gas 9 If gas supply line pressure is not within these limits call gas supplier 10 Turn off all gas appliances attached to gas supply line B Pilot Flame Adjustment Pilot flame adjustment was checked at the factory and should not require adjustment Under certain applications and conditions pilot adjustment may be necessary Before adjusting pilot flame confirm that gas supply line pressure is correct as explained in paragraph A above and then proceed 1 Open manual shut off valve located in gas supply line just ahead of furnace JOHNSON CONTROLS FORM 145 24 IOM1 908 2 Start furnace following Operating Instructions on front door 3 Pilot flame should cover gt of tip of flame sensor as shown in Figure 6 PILOT FLAME ADJUSTMENT PROPER FLAME ADJUSTMENT 7 ECTRODE FLAME ROD HOT SURFACE IGNITER NOTE GROUND ELECTRODE MUST NOT TOUCH FLAME ROD 050 IN MINIMUM CLEARANCE BEND GROUND ELECTRODE IF NECESSARY DO NOT BEND FLAME ROD 32804 LD13389 Fig 6 PILOT FLAME ADJUSTMENT 4 If you need to adjust pilot flame remove pilot ad justment cover screw on gas control See cover scre
18. AT TO BE SUPPLIED BY OTHERS SET THERMOSTAT HEAT ANTICIPATOR 0 4 AMPS UNE VOLTAGE TERMINAL BLOCK POWER SUPPLY NOTE PER LOCAL CODES a FIELD WIRING LD13386 Fig 5 FIELD WIRING DIAGRAM THERMOSTAT OPERATION Heating Operation Turn system switch to Heat and switch to Auto Set thermostat at desired tem perature Cooling Operation Turn system switch to Cool and Fan switch to Auto Set thermostat at desired tem perature Blower Operation To recirculate indoor air turn Fan switch to On and system switch to Unit Off Turn system switch Off and fan switch Auto Burner ignition is automatic with next heating cycle Thermostats with heat anticipators should have the heat anticipator set for 0 40 AMPS NOTE 12 FORM 145 24 10 1 908 17 SEQUENCE OF OPERATION ON HEATING CYCLE 1 Room thermostat calls for heat connecting R to W terminals on fan timer control module T9120G2032 2 Ventor motor starts amp vacuum switch normally open contacts close 3 The pilot gas valve amp the igniter are energized 4 When a flame signal is detected at the pilot burner the main gas valve opens the main burners ignite and the hot surface igniter is de energized The main burners normally ignite within five seconds after the call for heat 5 The air circulating fan starts thirty seconds after the main burners
19. ES REPLACE IGNITER FLAME ROD ASSEMBLY CHECK THAT PILOT GAS IS FLOWING WAIT ASSURE PILOT GAS TUBING IS PURGED RECYCLE CALL FOR HEAT IF NECESSARY MEASURE VOLTAGE BETWEEN 24V HOT AND 24 COMMON LEADS TO SmartValve CONTROL MUST MEASURE AT LEAST 19 5 VAC WITH IGNITER POWERED SEE INSET ATO IDENTIFY PROPER LEAD THIS CHECK MUST BE DONE WITH THE SmartValve CONTROL CONNECTED AND IGNITER POWERED YES REPLACE IGNITER FLAME ROD ASSEMBLY CHECK THAT PILOT FLAME MAKES GOOD CONTACT WITH PILOT BURNER FLAME ROD CHECK FOR GOOD ELECTRICAL CONNECTION THROUGH THE PILOT TUBING IF BOTH OF THE ABOVE ARE GOOD REPLACE IGNITER FLAME ROD ASSEMBLY CYCLE THERMOSTAT OFF AND BACK ON MAIN BURNER LIGHTS MAIN VALVE OPENS AND MAIN BURNER LIGHTS SYSTEM IS OKAY A IGNITER WILL CYCLE OFF AND BACK ON ONCE DURING THE 90 SECOND IGNITION TRIAL ALL VOLTAGE MEASUREMENTS MUST BE TAKEN WHILE THE IGNITER IS POWERED JOHNSON CONTROLS FORM 145 24 IOM1 908 INSET 24 VOLT THERMOSTAT OR PRESSURE END VIEW OF CONTROL HARNESS CONNECTOR SWITCH Je DO OUTPUT 24 VOLT HOT CHECK FOR DAMAGED OR MISSING TERMINALS IN CONNECTOR 24 VOLT COMMON INSET B HSI TERMINALS REPLACE SmartValve CONTROL REPLACE SmartValve CONTROL CHECK TRANSFORMER AND LINE VOLT SUPPLY REPLACE SmartValve CONTROL WHEN MEASURING VOLTAGE AT CONNECTIONS USE CARE TO ASSURE
20. FT INDUCER RELAY DRAFT INDUCER MOTOR e m FORM 145 24 IOM1 908 FAN TIMER BOARD ST9120 G 2032 HI LIMIT 24 VENTOR VACUUM SWITCH COOLING CONTACTOR 5 9600 HOT PILOT ass y SURFACE IGNITER FLAME SENSOR LD13594 JOHNSON CONTROLS 32 IGNITION SYSTEM TROUBLESHOOTING GUIDE V9501 SV9502 SmartValve TROUBLESHOOTING SEQUENCE NOTE BEFORE TROUBLESHOOTING BECOME FAMILIAR WITH THE STARTUP AND CHECKOUT PROCEDURE ALSO 3 CHECK BURNER ELEMENT FOR ASSURE SmartValve SWITCH IS IN ON POSITION RESISTANCE LESS THAN 10 OHMS WITH DISCONNECT SYSTEM CONTROL HARNESS SET THERMOSTAT CALL FOR HEAT ELEMENT AT ROOM TEMPERATURE CHECK CHECK FOR PROPER VOLTAGE AT CONTROL LINE VOLTAGE POWER HARNESS SEE INSET A VOLTAGE SHOULD BE LOW VOLTAGE TRANSFORMER 24V BETWEEN THERMOSTAT OR PRESSURE LIMIT CONTROLLER SWITCH AND 24V COMMON AND 24V A THERMOSTAT BETWEEN 24V COMMON AND 24 HOT WIRING AIR PROVING SWITCH ON COMBUSTION AIR BLOWER SYSTEM PLUG HARNESS INTO SmartValve CONTROL VENT DAMPER IF USED 15 OPEN AND END WAIT FOR INTERNAL CHECK DELAY SV9501 SWITCH MAKES OR PREPURGE 59502 IGNITER WARMS UP AND GLOWS RED YES TURN ON GAS SUPPLY PILOT BURNER LIGHTS YES WITH VOLTAGE AT SmartValve HSI ELEMENT OUTPUT SEE INSET B 24V NOMINAL PILOT BURNER CABLE CONNECTED MEASURE Y
21. It meets the requirement for a 100 shutoff gas control system Before installing furnace make sure you know all applicable codes National state and local codes may take precedence over any instructions in this manual Be sure to consult Authorities having jurisdiction over furnaces Local code authorities for information on electrical wiring In the Commonwealth of Massachu setts this product must be installed by a liscensed plumber or liscensed gas fitter NOTE Accepted for Use City of New York Department of Buildings MEA 394 94 E Wisconsin Building Products Evaluation 200102 H Commonwealth of Massachusetts Division of Reg istration Approval Code G3 0303 73 4 CORROSIVE VAPORS Do NOT install furnace in a corrosive or contaminated atmosphere Corrosive vapors in the atmosphere such as chlorinated hydrocarbons will affect the operation of this unit Do NOT sure store open containers of chlorine bleach or other household cleaners near the furnace 5 UNPACKING i Check the unit for indications of damage in ship ment Notify the Transportation Company of any damage and note the damage on the shipping receipt Rough handling may dislocate internal components NOTE ii Allow the shipping base to remain with the unit until it is ready to be set in its final location iii Rotate blowers to assure free movement iv The compressor is mounted on neoprene isolators with metal spa
22. Model RGAC SGAC Self Contained Cooling Gas Heating Units Supersedes 145 24 10 1 708 Form 145 24 10 1 908 RGAC AND SGAC INSTALLATION AND OPERATION INSTRUCTIONS Models RGAC amp SGAC R22 Category Ill Gas Heating Electric Cooling Units Models SGAC Capacities 12 000 18 000 24 000 amp 36 000 Btu Hr Cooling 20 000 40 000 60 000 amp 80 000 Btu Hr Input Heating Not all cooling capacities available all heating capacities FORM 145 24 IOM1 908 IMPORTANT READ BEFORE PROCEEDING GENERAL SAFETY GUIDELINES This equipment is a relatively complicated apparatus During installation operation maintenance or service individuals may be exposed to certain components or conditions including but not limited to refrigerants oils materials under pressure rotating components and both high and low voltage Each of these items has the potential if misused or handled improperly to cause bodily injury or death It is the obligation and respon sibility of operating service personnel to identify and recognize these inherent hazards protect themselves and proceed safely in completing their tasks Failure to comply with any of these requirements could result in serious damage to the equipment and the property in which it is situated as well as severe personal injury or death to themselves and people at the site This document is intended for use by owner authorized operating service pers
23. ace draws all combustion air from outdoors There is no need to provide combustion or ventilation air openings except as may be re quired by local codes service access panels must be place for the furnace to properly draw in outside combustion air When installing furnace in an alcove basement closet garage or utility room do not store items in front of fur nace or in front of closet or utility door which would prevent ready access for WARNING i service 12 FILTER RACK INSTALLATION FOR SIDE RE TURN Air filters are required to keep the air conditioning coil and blower motor clean Dirty equipment may cause dam age to the heat exchanger or air condi tioning unit The filter frame is provided for an 18 in X 25 in X 1 in filter The filter frame has to be field installed after snipping out the prepunched opening in the side of the unit Position the three sided filter frame so that the short side is towards the back of the furnace and the 1 inch duct flange is facing outwards The long sides of the frame should be pulled slightly towards each other so that the continuous slip formed on the back of the frame clears the opening in the cabinet Push the frame towards the back of the unit firmly until the short vertical part of the frame clips onto the cabinet Then insert the other vertical side of the frame between the ends of the top and bottom parts of the frame This will keep the top and bottom par
24. ace rating plate located on blower door Fig 7 PILOT FLAME ADJUSTMENT 2 05 mm 1 30 mm 18 PRESSURE REGULATOR ADJUSTMENT UNDER CAP SCREW FORM 145 24 IOM1 908 IGNITER CONNECTOR OUTLET PRESSURE TAP GNITION SYSTEM CONTROL SWITCH CONTROLS PILOT ADJUSTMENT CONNECTOR UNDER CAP SCREW LD13388 Fig 8 IGNITION SYSTEM CONTROL 24 DERATING FOR HIGH ALTITUDES A Installer responsibility For operation at elevations above 2 000 feet the density of air is reduced therefore the furnace should be derated at the rate of four percent 4 for each 1 000 feet above 2 000 feet of elevation It is the installers responsibility to see that the input is adjusted properly In Canada derate 10 for elevations for 2 000 to 4 500 feet If the gas supplier has not already derated the gas BTU valve derating must be achieved by reducing the size of the main burner orifices Contact gas supplier for more information on proper sizing Adjustment of the manifold pressure to a lower pressure reading than what is specified in Section 21 Manifold Pressure Adjustment of this manual is considered to be an improper derate procedure With a lower density of air and a lower manifold pressure at the burner orifice the orifice will not aspirate the proper amount of primary air into the burner Insufficient primary air can cause incom plete combustion yellow tipping and the possibility of carbon build u
25. acks Delivery of required circulating air For all furnaces design systems for minimum and maximum external static pressures detailed in Figure 3 See Section 26 on measuring ductwork static pressure EXTERNAL STATIC PRESSURE Inches of Water Column Input be Minimum Maximum BTU HR Input is on furnace rating plate on blower door Fig 3 SUPPLY AIR DUCT WORK Connect supply air duct to 1 in flange on furnace supply air outlet Duct attaching hardware only must be used on the supply air outlet flanges Refrigeration tubing is located under the top panel near these flanges Do not drill or screw in this area Supply air duct plenum connection must be at least the same size as the furnace supply air opening Seal supply air ductwork to furnace casing walls ceilings or floors it passes through Terminate ductwork outside furnace space JOHNSON CONTROLS FORM 145 24 IOM1 908 DUCT DAMPERS You may balance air flow with dampers installed in each branch run duct and adjust for even tem perature throughout the heated space For proper furnace operation make sure Supply air registers and return air grilles are open Rugs carpets drapes or furniture are clear of registers and grilles e Size and shape of supply air plenum is correct Number of supply air duct outlets is sufficient 11 COMBUSTION AIR SUPPLY The unit is approved as a DIRECT VENT APPLI ANCE This furn
26. ating Turn off furnace electrical power failure to do so could result in injury or death Use only replacement parts listed in parts list Failure to do so could im proper furnace operation resulting in damage injury or death Perform periodic preventive maintenance once be fore heating season begins and once during heating season Inspect clean and repair as needed the following items 1 The heat exchanger and flue gas passageways of the furnace should not require cleaning if the furnace has been operating normally If a build up of soot is found in the heat exchanger or the flue gas passageways this indicates incomplete combustion Check gas pressures at the inlet and manifold test ports on the gas valve Check that the main burner orifices are correct for the qual ity of gas and the altitude Check that the ventor motor is in good working order and that there is no obstruction of combustion air in or out of the furnace The cause of the soot build up should be diagnosed and corrected The heat exchanger can be cleaned if necessary by a probe such as is used to clear household drains Insert the probe into the outlet end of each tube and feed it through until it comes out of the inlet or burner end of the heat exchanger tube Any soot dislodged can be removed from the burner end of the tubes with a vacuum cleaner 2 All burners pilot collector box draft inducer as sembly and complete vent system Vent system mus
27. cing sleeves inside and secured with nuts that must be snug against the metal spacer sleeves v Check all refrigeration tubing to assure that it does not rub against any other parts 6 NORMAL INSTALLATION DO NOT install this furnace outdoors or in a mobile home trailer or recreational vehicle It is not de sign certified for these installations This furnace is suitable for a home built on site or a manufactured home completed at final site This unit is designed for indoor installation adjacent to an exterior wall having an opening for condenser airflow The air flow products must a Discharge directly to the outside b Discharge away from any obstructions that could cause discharged air recirculation FORM 145 24 1 1 908 DO NOT install this unit at an exterior wall location that will position the bottom of the wall grille below the exterior grade level Below grade installation will allow the accumulation of rain or snow into the wall sleeve and unit base and could result in water penetration into the building interior A CABINET CLEARANCES The unit is design certified for closet installation with the minimum clearances to combustible ma terials as stated on the data label No clearance is required from the top sides or back of the unit A minimum of 1 inch clearance is required from the front to any combustible materials A combustible door may be placed 1 inch from the front of the unit When the door is o
28. compatible with the unit or not approved by Johnson Controls have been used with or attached to the unit The defect or damage is not caused by Johnson Controls or it arises from circumstances beyond the control of Johnson Controls The unit is installed outside the United States or Canada or has been removed from the place where it was originally installed THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES OBLIGATIONS OR LIABILITIES EXPRESSED OR IMPLIED BY EMPLOYEES OR REPRESENTATIVES OF JOHNSON CONTROLS ALL STATUTORY EXPRESSED OR IMPLIED WARRANTIES INCLUDING THE IMPLIED WARRANTY OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY NEGATED AND EXCLUDED ANY CLAIMS FOR INCIDENTAL AND CONSEQUENTIAL DAMAGES OR ANY OTHER DAMAGES OR EXPENSES BEYOND THE TERMS OF THIS LIMITED WARRANTY ARE HEREBY EXPRESSLY NEGATED AND EXCLUDED JOHNSON CONTROLS 27 Subject to change without notice Printed in U S A Copyright 2008 by Unitary Products Group All rights reserved Form 145 24 IOM1 908 Supersedes 145 24 IOM1 708 Engineered Systems P O Box 1592 York Products York PA PA Group 17405 17405
29. e 17 Maintenance in this manual with user Make sure user understands the importance of following all safety precautions 1 PREPARING TO INSTALL FURNACE Literature Review the Manual Users Manual Information amp Parts List In particular see Users Information Manual amp Parts List for location and identification of furnace components After installing furnace give this Installer s Informa tion Manual Users Information Manual Warranty amp Parts List to user You may have questions as you install the furnace If you need help on any of the installation instructions or other matters relating to the furnace contact the office where you bought the furnace You may also refer to the furnace rating plate for a contact name 2 IMPORTANT SAFETY RULES Only use natural gas in furnaces desig nated for natural gas Only use Propane LP gas in furnace designed for Pro pane LP gas Make sure furnace will operate properly on gas type available to user Do not use this furnace with butane Using an incorrect gas supply could create a hazard resulting in dam age injury or death JOHNSON CONTROLS FORM 145 24 IOM1 908 A Use only the type of gas approved for this furnace refer to furnace rating plate B Install this furnace only in a location and position as specified in Section 5 amp 31 of these instructions C Provide for adequate combustion and ventilation air to the furnace by installing only a
30. has sufficient airflow b If air temperature rise is above maximum temperature rise specified on the nameplate gas input may be too high Check gas input following the instructions in Section 22 c If air temperature rise is still above maximum temperature rise specified more heating air flow is needed Operating furnace above maximum air temperature rise may cause poor heat ing performance and decreased heat exchanger life 6 Heating speed tap should not normally be reduced below initial factory setting Some duct system configurations and supply register locations may result in cold blow 7 After making heating airflow adjustments you must check air temperature rise following steps 3 amp 4 above to verify that resulting air temperature is within allowable range 8 If air temperature rise is still above that specified on furnace rating plate check ductwork design with a qualified heating engineer It may be necessary to resize the ductwork Recheck air temperature rise after revising duct system 9 Set room thermostat to desired setting 10 Remove thermometers and seal ductwork holes Failure to seal JOHNSON CONTROLS 27 MAINTAINING FURNACE IN GOOD WORKING ORDER Follow these procedures before inspect ing furnace WARNING Turn room thermostat to its lowest or off setting Turn off manual gas shut off valve e Wait at least five minutes for furnace to cool if it was recently oper
31. ke sure the ignition system control switch is in the ON position 2 Follow the sequence of operation as shown V9501 SV9502 SmartValve FAMILY SEQUENCE OF OPERATION START APPLY 24 VAC TO APPLIANCE THERMOSTAT CALLS FOR HEAT FIVE MINUTE RETRY DELAY PREPURGE SYSTEM CHECK PREPURGE SV9502 ONLY WAIT FOR FLAME SIGNAL TO DISAPPEAR PILOT VALVE IGNITER REMAIN OFF FLAME SIGNAL DETECTED INTERNAL CHECK OKAY YES TRIAL FOR PILOT VALVE OPENS THREE SECOND FLAME IGNITION IGNITER POWERED FAILURE RECYCLE DELAY NO PILOT LIGHTS AND FLAME IS SENSED VALVE CLOSES DURING TRIAL FOR IGNITION 2 IGNITER OFF YES MAIN IGNITER OFF BURNER MAIN VALVE OPENS OPERATION ELECTRONIC FAN TIMER EFT OUTPUT ENERGIZES MAIN AND PILOT VALVES CLOSE FLAME SIGNAL LOST EFT OUTPUT DE ENERGIZES NO THERMOSTAT CALL FOR HEAT ENDS FLAME LOST MORE THAN FIVE TIMES IN ONE CALL FOR HEAT MAIN AND PILOT VALVES CLOSE END EFT OUTPUT DE ENERGIZES IGNITER WILL TURN OFF ABOUT 30 SECONDS INTO THE TRIAL FOR IGNITION IF THE PILOT FLAME HAS NOT LIT IT WILL TURN BACK ON FOR THE FINAL 30 SECONDS OF THE 90 SECOND TRIAL FOR IGNITION THE PILOT VALVE WILL BE ENERGIZED DURING THE ENTIRE TRIAL FOR IGNITION THIS IS NORMAL OPERATION FOR THIS GAS IGNITION SYSTEM M17144 LD13597 If Main Burner Will NOT Come On With Call for Heat 1 Make sure the ignition system control switch is in the ON position
32. ly to level the unit D 2 SLIDE UNIT INTO CONTACT WITH WALL SLEEVE UNIT FLANGE MUST BE INSIDE WALL SLEEVE 45525 2 s The 5 series units are secured to wall sleeve by installing two 10 x gt inch self drilling sheet metal screws through the flange standing up at the back of the unit top These two screws will screw into the wall sleeve The series units secured to the wall sleeve using a piece of angle 13 8 inch x 13 8 inch x 16 inches long This angle should be placed on the top of the unit at the back with one flange facing down and clipping over the vertical flange at the top of wall sleeve Then screw this piece of angle to the top of the unit using two 10 x inch self drilling sheet metal screws required piece of angle and screws are packed in side the blower compartment of R series units JOHNSON CONTROLS 10 INSTALLING DUCT WORK Install all ductwork to meet current standard CAUTION e ASHRAE NFPA 90 Standard for Installation of Warm Air Heating and Air Systems State provincial and local codes Failure to follow these standards could reduce airflow or increase air leakage resulting in reduced system performance or furnace dam age Properly size ductwork based on heat loss and heat gain calculations Doing so assures e Good heating and cooling installations e Potentially fewer callb
33. n 10 years from the date of original installation During this time a new replacement heat exchanger will be furnished or at our sole option a credit for the replacement heat exchanger may be allowed Labor and other expenses involved in replacing the heat exchanger are not covered by this warranty This Warranty applies only to the heat exchanger and not to other parts of the furnace and only to the original homeowner and is subject to the terms and conditions hereof LABOR AND COST NOT COVERED This Warranty provides only replacement parts or credits and does not provide for or cover any labor shipping handling or other costs for service travel servicing removing or installing any parts EXCLUSIONS This Warranty shall be void if The unit is not installed by a licensed or otherwise qualified or contractor and in compliance with the Installation Manual applicable installation and good trade practices The defect or damage is caused by accident abuse negligence of any person or company misuse riot flood fire or Acts of God The unit is not operated and regularly serviced and maintained as called for in the Users Manual 4 Damages are caused by operating the unit in a commercial or corrosive atmosphere containing any damaging or dangerous chemicals The unit is modified or services in a manner not in accordance with the Installation Manual and Users Manual Components replacement parts or other accessories not
34. nd blower deck under burners and up each side where bulkhead mounts to casing Tighten screws until air leaks stop 13 Turn off electricity at electrical disconnect switch located next to furnace Remove jumper from terminal strip terminals and Reconnect all room thermostat wires to original terminal strip terminals See Section 16 Figure 5 14 Remove the U tube water manometer from gas control and replace outlet pressure tap Move gas control slide switch to ON position 15 Set room thermostat to desired setting JOHNSON CONTROLS 20 INLET GAS PRESSURE amp PILOT ADJUSTMENT You must have correct gas supply line and pilot gas pressures Correct pres sures give proper pilot ignition and burner operation Use a U tube wa ter manometer to measure actual gas pressure Failure to accurately adjust pressure could cause fire or explosion resulting in damage injury or death A Gas Supply Line Pressure 1 Turn OFF gas at manual shut off valve in gas sup ply line just ahead of furnace 2 Remove inlet pressure plug from gas control 3 Make sure valve is in OFF position then install 1 8 pipe manual shut off valve in hole vacated by plug 4 Attach U tube water manometer to 1 8 pipe manual shut off valve just installed 5 Open manual shut off valve in gas supply line just ahead of furnace 6 Open 1 8 pipe manual shut off valve leading to U tube water manometer
35. nection to gas control outlet pressure tap See Section 21 Open shut off valve in outlet pressure tap Let furnace warm up for 6 minutes JOHNSON CONTROLS 6 Manifold pressure should 3 5 inches Adjust by removing regulator cover screw on gas control Save cover screw for reinstallation Turn inner adjustment screw counter clockwise to de crease manifold pressure turn clockwise increase manifold pressure Set correct manifold pressure Install cover screw and tighten to torque of 5 inch pounds to prevent gas leakage Locate gas meter Determine which dial has the least cubic feet of gas and how many cubic feet per revolution it represents This is usually one half one or two cubic feet per revolution With stopwatch measure time it takes to consume two cubic feet of gas a If dial is 1 2 revolution measure time for four revolutions b If dial is 1 FT revolution measure for two revolutions If dial is 2 revolution measure for one revolution d After determining the number of seconds for two cubic feet of gas to flow through meter divide this time by two This gives average time fore one cubic foot of gas to flow through meter Example If it took 58 seconds for two cubic feet to flow it would take 29 seconds for one cubic foot to flow 9 Use this formula to calculate gas input N go Gas Btu Cu Ft x 3 6000 Seconds Hour Seconds for one cubic fo
36. ocal area accepts plugged tapping in gas control inlet 2 After in line manual shut off valve install a drip leg sediment trap at gas supply line inlet connection to furnace JOHNSON CONTROLS 3 When using black iron gas install an A G A C G A listed ground joint union between drip leg sediment trap and furnace gas control Locate ground joint union down stream of manual shutoff valve to allow easy servicing of burner assembly and gas control If local codes allow the use of a flexible gas con nector always use a new listed connector DO NOT use a connector that has previously serviced another gas appliance 4 Install gas pipe to inlet side of furnace gas con trol Do not thread gas pipe too far into con trol valve body Doing so may cause gas control to split or crack which could cause a gas leak or distortion or malfunction of gas control These could cause a fire or explosion resulting in damage injury or death 5 Isolate gas control from gas supply line pressure during leak check Gas supply line test pressure determines how you isolate gas control At gas supply line test pressure equal to or less than 14 inches W C 1 2 PSI isolate gas control from gas supply line by sliding furnace gas control switch to off position Unexpected surges could damage gas control causing gas leak resulting in fire or explosion When test pressure is above 14 inches W C 1 2 PSI completely disconnect
37. of each standard Gas Fired Central Furnaces AGA ANSI 221 47 CAN CGA 2 3 Heating amp Cooling Equipment UL1995 CAN CSA C22 2 No 236 Natural Gas and Propane Installation Codes CAN CGA B149 1 CAN CGA B149 2 U S National Fuel Gas Code ANSI 2223 1 54 U S National Electrical ANSI NFPA Code 70 Standard for the Installation of Warm Air Heating amp Air Conditioning Systems ASHRAE NFPA 90 21 22 FOR MORE INFORMATION CONTACT THESE PUBLISHERS ANSI American National Standards Institute 1430 Broadway New York NY 10018 212 354 3300 ASHRAE American Society of Heating Refrigerating amp Air Conditioning Engineers 1791 Tullie Circle N E Atlanta GA 30329 404 636 8400 NFPA National Fire Protection Association Batterymarch Park Quincey MA 02269 617 770 3000 CSA Canadian Standards Association 178 Rexdale Boulevard Toronto Ontario Canada M9W 1R3 416 747 4000 FORM 145 24 1 1 908 29 REFRIGERANT CHARGES All units are charged at the factory with R22 Unit Cooling Capacity Refrigerant Charge BTU HR 12 000 25 18 000 3lb 24 000 ab 30 000 45 36 000 JOHNSON CONTROLS 30 WIRING CONNECTION DIAGRAM SKYPAK GAS FURNACE WIRING CONNECTION DIAGRAM FORM 145 24 IOM1 908 208 230 VOLT POWER SUPPLY FUSED DISCONNECT BY OTHERS h WHITE 208V RED TRF 230V ORANGE POWER VENTOR WHITE
38. ollow instructions in below Measuring duct work static pressure Place slope gauge near furnace where level and adjust scale to read 0 00 inches W C Insert one static pressure tap into the supply air plenum Insert other static pressure tap in return air duct on the air entering side of the filter Connect pressure tap attached to supply air duct or warm air supply plenum to positive pressure side of slope gauge Connect pressure tap attached to return air duct to negative pressure side of slope gauge Start blower Heating speed blower can be run by jumping terminals and 24 volt terminal block located on the Control Module Cooling speed blower can be run by jumping terminals R and Y on 24 volt terminal block located on the Control Module 19 On cooling speed there will be a 4 sec ond on delay before the blower will start and a 100 second off delay before the blower will stop 6 With blower running read ductwork static pressure from slope gauge 7 Ductwork static pressure should not exceed 0 3 inches W C in order to ensure proper volume of airflow 8 Remove jumper wire from 24 volt terminal strip Remove pressure taps and seal holes in duct work Failure to seal holes could result in reduced system performance 26 MEASURING AIR TEMPERATURE RISE Factory Settings for Blower Speeds Te Heati li Unit Model emp eating Cooling Rise F Cycle Cycle GAD20121
39. on charges prepaid and which on examination proves to have been thus defective under normal domestic use not exceeding the fuel rating The defective part should be returned through a qualified servicing dealer Upon warranty determination the replacement part will be shipped freight collect and assumes the unexpired portion of this Limited Warranty When a defective part can be repaired or replaced Johnson Controls shall not be obligated to repair the entire unit or any part thereof other than the defective part This warranty applies only to the original homeowner and is subject to the terms and conditions hereof COMPRESSOR FIVE YEAR LIMITED WARRANTY In addition to the One Year Limited Warranty Johnson Controls warrants the compressor to be free from defects in workmanship or material for a period of five 5 years from the date of original installation If a compressor fails during this five year period a new com pressor will be supplied The customer will be responsible for freight costs from our factory for delivery of the replacement compres sor and also for the return of the defective compressor which may be required under the terms of the Warranty Labor and any other expense involved in replacing the compressor is not covered by this Warranty HEAT EXCHANGER TEN YEAR LIMITED WARRANTY In addition to the One Year Limited Warranty Johnson Controls warrants the heat exchanger to be free from defects in workmanship for a period of te
40. onnel It is expected that this individual possesses independent training that will en able them to perform their assigned tasks properly and safely It is essential that prior to performing any task on this equipment this individual shall have read and understood this document and any referenced materials This individual shall also be familiar with and comply with all applicable governmental standards and regulations pertaining to the task in question SAFETY SYMBOLS The following symbols are used in this document to alert the reader to areas of potential hazard ardous situation which if not avoided will result in death or serious injury DANGER WARNING indicates a potentially haz ardous situation which if not avoided could result in death or serious injury WARNING DANGER indicates an imminently haz CAUTION identifies a hazard which could lead to damage to the machine damage to other equipment and or environmental pollution Usually an instruction will be given together with a brief expla nation NOTE is used to highlight additional in formation which may be helpful to you NOTE All wiring must be in accordance with published specifications and must be performed ONLY by qualified service personnel Johnson Controls will not be responsible for damages problems resulting from improper connections to the controls or application of improper control signals Failure to follow this will void the manufactu
41. ot of gas Example Assume it took 56 25 seconds for one cu bic foot of gas to flow and heating value of 1 000 BTU CU FT 1 000 x 3 600 56 25 64 000 Btuh Gas Input If you left no other pilots on this is the furnace gas input If you left water heater dryer or range pilots on allow for them in calculating correct furnace gas input A quick way is to allow 1 000 Btuh for a water heater Allow 500 Btuh for dryer and 500 Btuh for each range burner pilot JOHNSON CONTROLS FORM 145 24 IOM1 908 Example If you left gas water heater dryer four range burner pilots and one oven pilot on allow Water heater pilot 1 000 Btuh Dryer pilot 500 Btuh 4 range burner pilots 2 000 Btuh 1 range oven pilot 500 Btuh 4 000 Btuh Subtracting 4 000 Btuh from 64 000 Btuh mea sured above equals 60 000 Btuh This would be the correct furnace gas input after allowing for pilots left on 10 Manifold pressure may be adjusted within the range of 3 2 inches W C to 3 8 inches W C to get rated input If you cannot get rated input with manifold pressure within the allowable range you will need to change orifices See Section 23 11 Turn off gas Remove 1 8 pipe manual shut off valves you used Install 1 8 pipe plugs in gas control inlet and outlet pressure taps Tighten to torque of 50 inch pounds Turn on gas Check both pipe plugs for gas leaks Use a commercial soap solution made for leak detection B Propane LP
42. ove if within 10 feet 3 horizontally Clearance above paved sidewalk or paved driveway located on public 7 feet 2 13m T 7 feet 2 13m property Clearance under veranda porch deck or balcony 12 inches 30 cm 1 In accordance with the current CSA B149 1 Natural Gas and Propane Installation Code 2 In accordance with the current ANSI Z223 1 NFPA 54 National Fuel Gas Code T Avent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings Permitted only if veranda porch deck or balcony is fully open on a minimum of two sides beneath the floor CLEARANCE IN ACCORDANCE WITH LOCAL INSTALLATION CODES AND THE REQUIREMENTS OF THE GAS SUPPLIER AND THE MANUFACTURER S INSTALLATION INSTRUCTIONS DEGAGEMENT CONFORME AUX CODES D INSTALLTION LOCAUX AUX EXIGENCES DU FOURNISSEUR DE GAZ ET AUX INSTRUCTIONS D INSTALLATION DU FABRICANT 26 JOHNSON CONTROLS FORM 145 24 IOM1 908 LIMITED WARRANTY RGAC SGAC FURNACE AIR CONDITIONER Johnson Controls warrants this product to be free from defects in workmanship or material for a period of one year from date of original installation or 18 months from date of shipment whichever comes first Johnson Controls obligation under this Warranty is LIMITED to repairing or replacing at our sole option at our factory any part thereof which shall be returned to our factory transportati
43. p B New orifice size 2 000 to 4 500 feet To accomplish altitude derate an orifice kit contain ing the required natural gas orifices is available through your furnace supplier for Canadian Instal lations only Asimilar propane LP gas orifice kit is also available Individual orifices are also available in a convenient lot size Use only the designated orifices to assure proper performance The natural gas orifice changes to 2 05 mm while the propane LP orifice changes to 1 30 mm JOHNSON CONTROLS REMOVE SCREWS Fig LD13390 9 CHANGING ORIFICES C Changing orifices Before changing orifices turn off elec trical power and gas Failure to do so could result in electrical shock or gas leak resulting in damage injury of death Set room thermostat to its lowest or off setting Turn off electricity at electrical disconnect switch next to furnace Turn off manual shut off valve in gas supply line just ahead of furnace 4 Move gas control slide switch to OFF position 10 11 12 13 14 15 Starting with burner farthest from gas control remove burner screws and burners Burners overlap Burner farthest from gas control is on top See Figure 9 Remove original gas orifices Hand tighten new orifices into manifold do not cross thread Then tighten to torque of 50 inch pounds Replace burners in reverse order from instructions in Step 5 Check burner
44. pen there must be 30 inches clearance to any obstruction to allow sufficient ac cess for service and the replacement of parts See Sections 10 amp 12 regarding return air duct connections to the unit and provision for service access The unit shall not be installed directly on carpeting tile or other combustible material other than wood flooring When installed in a residential garage the entire burner heat exchanger sec tion of the furnace must be at least 18 inches above the floor The unit must be located or protected or avoid physical damage by vehicles B VENTING REQUIREMENTS The unit is approved as a DIRECT VENT APPLI ANCE Combustion air and the discharged flue gas products are drawn and discharged directly to the outside of the building through the wall sleeve DO NOT CONNECT THIS FURNACE TO ANY FLUE PIPE OR CHIMNEY The location of the unit side wall vent termination with respect to other wall penetrations must com ply with the applicable requirements of the U S National Fuel Gas Code ANSI Z223 1 NFPA 54 or the Canadian Natural Gas and Propane Installation Code CSA B149 1 The minimum required clearances to the flue vent termination are summarized in Section 32 DIRECT VENT TERMINAL CLEARANCES Review this sec tion thoroughly prior to determining the final location of the furnace JOHNSON CONTROLS SKYPAK WALL SLEEVE GRILLE VENT TERMINATION LOCATION 4 1 2 Be i
45. rer s warranty and cause serious damage to prop WARNING erty or injury to persons gt 1 N JOHNSON CONTROLS FORM 145 24 IOM1 908 OF THIS DOCUMENT In complying with Johnson Controls policy for continu ous product improvement the information contained in this document is subject to change without notice While Johnson Controls makes no commitment to up date or provide current information automatically to the manual owner that information if applicable can be obtained by contacting the nearest Johnson Controls service office It is the responsibility of operating service personnel as to the applicability of these documents to the equipment in question If there is any question in the mind of oper ating service personnel as to the applicability of these documents then prior to working on the equipment they should verify with the owner whether the equipment has been modified and if current literature is available work on this type of equipment Failure to comply with this requirement could expose the worker the equipment and the building and its inhabitants to the risk of injury or property damage Work on this equipment should only be done by properly trained personnel who are qualified to The instructions are written assuming the individual who will perform this work is a fully trained HVAC amp R journeyman or equivalent certified in refrigerant handling and recovery techniques and
46. s detailed in Sections 5 6 amp 7 D Combustion products must be discharged outdoors Connect this furnace to the approved factory sup plied vent system only Vent installation must be as specified in Section 8 of these instructions E Never test for gas leaks with an open flame Use acommercial soap made specifically for the detec tion of leaks to check all connections as specified in Section 13 of these instructions F Always install furnace to operate within the furnace s intended temperature rise range with a duct system that has an external static pressure within the allowable range as specified in Sections 10 amp 26 of these instructions See rating plate G When a furnace is installed so that supply ducts carry air circulated by the furnace to areas out side the space containing the furnace the return air shall also be handled by duct s sealed to the furnace casing and terminating outside the space containing the furnace H A gas fired furnace for installation in a residential garage must be installed as specified in Section 6 of these instructions I This furnace is NOT to be used for temporary heat ing of buildings or structures under construction 3 MEETING CODES This furnace complies with American National Stan dard ANSIZ21 47 CSA 2 3 Gas Fired Central Fur naces and is certified for operation with either natural gas or propane LP gas for indoor installation in a building constructed on site
47. t not be loose and must not have holes or cracks 3 All gas pipes leading to furnace 4 All electrical wiring and connections including electrical ground JOHNSON CONTROLS FORM 145 24 IOM1 908 5 All supply air and return air ducts for obstructions air leaks and loose insulation 6 Blower housing motor and wheel air filters and draft inducer motor Blower motor and inducer motor do not require oiling A qualified service technician should follow these steps to remove the indoor circulating blower as sembly a Disconnect room thermostat wires from 24 volt terminal strip on Control Module b Locate the five blower motor wires that feed through the casing hem Disconnect the wires from the Control Module Label blower motor wires before re moval from the Control Module to ensure proper replacement NOTE Remove blower door Pull blower motor wires through casing hem Remove screws holding blower assembly to blower deck f Slide blower assembly out of unit cabinet g After cleaning blower assembly re assemble in reverse order making sure speed selections are in their original positions 7 Assure that the furnace is operating properly and safely 28 GETTING OTHER INFORMATION amp PUBLICA TIONS These publications can help you install the furnace You can usually find these at your local library or buy them directly from the publisher Be sure to consult current edition
48. th two 10 x inch self drilling hex head sheet metal screws using the pilot holes provided A roll of 1 inch wide x inch thick self adhesive sponge rubber gasket is packed in the blower compartment of the Skypak unit to be used for sealing between the wall sleeve and the unit Be fore moving the unit into final position apply the self adhesive gasket to all mating flanges on the wall sleeve Ensure to apply gasket material to the horizontal divider panel flange between the top and bottom sections of the wall sleeve Apply two layers of gasket tape at this location to ensure a satisfactory seal Should this joint not have a good seal rainwater may accumulate in the bottom of the unit Apply gasket material to the top surface of the horizontal lip located at the bottom of the wall sleeve WALL SLEEVE GASKET UNIT UNIT LEVELING LEG 1 RAISE UNIT BY MEANS OF LEVELLING LEGS UNIT FLANGE MUST CLEAR BOTTOM ANGLE OF WALL SLEEVE FORM 145 24 IOM1 908 Raise the unit by screwing down the three level ing screws until the flange at the bottom of the condenser is above the flange at the bottom of the wall sleeve Move the unit forward until the unit contacts the wall sleeve and makes a seal with the gasket on the wall sleeve Lower the unit by means of the three leveling legs until the unit bottom flange is resting on the wall sleeve bottom flange and the gasket is compressed Then use the front two leveling screws on
49. ts of the frame clipped into position If there is difficulty getting the front vertical piece installed Remove the entire filter frame and trim off any burns left where the opening was snipped out ALTERNATIVE FILTER ARRANGEMENTS 1 1 ton units only a filter frame to hold a 14 x 20 x 1 inch disposable filter may be fitted to the front of the blower compartment in place of the access door The filter frame and a section of the return duct con nected to it must be easily removable to allow room for removal of the blower and motor assembly BOTTOM RETURN PLENUMS When a bottom return plenum is used snip out the prepunched 11 x 20 inch opening in the bottom of the cabinet On bottom return applications a wire frame and media retaining clips are provided for installation of a hammock style filter MEDIA SIZES FOR BOTTOM RETURN Unit Size Filter Size R Series 25 x 26 x 1 S Series 25 x 28 x 1 There are no filters supplied with this unit The installing contractor must provide and install the recommended size filters LD13384 1013385 10 FORM 145 24 IOM1 908 13 INSTALLING GAS PIPING could result in serious injury death or property damage Never test for gas leaks with an open flame Use a commercially available soap solution FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly made specifically for the detection of leaks to check all connections A
50. ube water manometer to gas control outlet manifold pressure tap Set room thermostat to its highest temperature Turn on electricity at electrical disconnect switch located next to furnace Draft inducer should run and pilot igniter should glow but pilot burner should not light Manifold pressure should remain at zero Turn off electricity at electrical disconnect switch located next to furnace Move gas control slide switch to ON position FORM 145 24 IOM1 908 8 Turn on electricity at electrical disconnect switch located next to furnace Draft inducer should run pilot igniter should glow and pilot burner should light and ignite main burners Wait 30 seconds af ter main burner ignition for main blower to start To purge gas lines it may be necessary to wait several minutes for the pilot burner to light NOTE 9 Cycle electrical disconnect switch next to furnace on and off Watch at least three ignition cycles Pilot should ignite main burners smoothly 10 Burner flames should look the same with circula tion blower on and off If not move gas control slide switch to OFF position 11 Turn off electricity disconnect switch located next to furnace Disconnect all room thermostat wires at Control Module terminal strip To start blower on heating speed jump terminals and Turn on electricity at electrical disconnect switch next to furnace 12 Check for air leaks between bulkhead a
51. um operating voltages and fuse sizes are listed on the unit rating plate The power leads must be brought to the entry knockouts provided in the unit control box through a customer supplied fused disconnect switch placed within sight of the unit Ensure that the furnace shall be installed so that all wiring and electrical components are protected from water 16 INSTALLING ELECTRICAL WIRING Provide furnace with its own separate electrical circuit means of circuit pro tection and electrical disconnect switch Follow current National Electrical Code ANSI NFPA 70 CSA C22 1 C E C Part 1 and state and local codes Failure to provide these shut off means could cause electrical shock or fire resulting in damage injury or death Furnace must have proper electrical ground Failure to provide a proper electrical ground could cause electrical shock or fire resulting in damage injury or death All field connected wiring shall be suit able for a minimum 63 F 35 C tempera ture rise NOTE Field and internal wiring diagrams are attached to the back of the compressor compartment access door Select a location for room thermostat that is away from supply air registers on draft free interior wall and not near lights television direct sunlight or other heat sources Install thermostat following field wiring diagram Figure 5 11 ELECTRICAL BOX NOTE s FUSE DISCONNECT OR CIRCUIT BREAKER AND THERMOST
52. w for reinstallation Turn inner adjustment screw clockwise to decrease pilot flame counter clockwise to increase pilot flame Install cover screw and tighten to torque of 5 inch pounds to prevent gas leakage 5 Shut OFF furnace 6 If you will not be checking gas input now turn off gas Use manual shut off valve in gas supply line just ahead of furnace Remove shut off valve from gas control inlet pressure tap Install pressure tap plug Turn on gas 7 Check pilot adjustment cover screw and gas inlet pressure tap plug for gas leaks Use a commercial soap solution made for leak detection 21 ADJUSTING MANIFOLD PRESSURE Correct manifold pressure is necessary for proper ignition and burner operation Use a U tube water manometer to measure actual gas pressure Failure to accurately adjust pressure could cause heat exchanger failure asphyxiation fire or explosion resulting in damage injury or death 15 A Normal manifold pressures gas control outlet pressures Gas Supply 3 5 inches W C 9 5 inches W C Natural Gas Propane LP Gas Do not set manifold pressure for pro pane LP at 11 0 inches It could cause heat exchanger failure CAUTION Check gas supply pressure first following instructions in Section 20A B Connect a U tube water manometer to measure manifold pressure 1 Turn OFF gas at manual shut off valve located in gas supply line just ahead of furnace
53. x 16 Installing Electrical Wiring x 17 Sequence of x SUPPLY AIR WALL SLEEVE EVAPORATOR COIL ACCESS DOOR CONDENSER SECTION MAIN A ELECTRICAL ACCESS DOOR GAS HEAT SECTION ACCESS DOOR EVAPORATOR BLOWER ACCESS DOOR LD13220 4 JOHNSON CONTROLS assure both safe and proper operation please care fully follow the instructions in this manual to correctly install this new furnace INSTALLER After installing furnace en sure that the user receives 1 Users Information Manual Maintenance amp Service Manual 2 Operation amp Installation Instructions 3 Warranty Information Card USER Your furnace installer should give you the above important documents relating to your furnace Keep these as long as you keep your furnace Pass these documents on to later furnace purchases or Users Throughout this Installer s Information Manual we fre quently use the word you when referring to the person responsible for application installation and service of your furnace Please remember to have only qualified service technicians perform these services IMPORTANT SAFETY NOTE After installing the fur nace show the user how to turn off the electricity to furnace Point out control and switch locations for turn ing off the electricity Go over Section 3 and 5 of Users Information Manual and Pag
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