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INSTALLATION MANUAL - Northern Tool + Equipment

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1. 26 Gas PIPING eura aano usd eb a vega 10 Direct Vent Air Intake Connection and Vent Connection 27 Elecifical VVIDInIQ seric odes uw ore ps 12 Combustion Airflow Path Through The Furnace Casing 2 Thermostat Chart Single Stage Air Conditioners Outside and Ambient Combustion 28 with Two Stage Variable Speed Furnaces 13 Attic and Crawl Space Combustion Air Termination 29 Thermostat Chart Single Stage Heat Pump with Two Stage Gus VANE ad n VUE E ee RM TR 32 Variable Speed Furnace Hot Heat Pump or Conventional 14 Reading Gas Pressure 33 Thermostat Chart Two Stage AC with Furnace Control Board 33 Two Stage Variable Speed Furnace 15 Furnace Control Event Schedule 37 Thermostat Chart Two Stage HP with Two Stage Variable Wiring Diagram 39 Speed Furnace Hot Heat Pump or Conventional 16 LIST OF TABLES Unit Clearances to Combustibles 4 Equivalent Length of Fittings 24 Coil Projection Dimensions PC Series Coils 7 Combustion Air Intake and Vent Connection Cabinet and Duct Dimensions 9 size at Furnace All Models ntt eee 24 Recommended Fil
2. n Y PN Y nd A M s LN mm gt D od Dod Lond L RESIDENTIAL GAS FURNACE MODELS TM9V MP 96 AFUE Two Stage Variable Speed Multi position AU T ML in afl BEE HLD TIIT M ET T EF HN NE FoF y x REGIS m XA ISO 9001 Certified Quality Management System LIST OF SECTIONS SAFELY ae Eu A Eu Ora do 2 COMBUSTION AIR and VENT SYSTEM 23 DUCTWORK xx px e d de da n x 5 START UP AND ADJUSTMENTS 30 METERS ra d da EUR 9 SAFETY CONTROLS ar RC RR OR e 35 GAS PIPING 10 NORMAL OPERATION AND DIAGNOSTICS 35 ELECTRICAL POWER 11 REPLACEMENT PARTS LIST 38 CONDENSATE PIPING AND FURNACE REPLACEMENT PART CONTACT INFORMATION 38 VENTING CONFIGURATION 17 WIRING DIAGRAM 39 LIST OF FIGURES Duct Attachment 5 Typical Condensate drain vertical installation 17 Vertical Applications 6 Typical Combustion Pipe Drain Tee
3. jou SU esneo YOIUM pue 108 02 sdoo ou zey os eq pjnous sesou HuljnoJe J sDBuiuedo pesn un deo oj euns eq p nb seDueuo Huno esou ueuM FIGURE 25 Downflow Configuration Johnson Controls Unitary Products 20 438335 UIM C 1209 uonisod Sjeulqeo JOPIM pepiAoJd SI 120 SIU 0 9504 uoisuojxe esou 310 Bully 06 94 0 uonoeuuoo9 ojesuepuoo uonisod 514 esou 9 ules ojesuepuoo 9 SV YSONANI l4d 1l WLNOZIYOH UOlJISOd SIU esou JON UOIISOd 510 0 8509 06 94 ojesuepuoo Sjeuiqeo JOPIM iM s yey esou 4eBuo eu eJlnbaJ 3 LON uonisod SIU eJnsseJd per euint SIU 0 MO 138IV ea3oridNi 1491 IVLNOZIHOH jou esneo YOIUM pue 910 sdoo ou zey os eq pjnous sesou J sDBuiuedo pesnun deo eq p nb seDueuo Hun
4. W W1 W1 OUT Emergency Heat Emergency Heat Emergency Heat First Stage Heat First Stage Heat W2 W2 W2 OUT Third Stage Heat Second Stage Heat Second Stage Heat RC Y Y2 Y2 OUT 24 Volt Hot Second or Full Eas Second Stage Cool XFMR Stage Compressor Compressor O B Reversing Valve Reversing Valve Reversing Valve Reversind Valve a Reversing Valve 9 Energized in Cool Energized in Cool 9 Energized in Cool L L L X L X L Malfunction Light Malfunction Light Malfunction Light Malfunction Light Malfunction Light Y2 Y2 Y2 Second Stage Second Stage Second Stage Compressor Compressor Compressor a We i Auxiliary Heat Second Stage Heat Abc Elea Auxiliary Heat br DHUM BSG Dehumidification Bonnet Sensor Optional xternal Humidistat Bonnet Sensor Kit BS t Optional L Bonnet Sensor 51 37309243000 FIGURE 19 Thermostat Chart Single Stage Heat Pump with Two Stage Variable Speed Furnace Hot Heat Pump or Conventional 14 Johnson Controls Unitary Products 438335 UIM C 1209 AC 24C Two Stage Air Conditioner Two Stage Variable Speed Furnace ID MODELS PV 8 9 F L 8 9 V G L 8 9 V THERMOSTAT TM 8 9 V PP32U71124 ele TWO STAGE PP32U72124 VARIABLE SPEED AIR FURNACE CONDITIONER TWO STAGE VARIABLE SPEED FURNACE CONTROL C C C 24 Volt Common 24 Volt Common 24 Volt C
5. 18 Flange de ii di RC dl RE ntc 6 Upflow Configuration 19 Horizontal Right Application 6 Downflow Configuration 20 Horizontal Left Application 6 Horizontal Left Configuration 21 PC Series Upflow Coil Installation 7 Horizontal Right Configuration 22 Horizontal Left or Right application Right Shown 7 Dimensions s eseas TET tT QUITO OTI 23 Combustible Floor Base 7 Home 25 Horizontal Application 7 Termination Configuration 1 Pipe 26 Typical Attic Installation 8 Termination Configuration 2 Pipe 26 Typical Suspended Furnace Crawl Space Installation 8 Termination Configuration 2 Pipe Basement 26 Venting deer 8 Double Horizontal Combustion Air Intake Dimensions ha 9 and Vent Termination 26 Side Return Cutout Markings 9 Double Vertical Combustion Air Intake CAT de ii sect cd tactic nd thine tab 10 and Vent Termination
6. Volt Hot Cool XFMR Cool XFMR Y2 Y2 Y2 Y2 Second Stage Second Stage Second Stage Second Stage Compressor Compressor Compressor Compressor X L Malfunction Light DHUM Dehumidification FIGURE 18 Thermostat Chart Single Stage Air Conditioners with Two Stage Variable Speed Furnaces Johnson Controls Unitary Products SINGLE STAGE AIR CONDITIONER C 24 Volt Common Compressor Contactor 13 438335 UIM C 1209 HP 15A Single Stage Heat Pump Two Stage Variable Speed Furnace Hot Heat Pump or Conventional ID MODELS OD MODELS PV 8 9 YZB F L 8 9 V YMB G L 8 9 V H 3 THERMOSTAT THERMOSTAT THERMOSTAT TM 8 9 V BP21H50124 DN22U00124 BN21H00124 2 70124 DP21H40124 FURNACE HEAT PUMP DN21H00124 C C C 24 Volt Common 24 Volt Common 24 Volt Common 24 Volt Common 24 Volt Common Y1 1 Y Y1 Y1 f Single Stage EE Single Stage First Stage Compressor First Stage Compressor First Stage Compressor Compressor Compressor R R R R R 24 Volt Hot Heat XFMR 24 Volt Hot 24 Volt Hot 24 Volt Hot 24 Volt Hot G G G G Fan Fan Fan Fan E
7. NOT13S YAILNVHD N3 39v113 1001 1 S JONVSSINd 30 sn312vj NG YNAILVWYOASNVUYL dd S1i34uVddV 13 30 JOVIIS S1i34VddV 13 314150 1 30 3977113 VAO YNINYOISNVYL 11 NOISS3Hd 30 YNALVLAWNOD NOI LVSN3QNOO 30 11000949 die NOISS3Hd 30 YNALVINWWOD NG JOVLS JWAIXNIG die NOISS3 d 30 YNILVLIAWNWOD NG 3OVIS YIIWAYd dli JHINVD 3102 1N3W31nOu 30 YNALVINWWOD ZSO 11080 3102 LNAWF1NON 30 uniivinWWOD SOU JIVdIONIYd JLIW 7 30 YNALVLAWWNOD Sl NOIIIN9I Q 1 2 30 3113NOYld V ufiS 514 91 3120V1d323U 13 35184 65 6 3114314400S 30 YNALOW 37 ufiOd 51 G V 312V1d3238H 13 3518 4 85 84 3183144 0 38 YNALOW 31 YNOd 51 91 V 3129143234 13 35149 95 94 JdVdNOS V1 unS fv 514 V 375V1d323U 13 35184 GS Sd NOILONGNI NV 514 V 3120V1d303H 13 3S Ud WS bd JONVHD JOVIYNS 30 NOIIINO9I Q Sld V 312V1d323U 13 35149 S amp d NOILIN9I Q 31041NOO 30 ALLINOW d V ufiS 514 G V 312V1d3203H 13 35144 eS ed NOILINO9I Q JIOYLNOD 30 3i11300vV d ufiS Sid 21 V 312V1d3234 13 3S1Hd 15 14 JONWHD JIVINNS 30 NOILINOI NOI 279 30 3dWdNOS AD NOLINOFSIG 30 YNALVINWWOD 50 940 6 wig 1 con Ip 18 nua Cii SIRE 918 9 dim sc ae 30N3931 LHM 1 ES IHM 6 134 EIN 134 9 38431 NJ nud 61 eal 1 QN9 318 134 91 x18 il N y18 85 84 oo JN11 jo oo ASII yoron oh 8 Bc L Clo
8. ONId Nid 91 95 94 JAIWA 599 NO 13105 ONId Nid GS Gd YOLOW 4u32nQ0NI NO 137905 9 Nid vS vd UOLINOI JOVAYNS LOH NO 131905 9114 S d QuvO8 JDVNYNA NO 13105 ONId Nid G eS ed QHuVO8 IOYLNOD 3OVNUfMj NO 137205 ONId Nid 2 15 14 311 91 JVJYNS LOH NOI JAIVA 579 AD HILIMS L23NNO2SIQO 50 CAIA 118 940 30 uniidv2 9051 35 3WV4 9 035 4 5 038 Q4 18 034 4 038 Gp dt 2508 1508 1 418 SS Sd 3SIVNunOJ V 30 37081NO2 1081NO2 32vNunj 1N34308020V8 30 INNVYOVIC INV3DVIG NOLLOANNOD wv LHM mj g JAIVA SV9 3 NOI123NNOO 1715 1 S 104 1NO2 83NOILIIGNOO YIV OL e e 1VLSOWH3Hl 9N11002 J9VLS 2 9 9 519 39715 ONZ ONILVIH JOVIS 2 LO 31VSN31QNOOD 39915 LSI z E 825 168 d dil Az gt m SV8 403108 CI VH H9IH LONGNI 4031V21 JIQIWOH ual JIOINWAH 9313 3811141 2v3 YOLOW d alo 438018J ATO 1300 S m 318314400S 5 0002 0091 m 30 un310W ae 1 310N YIOA 09 1 6511 NOILIVLINJNI 1V sa JLON 335 09 1 GII AlddfS YIMOd LYJANO LNJNJTIVNYON O N 3184 30 YNILVLNAWWOD HOLIMS 5000 MS O N 3H VIN3A313 3 WVUOVIG IWV3DVIG WaAddv T NYO 3949108 119914 dud 183A N39 9 QV NYG NUE TONVTG JLI
9. coil drain pans are to be installed in the upflow horizontal configura tion then extra 2 5 1 cm minimum spacing may be needed to ensure against drain pan distortion On all installations without a coil a removable access panel is recom mended in the outlet duct such that smoke or reflected light would be observable inside the casing to indicate the presence of leaks in the heat exchanger This access cover shall be attached in such a manner as to prevent leaks Johnson Controls Unitary Products 438335 UIM C 1209 The duct system must be properly sized to obtain the correct airflow for the furnace size that is being installed Refer to Table 7 or the furnace rating plate for the correct rise range and static pressures If the ducts are undersized the result will be high duct static pres sures and or high temperature rises which can result in a heat exchanger OVERHEATING CONDITION This condition can result in premature heat exchanger failure which can result in personal injury property damage or death DUCT FLANGES Four flanges are provided to attach ductwork to the furnace These flanges are rotated down for shipment In order to use the flanges remove the screw holding an individual flange rotate the flange so it is in the upward position and reinstall the screw then repeat this for all 4 flanges If the flanges are not used they must remain in the rotated down posi tion as shipped Factory
10. B o 42 Mi 78 6C 83 884 872 D 985 8 amp 6 1id9 66 C 78 a 7 58 D 100020 Jumper Settings COOL Tap ADJ Tap 2019 1290 2008 1397 A B 1790 1174 1687 1131 1 i95 185 1630 1050 B A o 182 164 8 A 1x9 88 12 JH C B 9 995 i0 94 B 9 308 70 1 5 392 D B8 169 770 1394 938 C A y 8986 88 272 808 D 1062 885 125 88 C C 86 Hi 718 D 6 060812 Jumper Settings 1288 745 130 88 B 80 1239 80 C NMy i4 87 l3 768 D My 80016 Jumper Settings HEAT Tap ADJ Tap 1684 1095 1785 117 1542 1585 1047 1426 1420 1289 1201 100020 Jumper Settings HEAT Tap ADJ All CFM s are shown at 0 5 w c external static pressure hese units have variable speed motors that automatically adjust to provide constant CFM from 0 0 to 0 6 w c static pressure From 0 6 to 1 0 static pressure CFM is reduced by 2 per 0 1 increase in static Operation on duct systems with greater than 1 0 w c external static pressure Is not recommended NOTE At some settings LOW COOL and or LOW HEAT ai
11. If the heating value of your gas is significantly different it may be necessary to replace the NOTICE DO NOT set manifold pressure less than 3 2 w c or more than 3 8 W c for natural gas at sea level If manifold pressure is outside this range change main burner orifices NOTICE If orifice hole appears damaged or it is suspected to have been redrilled check orifice hole with a numbered drill bit of correct size Never rearill an orifice A burr free and squarely aligned orifice hole is essential for proper flame characteristics A CAUTION DO NOT bottom out gas valve regulator adjusting screw This can result in unregulated manifold pressure and result in excess over fire and heat exchanger failures Verify natural gas input rate by clocking meter 1 Turn off all other gas appliances and pilots 2 Run furnace for a minimum of minutes in heating operation 3 Measure time in sec for gas meter to complete 1 revolution and note reading The 2 cubic feet dial provides a more accurate mea surement of gas flow 4 Referto Table 15 for cubic feet of gas per hour 5 Multiply cubic feet per hour by heating valve BTU cu ft to obtain input If clocked rate does not match the input rate from the unit nameplate follow steps in next section to adjust the manifold pressure Repeat steps 2 5 until correct input is achieved A CAUTION Be sure to relight any gas ap
12. Maximum Supply Air Temperature specified in these instructions and on the fur nace rating plate Under NO circumstances can the furnace be allowed to operate above the Maximum Supply Air Temperature Operating the furnace above the Maximum Supply Air Temperature will cause premature heat exchanger failure high levels of Carbon Monoxide a fire hazard personal injury property damage and or death BLOWER OFF DELAY JUMPER HI HEAT DELAY JUMPER CONTINUOUS FAN SPEED JUMPER STATUS STAGING LOW VOLTAGE OO ELLE uia TERMINALS BLOWER SPEED DOOO DEHUMIDISTAT JUMPER COOLING PROFILE JUMPER FIGURE 41 Furnace Control Board Johnson Controls Unitary Products 33 438335 UIM C 1209 Table 18 Air Flow Data HIGH LOW SPEED COOLING AND HEAT PUMP CFM 050812 Jumper Settings 85 130 88 A m o BB 78 1X8 o 80 A A 1026 301 88 B 889 641 599 642 8 6 787 585 874 597 712 557 D A 728 561 6n 529 0 0 16 Jumper Settings 8 A 188 A B 838 i595 100 B PB i60 1058 16i 1088 A A 1405 94 1 938 B A 4g 94 i7 998 A C 78 o i284 88 o C PB a 88 M5 82 B OC 88 97 88 D
13. PVC D2665 PVC DWV F891 PVC DWV Cellular Core D2261 ABS DWV or F628 Schedule 40 ABS Pipe cement and primer must conform to ASTM Standard D2546 PVC or D2235 ABS If ABS pipe is to be used any joint where ABS pipe is joined to PVC pipe must be glued with cement that is approved for use with BOTH materials Metallic materials must not be used for venting or air intake 5 Ifa flexible connector is used in the vent system it must be made of a material that is resistant to acidic exposure and to at least 225 F 107 2 C temperature Flexible connectors are also allowed in the combustion air pipe 6 All models are supplied with 2 5 1 cm vent connections When the pipe must be increased to 3 7 6 cm diameter the transition from 2 to 3 must be done as close to the furnace as possible For upflow models the transition from 2 to 3 should be done immedi ately above the furnace For downflow or horizontal models the transition from 2 to 3 pipe should be done immediately after exit ing the furnace 7 n Canada vents shall be certified to ULC S636 Standard for Type BH Gas Venting Systems 8 n Canada the first three feet 91 4 cm of the vent must be readily accessible for inspection 9 For single pipe systems it is recommended to install the combus tion air coupling provided and install approximately 18 of PVC pipe on the furnace 10 Minimum vent length for all models is 5 feet 1 5 m TABLE 8 Maximum Eq
14. The cooling airflow is set to pro vide 90 percent of the maximum CFM The heating and cooling airflows must be field adjusted to match the HVAC system at installation See Table 18 for the HEAT COOL and ADJ jumper settings to use for spe cific airflows Johnson Controls Unitary Products 438335 UIM C 1209 CFM Board Delay Taps Selection The set of jumper pins on the control board labeled DELAY are used to set the delay profiles for the furnace These can be chosen so as to maximize the comfort and sound levels for various regions of the coun try Tap A is the default profile It provides a 30 second ramp up from zero airflow to full capacity and a 30 second ramp down from full capacity back to zero airflow Whenever there is a change in airflow mode such as from low heat to high heat the motor will take 30 seconds to ramp from one speed to the other Tap B is the humid profile This profile is best suited for installations where the humidity is frequently very high during cooling season such as in the southern part of the country On a call for cooling the blower will ramp up to 50 of full capacity and will stay there for two minutes then will ramp up to 82 of full capacity and will stay there for five min utes and then will ramp up to full capacity where it will stay until the wall thermostat is satisfied In every case it will take the motor 30 sec onds to ramp from one speed to another Tap C is the dry profile This
15. driveway located on public property codes id the requirements of the gas supplier 12 80 5 cm or in accordance with local installation M Clearance under veranda porch deck or balcony 12 30 5 cm t T codes and the requirements of the gas supplier 1 In accordance with the current CSA B149 1 00 Natural Gas and Propane Installation Code 2 n accordance with the current ANSI Z223 1 NFPA 54 National Gas Code accordance with the current ANSI Z21 47 CSA 2 3 American National Standard T Avent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings tt 12 30 5 cm up from the bottom edge of the structure for Two pipe direct vent applications per ANSI Z223 1 NFPA 54 National Gas Code i Permitted only if veranda porch deck or balcony is fully open on a minimum of two sides beneath the floor and the distance between the top of the vent termina tion and the underside of the veranda porch or deck is greater than 12 30 5 cm as specified in CSA B149 1 00 A vent shall not terminate less than 12 30 5 cm above a grade level Any fresh air or make up inlet for dryer or furnace area is considered to be forced air inlet Avoid areas where condensate drippage may cause problems such as above planters patios or adjacent to windows where steam may cause fogging A terminus of a vent shall be fitted with a cap in accordance wit
16. 30 Seconds THERMOSTAT INDUCER IGNITOR MAIN VALVE HUMIDIFIER ELECTRONIC AIR CLEANER CIRCULATING BLOWER FIGURE 42 Furnace Control Event Schedule Johnson Controls Unitary Products 52 0 Post Purgel 90 120 180 SEC LOFF Selectable Fan Off Delay 3 438335 UIM C 1209 SECTION REPLACEMENT PARTS LIST REPLACEMENT PART CONTACT INFORMATION This is a generic parts list To request a complete parts list refer to the contact information below e Visit our website at www source1parts com for the following information 1 Search for a part or browse the catalog 2 Find a dealer or distributor 3 Customer Service contact information a Click on the Brand Links button b Click on the Customer Service button You can contact us by mail Just send a written request to Johnson Controls Unitary Products Consumer Relations 5005 York Drive Norman OK 73069 38 Johnson Controls Unitary Products 438335 UIM C 1209 WIRING DIAGRAM SECTION 8011 2 2867 NOLIVIN3NI IV 1 YNOd SYNALINOFSIG S31 ZISSINYNOS 34431 N3 351 N3I8 3813 1100 LNIWADVIdWIY 30 31NVSOdWOOD 31101 FYAIND 30 713 YNOd S31134VW 530 IN3W3103S SIYNLVYIMNIL 530 v YFLSISIY LNVANOd XNVIYILVW 23AV 3313 1 1100 1 1nOL FIYLVd FOVIANIY 3813 1100 39V114 31 IS XAVdGIDINAW 13 53002 2 f0 13 232 N3IQVNVO 2113 3002 8 f10 13 NID 1VNOILIVN 2313 3009 V
17. Refer to AIR SOURCE FROM OUTDOORS AND VENT 2 One permanent openings commencing within 12 30 5 cm of the AND SUPPLY AIR SAFETY in these instructions for top of the enclosure shall be permitted where the equipment has additional information and safety check procedure clearances of at least 1 2 54 cm from the sides and back and 6 2 The duct shall be either metal or a material meeting the class 1 15 2 cm from the front of the appliance The opening shall com requirements of CAN4 S110 Standard for Air Ducts municate directly with the outdoors and shall have a minimum free 3 The duct shall be least the same cross sectional area as the free area of area of the air supply inlet opening to which it connects a 1 square in per 3000 Btu per hour 6 45 cm per 0 879 kW 4 The duct shall terminate within 12 30 5 cm above and within 24 of the total input rating of all equipment located in the enclo 61 cm horizontally from the burner level of the appliance having sure the largest input b Not less than the sum of all vent connectors in the confined 5 A square or rectangular shaped duct shall only be used when the space required free area of the supply opening is 9 58 06 or 3 duct shall be least the same cross sectional area as the free larger When a square or rectangular duct is used its small dimen area of the air supply inlet opening to which it connects id ai 4 T
18. downflow or horizontal left installations FIGURE 3 Coil Flange FURNACE ASSEMBLY MC SERIES COILS ONLY MC coils are supplied ready to be installed in a horizontal position A horizontal pan is factory installed MC coils should be installed in all hor izontal applications with the horizontal drain pan side down A Mounting Plate 9 S FIGURE 4 Horizontal Right Application For horizontal left hand applications no conversion is required to an MC coil when used with a downflow horizontal furnace A mounting plate supplied with every coil should always be installed on the side desig nated as top side See Figures 4 amp 5 Mounting Plate FIGURE 5 Horizontal Left Application FURNACE ASSEMBLY PC SERIES COILS These upflow coils are designed for installation on top of upflow fur naces only If the coil is used with a furnace of a different size use a 45 transition to allow proper air distribution through the coil 1 Position the coil casing over the furnace opening as shown in Figure 6 2 Place the ductwork over the coil casing flange and secure 3 Check for air leakage between the furnace and coil casing and seal appropriately A CAUTION Do not arill any holes or drive any screws into the front duct flange on the coil in order to prevent damaging coil tubing See Figure 6 Johnson Controls Unitary Products Flexible Duct Collar Field Fabricated Ductwork Do not dril
19. fluid or other leak detection methods Take appropriate action to stop any leak If a leak persists replace the faulty component The furnace and its equipment shutoff valve must be disconnected from the gas supply during any pressure testing of that system at test pres sures in excess of 0 5 psig 3 45 kPa The furnace must be isolated from the gas supply piping system by closing the equipment shutoff valve during any pressure testing of the gas supply system IGNITION SYSTEM SEQUENCE 1 Turn the gas supply ON at external valve and main gas valve 2 Set the thermostat above room temperature to call for heat 30 3 System start up will occur as follows a The induced draft blower motor will start and come up to speed Shortly after inducer start up the hot surface igniter will glow for about 17 seconds b After this warm up the ignition module will energize open the main gas valve c After flame is established the supply air blower will start in about 30 seconds HOT SURFACE IGNITION SYSTEM Do not attempt to light this furnace by hand with a match or any other means There may be a potential shock hazard from the components of the hot surface ignition system The fur nace can only be lit automatically by its hot surface ignition system CALCULATING THE FURNACE INPUT NAT GAS Burner orifices are sized to provide proper input rate using natural gas with a heating value of 1030 BTU Ft 38 4 MJ m
20. furnace it is acceptable to use the primary heat exchanger tubes as a lifting point provided that the tubes are lifted at the front of the heat exchangers where attached to the vestibule panel Do not use the top return bend of the heat exchangers as lifting points as the tubes may shift out of position or their location brackets baffles IMPORTANT moving or lifting SAFETY REQUIREMENTS A CAUTION This product must be installed in strict compliance with the installa tion instructions and any applicable local state and national codes including but not limited to building electrical and mechanical codes Refer to the unit rating plate for the furnace model number and then see the dimensions page of this instruction for return air ple num dimensions in Figure 13 The plenum must be installed according to the instructions Provide clearances from combustible materials as listed under Clearances to Combustibles Provide clearances for servicing ensuring that service access is allowed for both the burners and blower Johnson Controls Unitary Products These models ARE NOT CSA listed or approved for installation into a HUD Approved Modular Home or a Manufactured Mobile Home This furnace is not approved for installation in trailers or recre ational vehicles Furnaces for installation on combustible flooring shall not be installed directly on carpeting tile or other combustible
21. in the ducts about six feet 1 83 m from the furnace where they will not be affected by radiant heat Increase the blower speed to decrease the temperature rise decrease the blower speed to increase the rise VARIABLE SPEED MOTORS The variable speed motor must be configured so the blower will provide a sufficient airflow so that the furnace operates with in the temperature rise range on the rating plate and within the application limitations shown in Table 7 in these Instructions WATER ADJ USTMENT OF FAN CONTROL SETTINGS COLUMN GAS Heating Indoor Fan Off Delay PRESSURE SHOWN 3 5 IN This furnace is equipped with a time on time off heating fan control The fan on delay is fixed at 30 seconds The fan off delay has 4 settings 60 90 120 and 180 seconds The fan off delay is factory set to 120 sec onds The fan off setting must be long enough to adequately cool the furnace but not so long that cold air is blown into the heated space The fan off timing may be adjusted by positioning the jumper on two of the four pins as shown in Figure 41 FIGURE 40 Reading Gas Pressure ADJ USTMENT OF TEMPERATURE RISE ADANGER The temperature rise or temperature difference between the return air and the supply heated air from the furnace must be within the range shown on the furnace rating plate and within the application limitations shown in Table 7 ELECTRICAL AND PERFORMANCE DATA The supply air temperature cannot exceed the
22. the ignition control pro vides a 17 second ignitor warm up period the gas valve then opens the gas starts to flow ignition occurs and the flame sensor begins its sensing function The blower motor will energize 30 seconds after the gas valve opens if a flame is detected Normal furnace operation will continue until the thermostat circuit between R and W is opened which causes the ignition system and gas valve to de energize and the burner flames to be extinguished The vent motor will operate for 15 seconds and the blower motor will operate for the amount of time set by the fan off delay jumper located on the control board See Figure 41 The heat ing cycle is now complete and ready for the start of the next heating cycle If the flame is not detected within 7 seconds of the gas valve opening the gas valve is shut off and a retry operation begins Also if the flame is lost for 2 seconds during the 10 second stabilization period the gas valve is shut off and a retry operation begins During a retry operation the vent motor starts a 15 second inter purge and the ignitor warm up time is extended to 27 seconds If the flame is established for more than 10 seconds after ignition during a retry the control will clear the ignition attempt retry counter If three retries occur during a call for heat the furnace will shut down for one hour If at the end of the one hour shut down there is a call for heat the furnace will initiate a normal star
23. velocity through throwaway type filters may not exceed 300 feet per minute 91 4 m min All velocities over this require the use of high velocity Some accessories such as electronic air cleaners and pleated filters media may require a larger side opening Follow the instructions 2 Do not exceed 1800 CFM using a single side return and a 16x25 filter For supplied with that accessory for side opening requirements Do not CFM greater than 1800 you may use two side returns or one side and the cut the opening larger than the dimensions shown in Figure 13 bottom or one side return with a transition to allow use of a 20x25 filter Johnson Controls Unitary Products 9 438335 UIM C 1209 HORIZONTAL APPLICATION A CAUTION Horizontal Filters All filters and mounting provision must be field supplied All installa tions must have a filter installed Any branch duct rectangular or round duct attached to the plenum must attach to the vertical plenum before the filter The use of straps and or supports is required to support the weight of the external filter box Downflow Filters Downflow furnaces typically are installed with the filters located above the furnace extending into the return air plenum or duct Any branch duct rectangular or round duct attached to the plenum must attach to the vertical plenum above the filter height Filter s may be located in the duct system external to the furnace using an external d
24. 118 oo 38431 NI oo 11 831344 0 YNFLOW vS bd 39931 3 1 ___ ______ J mS Moin A GR dC TER LI Hal p JONVHD 32V JunS LHM 2 25 24 A 30 11 91 u31IN9I 32VjUnS LOH LHA I C 103N VOAS ILI ININ OVAG II LHM 30 INID 09 INIT 2VASII y18 418 311804 30 YNFLVINWNOD LHM MS O N 8000 dd AINO 1300N one Wi 0002 0091 D E n Q312310ud SYOLOW 63114915 YIMOd 11V 803 SI23NNOOSIQ 3Ql OUd GAGNNOYD ATYAdOYd 18 LSAW SIN3NOdWOO 1N3W32V ldiM 11V AINO SYOLINGNOD YAddOD 804 JTBVLINS SYOLIINNOD 234 601 4122 15937 1Y 30 ONILVY 3ufiVUddWil V ONIAVH 1 1 HLIM 030V1d34 38 LSAW LI Q32v1d3H 38 LSAW 32VNufj JHL HLIM 03114905 Sv 34IM 1VNIOIHO JHL JO 3 3002 A112 80 1V201 2 YO ONV 2320 3005 2313 NVIQVNYO 8 YO ONV 23N 3005 2313 IVNOIIVN V d3d 9 07313 11V SALON 83AHOJSNVHI YOLIVA YAMOd dd S391430 ONY ONIYIM 07313 321 30 ONIYIM AYOLOVG VAO u3 HOJSNVHI LI 31VSN3O0NOO HOLIMS 35055399 dIE JOVIS QNO23S HOLIMS JYNSSAYd 412 JOVIS 15813 HOLIMS 390553594 dll 3415 1337 HOLIMS 1 0 1104 2509 3415 1 918 HOLIMS 1 0 1104 1509 5 LINIT AYVWIYd 51 Quvog IOYLNOD JDVNYNA NO 13420S ONId Nid 91 6S 6d YOLOW Ju3MO8 NO 13920S 9 Nid G 8S 8d YOLOW H3MO 8 H3MO 8 NO 13 205
25. 2 vertical separation between combustion air intake and vent Maintain 12 minimum clearance above highest anticipated snow level 12 minimum below overhang 12 minimum separation between bottom of combustion air pipe and bottom of vent Maintain 12 minimum clearance above highest anticipated snow level or grade whichever is higher FIGURE 31 Termination Configuration 2 Pipe 26 12 Minimum below overhang 12 Minimum separation between bottom of combustion air intake and bottom of vent A ee Maintain 12 minimumclearance above highest anticipated snow level or grade whichever is higher FIGURE 32 Termination Configuration 2 Pipe Basement VENTING MULTIPLE UNITS Multiple units can be installed in a space or structure as either a single pipe configuration or a two pipe configuration The combustion air side of the single pipe configuration shown in Figure 30 is referred to in these instructions as ambient combustion air supply Follow the instructions for ambient combustion air installations paying particular attention to the section on air source from inside the building The vent for a single pipe system must be installed as specified in the venting section of these instructions with the vent terminating as shown in Figure 30 Each furnace must have a separate vent pipe Under NO circumstances can the two vent pipes be tied together The combustion air side of the two pipe con
26. 444 1638 337 122053 120640 B 1712 444 1698 416 i434 375 126072 1600 45 3 100 29 3 145 65 8 BTUH kW Nominal Cabinet Cabinet Dimensions Inches Input 120 851 2000066 D 2412 622 2398 156 707 SECTION Ill FILTERS SIDE RETURN FILTER INSTALLATION Locate the L shaped corner locators These indicate the size of the cut out to be made in the furnace side panel Refer to Figure 14 All applications require the use of a field installed filter All filters and mounting provision must be field supplied Filters must be installed external to the furnace cabinet DO NOT attempt to install filters inside the furnace NOTICE Single side return above 1800 CFM is approved as long as the filter velocity does not exceed filter manufacturer s recommendation and a transition is used to allow use on a 20x25 filter A 9 4 Furnace Side of Furnace L NY M ML Markings Table 4 Recommended Filter Sizes High Velocity 600 FPM FIGURE 14 Side Return Cutout Markings Bottom Install the side filter rack following the instructions provided with that m min Size in in accessory If a filter s is provided at another location in the return air 1200 84 0 B 16x25 16x25 system the ductwork may be directly attached to the furnace side panel 2000 568 D 16 22x20 IMPORTANT 1 Air
27. D FLASH This indicates that flame was sensed when there was not a call for heat The control will turn on both the inducer motor and supply air blower A gas valve that leaks or is slow closing would typi cally cause this fault 2 RED FLASHES This indicates that the normally open pressure switch contacts are stuck in the closed position The control confirms these contacts are open at the beginning of each heat cycle This would indicate a faulty pressure switch or miswiring 3 RED FLASHES This indicates the normally open pressure switch contact did not close after the inducer was energized This could be caused by a number of problems faulty inducer blocked vent pipe bro ken pressure switch hose or faulty pressure switch 4 RED FLASHES This indicates that the main limit switch has opened its normally closed contacts The control will operate the supply air blower and inducer This condition may be caused by dirty filter improperly sized duct system incorrect blower speed setting incorrect firing rate or faulty blower motor Also this fault code could be caused by a blown fuse located on the control board 5 RED FLASHES This fault is indicated if the normally closed contacts in the rollout switch opens The rollout control is manually reset If it has opened check for proper combustion air proper inducer operation and primary heat exchanger failure or burner problem Be sure to reset the switch and cycle power 24 VAC to the co
28. Duct ating Opening to Outside When a Category furnace is removed or replaced the original 2 000 BTUH 4 us BTUH 4 000 BTUH longer be correctly sized properly vent 5 13 An improperly sized vent system can cause CARBON MONOXIDE to spill into the living space causing personal injury and or death 7 16 om EXAMPLE Determining Free Area Appliance 1 Appliance 2 Total Input 100 000 30 000 130 000 4 000 32 5 Sq In Vertical Appliance 1 Appliance 2 Total Input 100 000 30 000 130 000 2 000 65 Sq In Horizontal Gable Vent Gable Vent Ventilated Ventilated Attic Attic SUB Top Above TA nlet a Insulation OP ABOVE Insulation Outlet Air b Water Heater Ventilated Crawl Space FIGURE 37 Outside and Ambient Combustion Air Air Supply Openings and Ducts Combustion Air Source from Outdoors 1 opening may be used in lieu of a duct to provide to provide the 1 Two permanent openings one within 12 30 5 cm of the top and outside air supply to an appliance unless otherwise permitted by one within 12 30 5 cm of bottom of the confined space Two per the authority having jurisdiction The opening shall be located manent openings shall communicate directly or by means of ducts within 12 30 5 cm horizontally from the burner level of the appli with the outdoors crawl spaces or attic spaces ance
29. ECTION I SAFETY This is a safety alert symbol When you see this symbol on labels or in manuals be alert to the potential for personal injury Understand and pay particular attention to the signal words DANGER WARNING or CAUTION DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It is also used to alert against unsafe practices and hazards involving only property dam age A WARNING Improper installation may create a condition where the operation of the product could cause personal injury or property damage Improper installation adjustment alteration service or mainte nance can cause injury or property damage Failure to carefully read and follow all instructions in this manual can result in fur nace malfunction death personal injury and or property dam age Only a qualified contractor installer or service agency should install this product SPECIFIC SAFETY RULES AND PRECAUTIONS 1 Only Natural gas or Propane LP gas are approved for use with this furnace 2 Install this furnace only in a location and position as specified in these instructions gas fired furnace for installation in a residen
30. HA LHM CINAWE 13 19109 138 034 JIIAYIS 31 23AV 814032084 30 INVAV SYNILINOFSIG 531 ZIYANO NOI LNVD3IYd amm 118 ori 8 39 113 fig 4n31002 30 1002 LINN SIHL 9NI21A83S AWM HIA 390339 SLIINNOISIG 11V N3q0 NOLLIIVO lgviuvA JSSILIA v 13 SAVE 31 uVd 331I INJA 39VIS 86 XOVNHOM GaadS WISVBIVA 9VIS OML 56 iagram D iring W FIGURE 43 39 Johnson Controls Unitary Products NOTES Subject to change without notice Published in U S A 438335 UIM C 1209 Copyright 2009 by Johnson Controls Inc All rights reserved Supersedes 438335 UIM B 0509 Johnson Controls Unitary Products 5005 York Drive Norman OK 73069
31. NT Condensate must be disposed of properly Follow local plumbing or wastewater codes The drain line must maintain a 1 4 per foot 20 mm m downward slope to the drain IMPORTANT If an external vent tee is being installed then it must have its own condensate trap before it is disposed into an open or vented drain This is not to be considered as a second trap as referenced elsewhere in this document Open Stand Pipe Anti siphon air vent To Open Or J Vented Drain FIGURE 22 Typical Condensate drain vertical installation The condensate will flow to the drain better if an open stand pipe is installed in the drain line See Figure 22 If evaporator coil or humidifier drains are combined with the furnace drain then the open stand pipe could be raised higher above the 5 NOTICE A loop has been added to the pressure switch vacuum hose How ever ensure that all pressure switch hoses are routed such that they prevent any condensate from entering the pressure switch A CAUTION It is possible for condensation to form inside the combustion air intake pipe in the summer months if significant length of combus tion air pipe passes through conditioned space This problem can be averted by the addition of a simple drain tee or a drain tee with a drain on the combustion air pipe as close to the furnace as possi ble as shown in Figure 23 This ts true for all long horizontal vent ing in any furnace con
32. OY YSAONGNI ldd IalvLos eaoricNi OPIS Jeujie uo jeuiqeo esou uoyiws eunsseJd uieJp ejesuepuo 5 UOnnsod siy esou Jeynb ules uejous pue 9jnoJ 83 esou uoyoug 9SOU U91 IMS oJnsseJd UBWOUS A40198J eu eui SI seoeuunj YOZ 001 104 For 060 amp 080K input furnaces the condensate drain is plumbed toward the right casing outlet from the factory jou eoeuunj SU esneo YOIUM pue o9 09 sdoo ou zey os 1nd eq sesou HuljnoJe J sDuiuedo deo suns eq p nb Huno esou ueuM Upflow Configuration FIGURE 24 Johnson Controls Unitary Products 19 438335 UIM C 1209 ONILN3A ACIS LHOIY 304 ONILILN3A ACIS L33 1 HOJ IaaJlvLOs MO IHNMOG MO IHNMOG euiqeo y epis Jeuyoe uonisod 514 0 9509 UOnisod siu 0 9509 Jeynb ules SJaulqeo 1 pIM si 1941 9509 19600 eui LON UOnisod siy esou eJnssaJd 9AO A uonisod 510 osou Joyn6 SAO
33. S Each car bon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and IAS certified 3 SIGNAGE A metal or plastic identification plate shall be perma nently mounted to the exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUC TIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes car bon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5 08 2 a 1 through 4 INSPECTION As soon as a unit is received it should be inspected for possible dam age during transit If damage is evident the extent of the damage should be noted on the carrier s freight bill A separate request for inspection by the carrier s agent should be made in writing Also before installation the unit should be checked for screws or bolts which may have loosened in transit There are no shipping or spacer brackets which need to be removed from the interior of this unit FURNACE LOCATION AND CLEARANCES The furnace shall be located using the following guide
34. STAGE REGULATOR ADJUSTMENT OUTLET PRESSURE PORT NC SERO C R zx INLET PRESSURE PORT LOW STAGE REGULATOR ADJUSTMENT ON OFF SWITCH FIGURE 39 Gas Valve IMPORTANT If gas valve regulator is turned in clockwise manifold pressure is increased If screw is turned out counterclockwise manifold pres sure will decrease 4 After the manifold pressure has been adjusted re calculate the furnace input to make sure you have not exceeded the specified input on the rating plate Refer to CALCULATING THE FURNACE INPUT NATURAL GAS 5 Once the correct BTU kW input has been established turn the gas valve to OFF and turn the electrical supply switch to OFF then remove the flexible tubing from the gas valve pressure tap and tighten the pressure tap plug using the 3 32 2 4 mm Allen wrench 6 Turn the electrical and gas supplies back on and with the burners in operation check for gas leakage around the gas valve pressure port for leakage using an approved non corrosive gas leak detec tion fluid or other non flammable leak detection methods Johnson Controls Unitary Products MANIFOLD PRESSURE U TUBE CONNECTION OUTLET PRESSURE TAP GAS VALVE 1 4 TUBING MAINIFOLD FLAME MAE PIPE SENSOR 438335 UIM C 1209 After about 5 minutes of operation determine the furnace temperature rise Take readings of both the return air and the heated air
35. V 8 9 YZE F L 8 9 V YZH G L 8 9 V H 5 THERMOSTAT TM 8 9 V H 8 TWO STAGE PP32U71124 VARIABLE SPEED TWO STAGE PP32U72124 HEAT PUMP FURNACE YORKGUARD VI VARIABLE SPEED CONTROL FURNACE CONTROL C C C 24 Volt Common 24 Volt Common 24 Volt Common Yi 1 1 First Stage Compressor Single Stage pe Single Stage Compressor Compressor 24 Volt Hot 24 Volt Hot 24 Volt Hot G G Fan Fan W W1 W1 OUT First Stage Heat First Stage Heat ET e Aa A 9 Second Stage Heat Second Stage Heat ux Heat Y Y2 Y2 OUT Second or Full P Second Stage Stage Compressor Compressor O O L X L X L Malfunction Light Malfunction Light Malfunction Light Y2 Y2 Second Stage Second Stage Compressor Compressor E W1 W First Stage Aux Heat Auxiliary Heat DHM DHUM BSG Dehumidistat Dehumidification Bonnet Sensor Kit Bonnet Sensor Optional HM 24VAC Humidifier 1 37309243000 BS Humidistat Optional Bonnet Sensor Step 1 of the Thermostat Change FFuel jumper Installer Table must be Move HEAT PUMP on the heat pump control set to Heat Pump jumper to YES to ON Step 2 of the Thermostat Move DHUM Change Hot Heat Pump Installer Table must be jumper to YES jumper on the heat pump set to 2 if humidistat is to be used control to ON if Hot Heat E2 P Switch must be in the Pum
36. ace rather than lifting by the cabinet flanges at the return air open ings bottom or sides or supply air opening It is acceptable to use the primary heat exchanger tubes as a lifting point provided that the tubes are lifted at the front of the heat exchang ers where attached to the vestibule panel Do not use the top return bend of the heat exchangers as lifting points as the tubes may shift out of position or their location brackets baffles DOWNFLOW APPLICATION To apply the furnace in a downflow position it will be necessary to rotate the vent blower 90 left or right so that the vent pipe passes through the side of the furnace casing See Figure 12 Rotate vent blower 90 either way LEFT SIDE VENT RIGHT SIDE VENT FIGURE 12 Downflow Venting Johnson Controls Unitary Products 438335 UIM C 1209 LEFT SIDE RIGHT SIDE Combustion Air Inlet Combustion Air Inlet eda iid EON Gas Pipe TN Drain Downflow Entry ae amp Downtlow Electrical Entry Electrical e Entry Vent Outlet Condensate Drain Condensate O 23 i Drain Thermostat a f Wiring Thermostat Optional Return Air Ni iring Cutout Either side 2 i E 29 5 For Cladded door add appoximately an additional 75 Combustion Air Inlet 20 SUPPLY END RETURN END FIGURE 13 Dimensions Table 3 Cabinet and Duct Dimensions Approximate Operating Weights 80078 1200040 B 1712
37. age Manifold Pressures in w c Altitude feet 0 7999 8000 8999 9000 9999 Gas Heating Value BTU cu ft mom 38 82 78 Altitude m 232017 Gas Heating Value First Stage Manifold Pressures kPa Altitude m 232017 Gas Heating Value PROPANE AND HIGH ALTITUDE CONVERSION KITS It is very important to choose the correct kit and or gas orifices for the altitude and the type of gas for which the furnace is being installed Only use natural gas in furnaces designed for natural gas Only use propane LP gas for furnaces that have been properly converted to use pro pane LP gas Do not use this furnace with butane gas Incorrect gas orifices or a furnace that has been improperly converted will create an extremely dangerous condition resulting in premature heat exchanger failure excessive sooting high levels of carbon monoxide personal injury property damage a fire hazard and or death High altitude and propane LP conversions are required in order for the appliance to satisfactory meet the application An authorized distributor or dealer must make all gas conversions In Canada a certified conversion station or other qualified agency using factory specified and or approved parts must perform the conversion The installer must take every precaution to insure that the furnace has been converted to the proper gas orifice size when the furnace is installed Do not attempt to drill out any orifices
38. ap on the gas valve Do not connect any tubing to the negative side of the manometer as it will reference atmospheric pressure Refer to Figure 40 for connection details IMPORTANT The cap for the pressure regulator must be removed entirely to gain access to the adjustment screw Loosening or tightening the cap does not adjust the flow of gas 32 NOTICE The regulated outlet pressure has been calibrated at the factory Additional pressure adjustment should not be necessary If adjust ment is necessary set to the following specifications After adjust ment check for gas leakage This gas valve has separate regulator adjustment screws for high fire and low fire as shown in Figure 39 The procedure below is used to adjust either the high fire manifold pressure or the low fire manifold pressure 1 Refer to Figure 39 for location of pressure regulator adjustment cap and adjustment screws on main gas valve 2 Turn gas and electrical supplies on and follow the operating instructions to place the unit back in operation 3 Adjust manifold pressure by adjusting gas valve regulator screw for the appropriate gas per the following Table 17 Nominal Manifold Pressure NOMINAL MANIFOLD PRESSURE Natural Gas High Fire Natural Gas Low Fire 3 5 w c 0 87 kPa 1 6 w c 0 40 kPa 9 8 w c 2 488 kPa 4 0 w c 0 99 kPa Propane LP Gas High Fire Propane LP Gas Low Fire HIGH
39. bus tion air intake Vent pipe cements into socket just above top panel Or vent pipe may be clamped into outlet of drain coupling FIGURE 36 Combustion Airflow Path Through The Furnace Casing This type of installation requires that the supply air to the appli ance s be of a sufficient amount to support all of the appliance s in the area Operation of a mechanical exhaust such as an exhaust fan kitchen ventilation system clothes dryer or fireplace may cre ate conditions requiring special attention to avoid unsatisfactory operation of gas appliances A venting problem or a lack of supply air will result in a hazardous condition which can cause the appli ance to soot and generate dangerous levels of CARBON MONOX IDE which can lead to serious injury property damage and or death An unconfined space is not less than 50 cu ft 1 42 m per 1 000 Btu hr 0 2928 kW input rating for all of the appliances installed in that area Rooms communicating directly with the space containing the appli ances are considered part of the unconfined space if doors are fur nished with openings or louvers A confined space is an area with less than 50 cu ft 1 42 m per 1 000 Btu hr 0 2928 kW input rating for all of the appliances installed in that area The following must be considered to obtain proper air for combus tion and ventilation in confined spaces Combustion Air Source From Outdoors The blocking effects of lo
40. d will be determined by the furnace model the total length of pipe required and the number of elbows required Table 8 lists the maximum equivalent length of pipe allowed for each model of furnace The equivalent length of elbows is shown in Table 10 The equivalent length of the vent system is the total length of straight pipe PLUS the equivalent length of all of the elbows The following rules must also be followed 1 Long radius sweep elbows are recommended Standard elbows may be used but since they have a longer equivalent length they will reduce the total length of pipe that will be allowed Short radius plumbing vent elbows are not allowed The standard dimensions of the acceptable elbows are shown below 2 The maximum equivalent length listed in Table 8 is for the vent pip ing and the air intake piping separately For example if the table allows 65 equivalent feet for a particular model then the vent can have 65 equivalent feet of pipe AND the combustion air intake can have another 65 equivalent feet of pipe 3 Three vent terminal elbows two for the vent and one for the com bustion air intake are already accounted for and need not be included in the equivalent length calculation Johnson Controls Unitary Products 438335 UIM C 1209 4 All combustion air and vent pipe must conform to American National Standards Institute ANSI and American Society for Testing and Materials ASTM standards D1785 Schedule 40
41. d with pipe hangers to prevent sagging 9 Seal around the openings where the combustion air and or vent piping pass through the roof or sidewalls COMBUSTION AIR VENTING IMPORTANT The vent must be installed with the minimum required clearances and must comply with local codes and requirements Johnson Controls Unitary Products 438335 UIM C 1209 VENT CLEARANCES V VENT TERMINAL X AIR SUPPLY AREA WHERE TERMINAL IS NOT PERMITTED OPERABLE FIGURE 29 Home Layout Direct Vent Terminal Clearances Vent Terminal Clearances Canadian Installations Installations USinstllaiot Installation A above grade veranda porch deck 12 30 5 12 30 5 balcony Two pipe direct vent applications 9 23 cm for 12 80 5 cm for models lt 100 000 BTUH 30 kW models 50 000 BTUH 15 kW 12 5 cm for 36 A 4 cm for models gt 100 000 BTUH Fa models 250 000 BTUH 15 kW tt Single pipe applications 4 feet 1 2 m C Clearance to permanently closed window 12 30 5 cm 12 30 5 cm D Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet 61 cm from the center line of the terminal 12 80 5 cm or in accordance with local installation 12 80 5 cm or in accordance with local installation E Clearance to unventilated soffit i codes and the requirements o
42. dards in addition to this installa tion manual The installation must comply with regulations of the serv ing gas supplier local building heating plumbing and other codes In absence of local codes the installation must comply with the national codes listed below and all authorities having jurisdiction In the United States and Canada follow all codes and standards for the following using the latest edition available STEP 1 Safety US National Fuel Gas Code NFGC NFPA 54 ANSI Z223 1 and the Installation Standards Warm Air Heating and Air Conditioning Systems ANSI NFPA 90B CANADA CAN CGA B149 1 National Standard of Canada Natu ral Gas and Propane Installation Codes NSCNGPIC STEP 2 General Installation e US Current edition of the NFGC NFPA 90B For copies con tact the National Fire Protection Association Inc Batterymarch Park Quincy MA 02269 or for only the NFGC contact the American Gas Association 400 N Capital N W Washington DC 20001 or www NFPA org CANADA NSCNGPIC For a copy contact Standard Sales CSA International 178 Rexdale Boulevard Etobicoke Toronto Ontario Canada M9W 1RS STEP 3 Combustion and Ventilation Air US Section 5 3 of the NFGC air for Combustion and Ventilation CANADA Part 7 of NSCNGPIC Venting Systems and Air Supply for Appliances STEP 4 Duct Systems e US and CANADA Air Conditioning Contractors Association ACCA Manual D Sheet Metal and Air Conditioning Co
43. e iy Mp Set heat anticipator in the room thermostat to 0 4 amps Setting wiring diagram ininig CUON l it lower will cause short cycles Setting it higher will cause the room through a conduit connector or other proper bushing that has been installed into the unit opening and the junction box In the junction box there is a black wire a white wire and a green ground screw IMPORTANT Connect the power supply as shown on the unit s wiring label located on the inside of the blower compartment door or the wiring Some electronic thermostats do not have adjustable heat anticipa schematic in this section Connect the black wire to L1 hot from tors They should be set to six cycles per hour Follow the thermo the power supply Connect the white wire to neutral Connect the stat manufacturer s instructions ground wire installer supplied to the green equipment ground screw An alternate wiring method is to use a field provided 2 The 24 volt 40 VA transformer is sized for the furnace components 5 1 cm x 4 10 2 cm box and cover on the outside of the fur only and should not be connected to power auxiliary devices such as nace Route the furnace leads into the box using a protective humidifiers air cleaners etc The transformer may provide power for an bushing where the wires pass through the furnace panel After air conditioning unit contactor making the wiring connections replace the wiring b
44. e Follow all notes procedures and required materials in the COMBUSTION AIR VENT PIPE SIZING section in these instructions when installing the combustion air pipe from the unit and into a ventilated attic space or crawl space DO NOT terminate vent pipe in an Attic or Crawl Space A WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monxide poisoning or death The following steps shall be followed for each appliance connected to the venting system being placed into operation while all other appliances connected to the venting system are not in operation Inspect the venting system for proper size and horizontal pitch Determine that there is no blockage restriction leakage corrosion or other deficiencies which could cause an unsafe condition above any insulation flooring or other material A crawl space combustion air installation consists of a straight pipe from the PVC coupling on the burner box that extends into the crawl space and terminates with a 1 4 6 4 mm mesh screen and no elbows Close all building doors and windows and all doors Turn on clothes dryers and TURN ON any exhaust fans such as range hoods and bathroom exhausts so they shall operate at maximum speed Open the fireplace dampers Do not operate a summer exhaust fan Follow the lighting instructions Place
45. e primary heat exchanger When a parallel flow arrangement is used dampers or other means used to control airflow must be ade quate to prevent chilled air from entering the furnace If manually oper ated the damper must be equipped with means to prevent the furnace or the air conditioner from operating unless the damper is in full heat or cool position When replacing an existing furnace if the existing plenum is not the same size as the new furnace then the existing plenum must be removed and a new plenum installed that is the proper size for the new furnace If the plenum is shorter than 12 30 5 cm the turbulent air flow may cause the limit controls not to operate as designed or the limit con trols may not operate at all The duct system is a very important part of the installation If the duct system is improperly sized the furnace will not operate properly The ducts attached to the furnace plenum should be of sufficient size so that the furnace operates at the specified external static pressure and within the air temperature rise specified on the nameplate IMPORTANT The minimum plenum height is 12 30 5 cm The furnace will not operate properly on a shorter plenum height The minimum recommended rectangular duct height is 4 10 2 cm attached to the plenum If a matching cooling coil is used it may be placed directly on the fur nace outlet and sealed to prevent leakage If thermoplastic evaporator A
46. editions If the vent system must be resized follow the appropriate tables in Appendix G of the above codes or for this appliance Specially Engineered Installations The above requirements shall be permitted to be waived where special engineering approved by the authority having jurisdiction provides an adequate supply of air for combustion and ventilation 12 minimum between bottom of air intake and any material below Be sure to instruct the owner not to block this intake pipe VENT BLOWER ROTATION For ease of venting the vent blower may be rotated 90 in either direc tion For upflow installations the vent may exit through the top or either side of the cabinet For downflow installations the vent blower must be rotated so that the vent exits through either side of the cabinet See Fig ures 24 27 for details FIGURE 38 Attic and Crawl Space Combustion Air Termination Johnson Controls Unitary Products 29 438335 UIM C 1209 SECTION VIII START UP AND ADJ USTMENTS The initial start up of the furnace requires the following additional procedures IMPORTANT All electrical connections made in the field and in the factory should be checked for proper tightness When the gas supply is initially connected to the furnace the gas piping may be full of air In order to purge this air it is recommended that the ground union be loosened until the odor of gas is detected When gas is d
47. etected immediately retighten the union and check for leaks Allow five minutes for any gas to dissipate before continuing with the start up procedure Be sure proper ventilation is available to dilute and carry away any vented gas GAS PIPING LEAK CHECK FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in serious injury death or property damage Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections A fire or explosion may result causing property damage personal injury or loss of life IMPORTANT Burner ignition may not be satisfactory on first startup due to resid ual air in the gas line or until gas manifold pressure is adjusted The ignition control will make three attempts to light before locking out It is recommended that when the gas supply is first connected to the furnace the ground union be loosened until the odor of gas is detected When gas is detected immediately tighten the union and check for gas leaks Allow five minutes for any gas to dissipate before continuing with the startup procedure Be sure that proper ventilation is available to dilute and carry away any vented gas With furnace in operation check all of the pipe joints gas valve connec tions and manual valve connections for leakage using an approved gas detector a non corrosive leak detection
48. ewed from the front of the furnace Forall 100 120 amp 130K input furnaces the main drain is plumbed through the casing left side opening when viewed from the front of the furnace NOTICE The Figures 24 27 show the condensate drain arrangement for the various possible furnace and vent blower positions The condensate hoses must slope downwards at all points A CAUTION The furnace condensate pan is self priming and contains an inter nal trap to prevent flue gas leaking Do not install an external con densate trap When drain hose routing changes are required shown in Figures 24 27 be sure to cap all un used openings If rerouting hoses excess length should be cut off so that no sagging loops will collect and hold condensate which will cause the furnace to not operate No hose clamps are needed for connecting to the condensate pan IMPORTANT The furnace evaporator coil and humidifier drains may be com bined and drained together The evaporator coil drain may have an external field supplied trap prior to the furnace drain connection to prevent conditioned air leakage All drain connections furnace evaporator coil or humidifier must be terminated into an open or vented drain as close to the respective equipment as possible Regular maintenance is required on condensate drainage system Johnson Controls Unitary Products 438335 UIM C 1209 IMPORTA
49. f the gas supplier codes and the requirements of the gas supplier E Gisaranceto oulside cone 12 30 5 cm or in accordance with local installation 12 30 5 cm or in accordance with local installation codes and the requirements of the gas supplier codes and the requirements of the gas supplier G Clearance to inside corner 3 feet 91 4 cm 3 feet 91 4 cm Above a meter regulator assembly within 3 feet Above a meter regulator assembly within 3 feet H Clearance to each side of center line 91 4 cm horizontally of the vertical center line of the 91 4 cm horizontally of the vertical center line of the extended above meter regulator assembly regulator vent outlet to a maximum vertical distance of regulator vent outlet to a maximum vertical distance of 15 feet 4 5 m above the meter regulator assembly 15 feet 4 5 m above the meter regulator assembly l Clearance to service regulator vent outlet 3 feet 91 4 cm bd E T Two pipe direct vent applications 9 23 cm for 12 80 5 cm for models lt 100 000 BTUH 30 kW models lt 50 000 BTUH 15 kW 12 30 5 cm for 3 feet 91 4 cm for models gt 100 000 BTUH 30 kW models 250 000 BTUH 15 kW Single pipe applications 4 feet 1 2 m K Clearance to a mechanical supply inlet 6 feet 1 83 m feet 91 4 cm above if within 10 feet 3 m orizontally L Clearance above paved sidewalk or paved 7 feet 2 13 m or in accordance with local installation 7 feet 2 13 m T
50. figuration This will prevent the condensate from entering the furnace 17 438335 UIM C 1209 a Exhaust Pipe CONDENSATE DRAIN TERMINATION A condensate sump pump MUST be used if required by local codes or if no indoor floor drain is available The condensate sump pump must be approved for use with acidic condensate A WARNING DO NOT terminate the condensate drain in a chimney or where the drain line may freeze If the drain line will be exposed to tempera tures below freezing adequate measures must be taken to prevent the drain line from freezing Failure to provide proper protection from freezing can result in improper operation or damage to the equipment and possible property damage When exposed to tem peratures below freezing use of a 3 to 6 watt per foot at 115 VAC 40 F 4 4 C self regulating shielded and waterproof heat tape is recommended on the drain line outside the furnace DO NOT trap the arain line at any other location than at the conden sate drain trap supplied with the furnace A WARNING Liquid anti freeze will cause damage to internal plastic parts of this furnace DO NOT attempt to winterize the furnace using liquid anti freeze x Combustion Air Pipe Tee with Drain Trap FIGURE 23 Typical Combustion Pipe Drain Tee 18 Johnson Controls Unitary Products 438335 UIM C 1209 ONI LN3 5 LHOIY SV ONI LN3A ACIS 1491 GALVL
51. figuration shown in Figure 31 can be installed so the combustion air pipe terminates as described in outdoor combustion air or ventilated combustion air sections in these instructions Follow the instructions for outdoor combustion air or venti lated combustion air and the instructions for installing the vent system with the vent terminating as shown in Figures 33 or 34 The two pipe system must have a separate combustion air pipe and a separate vent pipe for each furnace Under NO circumstances can the two combus tion air or vent pipes be tied together The combustion air and vent pipes must terminate in the same atmospheric zone COMBUSTION AIR 2 4 MIN FIGURE 33 Double Horizontal Combustion Air Intake and Vent Termination FIGURE 34 Double Vertical Combustion Air Intake and Vent Termination Johnson Controls Unitary Products COMBUSTION AIR SUPPLY All installations must comply with Section 5 3 Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 or Sections 7 2 7 3 or 7 4 of CAN CGA B149 1 or 2 Installation Code latest edi tions This furnace is certified to be installed with one of three possible com bustion air intake configurations 1 OUTDOOR COMBUSTION AIR This is a direct vent configuration where the combustion air is supplied through a PVC or ABS pipe that is connected to the PVC coupling attached to the furnace and is terminated in the same atmospheric zone as the vent T
52. for connec tion details 1 Turn gas and electrical supplies on and follow the operating instructions to place the unit back in operation Table 16 Inlet Gas Pressure Range INLET GAS PRESSURE RANGE Propane UP 4 5 w c 1 12 kPa 8 0 w c 1 99 kPa 10 5 w c 2 61 kPa 13 0 w c 3 24 kPa Minimum Maximum IMPORTANT The inlet gas pressure operating range table specifies what the minimum and maximum gas line pressures must be for the furnace to operate safely The gas line pressure MUST BE a minimum of 7 w c 1 74 for Natural Gas 11 w c 2 74 for Propane LP Gas in order to obtain the BTU input specified on the rating plate and or the nominal manifold pressure specified in these instructions and on the rating plate 2 Once the correct gas inlet pressure has been established see Table 16 turn the gas valve to OFF and turn the electrical supply switch to OFF then remove the flexible tubing from the gas valve pressure tap and tighten the pressure tap plug using the 3 32 2 4 mm Allen wrench 3 Turn the electrical and gas supplies back on and with the burners in operation check for gas leakage around the gas valve pressure port for leakage using an approved non corrosive gas leak detec tion fluid or other non flammable leak detection methods Read the manifold gas pressure Connect the positive side of the manometer to the adapter previously installed in the OUT P T
53. h is set in the auto position and the thermostat calls for cooling a circuit is completed between the R Y and G terminals The motor is energized through the Y1 cool terminal and runs on the speed selected on the COOL tap of the control board The fan off setting is fixed at 60 seconds for SEER enhancement The control board can accommodate two stage cooling When a two stage cool thermostat is connected to the Y1 and Y2 terminals on the board the blower will operate on LOW COOL speed when Y1 is energized and on HI COOL speed when Y1 and Y2 are energized Intermittent Blower Heating On cooling heating thermostats with a fan switch when the fan switch is set in the auto position and the thermostat calls for heating a circuit is completed between the R and W terminals The indoor fan motor is energized through the W1 heat terminal and runs on the speed selected on the HEAT tap of the control board Humidistat When a humidistat is installed in the system the Humidistat Installed jumper on the control board should be moved to the YES position The cooling CFM will then be reduced by 15 whenever the humidistat indicates high humidity 35 438335 UIM C 1209 Heating Cycle When the thermostat switch is set on HEAT and the fan is set on AUTO and there is a call for heat a circuit is completed between terminals R and W of the thermostat When the proper amount of combustion air is being provided the pressure switch will close
54. h the vent manufacturer s installation instructions or in accordance with the installation instructions for a special venting system Responsibility for the provision of proper adequate venting and air supply for application shall rest with the installer Vent shall extend high enough above building or a neighboring obstruction so that wind from any direction will not create a positive pressure in the vicinity of the vent IMPORTANT Consideration must be given for degradation of building materials by flue gases Sidewall termination may require sealing or shielding of building B Clearance to window or door that may be opened 12 80 5 cm or in accordance with local installation 12 80 5 cm or in accordance with local installation codes and the requirements of the gas supplier codes and the requirements of the gas supplier J Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance surfaces with a corrosion resistant material to protect against combustion product corrosion Consideration must be given to wind direction in order to prevent flue products and or condensate from being blown against the building surfaces If a metal shield is used it must be a stainless steel material at a minimum dimension of 20 51 cm It is recommended that a retaining type collar be used that is attached to the building sur face to prevent movement of the vent pipe Johnson Controls U
55. he blocking effects of louvers grilles and screens must be given air inlet supply from outdoors shall be equipped with a means consideration in calculating free area If the free area of a specific to prevent the direct entry of rain and wind Such means shall not louver or grille is not known Refer to Table 12 reduce the required free area of the air supply opening 7 air supply inlet opening from the outdoors shall be located not less than 12 30 5 cm above the outside grade level 28 Johnson Controls Unitary Products Ventilated Combustion Air The ventilated attic space or a crawl space from which the combustion air is taken must comply with the requirements specified in AIR SOURCE FROM OUTDOORS in this instruction or in Section 5 3 Air 438335 UIM C 1209 Ventilated Combustion Air Termination Refer to Figure 38 for required attic termination for the combustion air intake pipe For attic termination use two 90 elbows with the open end in a downward position Be sure to maintain 12 30 5 cm clearance for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 latest edition This type installation requires two properly sized pipes One brings combustion air from a properly ventilated attic space or crawl space and a second pipe that extends from the furnace vent connection top right of unit to the exterior of the building Refer to Table 8 for intake pipe sizing allowable length and elbow usag
56. his type of installation is approved on all models Refer to Figure 35 2 AMBIENT COMBUSTION AIR Combustion air is supplied from the area surrounding the furnace through openings in the furnace casing The combustion air and the vent pipes are not terminated in the same atmospheric zone Refer to Figure 30 for vent termina tions Refer to Ambient Combustion Air Supply for proper instal lation Refer to Figure 36 3 VENTILATED COMBUSTION AIR Combustion air is supplied through a PVC or ABS pipe that is connected to the PVC coupling attached to the burner box and is terminated in a ventilated attic or crawl space The combustion air and the vent pipes are not termi nated in the same atmospheric zone Refer to Figure 38 for attic and crawl space termination Only the combustion air intake may terminate in the attic The vent must terminate outside Outdoor Combustion Air Combustion Air Intake Vent Connections This installation requires combustion air to be brought in from outdoors This requires a properly sized pipe Shown in Figure 35 that will bring air in from the outdoors to the furnace combustion air intake collar on the burner box The second pipe Shown in Figure 35 is the furnace NOTICE An optional plastic birdscreen is shipped in the loose parts bag with every furnace This may be installed in the intake collar to prevent any small objects from entering the furnace Connects to collar on top Vent pipe cemen
57. ication and use must com ply with all manufacturer s installation instructions including Proper vent installation e Furnace operating under thermostatic control Return air duct sealed to the furnace e Air filters in place e Set furnace input rate and temperature rise per rating plate marking e Means for providing outdoor air required for combustion Return air temperature maintained between 55 F 13 C and 80 F 27 C The air filter must be replaced upon substantial completion of the construction process Clean furnace duct work and components upon substantial completion of the construction process and verify furnace operating conditions including ignition input rate temperature rise and venting according to the manufacturer s instructions 10 When installed in a non HUD Approved Modular Home or building constructed on site combustion air shall not be supplied from occupied spaces 11 The size of the unit should be based on an acceptable heat loss calculation for the structure ACCA Manual J or other approved methods may be used 12 When moving or handling this furnace prior to installation always leave the doors on the furnace to provide support and to prevent damage or warping of the cabinet When lifting the furnace by the cabinet support the ends of the furnace rather than lifting by the cabinet flanges at the return air openings bottom or sides or sup ply air opening 13 When lifting the
58. installed For duct attachment if needed FIGURE 1 Duct Attachment DUCTWORK INSTALLATION AND SUPPLY PLENUM CONNECTION UPFLOW HORIZONTAL Attach the supply plenum to the furnace outlet The use of an approved flexible duct connector is recommended on all installations This connection should be sealed to prevent air leakage The sheet metal should be crosshatched to eliminate any popping of the sheet metal when the indoor fan is energized FLOOR BASE AND DUCTWORK INSTALLATION DOWNFLOW Installations on combustible material or directly on any floors must use a combustible floor base shown in Figure 8 Follow the instructions supplied with the combustible floor base accessory This combustible floor base can be replaced with a matching cooling coil properly sealed to prevent leaks Follow the instructions supplied with the cooling coil cabinet for installing the cabinet to the duct con nector Plug intake and vent pipe holes in bottom panel and move grommet to desired vent side exit Downflow Air Conditioning Coil Cabinet The furnace should be installed with coil cabinet part number specifi cally intended for downflow application If a matching cooling coil is used it may be placed directly on the furnace outlet and sealed to pre vent leakage For details of the coil cabinet dimensions and installation requirements refer to the installation instructions supplied with the coil cabinet Attach the air conditioning c
59. l or Screw this flange e Dh _______ 2 Upflow 3 Alternate Secondary Drain Location Drain FIGURE 6 PC Series Upflow Coil Installation Table 2 Coil Projection Dimensions PC Series Coils PC42 PC43 PC36 PC37 Dimension should be at least 2 3 of dimension D See Figure 6 CRITICAL COIL PROJ ECTION The coil assembly must be located in the duct such that a minimum dis tance is maintained between the top of the coil and the top of the duct Refer to Table 2 COIL FURNACE ASSEMBLY HC SERIES COILS These coils are supplied ready to be installed in a right hand position or a left hand position When used in conjunction with a horizontal furnace blow through application the coil should be oriented with the opening of the A coil closest to the furnace See Figure 7 NOTICE Each coil is shipped with an external tie plate that should be used to secure the coil to the furnace It should be installed on the back side of the coil using the dimpled pilot holes See Figure 7 Use tie plate a supplied with coil DIMENSION C INCH 3 1 2 Gas Furnace FIGURE 7 Horizontal Left or Right application Right Shown Johnson Controls Unitary Products 438335 UIM C 1209 DOWNFLOW DUCT CONNECTORS All downflow installations must use a suitable duct connector approved by the furnace manufacturer for use with this furnace The duct connec t
60. lines 1 Where a minimum amount of air intake vent piping and elbows will be required 2 As centralized with the air distribution as possible 3 Where adequate combustion air will be available particularly when the appliance is not using outdoor combustion air 4 Where it will not interfere with proper air circulation in the confined space 5 Where the outdoor vent terminal will not be blocked or restricted Refer to VENT CLEARANCES located in SECTION VII of these instructions These minimum clearances must be maintained in the installation 6 Where the unit will be installed in a level position with no more than 1 4 6 4 mm slope side to side and front to back to provide proper condensate drainage Installation in freezing temperatures 1 Furnace shall be installed in an area where ventilation facilities provide for safe limits of ambient temperature under normal oper ating conditions Ambient temperatures must not fall below 32 F 0 C unless the condensate system is protected from freezing Improper installation in an ambient below 32 F 0 0 C could cre ate a hazard resulting in damage injury or death 2 Do not allow return air temperature to be below 55 F 13 C for extended periods To do so may cause condensation to occur in the main heat exchanger leading to premature heat exchanger failure this furnace is installed in an unconditioned space and extended power failure occu
61. lines formed by the intersection of furnace top and two sides and building joists studs or framing Vent Maintain required clearances to combustibles Filter rack must be a minimum distance Sheet metal in front of furnace of 18 45 7 cm d combustion air Openings is from the Recommended furnace Sediment Trap FIGURE 10 Typical Attic Installation This appliance is certified for line contact when the furnace is installed in the horizontal left or right position The line contact is only permissible between lines that are formed by the intersection of the top and two sides of the furnace and the building joists studs or framing This line may be in contact with combustible material Refer to Figure 10 When a furnace is installed in an attic or other insulated space keep all insulating materials at least 12 30 5 cm away from fur nace and burner combustion air openings IMPORTANT During installation doors should remain on the furnace when moving or lifting When moving or handling this furnace prior to installation always leave the doors on the furnace to provide support and to prevent damage or warping of the cabinet When lifting the furnace support the ends of the furnace rather than lifting by the cabinet flanges at the return air open ings bottom or sides or supply air opening It is acceptable to use the primary heat exchanger tubes as a lifting point provided tha
62. lve causing improper operation and or the valve to leak Gas piping may be connected from either side of the furnace using any of the gas pipe entry knockouts on both sides of the furnace Refer to Figure 13 10 Johnson Controls Unitary Products GAS ORIFICE CONVERSION FOR PROPANE LP This furnace is constructed at the factory for natural gas fired operation but may be converted to operate on propane LP gas by using a factory supplied LP conversion kit Follow the instructions supplied with the LP kit HIGH ALTITUDE GAS ORIFICE CONVERSION This furnace is constructed at the factory for natural gas fired operation at 0 7 999 feet 0 2 438 m above sea level Table 5 Nominal Manifold Pressure High Fire 438335 UIM C 1209 The manifold pressure must be changed in order to maintain proper and safe operation when the furnace is installed in a location where the altitude is greater than 7 999 feet 2 438 m above sea level Refer to Table 5 for proper manifold pressure settings HIGH ALTITUDE PRESSURE SWITCH CONVERSION For installation where the altitude is less than 5 000 feet 1 524m it is not required that the pressure switch be changed unless you are in an area subject to low pressure inversions Manifold Pressures in w c E Manifold Pressures kPa Altitude feet 0 7999 8000 8999 9000 9999 3 5 3 5 1100 2 Gas Heating Value BTU cu ft TABLE 6 Nominal Manifold Pressure Low Fire First St
63. material other than wood flooring e Check the rating plate and power supply to be sure that the elec trical characteristics match All models use nominal 115 VAC 1 Phase 60 Hz power supply DO NOT CONNECT THIS APPLI ANCE TO A 50 Hz POWER SUPPLY OR A VOLTAGE ABOVE 130 VOLTS Furnace shall be installed so the electrical components are pro tected from water Installing and servicing heating equipment can be hazardous due to the electrical components and the gas fired components Only trained and qualified personnel should install repair or service gas heating equipment Untrained service personnel can perform basic maintenance functions such as cleaning and replacing the air filters When working on heating equipment observe precau tions in the manuals and on the labels attached to the unit and other safety precautions that may apply COMBUSTION AIR QUALITY LIST OF CONTAMINANTS The furnace area must not be used as a broom closet or for any other storage purposes as a fire hazard may be created Never store items such as the following on near or in contact with the fur nace 1 Spray or aerosol cans rags brooms dust mops vacuum cleaners or other cleaning tools Soap powders bleaches waxes or other cleaning com pounds plastic items or containers gasoline kerosene ciga rette lighter fluid dry cleaning fluids or other volatile fluid Paint thinners and other painting compounds Paper bags boxes or other pa
64. nction in the combustion air blower heat exchanger or a blocked vent pipe con nection Corrective action is required These are manual reset controls that must be reset before operation can continue PRESSURE SWITCHES This furnace is supplied with three pressure switches which monitor the flow through the combustion air vent piping and condensate drain sys tem These switches de energize the gas valve if any of the following conditions are present Refer to SECTION VI CONDENSATE PIPING AND FURNACE VENTING CONFIGURATION for tubing connections 1 Blockage of vent piping or terminal 2 Failure of combustion air blower motor 3 Blockage of combustion air piping or terminals 4 Blockage of condensate drain piping LIMIT CONTROLS There is a high temperature limit control located on the furnace vesti bule panel near the gas valve This is an automatic reset control that provides over temperature protection due to reduced airflow This may be caused by 1 A dirty filter 2 Ifthe indoor fan motor should fail 3 Too many supply or return registers closed or blocked off The control module will lockout if the limit trips 5 consecutive times If this occurs control will reset amp try ignition again after 1 hour SECTION X NORMAL OPERATION AND DIAGNOSTICS NORMAL OPERATION SEQUENCE Heating and Cooling Airflow The heating and the cooling airflows are preset at the factory The heat ing airflow is set to the maximum CFM
65. nitary Products 25 438335 UIM C 1209 VENT SYSTEM This furnace is certified to be installed with one of two possible vent configurations 1 Horizontal vent system This vent system can be installed com pletely horizontal or combinations of horizontal vertical or offset using elbows 2 Vertical vent system This vent system can be installed completely vertical or a combination of horizontal vertical or offset using elbows VENT APPLICATIONS AND TERMINATION When selecting the location for a combustion air vent termination the following should be considered 1 Observe all clearances listed in vent clearances in these instruc tions 2 Termination should be positioned where vent vapors will not dam age plants or shrubs or air conditioning equipment 3 Termination should be located where it will not be affected by wind gusts light snow airborne leaves or allow recirculation of flue gases 4 Termination should be located where it will not be damaged or exposed to flying stones balls etc 5 Termination should be positioned where vent vapors are not objectionable 6 Horizontal portions of the vent system must slope upwards and be supported to prevent sagging 7 Direct vent systems must be installed so the vent and the combus tion air pipes terminate in the same atmospheric zone Refer to Figures 31 or 32 Maintain 12 minimum clearance above highest anticipated snow level Maximum 24 above roof 1
66. not try to repair controls Replace defective controls with UPG Source 1 Parts Never adjust pressure switch to allow furnace operation 36 FURNACE CONTROL DIAGNOSTICS The furnace has built in self diagnostic capability If a system problem occurs a blinking LED can flash red green or amber to indicate various conditions The control continuously monitors its own operation and the operation of the system If a failure occurs the LED 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 Flash sequence codes 1 through 11 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 SLOW GREEN FLASH Normal operation SLOW AMBER FLASH Normal operation with call for heat RAPID RED FLASH Twinning error incorrect 24V phasing Check twinning wiring RAPID AMBER FLASH Flame sense current is below 1 5 microamps Check and clean flame sensor Check for proper gas flow Verify that current is greater than 1 5 microamps at flame current test pad 4 AMBER FLASHES The control is receiving a Y signal from the thermostat without a G signal indicating improper thermostat wiring 1 RE
67. nt terminations kits 1HTO901 amp 1 0902 are also approved for use with these furnaces COMBUSTION AIR AND VENT PIPING ASSEMBLY The final assembly procedure for the combustion air and vent piping is as follows 1 Cut piping to the proper length beginning at the furnace 2 Deburr the piping inside and outside Chamfer bevel the outer edges of the piping 4 Dry fitthe vent piping assembly from the furnace to the outside ter mination checking for proper fit support and slope 5 Dry fit the combustion air piping assembly checking for proper fit support and slope on the following systems a Sealed combustion air systems from the furnace to the out side termination b Ventilated combustion air systems from the furnace to the attic or crawl space termination A CAUTION Solvent cements are flammable and must be used in well ventilated areas only Keep them away from heat sparks and open flames Do not breathe vapors and avoid contact with skin and eyes 6 Disassemble the combustion air and vent piping apply cement primer and the cement per the manufactures instructions Primer and cement must conform to ASTM D2564 for PVC or ASTM D2235 for ABS piping All joints must provide a permanent airtight and watertight seal 8 Support the combustion air and vent piping such that it is angled a minimum of 1 4 per foot 21 mm m so that condensate will flow back towards the furnace Piping should be supporte
68. ntractors Association National Association SMACNA or American Soci ety of Heating Refrigeration and Air Conditioning Engineers ASHRAE 1997 Fundamentals Handbook Chapter 32 STEP 5 Acoustical Lining and Fibrous Glass Duct US CANADA Current edition of SMACNA and NFPA 90B as tested by UL Standard 181 for Class I Rigid Air Ducts STEP 6 Gas Piping and Gas Pipe Pressure Testing e US NFGC chapters 2 3 4 amp 9 and National Plumbing Codes CANADA NSCNGPIC Part 5 STEP 7 Electrical Connections US National Electrical Code NEC ANSI NFPA 70 CANADA Canadian Electrical Code CSA C22 1 These instructions cover minimum requirements and conform to exist ing national standards and safety codes In some instances these instructions exceed certain local codes and ordinances especially those who have not kept up with changing residential and non HUD modular home construction practices These instructions are required as a minimum for a safe installation 438335 UIM C 1209 FOR FURNACES INSTALLED IN THE COMMON WEALTH OF MASSACHUSETTS ONLY For all side wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for resi dential purposes including those owned or operated by the Com monwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and po
69. ntrol after correcting the fail ure condition Also this fault code could be caused by a blown fuse located on the control board 6 RED FLASHES This indicates that after the unit was operating the pressure switch opened 4 times during the call for heat If the main blower is in a Delay on mode it will complete it and any subsequent delay off period The furnace will lock out for one hour and then restart 7 RED FLASHES This fault code indicates that the flame could not be established This no light condition occurred 3 times 2 retries during the call for heat before locking out Low gas pressure faulty gas valve dirty or faulty flame sensor faulty hot surface ignitor or burner problem may cause this The furnace will lock out for one hour and then restart 8 RED FLASHES This fault is indicated if the flame is lost 5 times 4 recycles during the heating cycle This could be caused by low gas pressure dirty or faulty flame sensor or faulty gas valve The furnace will lock out for one hour and then restart Johnson Controls Unitary Products 9 RED FLASHES Indicates reversed line voltage polarity or grounding problem Both heating and cooling operations will be affected Check polarity at furnace and branch Check furnace grounding Check that flame probe is not shorted to chassis 10 RED FLASHES Flame sensed with no call for heat Check gas valve and gas valve wiring 11 RED FLASHES This indicates that a primary or auxiliar
70. o esou ueuM FIGURE 26 Horizontal Left Configuration 21 Johnson Controls Unitary Products 438335 UIM C 1209 50 siy 0 9509 Jeyn6 uonisod 51 0 pepi oJd p e o cy ejesuepuoo OI3Al3O238 SV YSONANI LHOIY IVLNOZIHOH 5 siu 9SOU pepiAoJud 06 94 ojesuopuoo UOnisod siu JeynB ules MO 138IV Q3lVLOM LHOIY TVLNOZIHOH 1 jou eoeuunj SU esneo YOIUM pue 108 02 sdoo ou zey os 1no eq pjnous sesou BurnnoaJolJ J sDBuiuedo pesn un deo euns eq seDueuo esou ueuM FIGURE 27 Horizontal Right Configuration Johnson Controls Unitary Products 22 SECTION VII COMBUSTION AIR AND VENT SYSTEM COMBUSTION AIR AND VENT SAFETY This Category IV dual certified direct vent furnace is designed for resi dential application It may be installed without modification to the con densate system in a basement garage equipment room alcove attic or any other indoor location where all required clearance to combusti bles and other restrictions are met The combustion air and
71. oil cabinet to the duct connector and then position the furnace on top of the coil cabinet The connection to the fur nace air conditioning coil cabinet duct connector and supply air duct must be sealed to prevent air leakage 438335 UIM C 1209 COIL INSTALLATION IMPORTANT On all installations without a coil a removable access panel is rec ommended in the outlet duct such that smoke or reflected light would be observable inside the casing to indicate the presence of leaks in the heat exchanger This access cover shall be attached in such a manner as to prevent leaks COIL FURNACE ASSEMBLY MC FC PC SERIES COILS UPFLOW DOWNFLOW FIGURE 2 Vertical Applications FURNACE ASSEMBLY MC amp FC SERIES COILS These coils are factory shipped for installation in either upflow or down flow applications with no conversion Position the coil casing over or under the furnace opening as shown in Figure 2 after configuring coil flanges as required see Coil Flange sec tion below COIL FLANGE INSTALLATION The coils include removable flanges to allow proper fit up with furnaces having various inlet and outlet flange configurations The two flanges are attached to the top of the coil in the factory during production For proper configuration of flanges refer to Figure 3 FACTORY FLANGE LOCATION Used for upflow or horizontal right installations ALTERNATE FLANGE LOCATION Used for
72. ommon Yi 3 Ma Yi First Stage Compressor II e 21808 First Stage Compressor Compressor R R R 24 Volt Hot 24 Volt Hot 24 Volt Hot G G Comfort Alert Interface Fan Fan two pin connector E W1 W W1 First Stage Heat First Stage Heat W2 W2 Second Stage Heat Second Stage Heat Y Y2 Second or Full Stage Compressor O Reversing Valve L X L Malfunction Light Malfunction Light Y2 Y2 Second Stage Second Stage Compressor Compressor DHM DHUM Dehumidification Dehumidification HM 24VAC Humidifer Humidistat Optional Optional Harness Step 1 of Thermostat User Move DHUM Configuration Menu must jumper to YES be set to MLTISTG if humidistat is to be used E2 P Switch must be in the E2 position 1 Part Numbers SAP Legacy 265904 031 09169 449572 FIGURE 20 Thermostat Chart Two Stage AC with Two Stage Variable Speed Furnace Johnson Controls Unitary Products 15 438335 UIM C 1209 HP 24A Two Stage Heat Pump Two Stage Variable Speed Furnace Hot Heat Pump or Conventional O Reversing Valve 9 Reversing Valve Reversing Valve Energized in Cool Energized in Cool ID MODELS OD MODELS P
73. ors are designed to be connected to the rectangular duct under the floor and sealed Refer to the instructions supplied with the duct con nector for proper installation Refer to the separate accessory parts list at the end of these instructions for the approved accessory duct con nectors a FURNACE WARM AIR PLENUM WITH 1 FLANGES FIBERGLASS INSULATION FIBERGLASS TAPE UNDER FLANGE COMBUSTIBLE FLOOR BASE ACCESSORY FIGURE 8 Combustible Floor Base Accessory RESIDENTIAL AND MODULAR HOME UPFLOW RETURN PLENUM CONNECTION Return air may enter the furnace through the side s or bottom depend ing on the type of application Return air may not be connected into the rear panel of the unit BOTTOM RETURN AND ATTIC INSTALLATIONS Bottom return applications normally pull return air through a base plat form or return air plenum Be sure the return platform structure or return air plenum is suitable to support the weight of the furnace The internal bottom panel must be removed for this application Attic installations must meet all minimum clearances to combustibles and have floor support with required service accessibility HORIZONTAL APPLICATION FIGURE 9 Horizontal Application IMPORTANT This furnace may be installed in a horizontal position on either side as shown above It must not be installed on its back 438335 UIM C 1209 ATTIC INSTALLATION Line contact only permissible between
74. ot acceptable By using sweep elbows the total equivalent length will be 32 feet of 2 pipe 5 90 sweep 2 elbows 5 x 5 Total 32 equivalent feet 25 equivalent feet 57 equivalent feet of 2 pipe This is less than the 65 foot maximum equivalent length of 2 pipe allowed for that model and is thus acceptable Alternatively using 3 pipe and standard elbows the total equivalent length will be 32 feet of 3 pipe 5 90 standard 3 elbows 5 x 7 Total 32 equivalent feet 35 equivalent feet 67 equivalent feet of 3 pipe This is less than the 90 foot maximum equivalent length of 3 pipe allowed for that model and is thus acceptable TABLE 11 Combustion Air Intake and Vent Connection Size at Furnace All Models FURNACE VENT CONNECTION SIZES Intake Pipe Size 2 5 1 cm Vent Pipe Size 2 5 1 cm 24 IMPORTANT Furnace vent pipe connections are sized for 2 5 1 cm pipe Any pipe size change must be made outside the furnace casing in a ver tical pipe section to allow proper drainage of condensate An offset using two 45 degree elbows will be required for plenum clear ance when the vent is increased to 3 7 6 IMPORTANT Accessory concentric vent intake termination kits 1C T0302 and 1CTO308 and for Canadian applications 1CT0302 636 1 303 636 are available and approved for use with these fur naces Horizontal sidewall ve
75. ox cover and screws Refer to Figure 17 3 furnace s control system requires correct polarity of the power supply and a proper ground connection Refer to Figure 17 12 Johnson Controls Unitary Products 438335 UIM C 1209 For additional connection diagrams for all UPG equipment refer to Low Voltage System Wiring document available on line at www upgnet com in the Product Catalog Section AC 9A Single Stage Air Conditioner Two Stage Variable Speed Furnace ID MODELS PV 8 9 F L 8 9 V G L 8 9 V THERMOSTAT THERMOSTAT THERMOSTAT THERMOSTAT TM 8 9 V TWO STAGE DN22U00124 2070124 DN22C00124 DP22U70124 VARIABLE SPEED FURNACE C C C C 24 Volt Common 24 Volt Common 24 Volt Common 24 Volt Common M 54 Volt Common Y Y Y Yi md First Stage Compressor First Stage Compressor First Stage Compressor First Stage Compressor amp man Heat XFMR Heat XFMR Volt Hot Volt Hot 24 Volt Hot G G G G G Fan Fan Fan Fan Fan W E W1 W W1 W First Stage Heat W First Stage Heat First Stage Heat First Stage Heat First Stage Heat W2 Second Stage Heat Y Y2 Second or Full Stage Compressor Reversing Valve W2 W2 W2 W2 Second Stage Heat Second Stage Heat Second Stage Heat Second Stage Heat RC RC 24 Volt Hot 24
76. p Operation is desired E2 position Part Numbers SAP Legacy Part Numbers 126768 031 09137 SAP Legacy 18395 031 01996 265904 031 09169 340512 031 09178 449572 FIGURE 21 Thermostat Chart Two Stage HP with Two Stage Variable Speed Furnace Hot Heat Pump or Conventional 16 Johnson Controls Unitary Products ACCESSORY CONNECTIONS The furnace control will allow power switching control of various accessories ELECTRONIC AIR CLEANER CONNECTION Two 1 4 6 4 mm spade terminals EAC and NEUTRAL for electronic air cleaner connections are located on the control board The terminals provide 115 VAC 1 0 amp maximum during circulating blower operation HUMIDIFIER CONNECTION Two 1 4 6 4 mm spade terminals HUM and NEUTRAL for humidifier connections are located on the control board The terminals provide 115 VAC 1 0 amp maximum during heating system operation A mounting hole is provided on the control panel next to the furnace control board for mounting a humidifier transformer if required TWINNING These furnaces are not to be twinned If more than one furnace is needed in an application each furnace must have its own complete duct system and its own wall thermostat SECTION VI CONDENSATE PIPING AND FURNACE VENTING CONFIGURATION CONDENSATE DRAIN LOCATION As shipped from the factory e For all 040 060 amp 080K input furnaces the main drain is plumbed through the casing right side opening when vi
77. per products Never operate the furnace with the blower door removed To do so could result in serious personal injury and or equipment damage The furnace requires OUTDOOR AIR for combustion when the furnace is located in any of the following environments Buildings with indoor pools Chemical exposure e Commercial buildings e Furnaces installed in hobby or craft rooms Furnaces installed in laundry rooms Furnaces installed near chemical storage areas Restricted Environments The furnace requires OUTDOOR AIR for combustion when the furnace is located in an area where the furnace is being exposed to the follow ing substances and or chemicals e Antistatic fabric softeners for clothes dryers Carbon tetrachloride Cements and glues e Chlorine based swimming pool chemicals e Chlorinated waxes and cleaners Cleaning solvents such as perchloroethylene De icing salts or chemicals Halogen type refrigerants e Hydrochloric acid Johnson Controls Unitary Products 438335 UIM C 1209 Masonry acid washing materials e Permanent wave solutions Printing inks paint removers varnishes etc Water softening chemicals When outdoor air is used for combustion the combustion air intake duct system termination must be located external to the building and in an area where there will be no exposure to the substances listed above CODES AND STANDARDS Follow all national local codes and stan
78. pliance Some utility companies or local codes require pipe sizes larger than the minimum sizes listed in these instructions and in the codes The furnace rating plate and the instructions in this section specify the type of gas approved for this furnace only use those approved gases The instal lation of a drip leg and ground union is required Refer to Figure 16 NOTE Ground Union maybe installed inside or outside unit To Gas Supply External Manual Shut off Valve External Drip Leg E PAA CL External Manual Shut off Valve bius EN LL T Iz wy IZ lal SS A d Leg Ground Union Gas Pipe U Horizontal Drip Union FIGURE 16 Gas Piping IMPORTANT A CAUTION The gas valve body is a very thin casting that cannot take any external pressure Never apply a pipe wrench to the body of the gas An accessible manual shutoff valve must be installed upstream of the furnace gas controls and within 6 feet 1 8 m of the furnace The furnace must be isolated from the gas supply piping system by closing its individual external manual shutoff valve during any pressure testing of the gas supply piping system at pressures equal to or less than 0 5 psig 3 5 kPa valve when installing piping A wrench must be placed on the octa gon hub located on the gas inlet side of the valve Placing a wrench to the body of the gas valve will damage the va
79. pliances that were turned off at the start of this input check Johnson Controls Unitary Products 438335 UIM C 1209 Table 15 Gas Rate CU FT HR at Full Input Seconds For Size of Test Dial Seconds For Size of Test Dial 1 Revolution 1 Cu Ft 2 Cu Ft 5 Cu Ft 1 Revolution 1 Ft 2 Cu Ft 5 Ft 10 65 8 1 w a a 7385 305 514 1286 122 300 Johnson Controls Unitary Products 31 438335 UIM C 1209 ADJ USTMENT OF MANIFOLD GAS PRESSURE amp INPUT RATE Inlet and manifold gas pressure may be measured by connecting the U tube manometer to the gas valve with a piece of tubing Follow the appropriate section in the instructions below Refer to Figure 39 for a drawing of the locations of the pressure ports on the gas valve Turn gas off at the ball valve or gas cock on gas supply line before the gas valve Find the pressure ports on the gas valve marked Out P and In P 1 manifold pressure must be taken at the port marked OUT P 2 The gas line pressure must be taken at the port marked IN P 3 Using a 3 32 2 4 mm Allen wrench loosen the set screw by turn ing it 1 turn counter clockwise DO NOT REMOVE THE SET SCREW FROM THE PRESSURE PORT Read the inlet gas pressure Connect the positive side of the manometer to the IN P Tap on the gas valve Do not connect any tubing to the negative side of the manometer as it will reterence atmospheric pressure Refer to Figure 40
80. profile is best suited to parts of the country where excessive humidity is not generally a problem where the sum mer months are usually dry On a call for cooling the motor will ramp up to full capacity and will stay there until the thermostat is satisfied At the end of the cooling cycle the blower will ramp down to 50 of full capac ity where it will stay for 60 seconds Then it will ramp down to zero In every case it will take the motor 30 seconds to ramp from one speed to another Tap D is the normal profile best suited for most of the country where neither excessive humidity nor extremely dry conditions are the norm On a call for cooling the motor will ramp up to 63 of full capacity and will stay there for 90 seconds then will ramp up to full capacity At the end of the cooling cycle the motor will ramp down to 63 of full capac ity and will stay there for 30 seconds then will ramp down to zero In every case it will take the motor 30 seconds to ramp from one speed to another Continuous Blower Operation The blower will run continuously whenever the wall thermostat fan switch is in the ON position The furnace blower will run at the speed selected on the FAN SPEED jumpers on the main control board HI COOL LO COOL HI HEAT or LO HEAT When the jumper is in the VS G position the blower will run at 50 of the high cool speed Intermittent Blower Cooling On cooling heating thermostats with a fan switch when the fan switc
81. rches the following require ments shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or structure served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a n the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level b the event that the requirements of this subdivision can not be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided however that during said thirty 30 day period a battery operated carbon mon oxide detector with an alarm shall be installed 2 APPROVED CARBON MONOXIDE DETECTOR
82. rflow may be lower that what is required to operate an airflow switch on certain models of electronic air clean ers Consult the instructions for the electronic air cleaner for further details The ADJ D tap should not be used 34 Johnson Controls Unitary Products SECTION IX SAFETY CONTROLS CONTROL CIRCUIT FUSE A 3 amp fuse is provided on the control circuit board to protect the 24 volt transformer from overload caused by control circuit wiring errors This is an ATO 3 automotive type fuse and is located on the control board BLOWER DOOR SAFETY SWITCH A CAUTION Main power to the unit must still be interrupted at the main power disconnect switch before any service or repair work is to be done to the unit Do not rely upon the interlock switch as a main power dis connect Blower and burner must never be operated without the blower panel in place This unit is equipped with an electrical interlock switch mounted in the burner compartment This switch interrupts all power at the unit when the panel covering the blower compartment is removed Electrical supply to this unit is dependent upon the panel that covers the blower compartment being in place and properly positioned ROLLOUT SWITCH CONTROLS These controls are mounted on the burner assembly If the temperature in the area surrounding burner exceeds its set point the gas valve is de energized The operation of this control indicates a malfu
83. rs there will be potential damage to the internal components Following a power failure situation do not operate the unit until inspection and repairs are performed Liquid anti freeze will cause damage to internal plastic parts of this furnace DO NOT attempt to winterize the furnace using liquid anti freeze Clearances for access service Ample clearances should be provided to permit easy access to the unit The following minimum clearances are recommended 1 Twenty four 24 inches 61 cm between the front of the furnace and an adjacent wall or another appliance when access is required for servicing and cleaning 2 Eighteen 18 inches 46 cm at the side where access is required for passage to the front when servicing or for inspection or replacement of flue vent connections In all cases accessibility clearances shall take precedence over clear ances for combustible materials where accessibility clearances are greater Installation in a residential garage A gas fired furnace for installation in a residential garage must be installed so the burner s and the ignition source are located not less than 18 46 cm above the floor and the furnace must be located or protected to avoid physical damage by vehicles Table 1 Unit Clearances to Combustibles Application Upflow Vent Hear Side Front Combustible Combustible Combustible Closet Ene Coniad 1 For combustible floors only
84. t cycle If the problem has not been corrected the furnace will again lockout after three retries A momentary loss of gas supply flame blowout or a faulty flame probe circuit will result in a disruption in the flame and be sensed within 1 0 seconds The gas valve will de energize and the control will begin a recycle operation A normal ignition sequence will begin after a 15 sec ond inter purge If during the five recycles the gas supply does not return or the fault condition is not corrected the ignition control will lock out for 60 minutes During burner operation a momentary loss of power for 50 milliseconds or longer will de energize the gas valve When the power is restored the gas valve will remain de energized and the ignition sequence will immediately restart TROUBLESHOOTING The following visual checks should be made before troubleshooting 1 Check to see that the power to the furnace and the ignition control module is ON 2 The manual shut off valves in the gas line to the furnace must be open 3 Make sure all wiring connections are secure 4 Review the sequence of operation Start the system by setting the thermostat above the room temperature Observe the system s response Then use the troubleshooting section in this manual to check the system s operation Never bypass any safety control to allow furnace operation To do so will allow furnace to operate under potentially hazardous conditions Do
85. t the tubes are lifted at the front of the heat exchang ers where attached to the vestibule panel Do not use the top return bend of the heat exchangers as lifting points as the tubes may shift out of position or their location brackets baffles SUSPENDED FURNACE CRAWL SPACE INSTALLATION The furnace can be hung from floor joists or installed on suitable blocks or pad Blocks or pad installations shall provide adequate height to ensure the unit will not be subject to water damage Units may also be suspended from rafters or floor joists using rods pipe angle supports or straps Angle supports should be placed at the supply air end and near the blower deck Do not support at return air end of unit All four sus pension points must be level to ensure quite furnace operation When suspending the furnace use a secure platform constructed of plywood or other building material secured to the floor joists Refer to Figure 11 for typical crawl space installation Support Angle x3 gle x3 Maintain 6 minimum clearance between support rods and front of furnace FIGURE 11 Typical Suspended Furnace Crawl Space Installation IMPORTANT During installation doors should remain on the furnace when moving or lifting When moving or handling this furnace prior to installation always leave the doors on the furnace to provide support and to prevent damage or warping of the cabinet When lifting the furnace support the ends of the furn
86. ter SUPPLY VOLTAGE CONNECTIONS IMPORTANT The power connection leads and wiring box may be relocated to the left side of the furnace Remove the screws and cut wire tie holding excess wiring Reposition on the left side of the furnace and fasten using holes provided Junction Box Connect ground lead to screw LOW VOLTAGE CONTROL WIRING CONNECTIONS Install the field supplied thermostat by following the instructions that L1 Hot BL if come with the thermostat With the thermostat set in the OFF position Neutral and the main electrical source disconnected connect the thermostat wiring from the wiring connections on the thermostat to the terminal board on the ignition module as shown in Figures 18 21 Electronic thermostats may require the common wire to be connected Apply strain relief to thermostat wires passing through cabinet If air condition FIGURE 17 Electrical Wiring ing equipment is installed use thermostat wiring to connect the Y and C terminals on the furnace control board to the proper wires on the con 1 Provide a power supply separate from all other circuits Install densing unit unit outside overcurrent protection and disconnect switch per local national electrical codes The switch should be close to the unit for conve nience in servicing With the disconnect or fused switch in the OFF IM PORTANT osition check all wiring against the unit wiring label Refer to th
87. ter Sizes High Velocity 600 FPM 9 Estimated Free Area 27 Nominal Manifold Pressure High Fire 11 Unconfined Space Minimum 28 Nominal Manifold Pressure Low Fire 11 FICE 28 Ratings amp Physical Electrical Data 12 Gas Rate CU FT HR at Full Input 31 Maximum Equivalent Pipe Length 23 Inlet Gas Pressure Range 32 Elbow Dimensions 23 Nominal Manifold Pressure 32 Air Flow 29 i ta ee 34 438335 UIM C 1209 438335 UIM C 1209 These high efficiency compact units employ induced combustion reli able hot surface ignition and high heat transfer aluminized tubular heat exchangers The units are factory shipped for installation in upflow or horizontal applications and may be converted for downflow applica tions These furnaces are designed for residential installation in a basement closet alcove attic recreation room or garage and are also ideal for commercial applications All units are factory assembled wired and tested to assure safe dependable and economical installation and oper ation These units are Category IV listed and may not be common vented with another gas appliance as allowed by the National Fuel Gas Code S
88. the appliance being inspected in operation Adjust thermostat so the appliance shall operate contin uously Test each appliance such as a water heater equipped with a draft hood for spillage down draft or no draft at the draft hood relief open ing after 5 minutes of main burner operation Appliances that do not have draft hoods need to be checked at the vent pipe as close to the appliance as possible Use a combustion analyzer to check the and CO levels of each appliance Use a draft gauge to check for a downdraft or inadequate draft condition After it has been determined that each appliance properly vents when tested as outlined above return doors windows exhaust fans fire place dampers and any other gas burning appliance to their normal condition If improper venting is observed during any of the above tests a problem exists with either the venting system or the appliance does not have enough combustion air Supply Air from outside to complete combustion This condition must be corrected before the appliance can function safely NOTE An unsafe condition exists when the CO reading exceeds 40 ppm and the draft reading is not in excess of 0 1 in w c 25 kPa with all of the appliance s operating at the same time 8 Any corrections to the venting system and or to the supply outside air system must be in accordance with the National Fuel Gas Code Z223 1 or CAN CGA B149 1 Natural Gas and Propane Installation Code latest
89. the venting system must be installed in accordance with Section 5 3 Air for Com bustion and Ventilation of the National Fuel Gas Code Z223 1 NFPA 54 latest edition or Sections 7 2 7 3 or 7 4 of CSA B149 1 National Gas and Propane Codes latest edition or applicable provisions of the local building code and these instructions IMPORTANT The VENT SYSTEM must be installed as specified in these instruc tions for Residential and non HUD Modular Homes The direct vent system is the only configuration that can be installed in a non HUD Modular Home This furnace may not be common vented with any other appliance since it requires separate properly sized air intake and vent lines The furnace shall not be connected to any type of B BW or L vent or vent connector and not connected to any portion of a factory built or masonry chimney The furnace shall not be connected to a chimney flue serving a sep arate appliance designed to burn solid fuel A CAUTION When combustion air pipe is installed above a suspended ceiling or when it passes through a warm and humid space the pipe must be insulated with 1 2 Armaflex or other heat resistant type insulation if two feet or more of pipe is exposed Vent piping must be insulated if it will be subjected to freezing tem peratures such as routing through unheated areas or through an unused chimney COMBUSTION AIR VVENT PIPE SIZING The size of pipe require
90. tial garage must installed as specified in these instructions 4 Provide adequate combustion and ventilation air to the furnace space as specified in these instructions 5 Combustion products must be discharged outdoors Connect this furnace to an approved vent system only as specified in SEC TION VII COMBUSTION AIR and VENT SYSTEM of these instructions 6 Test for gas leaks as specified in these instructions A WARNING FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in serious injury death or property damage Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for detection of leaks to check all connections A fire or explosion may result causing prop erty damage personal injury or loss of life 7 Always install the furnace to operate within the furnace s intended temperature rise range Only connect the furnace to a duct system which has an external static pressure within the allowable range as specified on the furnace rating plate 8 When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace the return air shall also be handled by duct s sealed to the fur nace casing and terminating outside the space containing the fur nace 9 Itis permitted to use the furnace for heating of buildings or struc tures under construction where the appl
91. to obtain the proper orifice size Drilling out a gas orifice will cause misalignment of the burner flames causing premature heat exchanger burnout high levels of carbon monoxide excessive sooting a fire hazard personal injury property damage and or death SECTION V ELECTRICAL POWER ELECTRICAL POWER CONNECTIONS A CAUTION Use copper conductors only Johnson Controls Unitary Products Field wiring to the unit must be grounded Electric wires that are field installed shall conform to the temperature limitation for 63 F 35 C rise wire when installed in accordance with instructions Refer to Table 7 in these instructions for specific furnace electrical data 11 438335 UIM C 1209 Table 7 Ratings amp Physical Electrical Data Input Output Nominal Cabinet Width High Fire Low Fire High Low High Low Airflow Total Unit Air Temp Rise Air Temp Rise 024 EL E 1 Input Max Outlet Min Wire Size Operating High Low Air Temp emer Over current awg 75 ft Weight Protect OneWay 155 Annual Fuel Utilization Efficiency AFUE numbers are determined in accordance with DOE test procedures Wire size and over current protection must comply with the National Electrical Code NFPA 70 latest edition and all local codes The furnace shall be installed so that the electrical components are protected from wa
92. ts of burner box into socket just above top panel g pers LT 7 del Or vent pipe may be clamped into outlet of drain coupling FIGURE 35 Direct Vent Air Intake Connection and Vent Connection The combustion air intake pipe should be located either through the wall horizontal or side vent or through the roof vertical vent Care should be taken to locate side vented systems where trees or shrubs will not block or restrict supply air from entering the terminal Also the terminal assembly should be located as far as possible from a swimming pool or a location where swimming pool chemicals might be stored Be sure the terminal assembly follows the outdoor clearances listed in Section 1 Outdoor Air Contaminants Johnson Controls Unitary Products 438335 UIM C 1209 Ambient Combustion Air Supply This type installation will draw the air required for combustion from within the space surrounding the appliance and from areas or rooms adjacent to the space surrounding the appliance This may be from within the space in a non confined location or it may be brought into the furnace area from outdoors through permanent openings or ducts It is not piped directly into the furnace A single properly sized pipe from the furnace vent connector to the outdoors must be provided It is recom mended that the supplied intake coupling and 18 46 cm of pipe be attached to the furnace to prevent accidental blockage of the com
93. uct filter box attached to the furnace plenum or at the end of the duct in a return filter grille s The use of straps and or supports is required to support the weight of the external filter box SECTION IV GAS PIPING GAS SAFETY An overpressure protection device such as a pressure regulator must be installed in the gas piping system upstream of the furnace and must act to limit the downstream pressure to the gas valve so it does not exceed 0 5 psig 14 w c 8 48 kPa Pressures exceed ing 0 5 psig 14 w c 3 48 kPa at the gas valve will cause damage to the gas valve resulting in a fire or explosion or cause damage to the furnace or some of its components that will result in property damage and loss of life To Gas HIGH STAGE REGULATOR ADJUSTMENT OUTLET PRESSURE NI N PRESSURE PORT LOW STAGE REGULATOR SWITCH ADJUSTMENT FIGURE 15 Gas Valve IMPORTANT Plan your gas supply before determining the correct gas pipe entry Use 90 degree service elbow s or short nipples and conventional 90 degree elbow s to enter through the cabinet access holes GAS PIPING INSTALLATION Properly sized wrought iron approved flexible or steel pipe must be used when making gas connections to the unit If local codes allow the use of a flexible gas appliance connection always use a new listed con nector Do not use a connector that has previously serviced another gas ap
94. uipped with memory that will store up to five error codes to allow a service technician to diagnose problems more easily This memory will be retained even if power to the furnace is lost This feature should only be used by a qualified service tech nician If more than five error codes have occurred since the last reset only the five most recent will be retained The furnace control board has a but ton labeled LAST ERROR that is used to retrieve error codes This function will only work if there are no active thermostat signals So any call for heating cooling or continuous fan must be terminated before attempting to retrieve error codes To retrieve the error codes push the LAST ERROR button The LED on the control will then flash the error codes that are in memory starting with the most recent There will be a two second pause between each flash code After the error codes have all been displayed the LED will resume the normal slow green flash after a five second pause To repeat the series of error codes push the button again If there are no error codes in memory the LED will flash two green flashes To clear the memory push the LAST ERROR button and hold it for more than five seconds The LED will flash three green flashes when the memory has been cleared then will resume the normal slow green flash after a five second pause Thermostat Calling for Heat lt Thermostat Satisfied Seconds 02 17 22 Fan on Delay
95. uivalent Pipe Length Maximum Equivalent length feet m 19 8 27 4 19 8 27 4 Model Input BTUH kW Pipe Size Inches cm 60 000 17 6 80 000 23 4 80 000 23 4 4062 100 000 29 3 90 27 4 120 000 35 1 250 30 9 2 120 000 35 1 90 27 4 65 90 65 90 2 PO N NI OI NNI Ol Ny OI C O O C3 STANDARD ELBOW LONG SWEEP ELBOW FIGURE 28 Dimensions TABLE 9 Elbow Dimensions Ebow A Dimension 2 Standard 2 5 16 3 Standard 3 1 16 3 Sweep 51 4 1 16 Dimensions are those required in Standard ASTM D 3311 23 438335 UIM C 1209 TABLE 10 Equivalent Length of Fittings Equivalent Length 5 feet of 2 pipe 7 feet of 2 pipe 3 1 2 feet of 2 pipe 5 feet of 3 pipe 3 90 standard elbow 7 feet of 3 pipe 3 45 standard elbow TO fest of 3 pipe Example 2 90 sweep elbow 2 45 sweep elbow 2 90 standard elbow 2 45 standard elbow 3 90 sweep elbow 3 45 sweep elbow An 80 000 BTUH furnace requires 32 feet of pipe and five 90 elbows Using 2 pipe and standard elbows the total equivalent length will be 32 feet of 2 pipe 5 90 standard 2 elbows 5 x 7 Total 32 equivalent feet 35 equivalent feet 67 equivalent feet of 2 pipe This exceeds the 65 foot maximum equivalent length of 2 pipe allowed for that model and is thus n
96. uvers grilles and screens must be given con sideration in calculating free area If the free area of a specific louver or grille is not known refer to Table 12 to estimate free area Table 12 Estimated Free Area Wood or Metal Wood 20 25 Louvers or Grilles Metal 60 70 1 4 6 4 mm mesh or larger 10096 Screens Do not use less than 1 4 6 4 mm mesh Free area of louvers and grille varies widely the installer should follow louver or grille manufacturer s instructions 27 438335 UIM C 1209 Dampers Louvers and Grilles Canada Only Table 13 Unconfined Space Minimum Area 1 The free area of a supply air opening shall be calculated by sub ES tracting the blockage area of all fixed louvers grilles or screens BTUH Input Rating Feauiredter Each Open from the gross area of the opening mU 2 2 Apertures in a fixed louver a grille or screen shall have no dimen 60 000 60 387 sion smaller than 1 4 6 4 mm 80 in 516 cm 3 A manually operated damper or manually adjustable louvers are 100 in 645 cm not permitted for use cally adj iene 4 automatically operated damper or automatically adjustable lou TED vers shall be interlocked so that the main burner cannot operate unless either the damper or the louver is in the fully open position Table 14 Free Area Minimum Free Area Required for Each Opening dia Horizontal Duct Vertical Duci or Round
97. when used with special sub base 24 clearance in front and 18 on side recommended for service access All furnaces approved for alcove and attic installation Johnson Controls Unitary Products SECTION Il DUCTWORK DUCTWORK GENERAL INFORMATION The duct system s design and installation must 1 Handle an air volume appropriate for the served space and within the operating parameters of the furnace specifications 2 Be installed in accordance of National Fire Protection Association as outlined in NFPA standard 90B latest editions or applicable national provincial state and local fire and safety codes 3 Create a closed duct system For residential and non HUD Modu lar Home installations when a furnace is installed so that the sup ply ducts carry air circulated by the furnace to areas outside the space containing the furnace the return air shall also be handled by a duct s sealed to the furnace casing and terminating outside the space containing the furnace 4 Complete a path for heated or cooled air to circulate through the air conditioning and heating equipment and to and from the condi tioned space A CAUTION The cooling coil must be installed in the supply air duct down stream of the furnace Cooled air may not be passed over the heat exchanger When the furnace is used with a cooling coil the coil must be installed parallel with or in the supply air side of the furnace to avoid condensa tion in th
98. y limit switch has opened its normally closed contacts and has remained open for more than five minutes This condition is usually caused by a failed blower motor or blower wheel Cycle power 24 VAC to the control to reset the hard lockout condition after correcting the failure condition 12 RED FLASHES This code indicates an open igniter circuit which could be a disconnected or loose wire or a cracked or broken igniter STEADY ON RED Control failure Replace control board 60 MINUTE AUTOMATIC RESET FROM LOCKOUT This control includes a watchdog type circuit that will reset from a lockout condition after 60 minutes Operational faults 6 7 8 will be reset This provides protection to an unoccupied structure if a temporary condition exists causing a furnace malfunction An example would be a low incoming gas supply pressure preventing unit operation When the gas pressure is restored at some point the watchdog would restart the unit and pro vide heat for the house NOTICE If a flame is detected the control flashes the LED for 1 8 of a second and then enters a flame stabilization period 438335 UIM C 1209 IGNITION CONTROL FLAME SENSE LEVELS Normal flame sense current is approximately 3 7 microamps DC Low flame signal warning starts at 1 5 microamps Low flame signal control lockout point is 0 1 microamps DC DIAGNOSTIC FAULT CODE STORAGE AND RETRIEVAL The control in this furnace is eq

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