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4716 203rd St Ne_BLD5745_2025
Permit Packet Coversheet Community and Economic Development City of Arlington • 18204 59th Avenue NE • Arlington, WA 98223 • Phone (360) 403-3551 Page 1 of 1 Permit Number: Permit Type: Address/Parcel: Completed (Month/Year): Land Use Notice of Decision Staff Report Application Narrative Legal Description Vicinity Map Site Plan Landscape Plan Complete Streets Checklist Traffic Impact Analysis Snohomish County Traffic Mitigation Offer WSDOT Traffic Offer Form Tree Survey Stormwater Drainage Report Geotech Report Critical Area Evaluation Form SEPA Checklist Public Notice Material Noticing and Related Documents Water / Sewer Availability Certificate Unanticipated Discovery Plan Form Aerial Photo of Site Proposed Building Materials Lighting Plans and Lighting Cut Sheets Color Elevations Design Matrix Plat Map Title Report Lot Closures Preliminary Civil Plans Archaeological Survey o Confidential Documents. Contact the City to obtain. Topography (Existing Conditions) CC&R’s Deeds / Easements / Conveyances /Dedications Developer’s Agreement Recorded Copies Bonding or Assignment of Funds o Confidential Documents. Contact the City to obtain. Letters and Project Documents Other: Civil Issued Permit Application Other Applications Construction Calculation Worksheet Approved Plans Review Comment Form Letters and Project Documents Other Agency Permits Reports: o Drainage Report Pg: o Stormwater Pg: o Geotech Pg: o All Other Reports SEPA and Noticing Materials Inspections As-Builts Other: Building Issued Permit Application Additional Applications Approved Plans Site Plan Letters and Project Documents Calculations Project Specification Manuals Reports Certificate of Occupancy Inspections Other: BLD5745 Residential Mechanical 4716 203rd St Ne May 2024 ✔ ✔ ✔ Johnson Controls Unitary Products 1183509-UIM-N-0218 R-410A OUTDOOR SPLIT-SYSTEM AIR CONDITIONING MODELS: 13, 14 & 17 SEER YCD, YCE, YCG, YCS, YFD, YFE, TC3, TC4, TC7, CC7, TW4, TF3, TF4, TCD, TCG, RAC13L, RAC14L, RAC17L, RAW14L, RAC13F, RAC14F SERIES 1.5 TO 5 TONS – 1 & 3 PHASE INSTALLATION MANUAL ® LIST OF SECTIONS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 COIL METERING DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 EVACUATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 SYSTEM CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTRUCTING THE OWNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 START UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 LIST OF FIGURES Typical Installation Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Alternative Installation Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Installation of Vapor Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Underground Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Heat Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Recommended Distributor Adjustment . . . . . . . . . . . . . . . . . . . . . . . .6 Piston Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 TXV Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 TXV Bulb and Equalizer line Installations . . . . . . . . . . . . . . . . . . . . . .7 Proper Bulb Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Vertical Temperature Bulb Orientation . . . . . . . . . . . . . . . . . . . . . . . . .8 Outdoor Unit Swing Away Control Box . . . . . . . . . . . . . . . . . . . . . . .10 Outdoor Unit Control Box (Single Phase - Smaller Base) . . . . . . . . 10 Outdoor Unit Control Box (Single Phase - Larger Base) . . . . . . . . . 10 Outdoor Unit Control Box (Three Phase) . . . . . . . . . . . . . . . . . . . . . 11 Typical Field Wiring (Air Handler / Electrical Heat) (Single-Phase) . 11 Typical Field Wiring (Air Handler / Electrical Heat) (Three-Phase) . . 12 Thermostat Chart - PSC Air Handler with Single Stage Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Thermostat Chart - Single Stage PSC Furnace with Single Stage Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Wiring Diagram - Single Phase 13 & 14 Seer . . . . . . . . . . . . . . . . . . 14 Wiring Diagram - Single Phase 17 Seer . . . . . . . . . . . . . . . . . . . . . . 15 Wiring Diagram - Three Phase 13 Seer . . . . . . . . . . . . . . . . . . . . . . 16 Wiring Diagram - Three Phase 17 Seer . . . . . . . . . . . . . . . . . . . . . . 17 LIST OF TABLES Application Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 R-410A Saturation Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SECTION I: GENERAL These outdoor condensing units are designed to be connected to a matching UPG indoor coil. They are equipped with a filter-drier located in the liquid line. Units with quick-connect coupling connections are factory charged with refrigerant to be matched with the appropriate pre-charged line set, and UPG indoor coil. SECTION II: 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. 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 maintenance can cause injury or property damage. Refer to this manual for assis- tance or for additional information, consult a qualified contractor, installer or service agency. CAUTION This product must be installed in strict compliance with the enclosed installation instructions and any applicable local, state, and national codes including, but not limited to building, electrical, and mechanical codes. CAUTION R-410A systems operate at higher pressures than R-22 systems. Do not use R-22 service equipment or components on R-410A equip- ment. Service equipment Must Be Rated for R-410A. ! ! ! 1183509-UIM-N-0218 2 Johnson Controls Unitary Products 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 delivery receipt. A separate request for inspection by the carrier’s agent should be made in writing. See Local Distributor for more information. Requirements For Installing/Servicing R-410A Equipment • Gauge sets, hoses, refrigerant containers, and recovery system must be designed to handle the POE type oils, and the higher pressures of R-410A. • Manifold sets should be high side and low side with low side retard. • All hoses must have a 700 psig service pressure rating. • Leak detectors should be designed to detect HFC refrigerant. • Recovery equipment (including refrigerant recovery containers) must be specifically designed to handle R-410A. • Do not use an R-22 TXV. LIMITATIONS The unit should be installed in accordance with all National, State and Local Safety Codes and the limitations listed below: 1. Limitations for the indoor unit, coil, and appropriate accessories must also be observed. 2. The outdoor unit must not be installed with any duct work in the air stream. The outdoor fan is the propeller type and is not designed to operate against any additional external static pressure. 3. The maximum and minimum conditions for operation must be observed to ensure a system that will give maximum performance with minimum service. 4. The unit should not be operated at outdoor temperatures below 55°F without an approved low ambient operation accessory kit installed. 5. The maximum allowable line length for this product is 80 feet. To install more than the maximum allowable line length, consult the Piping Application Guide (P/N 247077). SECTION III: UNIT INSTALLATION LOCATION Before starting the installation, select and check the suitability of the location for both the indoor and outdoor unit. Observe all limitations and clearance requirements. The outdoor unit must have sufficient clearance for air entrance to the condenser coil, air discharge, and service access. See Figures 1 & 2. If the unit is to be installed on a hot sun exposed roof or a paved ground area that is seasonally hot, the unit should be raised sufficiently above the roof or ground to avoid taking the accumulated layer of hot air into the outdoor unit. If the system is being installed during seasonally cold weather of 55°F or below, the preferred method is to weigh in the charge. For charging or checking the system charge at 55°F or below, refer to the “Optional Cold Weather Charging” procedures near the end of SECTION VI: SYSTEM CHARGE. There is an “Optional Cold Weather Charging” accessory kit to prevent the outdoor unit from taking in cold air below 55°F. The kit part number can be found in the list of accessory kits on the UPGNET web site. Provide adequate structural support for the unit. ADD-ON REPLACEMENT/RETROFIT When this unit is being used as a replacement for an R-410A unit, it is required that the outdoor unit, indoor coil, and metering device all be replaced. The following steps should be performed in order to insure proper system operation and performance. Line-set change out is also recommended. 1. Change-out of the indoor coil to an approved R-410A coil/ con- densing unit combination with the appropriate metering device. 2. Change-out of the line-set when replacing an R-22 unit with an R410-A unit is highly recommended to reduce cross-contamina- tion of oils and refrigerants. 3. If change-out of the line set is not practical, then the following pre- cautions should be taken. • Inspect the line set for kinks, sharp bends, or other restrictions, and for corrosion. • Determine if there are any low spots which might be serving as oil traps. • Flush the line set with a commercially available flush kit to remove as much of the existing oil and contaminants as possible. • Install a suction line filter-drier to trap any remaining contami- nants, and remove after 50 hours of operation. 4. If the outdoor unit is being replaced due to a compressor burnout, then installation of a 100% activated alumina suction-line filter drier in the suction-line is required, in addition to the factory installed liquid-line drier. Operate the system for 10 hours. Monitor the suction drier pressure drop. If the pressure drop exceeds 3 psig, replace both the suction-line and liquid-line driers. After a total of 10 hours run time where the suction-line pressure drop has not exceeded 3 psig, replace the liquid line drier, and remove the suction-line drier. Never leave a suction-line drier in the system longer than 50 hours of run time. TABLE 1: Application Limitations Ambient Air Temperature on Outdoor Coil Air Temperature on Indoor Coil MODEL Min. DB Max. DB Min. WB Max. WB YCD/TC3/RAC13L 55°F 115°F 57°F 72°F YCS/YFE/YCE/TW4/TF4/TC4/ RAC14L/RAW14L/RAC14F/ YCG/TC7/CC7/RAC17L 55°F 125°F 57°F 72°F NOTICE For multiple unit installations, units must be spaced a minimum of 24” (61 cm) apart (coil face to coil face). 1183509-UIM-N-0218 Johnson Controls Unitary Products 3 FIGURE 1: Typical Installation Clearances 127( (QVXUHDPLQLPXPRI ´FOHDUDQFHEHWZHHQ DQ\WZRXQLWV ´&/($5$1&( $5281'3(5,0(7(5 ´FOHDUDQFH SHUPLVVLEOHRQRQH VLGHRQO\VHH $OWHUQDWLYH ,QVWDOODWLRQ &OHDUDQFHV ´29(5+($'&/($5$1&( 0,1,080´6(59,&($&&(66&/($5$1&( 0DLQWDLQPLQLPXPFOHDUDQFHRQRQHVLGHRIDFFHVVSDQHO :($7+(53522) ',6&211(&7 6:,7&+ 1(&&/$66:,5,1* 7+(50267$7 1(&&/$66:,5,1* 72)851$&(25 $,5+$1'/(5 7(50,1$/%/2&. 1(&&/$66:,5,1* &21752/ $&&(66 3$1(/ 6($/23(1,1*6 8VHSHUPDJXPRUHTXLYDOHQW 127( $OORXWGRRUZLULQJ PXVWEHZHDWKHUSURRI 612:3803836 8VHLQGHHSVQRZDUHDV ZLWK¿IWKSXPSXSXQGHU FHQWHURIFRPSUHVVRU $ %5$&(6 8VHIRUZDOOPRXQWZLWK FHQWHUEUDFHXQGHU FHQWHURIFRPSUHVVRU 127( (QVXUHDGHTXDWH ZDOOVXSSRUW &$87,21 6SHFLDOFDUHPXVWEHWDNHQWRDYRLGUHFLUFXODWLRQRIGLVFKDUJHDLUWKURXJKFRQGHQVHUFRLO FIGURE 2: Alternative Installation Clearances $ 0,1,080&/($5$1&(%(7:((181,76 127( &OHDUDQFHEHWZHHQWZRXQLWVPD\EH UHGXFHGWR´PLQLPXPSURYLGHG WKHVHUYLFHDFFHVVFOHDUDQFHLV LQFUHDVHGWR´PLQLPXPDQGWKH FOHDUDQFHRQHDFKUHPDLQLQJVLGH LVPDLQWDLQHGDW´PLQLPXP 127( &OHDUDQFHWRRQHVLGHRIWKH XQLWPD\EHUHGXFHGWR´SURYLGHG WKHFOHDUDQFHWRHDFKUHPDLQLQJVLGH LVLQFUHDVHGWR´PLQLPXPWKH VHUYLFHDFFHVVLVLQFUHDVHGWR´ PLQLPXPDQGWKHFOHDUDQFHVEHWZHHQ DQ\WZRXQLWVLVPDLQWDLQHGDW´ PLQLPXP 0,1,080&/($5$1&()520:$// ´´ ´ 6(59,&( $1'81,7 7281,7 ´ 6(59,&( ´ ´ ´ :$// )(1&( ´ 6(59,&( ´ 6(59,&( ´ 6(59,&( ´ 81,7 7281,7 ´ 81,7 7281,7 ´ ´´´ ´ :$// )(1&( &$87,21 6SHFLDOFDUHPXVWEHWDNHQWRDYRLGUHFLUFXODWLRQRIGLVFKDUJHDLUWKURXJKFRQGHQVHUFRLO 1183509-UIM-N-0218 4 Johnson Controls Unitary Products GROUND INSTALLATION The unit should be installed on a solid base that is 2” (5.1 cm) above grade and will not shift or settle, causing strain on the refrigerant lines and possible leaks. Maintain the clearances shown in Figures 1 & 2 and install the unit in a level position. The base pad should not come in con- tact with the foundation or side of the structure because sound may be transmitted to the residence. The length of the refrigerant tubing between the outdoor unit and indoor coil should be as short as possible to avoid capacity and efficiency losses. Excessive spacing of the outdoor unit from the home can result in the refrigerant lines being restricted by trampling or being punctured by lawn mowers. Locate the outdoor unit away from bedroom windows or other rooms where sound might be objectionable. Adverse effects of snow or sleet accumulating on the outdoor coil can be eliminated by placing the outdoor unit where the prevailing wind does not blow across the unit. Trees, shrubs, corners of buildings, and fences standing off from the coil can reduce capacity loss due to wind chill effect. Provide ample clearance from shrubs to allow adequate air to pass across the outdoor coil without leaves or branches being pulled into the coil. ROOF INSTALLATION When installing units on a roof, the structure must be capable of sup- porting the total weight of the unit, including a pad, lintels, rails or any components used to minimize the transmission of sound or vibration into the conditioned space. WALL MOUNT INSTALLATION Care must be taken to mount the outdoor unit on a solid base that is sloped to shed water, secure from settlement, and is isolated from the structural foundation or walls to prevent sound and vibration transmis- sion into the living space. On occasion, site conditions may require direct wall mounted brackets to be used to locate and support the outdoor unit. In these applications, care must be taken to address unit base pan support, structural integ- rity, safe access and serviceability, as well as the possible sound and vibration transmission into the structure. These applications are best served by a properly engineered solution. LIQUID LINE FILTER-DRIER The air conditioning unit’s filter/dryer is located inside the unit on the liq- uid line between the outdoor coil and the liquid valve inside the unit. PIPING CONNECTIONS The outdoor condensing unit must be connected to the indoor evapora- tor coil using field supplied refrigerant grade (ACR) copper tubing that is internally clean and dry. Units should be installed only with the tubing sizes for approved system combinations as specified in tabular data sheet. The charge given is applicable for total tubing lengths up to 15 feet (4.6 m). See Piping Application Guide (P/N 24077) for installing tubing of longer lengths and elevation differences. PRECAUTIONS DURING LINE INSTALLATION 1. Install the lines with as few bends as possible. Care must be taken not to damage the couplings or kink the tubing. Use clean hard drawn copper tubing where no appreciable amount of bending around obstruction is necessary. If soft copper must be used, care must be taken to avoid sharp bends which may cause a restriction. 2. The lines should be installed so that they will not obstruct service access to the coil, air handling system, or filter. 3. Care must also be taken to isolate the refrigerant lines to minimize noise transmission from the equipment to the structure. 4. The vapor line must be insulated with a minimum of 1/2” foam rub- ber insulation (Armaflex or equivalent). Liquid lines that will be exposed to direct sunlight, high temperatures, or excessive humid- ity must also be insulated. 5. Tape and suspend the refrigerant lines as shown. DO NOT allow tube metal-to-metal contact. See Figure 3. 6. Use PVC piping as a conduit for all underground installations as shown in Figure 4. Buried lines should be kept as short as possible to minimize the build up of liquid refrigerant in the vapor line during long periods of shutdown. 7. Pack fiberglass insulation and a sealing material such as perma- gum around refrigerant lines where they penetrate a wall to reduce vibration and to retain some flexibility. 8. For systems with total line length exceeding 75 feet (22.86 m), see Piping Application Guide (P/N 24077) for vapor and liquid line siz- ing, calibration of liquid line pressure loss or gain, determination of vapor line velocity, elevation limitations, TXV connections, system charging or traps. CAUTION Failure to do so or using a substitute drier or a granular type may result in damage to the equipment. Filter-Drier Source 1 Part No. Apply with Models S1-401021 All ! NOTICE Using a larger than specified line size could result in oil return prob- lems. Using too small a line will result in loss of capacity and other problems caused by insufficient refrigerant flow. Slope horizontal vapor lines at least 1" (2.5 cm) every 20 feet (6.1 m) toward the out- door unit to facilitate proper oil return. If more than the 80 foot line length is necessary, facilitate proper refrigerant velocity with adjusted line diameter in accordance with the Piping Application Guide (P/N 24077). CAUTION This system uses R-410A refrigerant which operates at higher pres- sures than R-22. No other refrigerant may be used in this system. Gauge sets, hoses, refrigerant containers, and recovery system must be designed to handle R-410A. If you are unsure, consult the equip- ment manufacturer. WARNING Never install a suction-line filter drier in the liquid line of an R-410A system. Failure to follow this warning can cause a fire, injury or death. FIGURE 3: Installation of Vapor Line ! ! Liquid Line Incorrect Correct Tape Sheet Metal Hanger Insulated Vapor Line A0151-001 1183509-UIM-N-0218 Johnson Controls Unitary Products 5 PRECAUTIONS DURING BRAZING OF LINES All outdoor unit and evaporator coil connections are copper-to-copper and should be brazed with a phosphorous-copper alloy material such as Silfos-5 or equivalent. DO NOT use soft solder. The outdoor units have reusable service valves on both the liquid and vapor connections. The total system refrigerant charge is retained within the outdoor unit during shipping and installation. The reusable service valves are pro- vided to evacuate and charge per this instruction. Serious service problems can be avoided by taking adequate precau- tions to assure an internally clean and dry system. PRECAUTIONS DURING BRAZING SERVICE VALVE Precautions should be taken to prevent heat damage to service valve by wrapping a wet rag around it as shown in Figure 5. Also, protect all painted surfaces, insulation, and plastic base during brazing. After braz- ing, cool joint with wet rag. Valve can be opened by removing the service valve cap and fully insert- ing a hex wrench into the stem and backing out counter-clockwise until valve stem just touches the chamfered retaining wall. Connect the refrigerant lines using the following procedure: 1. Remove the cap and Schrader core from both the liquid and vapor service valve service ports at the outdoor unit. Connect low pres- sure nitrogen to the liquid line service port. 2. Braze the liquid line to the liquid valve at the outdoor unit. Be sure to wrap the valve body with a wet rag. Allow the nitrogen to con- tinue flowing. 3. Carefully remove the plugs from the indoor coil liquid and vapor connections at the indoor coil. 4. Braze the liquid line to the indoor coil liquid connection. Nitrogen should be flowing through the indoor coil. 5. Slide the grommet away from the vapor connection at the indoor coil. Braze the vapor line to the evaporator vapor connection. After the connection has cooled, slide the grommet back into original position. 6. Protect the vapor valve with a wet rag and braze the vapor line connection to the outdoor unit. The nitrogen flow should be exiting the system from the vapor service port connection. After this con- nection has cooled, remove the nitrogen source from the liquid fit- ting service port. 7. Replace the Schrader core in the liquid and vapor valves. 8. Go to SECTION IV for TXV installation. 9. Leak test all refrigerant piping connections including the service port flare caps to be sure they are leak tight. DO NOT OVER- TIGHTEN (between 40 and 60 inch - lbs. maximum). 10. Evacuate the vapor line, indoor coil, and liquid line to 500 microns or less. 11. Replace cap on service ports. Do not remove the flare caps from the service ports except when necessary for servicing the system. FIGURE 4: Underground Installation CAUTION Dry nitrogen should always be supplied through the tubing while it is being brazed, because the temperature required is high enough to cause oxidation of the copper unless an inert atmosphere is provided. The flow of dry nitrogen should continue until the joint has cooled. Always use a pressure regulator and safety valve to insure that only low pressure dry nitrogen is introduced into the tubing. Only a small flow is necessary to displace air and prevent oxidation. WARNING This is not a backseating valve. The service access port has a valve core. Opening or closing valve does not close service access port. If the valve stem is backed out past the chamfered retaining wall, the O-ring can be damaged causing leakage or system pressure could force the valve stem out of the valve body possibly causing personal injury. TO INDOOR COIL TO OUTDOOR UNITLIQUIDLINE CA P PVC CONDUIT INSULATED VAPOR LINE A0152-001 ! ! FIGURE 5: Heat Protection CAUTION Do not install any coil in a furnace which is to be operated during the heating season without attaching the refrigerant lines to the coil. The coil is under pressure which must be released to prevent excessive pressure build-up and possible coil damage. NOTICE Line set and indoor coil can be pressurized to 250 psig with dry nitro- gen and leak tested with a bubble type leak detector. Then release the nitrogen charge. Do not use the system refrigerant in the outdoor unit to purge or leak test. CAUTION Do not connect manifold gauges unless trouble is suspected. Approx- imately 3/4 ounce of refrigerant will be lost each time a standard man- ifold gauge is connected. $ :(75$*6 :UDSZHWUDJV DURXQGVHUYLFHYDOYH RUUHIULJHUDQWOLQHV SULRUWREUD]LQJ ! ! 1183509-UIM-N-0218 6 Johnson Controls Unitary Products 12. Release the refrigerant charge into the system. Open both the liq- uid and vapor valves by removing the plunger cap and with an allen wrench back out counter-clockwise until valve stem just touches the chamfered retaining wall. If the service valve is a ball valve, use a Crescent wrench to turn valve stem one-quarter turn counterclockwise to open. Do not overturn or the valve stem may break or become damaged. See “PRECAUTIONS DURING BRAZING SERVICE VALVE”. 13. Replace plunger cap finger tight, then tighten an additional 1/12 turn (1/2 hex flat). Cap must be replaced to prevent leaks. See “System Charge” section for checking and recording system charge. SECTION IV: COIL METERING DEVICES A piston or a TXV is to be installed in the field. There is an installation manual that comes with the TXV kit. It is recommended to install the piston or TXV kit prior to installation of coil and brazing of line set. Until brazing is completed and cooled, the TXV sensing bulb must not be installed. The outdoor technical guide for outdoor units should be consulted for required piston or TXV on the indoor coil. The piston and the Schrader core are supplied with the outdoor unit. When the piston is used instead of the TXV, the Schrader core is installed in the suction line equalizer connection port and is capped with the supplied plastic cap. The Schrader core must not be installed if the TXV is installed, because the TXV equalizer line attaches to the equalizer connection port. PISTON INSTALLATION Install Schrader Valve Core and Piston as follows: 1. After holding charge is completely discharged, remove black plas- tic cap from equalizer connection port on the vertical part of the vapor line. 2. Distributor position must be adjusted to allow the preformed liquid line assembly to properly line up with the hole in the tubing access panel. Raise the distributor body approximately 2” toward the top of the coil or what would be the top of the coil if coil was in the upflow position. See Figure 6. Adjust as necessary. 3. Install Schrader valve core supplied with the outdoor unit into the equalizer fitting connection port using a valve core tool. 4. Loosen and remove the liquid line connection nut and the sealing disc from the distributor assembly. Note that the fitting has right hand threads. 5. Slide the nut over the liquid line to be installed, and discard the seal disc. 6. Install required size piston into the distributor. Refer to supplied Tabular Data Sheet for specific piston size and indoor coil match up. 7. Verify that the Teflon washer is still in place in the distributor open- ing. See Figure 7. 8. After piston is installed, install the liquid line to the top of the pis- ton/distributor assembly. Hand tighten, and turn an additional 1/4 turn to seal. Do not over tighten fittings. 9. Replace black plastic cap on unused equalizer fitting connection port. 10. After line set is installed, leak test the system. WARNING Never attempt to repair any brazed connections while the system is under pressure. Personal injury could result. CAUTION COIL UNDER PRESSURE. Verify that pressure has been released by depressing Schrader valve core. The coil requires a metering device to be added. See outdoor unit documentation for correct TXV or piston to be used. NOTICE To prevent moisture and contaminates from entering the system, the coil should not be open to atmosphere for extended periods of time. If the coil cannot be brazed into the refrigeration system during a rou- tine installation period, the ends should be temporarily closed or plugged. For a short term delay, use masking tape over the ends of the copper tubing to close the tube from the air. For a longer term delay, use plugs or caps. There is no need to purge the coil if this pro- cedure is followed. WARNING Failure to install Schrader Valve Core in the vapor line equalizer con- nection port for piston applications could result in total refrigerant loss of the system! ! ! ! FIGURE 6: Recommended Distributor Adjustment FIGURE 7: Piston Installation CAUTION Do not overtorque. Do not use slip joint pliers. This will distort the alu- minum distributor and the brass fitting (potentially causing leaks). $ A0305-001 DISTRIBUTOR PISTON LIQUID LINE SWIVEL COUPLING (This fitting is a right-handed thread. Turn counter-clockwise to remove.) TEFLON WASHER ! 1183509-UIM-N-0218 Johnson Controls Unitary Products 7 THERMOSTATIC EXPANSION VALVE (TXV) INSTALLATION The following are basic steps for installation. For detailed instructions, refer to the Installation Instructions accompanying the TXV kit. Install TXV kit as follows: 1. Relieve the holding charge by depressing Schrader core on the suction manifold stub out. 2. After holding charge is completely discharged, loosen and remove the Schrader core. 3. Place a backup wrench on distributor, loosen and remove brass distributor nut. Retain brass nut for use on liquid line. Keep Teflon washer in place and discard clear disk. 4. Install the thermal expansion valve to the distributor assembly with supplied fittings. Ensure Teflon washer is seated in distributor. Hand tighten and turn an additional 1/4 turn to seal. Do not over- tighten fittings. See Figure 8. 5. Slide the nut removed in step 3 over the supplied liquid line. Place supplied Teflon washer from TXV kit in place on TXV, and install liq- uid line to the top of the thermal expansion valve. Adjust assembly so liquid line aligns with hole in access panel. See Figure 9. Hand tighten the liquid line, and apply an additional 1/4 turn to seal. 6. Install the TXV equalizer line onto the vapor line by hand tightening the 1/4” SAE coupling nut to the equalizer fitting, and apply an addi- tional 1/3 turn to seal. See Figures 9, 10 & 11. 7. Pass the temperature sensing bulb tube for the TXV through the tube opening in the split grommet of the access panel. 8. Install the TXV bulb to the vapor line near the cabinet, using the bulb clamp(s) furnished with the TXV assembly. Ensure the bulb is making maximum contact. See Figures 9, 10 & 11, and accomplish the following: a. If possible, install the temperature bulb on a horizontal run of the vapor line. Ensure that the bulb is installed at a 10 o’clock or 2 o’clock position. See Figure 10. b. If bulb installation is made on a vertical run, ensure that the bulb is a minimum of 8 inches (20.3 cm) away from elbow coming out of the coil. Position the bulb with the tail of the bulb at the top, so that the bulb acts as a reservoir. See Fig- ure 11. c. Insulate the bulb using thermal insulation provided to protect it from the effect of the surrounding ambient temperature. Cover completely to insulate. 9. After line set is installed, leak test the system. CAUTION Outdoor unit model numbers ending with an “H” have a factory installed hard start kit which is required when a TXV is installed. Out- door unit model numbers with no “H” ending do not require a hard start kit unless local regulations dictate it. IMPORTANT Refer to the Technical Guide for the unit to determine the proper TXV kit to be used on this product. CAUTION Do not over-torque. Do not use slip joint pliers. This will distort the aluminum distributor and the brass fitting (potentially causing leaks). FIGURE 8: TXV Installation WARNING Schrader valve core MUST NOT be installed with TXV installation. Poor system performance or system failure could result. ! ! TXV / DISTRIBUTOR COUPLING LIQUID LINE /TXV COUPLING TEFLON WASHER TXV TEFLON WASHER DISTRIBUTOR A0281-002 ! CAUTION In all cases, mount the TXV temperature sensing bulb after vapor line is brazed and sufficiently cooled. Failure to use suction line split grommet may result in TXV failure. FIGURE 9: TXV Bulb and Equalizer line Installations FIGURE 10: Proper Bulb Location ! TXV BULB (Wrap with insulation.) VAPOR LINE LIQUID LINE TVX EQUALIZER LINE THERMAL EXPANSION VALVE TXV) DISTRIBUTOR BODY A0279-002 TXV BULB (Cover completely with insulation.) VAPOR LINE OF LINE SET A0269-002 CLAMP A DETAIL A TXV SENSING BULB (Pass through split hole in grommet.) VAPOR LINE NUT NUT Bulb at 10 o’clock position. Bulb at 2 o’clock position. SCREW SCREW CLAMP 1183509-UIM-N-0218 8 Johnson Controls Unitary Products SECTION V: EVACUATION It will be necessary to evacuate the system to 500 microns or less. If a leak is suspected, leak test with dry nitrogen to locate the leak. Repair the leak and test again. To verify that the system has no leaks, simply close the valve to the vacuum pump suction to isolate the pump and hold the system under vacuum. Watch the micron gauge for a few minutes. If the micron gauge indicates a steady and continuous rise, it’s an indication of a leak. If the gauge shows a rise, then levels off after a few minutes and remains fairly constant, it’s an indication that the system is leak free but still contains moisture and may require further evacuation if the reading is above 500 microns. SECTION VI: SYSTEM CHARGE To ensure that your unit performs at the published levels, it is important that the indoor airflow is determined and refrigerant charge added accordingly. MEASURE INDOOR AIR FLOW To determine rated air flow for a specific match, consult the technical lit- erature at www.upgnet.com. When attempting to match this air flow, select the lowest possible speed tap, measure the actual flow, and adjust as necessary. To measure actual air flow, it is not an acceptable method to just check the jumper pin setting tables and is to assume 0.5” water column total external static pressure. To determine indoor air flow, first measure the static pressure with a manometer between the filter and blower. On a single-piece air handler, take a second reading after the coil. On a furnace or modular air han- dler, take the second reading after the heat exchanger but before the indoor coil. Add the negative return static to the positive supply static to determine the system total static pressure. Treat the negative return static as a positive pressure (even though it is a negative reading). If there is static pressure on the blower (i.e. -.10) return, add it to a supply static (.40) which equals a (.50) total system static pressure. Compare this value to the table for the indoor unit's static pressure vs. CFM or to a curve chart. SYSTEM CHARGING The factory charge in the outdoor unit includes enough charge for the unit, a 15 ft. (4.6 m) line set, and the smallest indoor coil match-up. Some indoor coil matches may require additional charge. See tabular data sheet provided in unit literature packet for charge requirements. The “TOTAL SYSTEM CHARGE” must be permanently stamped on the unit data plate. TOTAL SYSTEM CHARGE is determined as follows: 1. Determine the Base Charge shipped in the outdoor unit from the Tabular Data Sheet included with the outdoor unit. 2. Determine the charge adder for the matched indoor unit from the Tabular Data Sheet included with the outdoor unit. 3. If the lineset length is greater than 15 feet (4.6 m), calculate the charge adder for actual lineset length using the Tabular Data Sheet included with the outdoor unit. 4. Once the charge adders for matched indoor unit and for lineset have been weighed in, verify the system operation against the temperatures and pressures in the Charging Chart for the outdoor unit. Locate Charging Charts on the outdoor unit and also in the Service Application Data on www.upgnet.com. Follow the Subcool or the Superheat charging procedure in the section below accord- ing to the type of indoor metering device in the system, and allow ten minutes after each charge adjustment for the system operation to stabilize. Record the charge adjustment made to match the Charging Chart. 5. Verify that TOTAL SYSTEM CHARGE = Base Charge (as shipped) + charge adder for matched indoor unit + charge adder for actual lineset length + charge adjustments to match Charging Chart. 6. Permanently stamp the unit data plate with the TOTAL SYSTEM CHARGE as defined above. This method is to be used whenever additional refrigerant is required for the system charge. FIGURE 11: Vertical Temperature Bulb Orientation 9$325/,1( 2)/,1(6(7 $ &/$03 7;9 7(03(5$785( %8/% 7$,/(1'83 ´ FP (QVXUHEXOELV DWOHDVW´IURPDQ\EHQG 127( (QVXUHEXOELVRQRSSRVLWH VLGHRIWXELQJEHQGSODQH NOTICE For cold weather charging of the system at temperatures of 55°F or below, refer to the “Optional Cold Weather Charging” procedures near the end of SECTION VI: SYSTEM CHARGE. CAUTION R-410A refrigerant cylinders are rose colored. Always charge the system slowly with liquid R-410 refrigerant. CAUTION Do not leave the system open to the atmosphere. WARNING DO NOT attempt to pump “Total System Charge” into outdoor unit for maintenance or service. This may cause damage to the compressor and/or other components. Recover and weigh “System Charge” into an appropriate recovery cylinder for any instances requiring evacua- tion. WARNING It is recommended to not attempt to pump more than the “Factory Charge” and an additional 15 foot line charge into a tube and fin out- door unit for maintenance or service. This can cause damage to the compressor and/or other components. CAUTION Refrigerant charging should only be carried out by a qualified air con- ditioning contractor. ! ! ! ! ! 1183509-UIM-N-0218 Johnson Controls Unitary Products 9 If a calibrated charging cylinder or accurate weighing device is avail- able, add refrigerant accordingly. Otherwise, model-specific charging charts are provided on the access panel of the unit. SUBCOOLING CHARGING METHOD - TXV INDOOR The outdoor unit comes equipped with subcooling charts optimized for that particular unit. Please follow the instructions on the unit. If those instructions are not readily available, follow the instructions below. 1. Set the system running in cooling mode by setting the thermostat at least 6°F below the room temperature and operate system for at least 10 – 15 minutes. 2. Refer to the technical guide for the recommended indoor airflow and verify it is correct (it should be 350- 400 SCFM per ton). 3. Measure and record the indoor wet bulb (WB) and the outdoor ambient dry bulb (DB) temperature. 4. Using the charging chart located on the unit, find the intersection of the indoor wet bulb and the outdoor dry bulb. This is the recom- mended liquid pressure (and subcooling value). 5. Measure and record the pressure at the liquid valve pressure port and compare to the value obtained in step 4. 6. Add charge if the measured liquid pressure is lower than the rec- ommended value. Remove / recover charge if the measured liquid pressure is above the recommended value. Condenser subcooling is obtained by calculating the difference of the saturated refrigerant temperature of the pressure measured at the liquid base valve and the liquid tube temperature as measured at the liquid base valve. Subcooling Temp. (TC) = Saturated Temp. (TS) – Liquid Temp. (T). SUPERHEAT CHARGING METHOD - PISTON INDOOR 1. Set the system running in cooling mode by setting the thermostat at least 6°F below the room temperature and operate system for at least 10 – 15 minutes. 2. Refer to the technical guide for the recommended airflow and ver- ify indoor airflow (it should be about 350-450 SCFM per ton). 3. Measure and record the outdoor ambient (DB) temperature and the suction pressure at the suction service valve. 4. Using the charging chart located on the unit, find the intersection of the outdoor ambient dry bulb and the suction pressure obtained in step 3. This is the recommended suction tube temperature at the service valve. 5. Measure and record the suction tube temperature at the service valve and compare to the recommended temperature obtained in step 4. 6. Add charge if the measured suction temperature in step 5 is above the recommended value. Remove / recover refrigerant if the mea- sured suction temperature is below the recommended value. OPTIONAL COLD WEATHER CHARGING 1. Assemble the charging tent. 2. Slide charging tent over top of condenser unit. 3. Position the door zipper over the lineset so charging tent sits evenly on ground. 4. Make sure distance around condenser inside of charging tent is even for airflow. 5. Stake down the edges of the charging tent cover to prevent the unit fan from blowing the charging tent away. 6. Start condenser. CAUTION Compressor damage will occur if system is improperly charged. On new system installations, charge system per tabular data sheet for the matched coil and follow guidelines in this instruction. Example: The liquid pressure listed at the intersection of the indoor WB and the outdoor DB 320 psig. Pressure at the liquid valve is 305 psig. It would be necessary to add refrigerant to increase the liquid pressure to 320 psig. ! CAUTION IT IS UNLAWFUL TO KNOWINGLY VENT, RELEASE OR DIS- CHARGE REFRIGERANT INTO THE OPEN AIR DURING REPAIR, SERVICE, MAINTENANCE OR THE FINAL DISPOSAL OF THIS UNIT. Example: The suction tube temperature listed on the table at the intersection of the outdoor DB and the suction pressure is 63°F. Temperature of the suction tube at the service valve is 68°F. It would be necessary to add refrigerant to drop the suction tube temperature to 63°F. ! TABLE 2: R-410A Saturation Properties TEMP. °F PRESSURE PSIG TEMP. °F PRESSURE PSIG TEMP. °F PRESSURE PSIG TEMP. °F PRESSURE PSIG TEMP. °F PRESSURE PSIG 45 130 60 170 75 217 90 274 105 341 46 132 61 173 76 221 91 278 106 345 47 135 62 176 77 224 92 282 107 350 48 137 63 179 78 228 93 287 108 355 49 140 64 182 79 232 94 291 109 360 50 142 65 185 80 235 95 295 110 365 51 145 66 188 81 239 96 299 111 370 52 147 67 191 82 243 97 304 112 375 53 150 68 194 83 247 98 308 113 380 54 153 69 197 84 250 99 313 114 385 55 156 70 201 85 254 100 317 115 391 56 158 71 204 86 258 101 322 116 396 57 161 72 207 87 262 102 326. 117 401 58 164 73 211 88 266 103 331 118 407 59 167 74 214 89 270 104 336 119 412 NOTICE For better airflow, the size of the charging tent must be at least 70"x70”x70” and must have some adjustable flaps or windows to con- trol the temperature inside the charging tent. The charging tent must not have a floor or floor covering. Be sure to follow the “System Charge” procedures from Section VI of this Installation Manual. 1183509-UIM-N-0218 10 Johnson Controls Unitary Products 7. For better temperature measurement inside the charging tent, use a thermocouple to monitor temperature readings. Locate the ther- mocouple monitor approximately 8-10 inches away from the coil guard and 2/3 the way above the bottom of the coil on the opposite side from the control box. 8. Based on outdoor ambient temperature, begin adjusting windows in order to achieve a stable temperature above 55°F inside tent. Note that the colder the outdoor ambient temperature is the fewer windows need removal. 9. Use condenser charging chart. Verify that the outdoor ambient temperature listed on the charging chart is the temperature inside the charging tent. 10. Carefully adjust the charging tent windows until reaching the desired temperature, and allow the unit to stabilize for a minimum of 15 minutes. Check the thermocouple to make sure the tempera- ture is still maintained at desired temperature. If the temperature is out of range, adjust the windows by opening or closing them. 11. Once the condition inside the charging tent is STABILIZED, follow the “System Charge” procedure to adjust charge in the unit. 12. Add or remove charge, and adjust windows to maintain the desired temperature inside the tent. SECTION VII: ELECTRICAL CONNECTIONS GENERAL INFORMATION & GROUNDING The control box cover is held in place with 3 screws (one screw in each lower corner and one screw at the top center post). The control box can swing open by removing the screw from the center of each side of the control box and allowing the control box to lower an inch or so into a pivotal position. The control box can then swing open from the left by rotating on the right side pivots for easy service of refrigeration components. If no wir- ing is in or routed through the control box, it can be removed from the unit by lifting slightly, tilting the top hinge out, and lifting the bottom hinge out. During the installation, it is recommended to route the low voltage wiring for the thermostat along the unit whip to help facilitate the swing away feature of the control box. Refer to Figure 12. Check the electrical supply to be sure that it meets the values specified on the unit nameplate and wiring label. Power wiring, control (low voltage) wiring, disconnect switches and over current protection must be supplied by the installer. Wire size should be sized per NEC requirements. The complete connection diagram and schematic wiring label is located on the inside surface of the unit service access panel. FIELD CONNECTIONS POWER WIRING 1. Install the proper size weatherproof disconnect switch outdoors and within sight of the unit. 2. Remove the screws at the top and sides of the corner cover. Slide the control box cover down and remove from unit. 3. Run power wiring from the disconnect switch to the unit. 4. Route wires from disconnect through power wiring exit provided and into the unit control box as shown in Figures 12, 13, 14 & 15. 5. Install the proper size time-delay fuses or circuit breaker, and make the power supply connections. NOTICE A flexible electrical whip must be installed in order to use the swing away function of the control box. Other type electrical whips require the wiring to be disconnected in order to swing the control box open. FIGURE 12: Outdoor Unit Swing Away Control Box $ +,*+92/7$*( (/(&75,&$/:+,3 &21752/%2; 6ZLQJDZD\ CAUTION All field wiring must USE COPPER CONDUCTORS ONLY and be in accordance with Local, National, Fire, Safety & Electrical Codes. This unit must be grounded with a separate ground wire in accordance with the above codes. FIGURE 13: Outdoor Unit Control Box (Single Phase - Smaller Base) FIGURE 14: Outdoor Unit Control Box (Single Phase - Larger Base) ! 5(9(56,%/(+,*+ 92/7$*(&21'8,7 3/$7( *5281' /8* 67$57 &$3$&,725 &217$&725 581 &$3$&,725 /2:92/7$*( ),(/':,5,1* /2: 92/7$*( %2; 67$57 5(/$< $ +,*+92/7$*( ),(/':,5,1* 2SWLRQDODFFHVVRULHVRQVRPHPRGHOV 67$57 5(/$< &217$&725 67$57 &$3$&,725 *5281' /8* 5(9(56,%/( +,*+92/7$*( &21'8,73/$7( 581 &$3$&,725 /2: 92/7$*( %2; $ /2:92/7$*( ),(/':,5,1* +,*+92/7$*( ),(/':,5,1* 2SWLRQDODFFHVVRULHVRQVRPHPRGHOV 1183509-UIM-N-0218 Johnson Controls Unitary Products 11 FIELD CONNECTIONS CONTROL WIRING 1. Route low voltage wiring into bottom of control box as shown in Figure 13, 14 or 15. Make low voltage wiring connections inside the low voltage box per Figure 16. 2. The complete connection diagram and schematic wiring label is located on the inside surface of the unit service access panel. 3. Replace the control box cover removed in Step 2 of the FIELD CONNECTINS POWER WIRING procedures. 4. All field wiring to be in accordance with national electrical codes (NEC) and/or local-city codes. 5. Mount the thermostat about 5 ft. above the floor, where it will be exposed to normal room air circulation. Do not place it on an out- side wall or where it is exposed to the radiant effect from exposed glass or appliances, drafts from outside doors or supply air grilles. 6. Route the 24-volt control wiring (NEC Class 2) from the outdoor unit to the indoor unit and thermostat. FIGURE 15: Outdoor Unit Control Box (Three Phase) 5(9(56,%/(+,*+ 92/7$*(&21'8,7 3/$7( *5281' /8* &217$&725 )$1 &$3$&,725 /2:92/7$*( ),(/':,5,1* /2: 92/7$*( %2; $ +,*+92/7$*( ),(/':,5,1* 2SWLRQDODFFHVVRULHVRQVRPHPRGHOV NOTICE A Start Assist Kit is available and recommended for long line set applications or in areas of known low voltage problems. The kit may be required when a TXV is used (reference the Tabular Data Sheet to determine if applicable). NOTICE To eliminate erratic operation, seal the hole in the wall at the thermo- stat with permagum or equivalent to prevent air drafts affecting the operation of in the thermostat. FIGURE 16: Typical Field Wiring (Air Handler / Electrical Heat) (Single-Phase) $//),(/':,5,1*72%(,1$&&25'$1&(:,7+ (/(&75,&&2'( 1(& $1'25/2&$/&2'(6 32:(5:,5,1* &217$&725 7(50,1$/6 &2,/*1' /8* & < 5 * : < 5 * : 32:(5:,5,1* &21752/:,5,1* )$&725<:,5,1* 92/7&21752/:,5,1* 0,1,080*$:,5( 1(&&/$66 )851$&(25$,5+$1'/(5 7(50,1$/%/2&. 52207+(50267$7&21'(16,1*81,7 $//287'225:,5,1*0867%(:($7+(53522)86(&233(5&21'8&725621/< $ 7(50,1$/:,621/< 5(48,5('216<67(06 :,7++($7 1183509-UIM-N-0218 12 Johnson Controls Unitary Products For additional connection diagrams for all UPG equipment refer to “Low Voltage System Wiring” document available online at www.upgnet.com in the Product Catalog Section. FIGURE 17: Typical Field Wiring (Air Handler / Electrical Heat) (Three-Phase) FIGURE 18: Thermostat Chart - PSC Air Handler with Single Stage Air Conditioner $//),(/':,5,1*72%(,1$&&25'$1&(:,7+(/(&75,&&2'( 1(& $1'25/2&$/&2'(6 32:(5:,5,1* &217$&725 7(50,1$/6 &2,/ *1' /8* & < 5 * : < 5 * : 32:(5:,5,1* &21752/:,5,1* )$&725<:,5,1* 92/7&21752/:,5,1* 0,1,080*$:,5( 1(&&/$66 )851$&(25$,5+$1'/(5 7(50,1$/%/2&. 52207+(50267$7&21'(16,1*81,7 $//287'225:,5,1*0867%(:($7+(53522)86(&233(5&21'8&725621/< 7(50,1$/:,621/< 5(48,5('216<67(06 :,7++($7 $ $ 1183509-UIM-N-0218 Johnson Controls Unitary Products 13 SECTION VIII: INSTRUCTING THE OWNER Assist owner with processing warranty cards and/or online registration. Review Owners Guide and provide a copy to the owner and guidance on proper operation and maintenance. Instruct the owner or the opera- tor how to start, stop and adjust temperature setting. When applicable, instruct the owner that the compressor is equipped with a crankcase heater to prevent the migration of refrigerant to the compressor during the OFF cycle. The heater is energized only when the unit is not running. If the main switch is disconnected for long peri- ods of shut down, do not attempt to start the unit until 8 hours after the switch has been connected. This will allow sufficient time for all liquid refrigerant to be driven out of the compressor. The installer should also instruct the owner on proper operation and maintenance of all other system components. MAINTENANCE 1. Dirt should not be allowed to accumulate on the outdoor coils or other parts in the air circuit. Clean as often as necessary to keep the unit clean. Use a brush, vacuum cleaner attachment, or other suitable means. 2. The outdoor fan motor is permanently lubricated and does not require periodic oiling. 3. If the coil needs to be cleaned, use clean water to wash dust, dirt, and debris from outdoor condensing coil. 4. Refer to the furnace or air handler instructions for filter and blower motor maintenance. 5. The indoor coil and drain pan should be inspected and cleaned regularly to prevent odors and assure proper drainage. FIGURE 19: Thermostat Chart - Single Stage PSC Furnace with Single Stage Air Conditioner $ NOTICE DO NOT use coil cleaners to clean outdoor condensing coil. Cleaners containing HF –, hydroxides, chlorides, and sulfates can greatly reduce the lifetime of the micro channel coil. CAUTION IT IS UNLAWFUL TO KNOWINGLY VENT, RELEASE OR DIS- CHARGE REFRIGERANT INTO THE OPEN AIR DURING REPAIR, SERVICE, MAINTENANCE OR THE FINAL DISPOSAL OF THIS UNIT. ! 1183509-UIM-N-0218 14 Johnson Controls Unitary Products SECTION IX: WIRING DIAGRAM FIGURE 20: Wiring Diagram - Single Phase 13 & 14 Seer C R S S C R FAN MOTOR GND 5 2 1 C HERM FAN HIGH VOLTAGE FACTORY WIRING LOW VOLTAGE FACTORY WIRING OPTIONAL WIRING FIELD WIRING, LINE VOLTAGE DU A L CA P A C I T O R HPS SR SC JUNCTION BOX TURN OFF ELECTRICAL POWER BEFORE SERVICING TOPREVENT POSSIBLE DAMAGE TO THE EQUIPMENT AND POSSIBLE PERSONAL INJURY. TO PREVENT ELECTRICAL SHOCK OPEN REMOTE DISCONNECT SO ELECTRICAL SUPPLY TO AIR CONDITIONER IS SHUT OFF. COMPONENTS SHOWN IN DASHED LINES ARE OPTIONAL. DUAL CAPACITOR SHOWN SEPARATE CAPACITORS MAY BE USED ON ACTUAL UNIT. WIRING MUST CONFORM TO NATIONAL AND LOCAL CODES. IF ANY OF THE ORIGINAL WIRE SUPPLIED WITH THIS UNIT MUST BE REPLACED, IT MUST BE REPLACED WITH TYPE 105°C. THERMOPLASTIC OR ITS EQUIVALENT. WHERE POWER SUPPLY HAS ONE (1) 230 VOLT CONDUCTOR AND ONE (1) NEUTRAL CONDUCTOR, CONNECT L2 OF CONTACTOR TO NEUTRAL. GND. 24 VAC CONTROL CIRCUIT (20 VA MIN.) 208-230 VAC 60 Hz 1 PHASE SUPPLY 220-240 VAC 50 Hz 1 PHASE SUPPLY USE COPPER CONDUCTORS ONLY CONTACTOR GND. LUG HS CCH HPS - HIGH PRESSURE SWITCH LPS - LOW PRESSURE SWITCH CCH - CRANKCASE HEATER HS - HEATER SWITCH SR - START RELAY SC - START CAPACITOR CC - CONTACTOR COIL DANGER - SHOCK HAZARD CAUTION 1 2 3 4 5 BL K BL K BL K BR N BLK RE D RED BR N RE D RE D GRN BRN BRN RED YEL RE D BLU BLK BLK BL K T1 T2 L1 L2 CC COMPRESSOR MOTOR BL K 2 5 1 1 1 1183564-UWD-B-0215 LPS 1 BLU YE L / P N K OR Y E L YE L / P N K OR Y E L 1183509-UIM-N-0218 Johnson Controls Unitary Products 15 FIGURE 21: Wiring Diagram - Single Phase 17 Seer C R S 5 2 1 C HERM FAN HIGH VOLTAGE FACTORY WIRING LOW VOLTAGE FACTORY WIRING OPTIONAL WIRING FIELD WIRING, LINE VOLTAGE DU A L CA P A C I T O R HPS SR SC JUNCTION BOX DANGER - SHOCK HAZARD TURN OFF ELECTRICAL POWER BEFORE SERVICING TO PREVENT POSSIBLE DAMAGE TO THE EQUIPMENT AND POSSIBLE PERSONAL INJURY. TO PREVENT ELECTRICAL SHOCK OPEN REMOTE DISCONNECT SO ELECTRICAL SUPPLY TO AIR CONDITIONER IS SHUT OFF. COMPONENTS SHOWN IN DASHED LINES ARE OPTIONAL. DUAL CAPACITOR SHOWN SEPARATE CAPACITORS MAY BE USED ON ACTUAL UNIT. WIRING MUST CONFORM TO NATIONAL AND LOCAL CODES. IF ANY OF THE ORIGINAL WIRE SUPPLIED WITH THIS UNIT MUST BE REPLACED, IT MUST BE REPLACED WITH TYPE 105°C. THERMOPLASTIC OR ITS EQUIVALENT. WHERE POWER SUPPLY HAS ONE (1) 230 VOLT CONDUCTOR AND ONE (1) NEUTRAL CONDUCTOR, CONNECT L2 OF CONTACTOR TO NEUTRAL. HPS - HIGH PRESSURE SWITCH LPS - LOW PRESSURE SWITCH CCH - CRANKCASE HEATER HS - HEATER SWITCH SR - START RELAY SC - START CAPACITOR CC - CONTACTOR COIL GND. 24 VAC CONTROL CIRCUIT (20 VA MIN.) 208-230 VAC 60 Hz 1 PHASE SUPPLY 220-240 VAC 50 Hz 1 PHASE SUPPLY USE COPPER CONDUCTORS ONLY CONTACTORGND. LUG HS CCH CAUTION 1 2 3 4 5 BL K BL K BL K BR N RE D RE D BRN RED YEL RE D BLUBLK BLK BL K T1 T2 L1 L2 CC COMPRESSOR MOTOR BL K 2 5 1 1 1 5160254-UWD-B-0116 LPS 1 BLU YE L / P N K OR Y E L YE L / P N K OR Y E L S C R FAN MOTOR 635 PL U G 421 GR N / Y E L BLU RED BLK BL K VS CONTROL BL U YE L O R W H T OR O R G O R P U R BLK RED BL U SLV SLV RE D O R BR N RE D O R B R N 1183509-UIM-N-0218 16 Johnson Controls Unitary Products FIGURE 22: Wiring Diagram - Three Phase 13 Seer 5203528-UWD-A-0416 HIGH VOLTAGE FACTORY WIRING LOW VOLTAGE FACTORY WIRING OPTIONAL WIRING FIELD WIRING, LINE VOLTAGE TURN OFF ELECTRICAL POWER BEFORE SERVICING TO PREVENT POSSIBLE DAMAGE TO THE EQUIPMENT AND POSSIBLE PERSONAL INJURY. TO PREVENT ELECTRICAL SHOCK OPEN REMOTE DISCONNECT SO ELECTRICAL SUPPLY TO AIR CONDITIONER IS SHUT OFF. COMPONENTS SHOWN IN DASHED LINES ARE OPTIONAL. BLACK WIRE WILL BE REMOVED IF LOW AMBIENT KIT IS INSTALLED. WIRING MUST CONFORM TO NATIONAL AND LOCAL CODES. IF ANY OF THE ORIGINAL WIRE SUPPLIED WITH THIS UNIT MUST BE REPLACED, IT MUST BE REPLACED WITH TYPE 105°C. THERMOPLASTIC OR ITS EQUIVALENT. HPS - HIGH PRESSURE SWITCH LPS - LOW PRESSURE SWITCH CCH - CRANKCASE HEATER HS - HEATER SWITCH CC - CONTACTOR COIL FC - FAN CAPACITOR DANGER - SHOCK HAZARD CAUTION 1 2 3 4 HPS JUNCTION BOX 24 VAC CONTROL CIRCUIT (20 VA MIN.) BLU CC BL K 1 LPS 1 BLUYE L / P N K OR Y E L YE L / P N K OR Y E L GND C R FAN MOTOR S BRN GRN RED BLK 208-230 VAC 60 Hz 3 PHASE SUPPLY 460 VAC 60 Hz 3 PHASE SUPPLY 575 VAC 60 Hz 3 PHASE SUPPLY USE COPPER CONDUCTORS ONLY COMPRESSORRE D CCH BL K HS BL K BL K BL K FC BR N T3 T2 T1 RE D BL K BR N RE D BL K GND LUG GND CONTACTOR 3 BL K T3 T2 T1L2 L1L3 1 1183509-UIM-N-0218 Johnson Controls Unitary Products 17 FIGURE 23: Wiring Diagram - Three Phase 17 Seer RE D 5275753-UWD-C-1017 HIGH VOLTAGE FACTORY WIRING LOW VOLTAGE FACTORY WIRING OPTIONAL WIRING FIELD WIRING, LINE VOLTAGE TURN OFF ELECTRICAL POWER BEFORE SERVICING TO PREVENT POSSIBLE DAMAGE TO THE EQUIPMENT AND POSSIBLE PERSONAL INJURY. TO PREVENT ELECTRICAL SHOCK OPEN REMOTE DISCONNECT SO ELECTRICAL SUPPLY TO AIR CONDITIONER IS SHUT OFF. COMPONENTS SHOWN IN DASHED LINES ARE OPTIONAL. WIRING MUST CONFORM TO NATIONAL AND LOCAL CODES. IF ANY OF THE ORIGINAL WIRE SUPPLIED WITH THIS UNIT MUST BE REPLACED, IT MUST BE REPLACED WITH TYPE 105°C. THERMOPLASTIC OR ITS EQUIVALENT. HPS - HIGH PRESSURE SWITCH LPS - LOW PRESSURE SWITCH CCH - CRANKCASE HEATER HS - HEATER SWITCH CC - CONTACTOR COIL VS - VARIABLE SPEED DANGER - SHOCK HAZARD CAUTION 1 2 3 HPS JUNCTION BOX 24 VAC CONTROL CIRCUIT (20 VA MIN.) BLU CC BL K 1 LPS 1 BLUYE L / P N K OR Y E L YE L / P N K OR Y E L 208-230 VAC 60 Hz 3 PHASE SUPPLY 460 VAC 60 Hz 3 PHASE SUPPLY 575 VAC 60 Hz 3 PHASE SUPPLY USE COPPER CONDUCTORS ONLY COMPRESSOR CCH BL K HS BL K BL K BL K T3 T2 T1 BL K BR N RE D BL K GND LUG GND CONTACTOR 3 BL K T3 T2 T1L2 L1L3 1 S C R FAN MOTOR 635 PL U G 421 GR N / Y E L BLU RED BLK BL K VS CONTROL BL U YE L O R W H T OR O R G O R P U R BL K RED BL U SLV SLV RE D 1183509-UIM-N-0218 18 Johnson Controls Unitary Products NOTES 1183509-UIM-N-0218 Johnson Controls Unitary Products 19 SECTION X: START UP SHEET Air Conditioning and Heating Start-Up Sheet Proper start-up is critical to customer comfort and equipment longevity Name Address City State or Province Zip or Postal Code Indoor Unit Model #Indoor Unit Serial # Indoor Coil Model #Indoor Coil Serial # Upflow Downflow Horizontal Left Horizontal Right Unit is level Venting system properly sized, within the limitations of the charts in the installation instructions. Condensate drain for indoor coil properly connected Filter Type Intake Size Exhaust Size # of 90 Degree Ells # 0f 45 Degree Ells Length Length # 0f 45 Degree Ells# of 90 Degree Ells Polarity is correct (120vac indoor units) black is L1 (hot), white is N (neutral)Ground wire is connected Indoor unit (volts AC) Low voltage values: "R" and "C" at Indoor unit control board (volts AC) Thermostat Type Other System Equipment and Accessories Owner Information Equipment Data Venting (if applicable) Electrical: Line Voltage Outdoor Unit Model #Outdoor Unit Serial # Filter, Thermostat, Accessories Filter Location(s) Connections -- Per Installation Instructions and Local Codes Gas piping is connected (if applicable) Supply plenum and return ducts are connected and sealed Filter Size Vent system is connected (if applicable) Thermostat wiring complete Heat anticipator is set to the recommended value listed in the Installation Instructions Electrical: Low Voltage Technician Performing Start-Up Installing Contractor Name Start-Up Date Condensate drain for furnace (if applicable) Refrigerant piping complete and leak tested Outdoor unit (volts AC)Overcurrent Protection Breaker / Fuses Amperes "R" and "C" Outdoor unit control board (volts AC) Heating Set-Up Natural Gas LP Gas (Requires LP Conversion Kit)Electric Air Handler LP Gas Conversion Kit Part # Used LP Kit Installed By Inlet Gas Pressure (in. w.c.") Calculated input in btuh - clock the gas meter (Nat Gas Only) Manifold Gas Pressure (in. w.c.") Heating Type Heat anticipator recommended value Electric Heat Kit Part # (if applicable)KW installed Page 1 of 2 (7/5/16) Rated BTU/H (furnaces) Subject to change without notice. Published in U.S.A.1183509-UIM-N-0218 Copyright © 2018 by Johnson Controls, Inc. All rights reserved. Supersedes: 1183509-UIM-M-1117 York International Corp. 5005 York Drive Norman, OK 73069 Supply static after indoor coil (in w.c.") Return Static (in w.c.") before filter Total External Static Pressure Installation debris disposed of and indoor and outdoor areas cleaned up? Explain operation of system to equipment owner Low 1 2 Medium Low Medium 3 4 Medium High High 5 A B DC A B C D Explain the importance of regular filter replacement and equipment maintenance Air Side: System Total External Static Pressure Owner Education Supply static before indoor coil (in w.c.") Return Static (in w.c.") after filter (furnace side) Cooling Indoor Blower Set-Up Clean Up Provide owner with the owner's manual Explain thermostat use and programming (if applicable) to owner Cycle Test Operate the unit through several heating cycles (if applicable) from the thermostat, noting and correcting any problems Operate the unit through continuous fan cycles from the thermostat, noting and correcting any problems Operate the unit through a cooling cycles, noting and correcting any problems COOL ADJUSTECM X-13 PSC A B C DDELAY Heating Indoor Blower Set-Up ECM X-13 PSC A 1 5 High 2 3 4 Low Medium Low Medium Medium High DBC Maximum Rated ESP (in w.c.") Page 2 of 2 (7/5/16) HEAT Refrigerant Charge and Metering Device TXV Fixed OrificeR-407C R-410A Oz. # 45s# Elbows Additional Lineset Length Adder per foot - lbs. Total Added - lbs.Oz. Comments Section Liquid Line Temp Low Side PressureSuction Line TempHigh Side Pressure Subcooling Superheat Orifice Size TXV # Temperature RiseReturn Air: Dry Bulb Supply Air: Dry Bulb Wet BulbWet Bulb Outside Air: Dry Bulb Temperature DropReturn Air: Dry Bulb Supply Air: Dry Bulb Wet BulbWet Bulb Johnson Controls Ducted Systems 5750144-UIM-H-0423 Two Stage Standard ECM Residential Gas Furnaces Models: TM9Y Series (96% AFUE Multi-position) INSTALLATION MANUAL Assembled at a facility with an ISO 9001:2015-certified Quality Management System List of sections Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Electrical power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Twinning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Condensate piping and furnace venting configuration . . . . 13 Combustion air and vent system . . . . . . . . . . . . . . . . . . . . . . 19 Start-up and adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Safety controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Normal operation and diagnostics . . . . . . . . . . . . . . . . . . . . 34 Replacement parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Start-up sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 List of figures Duct attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Combustible floor base accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Furnace and coil attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Horizontal application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Typical attic installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Typical suspended furnace/crawl space installation . . . . . . . . . . . . . 7 Downflow venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Side return cutout markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Left side supply gas pipe arrangement . . . . . . . . . . . . . . . . . . . . . . . 9 Gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Thermostat chart - two stage AC with two stage standard ECM furnaces . . . . . . . . . . . . . . . . . . . . . . 12 Thermostat chart - two stage HP with two stage standard ECM furnace . . . . . . . . . . . . . . . . . . . . . . . 13 Typical. condensate drain, vertical installation . . . . . . . . . . . . . . . . . 14 Upflow configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Downflow configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Horizontal left configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Horizontal right configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Home layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Termination configuration - one pipe . . . . . . . . . . . . . . . . . . . . . . . .23 Termination configuration - two pipe . . . . . . . . . . . . . . . . . . . . . . . .23 Termination configuration - two pipe basement . . . . . . . . . . . . . . . .23 Double horizontal combustion air intake and vent termination . . . . .24 Double vertical combustion air intake and vent termination . . . . . . .24 Downward venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Direct vent air intake connection and vent connection . . . . . . . . . . .24 Combustion airflow path through the furnace casing . . . . . . . . . . . .25 Ambient combustion air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Attic and crawl space combustion air termination . . . . . . . . . . . . . .27 Gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Reading gas pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Measuring external duct static . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Furnace control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 List of tables Unit clearances to combustibles . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cabinet and duct dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Recommended Filter Sizes (High Velocity 600 FPM) . . . . . . . . . 8 Nominal manifold pressure - high fire . . . . . . . . . . . . . . . . . . . . 10 Nominal manifold pressure - low fire . . . . . . . . . . . . . . . . . . . . . 10 Ratings and physical/electrical data . . . . . . . . . . . . . . . . . . . . . 11 Maximum equivalent pipe length . . . . . . . . . . . . . . . . . . . . . . . . 20 High altitude pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . 21 Elbow dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Equivalent length of fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Combustion air intake and vent connection size at furnace (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Estimated free area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Unconfined space minimum area . . . . . . . . . . . . . . . . . . . . . . . 25 Free area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Gas rate (cu ft/h) at full input . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Inlet gas pressure range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Nominal manifold pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Default blower speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Blower performance CFM - any position (without filter) . . . . . . 33 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. 5750144-UIM-H-0423 2 Johnson Controls Ducted Systems Section I: Safety This is a safety alert symbol. When you see this symbol on labels or in manuals, be alert to the potential for personal injury. 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. 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. 3.A gas-fired furnace for installation in a residential garage must be 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 SECTION VIII, "Combustion air and vent system" of these instructions. 6.Test for gas leaks as specified in these instructions. 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 furnace casing and terminating outside the space containing the furnace. 9.It is permitted to use the furnace for heating of buildings or struc- tures under construction where the application and use must com- ply with all manufacturer’s installation instructions including: •Proper vent installation; •Furnace operating under thermostatic control; •Return air duct sealed to the furnace; •Air filters in place; •Set furnace input rate and temperature rise per rating plate mark- ing; •Means for providing outdoor air required for combustion; •Return air temperature maintained between 55ºF (13ºC) and 80ºF (27ºC); •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-oper- ating 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 occu- pied 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 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 lift- ing points as the tubes may shift out of position or their location brackets/baffles. Safety requirements •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 8. The plenum must be installed according to the instructions. •Provide clearances from combustible materials as listed under Clearances to Combustibles. See Table1. •Provide clearances for servicing. Ensure that service access is allowed for both the burners and blower. •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 upflow installation on combustible flooring shall not be installed directly on carpeting, tile or other combustible mate- rial other than wood flooring. •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 V. •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 licensed personnel should install, repair, or service gas heating equipment. Unlicensed service personnel can per- form basic maintenance functions such as cleaning and replacing the air filters. When working on heating equipment, observe pre- cautions in the manuals and on the labels attached to the unit and other safety precautions that may apply. 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 maintenance can cause injury or property damage. Failure to carefully read and follow all instructions in this manual can result in furnace mal- function, death, personal injury and/or property damage. Only a qualified contractor, installer or service agency should install this product. 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 property damage, personal injury, or loss of life. ! ! Important: During installation, doors should remain on the furnace when moving or lifting. CAUTION This product must be installed in strict compliance with the installation instructions and any applicable local, state, and national codes including, but not limited to building, electrical, and mechanical codes. ! 5750144-UIM-H-0423 Johnson Controls Ducted Systems 3 Combustion air quality (list of contaminants) The furnace requires OUTDOOR AIR for combustion when the furnace is located in any of the following environments. •Buildings with indoor pools •Chemical exposure •Commercial buildings •Furnaces installed in hobby or craft rooms •Furnaces installed in laundry rooms •Furnaces installed near chemical storage areas •Restricted environments 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. •Antistatic fabric softeners for clothes dryers •Carbon tetrachloride •Cements and glues •Chlorine based swimming pool chemicals •Chlorinated waxes and cleaners •Cleaning solvents (such as perchloroethylene) •De-icing salts or chemicals •Halogen type refrigerants •Hydrochloric acid •Masonry acid washing materials •Permanent wave solutions •Printing inks, paint removers, varnishes, etc. •Water softening chemicals 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 standards in addition to this installa- tion manual. The installation must comply with regulations of the serv- ing gas supplier, local building, heating, plumbing, and other codes. In absence of local codes, the installation must comply with the national codes listed below and all authorities having jurisdiction. In the United States and Canada, follow all codes and standards for the following, using the latest edition available: 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) General installation •US: Current edition of the NFGC and 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 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 Duct systems •US and CANADA: Air Conditioning Contractors Association (ACCA) Manual D, Sheet Metal and Air Conditioning Contractors Association National Association (SMACNA), or American Soci- ety of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) 1997 Fundamentals Handbook Chapter 32. Acoustical lining and fibrous glass duct •US and CANADA: Current edition of SMACNA and NFPA 90B as tested by UL Standard 181 for Class I Rigid Air Ducts Gas piping and gas pipe pressure testing •US: NFGC; chapters 2, 3, 4, & 9 and National Plumbing Codes •CANADA: NSCNGPIC Part 5 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. WARNING The furnace area must not be used as a broom closet or for any other storage purposes, as a fire hazard may be created. Never store items such as the following on, near, or in contact with the furnace. 1.Spray or aerosol cans, rags, brooms, dust mops, vacuum clean- ers or other cleaning tools. 2.Soap powders, bleaches, waxes or other cleaning compounds; plastic items or containers; gasoline, kerosene, cigarette lighter fluid, dry cleaning fluids or other volatile fluid. 3.Paint thinners and other painting compounds. 4.Paper bags, boxes or other paper products. Never operate the furnace with the blower door removed. To do so could result in serious personal injury and/or equipment damage. ! 5750144-UIM-H-0423 4 Johnson Controls Ducted Systems 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 guidelines: 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. See “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 in. (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 pro- vide for safe limits of ambient temperature under normal operating conditions. Ambient temperatures must not fall below 32°F (0°C) unless the condensate system is protected from freezing. 2.Do not allow return air temperature to be below 55º F (13°C) for extended periods. To do so may cause condensation to occur in the main heat exchanger, leading to premature heat exchanger failure. 3.If this furnace is installed in an unconditioned space and an extended power failure occurs, there will be potential damage to the internal components. Following a power failure situation, do not operate the unit until inspection and repairs are performed. Clearances for access/service: Ample clearances should be provided to permit easy access to the unit. The following minimum clearances are recommended: 1.24 in. (61 cm) between the front of the furnace and an adjacent wall or another appliance, when access is required for servicing and cleaning. 2.18 in. (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 in. (46 cm) above the floor, and the furnace must be located or protected to avoid physical damage by vehicles. For furnaces installed in the Commonwealth of Massachusetts only For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for resi- dential purposes, including those owned or operated by the Com- monwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following require- ments shall be satisfied: 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.In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back- up may be installed on the next adjacent floor level. b.In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed. 2.APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above pro- visions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified. 3.SIGNAGE. A metal or plastic identification plate shall be perma- nently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heat- ing appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, "GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS". 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. WARNING Improper installation in an ambient below 32ºF (0.0° C) could create a hazard, resulting in damage, injury, or death. 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. Table 1: Unit clearances to combustibles Application Upflow Downflow Horizontal Top (in.)1 0 0 Vent (in.)0 0 0 Rear (in.)0 0 0 Side (in.)0 0 1 Front1 (in.) 1.24 in. clearance in front and 18 in. on side recommended for service access.All furnaces approved for alcove and attic installation. 0 0 0 Floor Combustible Combustible2 2.For combustible floors only when used with combustible floor base accessory. Combustible Closet Yes Yes Yes Line Contact No No Yes ! ! 5750144-UIM-H-0423 Johnson Controls Ducted Systems 5 Section II: 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 with the National Fire Protection Associ- ation as outlined in NFPA standard 90B (latest editions) or applica- ble national, provincial, state, and local fire and safety codes. 3.Create a closed duct system. For residential and non-HUD Modular Home installations, when a furnace is installed so that the supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by a duct(s) sealed to the furnace casing and terminating outside the space containing the furnace. 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. When the furnace is used with an indoor coil, the coil must be installed parallel with, or in the supply air side of the furnace to avoid condensa- tion in the primary heat exchanger. When a parallel flow arrangement is used, dampers or other means used to control airflow must be ade- quate to prevent chilled air from entering the furnace. If manually oper- ated, the damper must be equipped with means to prevent the furnace or the air conditioner from operating unless the damper is in full heat or cool position. When replacing an existing furnace, if the existing plenum is not the same size as the new furnace then the existing plenum must be removed and a new plenum installed that is the proper size for the new furnace. If the plenum is shorter than 12 in. (30.5 cm) the turbulent air flow may cause the limit controls not to operate as designed, or the limit controls 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. If a matching cased indoor coil is used, it may be placed directly on the furnace outlet and sealed to prevent leakage. If an uncased indoor coil with a thermoplastic drain pan is to be installed in the upflow/horizontal configuration, then extra 2 in. (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. 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. Repeat this for all 4 flanges. If the flanges are not used, they must remain in the rotated down posi- tion as shipped. Ductwork installation and supply plenum connec- tion - 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 2. Follow the instructions supplied with the combustible floor base accessory. This combustible floor base can be replaced with a matching indoor coil, properly sealed to pre- vent leaks. Follow the instructions supplied with the indoor coil cabinet for installing the cabinet to the duct connector. Plug intake and vent pipe holes in bottom panel and move grommet to desired vent side exit. Downflow air - indoor coil cabinet The furnace should be installed with coil cabinet part number specifi- cally intended for downflow application. If a matching indoor 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 indoor coil cabinet to the duct connector, and then position the furnace on top of the coil cabinet. The connection to the furnace, coil cabinet, duct connector, and supply air duct must be sealed to pre- vent air leakage. CAUTION The indoor coil must be installed in the supply air duct, downstream of the furnace. Cooled air may not be passed over the heat exchanger. Important: The minimum plenum height is 12 in. (30.5 cm). The fur- nace will not operate properly on a shorter plenum height. The mini- mum recommended rectangular duct height is 4 in. (10.2 cm) attached to the plenum. WARNING The duct system must be properly sized to obtain the correct airflow for the furnace size that is being installed. Refer to the furnace rating plate for the correct rise range and static pressures or to Table 6 for the correct rise range. 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. ! ! Figure 1: Duct attachment Factory installed For duct attachment, if needed. 5750144-UIM-H-0423 6 Johnson Controls Ducted Systems Coil installation The indoor coil must be mounted on the supply side of the furnace as shown in Figure 3. Refer to the Installation Instructions provided with each indoor coil. Residential and modular home upflow return ple- num 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. Side return application Side return applications pull return air through an opening cut in the side of the furnace casing. This furnace is supplied with a bottom block- off panel that should be left in place if a side return is to be used. If the furnace is to be installed on a flat, solid surface, this bottom panel will provide an adequate seal to prevent air leakage through the unused bottom opening. However, if the furnace is to be installed on a surface that is uneven, or if it is to be installed on blocks or otherwise raised off the floor, it will be necessary to seal the edges of the bottom panel to the casing using tape or other appropriate gasket material to prevent air leakage. Figure 2: Combustible floor base accessory FURNACE WARM AIR PLENUM WITH 1” FLANGES FIBERGLASS INSULATION FIBERGLASS TAPE UNDER FLANGE COMBUSTIBLE FLOOR BASE ACCESSORY Important: On all installations without a coil, a removable access panel is recommended 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. Figure 3: Furnace and coil attachment $ 127( 9HULI\WKDWDOOGUDLQV DUHWUDSSHGRUSOXJJHG 83)/2: $33/,&$7,21 '2:1)/2: $33/,&$7,21 35,0$5<'5$,1 75$3&211(&7,21 6(&21'$5<'5$,1 75$3&211(&7,21 '5$,13/8* )25+25,=217$/ 6(&21'$5<'5$,1 35,0$5<'5$,1 75$3&211(&7,21 &2,/ &2,/ 5,*+7)/2: $33/,&$7,21 /()7)/2: $33/,&$7,21 &2,/ &2,/ '5$,13/8* )259(57,&$/ 6(&21'$5<'5$,1 )851$&( )851$&( )851$&( )851$&( 5750144-UIM-H-0423 Johnson Controls Ducted Systems 7 Bottom return and attic installations Bottom return applications normally pull return air through a base plat- form or return air plenum. Be sure the return platform structure or return air plenum is suitable to support the weight of the furnace. 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 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. See Figure 5. 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 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. Suspended furnace/crawl space installation The furnace can be hung from floor joists or installed on suitable blocks or pads. Blocks or pad installations shall provide adequate height to ensure that the unit will not be subject to water damage. Units may also be suspended from rafters or floor joists using rods, pipe angle supports or straps. In all cases, the furnace should be supported with rods, straps, or angle supports at three locations to properly sup- port the furnace. Place one support at the supply end of the furnace, one support located approximately in the center of the furnace near the blower shelf, and the third support should be at the return end of the fur- nace. Maintain a 6 in. (15.2 cm) minimum clearance between the front of the furnace and the support rods or straps. All six suspension points must be level to ensure proper and quiet fur- nace operation. When suspending the furnace, use a secure platform constructed of plywood or other building materials secured to the floor or ceiling joists. See Figure 6 for details and additional information. Downflow application The furnace is shipped in the upflow configuration. To configure the fur- nace in a downflow position, it is necessary to rotate the vent blower 90° left or right so that the vent pipe passes through the side of the fur- nace casing. See Figure 7. Figure 4: 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. Figure 5: Typical attic installation WARNING When a furnace is installed in an attic or other insulated space, keep all insulating materials at least 12 in. (30.5 cm) away from furnace and burner combustion air openings. Important: During installation, doors should remain on the furnace when moving or lifting. Return Air Sediment Trap Gas Piping Supply Air Vent (Maintain required clearances to combustibles) Line contact only permissible between lines formed by the intersection of furnace top and two sides and building joists, studs or framing 12” 30” MIN. Work Area Filter rack must be a minimum distance of 18” (45.7 cm) from the furnace 12” Sheet metal in front of furnace combustion air Openings is Recommended ! Figure 6: Typical suspended furnace/crawl space installation Figure 7: Downflow venting Support Rod Support Angle (x3) Maintain 6” minimum clearance between support rods and front of furnace /()76,'(9(17 5,*+76,'(9(17 5RWDWHYHQW EORZHU HLWKHUZD\ $ 5750144-UIM-H-0423 8 Johnson Controls Ducted Systems Section III: Filters Filter installation All applications require the use of a field installed filter. All filters and mounting provision must be field supplied. Filters must be installed external to the furnace cabinet. DO NOT attempt to install filters inside the furnace. 1.Air velocity through throwaway type filters may not exceed 300 ft/min (91.4 m/min). All velocities over this require the use of high velocity filters. 2.Do not exceed 1800 CFM using a single side return and a 16x25 filter. For CFM greater than 1800, you may use two side returns or one side and the bottom or one side return with a transition to allow use of a 20x25 filter. Side return Locate the “L” shaped corner locators. These indicate the size of the cut- out to be made in the furnace side panel. See Figure 9. Install the side filter rack following the instructions provided with that accessory. If a filter(s) is provided at another location in the return air system, the ductwork may be directly attached to the furnace side panel. Figure 8: Dimensions )5217 $ /()76,'( &RPEXVWLRQ$LU,QOHW &RQGHQVDWH'UDLQ 'RZQIORZ 7KHUPRVWDW :LULQJ ´ *DV3LSH (QWU\ (OHFWULFDO (QWU\ &RQGHQVDWH 'UDLQ 7KHUPRVWDW :LULQJ 5,*+76,'( &RQGHQVDWH'UDLQ 'RZQIORZ ´ ´ ´ ´ &RPEXVWLRQ$LU,QOHW *DV3LSH (QWU\ (OHFWULFDO (QWU\ &RQGHQVDWH 'UDLQ 2SWLRQDO5HWXUQ$LU &XWRXW (LWKHUVLGH ´ & 6833/<(1' ´ ´ ´ % ´´ ´ &RPEXVWLRQ $LU,QOHW 5(7851(1' % ´ ´9HQW &RQQHFWLRQ 2XWOHW ´9HQW &RQQHFWLRQ 2XWOHW ´9HQW &RQQHFWLRQ 2XWOHW $ Table 2: Cabinet and duct dimensions Btu/h (kW) Input Nominal CFM (m3/min) Cabinet Size Cabinet Dimensions Approximate Operating Weights A (in)A (cm)B (in)B (cm)C (in)C (cm)lb (kg) 40 (11.7)1000 (28.3)A 14 1/2 36.8 13 3/8 34.0 11 3/4 29.8 113 (51.2) 60 (17.6)1200 (34.0)B 17 1/2 44.4 16 3/8 41.6 13 1/4 33.7 119 (54.0) 80 (23.4)1200 (34.0)B 17 1/2 44.4 16 3/8 41.6 14 3/4 37.5 123 (57.1) 80 (23.4)1600 (45.3)C 21 53.3 19 7/8 50.5 16 1/2 41.9 130 (59.0) 100 (29.3)1600 (45.3)C 21 53.3 19 7/8 50.5 18 1/4 46.4 136 (61.1) 100 (29.3)2000 (56.6)C 21 53.3 19 7/8 50.5 18 1/4 46.4 143 (64.8) 120 (35.1)2000 (56.6)D 24 1/2 62.2 23 3/8 59.4 21 3/4 55.2 154 (69.8) Table 3: Recommended Filter Sizes (High Velocity 600 FPM) CFM (m³/min) Cabinet Size Side (in) Bottom (in) 1000 (28.3)A 16 x 25 14 x 25 1200 (34.0)B 16 x 25 16 x 25 1600 (45.3)C 16 x 25 20 x 25 2000 (56.6)C (2) 16 x 25 20 x 25 2000 (56.6)D (2) 16 x 25 22 x 25 NOTICE Single side return above 1800 CFM is approved as long as the filtervelocity does not exceed filter manufacturer’s recommendation and a transition is used to allow use on a 20x25 filter. Figure 9: Side return cutout markings Important: Some accessories such as electronic air cleaners and pleated media may require a larger side opening. Follow the instruc- tions supplied with that accessory for side opening requirements. Do not cut the opening larger than the dimensions for the “Optional Return Air Cutout” shown in Figure 8. Front of Furnace Corner Markings Side of Furnace 5750144-UIM-H-0423 Johnson Controls Ducted Systems 9 Horizontal application Horizontal filters 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 duct filter box attached to the furnace plenum or at the end of the duct in a return filter grille(s). The use of straps and/or supports is required to support the weight of the external filter box. Section IV: Gas piping Gas safety Gas piping installation Properly sized wrought iron, approved flexible or steel pipe must be used when making gas connections to the unit. 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 fur- nace. For left side supply gas pipe arrangement, two 1/2 in. elbows and two 1/2 in. x 1 1/2 in. pipe nipples must be used. The arrangement shown in Figure 11 aligns entrance hole in furnace casing with supply gas pipe. Furnace casing does not support installations completed using street- elbows. If local codes allow the use of a flexible gas appliance connection, always use a new listed connector. Do not use a connector that has previously serviced another gas appliance. Use only approved gases. Use a drip leg and ground union as required. See Figure 12. The furnace must be isolated from the gas supply piping system by closing its individual external manual shutoff valve during any pressure testing of the gas supply piping system at pressures equal to or less than 0.5 psig (3.5 kPa). Gas piping may be connected from either side of the furnace using any of the gas pipe entry knockouts on both sides of the furnace. See Fig- ures 8 and 12. 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. CAUTION All filters and mounting provision must be field supplied. All installa- tions must have a filter installed. DANGER An overpressure protection device, such as a pressure regulator, must be installed in the gas piping system upstream of the furnace and must act to limit the downstream pressure to the gas valve so it does not exceed 0.5 psig (14 in. W.C., 3.48 kPa). Pressures exceed- ing 0.5 psig (14 in. W.C., 3.48 kPa) at the gas valve will cause dam- age to the gas valve, resulting in a fire or explosion or will cause damage to the furnace or some of its components that will result in property damage and loss of life. Figure 10: Gas valve Important: Plan the gas supply routing before determining the cor- rect gas pipe entry. Use 90° conventional elbow(s) and short pipe nip- ples to enter through the cabinet access holes. Important: Ensure that the gas connections have a 1/2 in. National Pipe Thread (NPT). ! ! INLET WRENCH BOSS INLET PRESSURE PORT ON OFF SWITCH LOW STAGE REGULATOR ADJUSTMENT OUTLET OUTLET PRESSURE PORT VENT PORT HIGH STAGE REGULATOR ADJUSTMENT Figure 11: Left side supply gas pipe arrangement Important: An accessible manual shutoff valve must be installed upstream of the furnace gas controls and within 6 ft (1.8 m) of the fur- nace. CAUTION The gas valve body is a very thin casting that cannot take any exter- nal pressure. Never apply a pipe wrench to the body of the gas valve when installing piping. A wrench must be placed on the octagon hub located on the gas inlet side of the valve. Placing a wrench to the body of the gas valve will damage the valve causing improper opera- tion and/or the valve to leak. $ 72*$6 6833/< (/%2: (/%2: ´[´ 3,3(1,33/( ´[´ 3,3(1,33/( *$6 9$/9( ! 5750144-UIM-H-0423 10 Johnson Controls Ducted Systems High altitude manifold pressure adjustment This furnace is constructed at the factory for natural gas-fired operation at 0 – 7,999 ft (0 – 2,438 m) above sea level. 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 ft (2,438 m) above sea level. See Tables 4 and 5 for proper manifold pressure settings. High fire manifold pressure must be set before adjusting low fire. High altitude pressure switch conversion For installation where the altitude is less than 5,000 ft (1,524 m), it is not required that the pressure switch be changed unless you are in an area subject to low pressure inversions. Figure 12: Gas piping 8SIORZ &RQILJXUDWLRQ 'RZQIORZ &RQILJXUDWLRQ +RUL]RQWDO &RQILJXUDWLRQ ([WHUQDO 0DQXDO 6KXWRII 9DOYH ([WHUQDO 0DQXDO 6KXWRII 9DOYH ([WHUQDO0DQXDO 6KXWRII9DOYH 7R*DV 6XSSO\ 7R*DV 6XSSO\ 7R*DV 6XSSO\ 7R*DV 6XSSO\ 7R*DV 6XSSO\ 7R*DV 6XSSO\ 'ULS /HJ 'ULS /HJ 'ULS /HJ 'ULS /HJ 'ULS/HJ 'ULS /HJ *DV 3LSH *DV 9DOYH *DV 3LSH *DV 9DOYH *DV 3LSH *DV 9DOYH *URXQG 8QLRQ *URXQG 8QLRQ *URXQG 8QLRQ *URXQG 8QLRQ *URXQG 8QLRQ *URXQG 8QLRQ 127( *URXQG8QLRQPD\EHLQVWDOOHGLQVLGHRURXWVLGHXQLW $ Table 4: Nominal manifold pressure - high fire Manifold Pressures Manifold Pressures Gas Heating Value (Btu/cu ft) Altitude (ft)Gas Heating Value (MJ/cu m) Altitude (m) 0-7999 8000-8999 9000-9999 0-2437 2438-2742 2743-3048 in. W.C.in. W.C.in. W.C.kPa kPa kPa 800 3.5 3.5 3.5 29.8 0.9 0.9 0.9 850 3.5 3.5 3.5 31.7 0.9 0.9 0.9 900 3.5 3.5 3.5 33.5 0.9 0.9 0.9 950 3.5 3.5 3.3 35.4 0.9 0.9 0.8 1000 3.5 3.2 2.9 37.3 0.9 0.8 0.7 1050 3.5 2.9 2.7 39.1 0.9 0.7 0.7 1100 3.2 2.7 2.4 41.0 0.8 0.7 0.6 2500 (LP)9.8 8.2 7.5 93.2 (LP)2.4 2.0 1.9 Table 5: Nominal manifold pressure - low fire First Stage Manifold Pressures First Stage Manifold Pressures Gas Heating Value (Btu/cu ft) Altitude (ft)Gas Heating Value (MJ/cu m) Altitude (m) 0-7999 8000-8999 9000-9999 0-2437 2438-2742 2743-3048 in. W.C.in. W.C.in. W.C.kPa kPa kPa 800 1.7 1.7 1.7 29.8 0.4 0.4 0.4 850 1.7 1.7 1.7 31.7 0.4 0.4 0.4 900 1.7 1.7 1.7 33.5 0.4 0.4 0.4 950 1.7 1.7 1.5 35.4 0.4 0.4 0.4 1000 1.6 1.5 1.4 37.3 0.4 0.4 0.3 1050 1.5 1.4 1.3 39.1 0.4 0.3 0.3 1100 1.3 1.2 1.1 41.0 0.3 0.3 0.3 2500 (LP)4.1 3.8 3.5 93.2 (LP)1.03 1.0 0.9 5750144-UIM-H-0423 Johnson Controls Ducted Systems 11 Section V: Electrical power Electrical power connections 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. See Table 6 in these instructions for specific furnace electrical data. Annual Fuel Utilization Efficiency (AFUE) numbers are determined in accordance with DOE test procedures. Wire size and over current protection must comply with the National Electrical Code (NFPA-70-latest edition) and all local codes. The furnace shall be installed so that the electrical components are protected from water. Supply voltage connections 1.Provide a power supply separate from all other circuits. Install over- current protection and disconnect switch per local/national electrical codes. The switch should be close to the unit for convenience in servicing. With the disconnect or fused switch in the OFF position, check all wiring against the unit wiring label. See the wiring diagram in this manual. DANGER PROPANE AND HIGH ALTITUDE CONVERSION KITS It is very important to choose the correct kit and/or gas orifices for the altitude and the type of gas for which the furnace is being installed. Only use natural gas in furnaces designed for natural gas. Only use propane (LP) gas for furnaces that have been properly converted to use pro- pane (LP) gas. Do not use this furnace with butane gas. Incorrect gas orifices or a furnace that has been improperly converted will create an extremely dangerous condition resulting in premature heat exchanger failure, excessive sooting, high levels of carbon monoxide, personal injury, property damage, a fire hazard and/or death. High altitude and propane (LP) conversions are required in order for the appliance to satisfactorily 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 ensure that the furnace has been converted to the proper gas orifice size when the furnace is installed. Do not attempt to drill out any orifices to obtain the proper orifice size. Drilling out a gas orifice will cause misalignment of the burner flames, caus- ing premature heat exchanger burnout, high levels of carbon monoxide, excessive sooting, a fire hazard, personal injury, property damage and/or death. ! CAUTION Use copper conductors only. ! Table 6: Ratings and physical/electrical data Input High/Low Output High/Low Nominal Airflow Cabinet Width Total Unit Amps AFUE High Fire Air Temp. Rise MBH kW MBH kW CFM m3/min in.cm %°F °C 40/26 12/8 38/25 11/7 1000 28.3 14 1/2 36.8 8.7 96 25-55 14-31 60/39 18/11 58/37 17/11 1200 34 17 1/2 44.4 8.7 95.5 35-65 19-36 80/52 23/15 77/50 22/14 1200 34 17 1/2 44.4 8.7 96 45-75 25-42 80/52 23/15 77/50 22/14 1600 45.3 21 53.3 8.7 96 40-70 22-39 100/65 29/19 96/62 28/18 1600 45.3 21 53.3 8.7 96 50-80 28-45 100/65 29/19 96/62 28/18 2000 56.6 21 53.3 10.3 96 45-75 25-42 120/78 35/23 115/75 33/22 2000 56.6 24 1/2 62.2 10.3 96 50-80 28-45 Low Fire Air Temp. Rise Max. Outlet Air Temp.Blower Blower Size Recommended Fuse or Circuit Breaker Amps Gas Pipe Connection, NPT (in.) Operating Weight °F °C °F °C HP A in.cm lb kg 25-55 14-30 190 88 1/2 6.8 11 x 8 27.9 x 20.3 15 1/2 113 51.2 35-65 19-36 190 88 1/2 6.8 11 x 8 27.9 x 20.3 15 1/2 119 54.0 35-65 19-36 190 88 1/2 6.8 11 x 8 27.9 x 20.3 15 1/2 123 57.1 25-55 14-30 190 88 1/2 6.8 11 x 10 27.9 x 25.4 15 1/2 130 59.0 30-60 17-33 190 88 1/2 6.8 11 x 10 27.9 x 25.4 15 1/2 136 61.6 30-60 17-33 190 88 3/4 8.4 11 x 11 27.9 x 27.9 15 1/2 143 64.8 45-75 25-42 190 88 3/4 8.4 11 x 11 27.9 x 27.9 15 1/2 154 69.8 Figure 13: Electrical wiring Electrical Entry Junction Box L1-Hot Neutral Connect ground lead to screw BLK WHT 5750144-UIM-H-0423 12 Johnson Controls Ducted Systems 2.Remove the wiring box cover screws. Route all power wiring through a conduit connector or other proper bushing that is field installed into the unit opening and the junction box. In the junction box there is a black wire, a white wire and a green ground screw. Connect the power supply as shown on the unit’s wiring label located on the inside of the blower compartment door, or the wiring schematic in this section. Connect the black wire to L1 (hot) from the power supply. Connect the white wire to neutral. Connect the ground wire (installer-supplied) to the green (equipment ground) screw. An alternate wiring method is to use a field-provided 2 in. (5.1 cm) x 4 in. (10.2 cm) box and cover on the outside of the fur- nace. Route the furnace leads into the box using a protective bush- ing where the wires pass through the furnace panel. After making the wiring connections replace the wiring box cover and screws. See Figure 13. 3.The furnace's control system requires correct polarity of the power supply and a proper ground connection. See Figure 13. Low voltage control wiring connections Install the field-supplied 18ga minimum thermostat wiring by following the instructions that come with the thermostat. With the thermostat set in the OFF position and the main electrical source disconnected, con- nect the thermostat wiring from the wiring connections on the thermo- stat to the terminal board on the ignition module, as shown in Figures 14 or 15. Electronic thermostats require the common wire to be con- nected. Do not use power stealing thermostats. Apply strain relief to thermostat wires passing through cabinet. If air conditioning equipment is installed, use thermostat wiring to connect the Y and C terminals on the furnace control board to the proper wires on the condensing unit (unit outside). The 24 V, 40 VA transformer is sized for the furnace components only, and should not be connected to power auxiliary devices such as humid- ifiers and air cleaners. The transformer may provide power for an air conditioning unit contactor. Important: The power connection leads and wiring box may be relo- cated to the opposite side of the furnace. Remove the screws and cut wire tie holding excess wiring. Reposition on the opposite side of the furnace and fasten using holes provided. Important: Set the heat anticipator in the room thermostat to 0.4 amps. Setting it lower will cause short cycles. Setting it higher will cause the room temperature to exceed the set points. Important: Some electronic thermostats do not have adjustable heat anticipators. They should be set to six cycles per hour. Follow the thermostat manufacturer's instructions. Figure 14: Thermostat chart - two stage AC with two stage standard ECM furnaces $ 7ZR6WDJH$LU&RQGLWLRQHU±7ZR6WDJH)XUQDFH 67'(&0 < )LUVW6WDJH &RPSUHVVRU RU2 5HYHUVLQJ9DOYH * )DQ : 6HFRQG6WDJH+HDW 5 ±9ROW+RW : )LUVW6WDJH+HDW & ±9ROW&RPPRQ & ±9ROW&RPPRQ 5 ±9ROW+RW << 6HFRQGRU)XOO 6WDJH&RPSUHVVRU < )LUVW 6WDJH&RPSUHVVRU * )DQ 7:267$*( )851$&( 67'(&0 7:267$*( $,5 &21',7,21(5 & ±9ROW&RPPRQ 5 ±9ROW+RW < )LUVW6WDJH &RPSUHVVRU < 6HFRQG6WDJH &RPSUHVVRU < 6HFRQG6WDJH &RPSUHVVRU :: )LUVW6WDJH+HDW : 6HFRQG6WDJH+HDW 7+(50267$7 5750144-UIM-H-0423 Johnson Controls Ducted Systems 13 If using a single stage air conditioning or heat pump unit, connect the “Y” connection to Y/Y2 on furnace control board. Accessory connections The furnace control will allow power-switching control of various accessories. Electronic air cleaner connection Two 1/4 in. (6.4 mm) spade terminals (EAC-H and NEUTRAL) for elec- tronic air cleaner connections are located on the control board. The ter- minals provide 115 VAC (1.0 amp maximum) during circulating blower operation. Humidifier connection Two 1/4 in. (6.4 mm) spade terminals (HUM and NEUTRAL) for humidi- fier 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. Single stage thermostat If a single stage thermostat is used, the high/low input staging will be controlled by the furnace control board. Using the dipswitch settings the control provides multiple options for furnace staging. If the staging dip- switches are set to 10 or 20 position, the furnace will switch from low fire to high fire after 10 or 20 min and will stay in high fire until the ther- mostat is satisfied. If the staging dipswitches are set to AUTO position, the furnace will automatically stage from low fire to high fire, using recent heating duty cycle information in an adaptive algorithm to determine the optimal time to energize 2nd stage operation. If the staging dipswitches are set to OFF position and a single stage thermostat is used, the furnace will only operate at low fire. Section VI: 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 VII: Condensate piping and furnace venting configuration CONDENSATE DRAIN LOCATION As shipped from the factory: •For all 040, 060, & 080K input furnaces the main drain is plumbed through the casing right-side opening when viewed from the front of the furnace. •For all 100, 120, & 130K input furnaces the main drain is plumbed through the casing left-side opening when viewed from the front of the furnace. •Condensate drain line may be routed to either side of the furnace in upflow or downflow configurations. The condensate hoses must slope downwards at all points. When drain hose routing changes are required (shown in Figures 17 - 20), be sure to cap all unused openings. Figure 15: Thermostat chart - two stage HP with two stage standard ECM furnace $ 7ZR6WDJH+HDW3XPS±7ZR6WDJH)XUQDFH 67'(&0 < )LUVW6WDJH &RPSUHVVRU * )DQ : 6HFRQG6WDJH+HDW 5 ±9ROW+RW : )LUVW6WDJH+HDW & ±9ROW&RPPRQ & ±9ROW&RPPRQ 5 ±9ROW+RW << 6HFRQGRU)XOO 6WDJH&RPSUHVVRU < )LUVW 6WDJH&RPSUHVVRU * )DQ 7:267$*( )851$&( 67'(&0 7:267$*( +($73803 & ±9ROW&RPPRQ 5 ±9ROW+RW < )LUVW6WDJH &RPSUHVVRU < 6HFRQG6WDJH &RPSUHVVRU < 6HFRQG6WDJH &RPSUHVVRU :: )LUVW6WDJH+HDW : 6HFRQG6WDJH+HDW 7+(50267$7 <287 6HFRQG6WDJH &RPSUHVVRU 2 5HYHUVLQJ9DOYH (QHUJL]HGLQ&RRO : :287 )LUVW6WDJH+HDW :287 6HFRQG6WDJH+HDW RU2 5HYHUVLQJ9DOYH NOTICE The Figures 17 - 20 show the condensate drain arrangement for the various possible furnace and vent blower positions. CAUTION The furnace condensate pan is self priming and contains an internal trap to prevent flue gas leaking. Do not install an external condensate trap. ! 5750144-UIM-H-0423 14 Johnson Controls Ducted Systems 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. The condensate will flow to the drain better if an open stand pipe is installed in the drain line. See Figure 16. If indoor coil or humidifier drains are combined with the furnace drain, then the open stand pipe could be raised higher, but not above the 5 in. maximum. Do not drain other devices (humidifier, indoor coil, etc.) into the top opening of the vent stand pipe. Instead, install a second tee in the vented drain tube below the furnace drain tee and route additional drainage through the new tee. 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. Important: The furnace, indoor coil, and humidifier drains may be combined and drained together. The indoor coil drain may have an external, field-supplied trap prior to the furnace drain connection to prevent conditioned air leakage. All drain connections (furnace, indoor coil, or humidifier) must be terminated into an open or vented drain as close to the respective equipment as possible. Regular main- tenance is required on condensate drainage system. Important: Condensate must be disposed of properly. Follow local plumbing or wastewater codes. The drain line must maintain a 1/4 in./ ft (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 refer- enced elsewhere in this document. Figure 16: Typical. condensate drain, vertical installation 23(167$1'3,3( $QWLVLSKRQDLUYHQW 7223(125 9(17(''5$,1 7(( $ ´0D[ 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. CAUTION It is possible for condensation to form inside the combustion air (intake) pipe in the summer months if significant length of combustion air pipe passes through conditioned space. This problem can be averted by installing the supplied vent drain and drain hose located in the loose parts bag. The intake drain hose is to be installed by con- necting it to the inlet pipe coupling and to the collector box as shown in Figures 17, 19, and 20. The drain hose must not sag or droop after it is installed. If glue is used when connecting the intake pipe to the intake coupling, the drain opening in the vent drain must not be plugged. If the intake drain is used, the bird screen cannot be installed. This is only approved for upflow and horizontal applications when the intake pipe is located on the top of the furnace. This is true for all long horizontal venting in any furnace configuration. This will keep condensate from entering the furnace. 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 temperatures below freezing, adequate measures must be taken to prevent the drain line from freezing. Failure to provide proper protection from freezing can result in improper operation or damage to the equipment and possible property damage. When exposed to temperatures below freezing, use of a 3 to 6 watt per foot at 115 VAC, 40°F (4.4°C) self-regulating, shielded and waterproof heat tape is recommended on the drain line outside the furnace. DO NOT trap the drain line at any location. The furnace has a con- densate drain trap built into the drain pan. 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. ! ! ! 5750144-UIM-H-0423 Johnson Controls Ducted Systems 15 Figure 17: Upflow configuration A0945-001 5750144-UIM-H-0423 16 Johnson Controls Ducted Systems Figure 18: Downflow configuration AI R F L O W AI R F L O W Mo v e r a i n gu t t e r h o s e to t h i s p o s i t i o n . DO W N F L O W - I N D U C E R R O T A T E D FO R L E F T S I D E V E N T I N G DO W N F L O W - I N D U C E R R O T A T E D FO R R I G H T S I D E V E N T I N G Mo v e p r e s s u r e s w i t c h ho s e t o t h i s p o s i t i o n . NO T E : M a y r e q u i r e th e l o n g e r h o s e t h a t is p r o v i d e d w i t h wi d e r c a b i n e t s . Mo v e c o n d e n s a t e dr a i n h o s e t o t h i s po s i t i o n ( m a y e x i t ei t h e r s i d e o f t h e ca b i n e t ) . Mo v e r a i n g u t t e r ho s e t o t h i s p o s i t i o n . Wh e n d r a i n h o s e r o u t i n g c h a n g e s a r e r e q u i r e d , b e s u r e t o c a p a l l u n - u s e d o p e n i n g s . If r e r o u t i n g h o s e s - e x c e s s l e n g t h s h o u l d b e c u t o f f s o t h a t n o s a g g i n g l o o p s w i l l c o l l e c t an d h o l d c o n d e n s a t e , w h i c h w i l l c a u s e t h e f u r n a c e t o n o t o p e r a t e . 1 2 43 5750144-UIM-H-0423 Johnson Controls Ducted Systems 17 Figure 19: Horizontal left configuration A0947-001 5750144-UIM-H-0423 18 Johnson Controls Ducted Systems Figure 20: Horizontal right configuration A0946-001 5750144-UIM-H-0423 Johnson Controls Ducted Systems 19 Section VIII: Combustion air and vent system Combustion air and vent safety This Category IV, dual certified direct vent furnace is designed for resi- dential application. It may be installed without modification to the con- densate system in a basement, garage, equipment room, alcove, attic or any other indoor location where all required clearance to combusti- bles and other restrictions are met. The combustion air and the venting system must be installed in accordance with Section 5.3, Air for Com- bustion and Ventilation, of the National Fuel Gas Code Z223.1/NFPA 54 (latest edition), or Sections 7.2, 7.3 or 7.4 of CSA B149.1, National Gas and Propane Codes (latest edition) or applicable provisions of the local building code and these instructions. Combustion air/vent pipe sizing The size of pipe required will be determined by the furnace model, the total length of pipe required and the number of elbows required. Table 7 lists the maximum equivalent length of pipe allowed for each model of furnace. The equivalent length of pipe for each elbow installed is listed 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.If venting with PVC, drain, waste, and vent (DWV) elbows with a long radius (sweep) are recommended. Standard DWV elbows may be used, but since they have a longer equivalent length, they will reduce the total length of pipe that will be allowed. If venting with CPVC, long radius (sweep) elbows such as Spears Manufacturing LabWaste(R) series must be used. Short radius (plumbing or pres- sure) elbows are not allowed for venting. The standard dimensions of the acceptable elbows are shown in Figure 21 and Table 9. 2.The maximum equivalent length listed in Table 7 is for the vent pip- ing and the air intake piping separately. For example, if the table allows 65 equivalent ft for a particular model, then the vent can have 65 equivalent ft of pipe, AND the combustion air intake can have another 65 equivalent ft 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. 4.If a flexible connector is used in the vent system, it must be made of a material that is resistant to acidic exposure and to at least 225°F (107.2°C) temperature. Flexible connectors are also allowed in the combustion air pipe. 5.All PVC, CPVC, or ABS combustion air and vent pipe must conform to American National Standards Institute (ANSI) and American Society for Testing and Materials (ASTM) standards D1785 (Sched- ule 40 PVC), D2665 (PVC-DWV), D2846 (CPVC), F441 (CPVC), F442 (CPVC), D2261 (ABS-DWV) or F628 (Schedule 40 ABS). All IPEX System 1738 must conform to UL 1738 Standards and Amer- ican Society for Testing and Materials (ASTM) standards D2665. Pipe cement and primer must conform to ASTM Standard D2546 (PVC), F493 (CPVC), 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. 6.All models are supplied with 2 in. (5.1 cm) vent connections. When the pipe must be increased to 3 in. (7.6 cm) diameter, the transition from 2 in. to 3 in. must be done as close to the furnace as possible. The 2 in. to 3 in. increase should be installed in the vertical position as to not create an area that will pool water. 7.In Canada, vents shall be certified to ULC S636, Standard for Type BH Gas Venting Systems. 8.In Canada, the first 3 ft (91.4 cm) of the vent must be readily acces- sible for inspection. 9.For single pipe systems it is recommended to install the combustion air coupling provided and install approximately 18 in. of pipe on the furnace. 10.Minimum vent length for all models is 5 ft (1.5 m). Polypropylene vent/intake piping The ULC S636 approved polypropylene (PP) vent piping materials listed below have been tested and approved for use with this furnace. DO NOT mix parts made by different manufacturers. The entire vent/air intake system must be made from pipe, fittings and termination made by the same manufacturer. Only single-wall rigid polypropylene pipe is approved for these furnaces. Use of flexible polypropylene pipe is not allowed. Selkirk Polyflue (Hart & Cooley) part numbers •Horizontal concentric termination - 2 in. - 2PF-HCT •Horizontal concentric termination - 3 in. - 3PF-HCT •Locking band - PF-LB Consult the Polyflue installation instructions for assembly details. For other Polyflue pipe and fitting part numbers, visit website www.polyflue.com DuraVent PolyPro part numbers •Adapter to air intake coupling - 2PPS-ADL •Adapter connector - PPS-PAC •Twin pipe horizontal termination - 2 in. - 2PPS-HTPL •Twin pipe horizontal termination - 3 in. - 3PPS-HTPL Consult the PolyPro installation instructions for assembly details. For other PolyPro pipe and fitting part numbers, visit website www.duravent.com Centrotherm InnoFlue •Adapter to air intake coupling - ISAGL0202 •Adapter to draft inducer blower - ISAAL0202 •Low profile wall termination - 2 in. - ISLPT0202 •Low profile wall termination - 3 in. - ISLPT0303 Consult the InnoFlue installation instructions for assembly details. For other InnoFlue pipe and fitting part numbers, visit website www.centrotherm.us.com IPEX System 1738 •2 in. PVC FGV coupling - 397352 •3 in. PVC FGV coupling - 397353 Consult the IPEX System 1738 installation instructions for assembly details. For other IPEX System 1738 pipe and fitting part numbers, visit website www.ipexna.com/usa/products/plumbing-mechanical/flue-gas- venting-systems/system-1738-pvc Important: The VENT SYSTEM must be installed as specified in these instructions 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. WARNING 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 sepa- rate appliance designed to burn solid fuel. CAUTION When combustion air pipe is installed above a suspended ceiling or when it passes through a warm and humid space, the pipe may need insulated if 2 ft 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. ! ! 5750144-UIM-H-0423 20 Johnson Controls Ducted Systems Table 7: Maximum equivalent pipe length Elevation Sea level - 2000 Elevation 6001 - 7000 Model Input (Btu/h)Pipe Size (in)Max. equivalent Length (ft)Model Input (Btu/h)Pipe Size (in)Max. equivalent Length (ft) 40,000 2 65 40,000 2 40 40,000 3 90 40,000 3 65 40,000 4 150 40,000 4 130 60,000 2 65 60,000 2 40 60,000 3 90 60,000 3 65 60,000 4 150 60,000 4 130 80,000 2 65 80,000 2 30 80,000 3 90 80,000 3 65 80,000 4 150 80,000 4 130 100,000 2 30 100,000 2 5 100,000 3 90 100,000 3 65 100,000 4 150 100,000 4 130 120,000 3 90 120,000 3 65 120,000 4 150 120,000 4 130 Elevation 2001 - 4000 Elevation 7001-8000 Model Input (Btu/h)Pipe Size (in)Max. equivalent Length (ft)Model Input (Btu/h)Pipe Size (in)Max. equivalent Length (ft) 40,000 2 55 40,000 2 35 40,000 3 80 40,000 3 60 40,000 4 145 40,000 4 125 60,000 2 55 60,000 2 35 60,000 3 80 60,000 3 60 60,000 4 145 60,000 4 125 80,000 2 55 80,000 2 25 80,000 3 80 80,000 3 60 80,000 4 145 80,000 4 125 100,000 2 20 100,000 2 NA 100,000 3 80 100,000 3 60 100,000 4 145 100,000 4 125 120,000 3 80 120,000 3 60 120,000 4 145 120,000 4 125 Elevation 4001 - 5000 Elevation 8001-9000 Model Input (Btu/h)Pipe Size (in)Max. equivalent Length (ft)Model Input (Btu/h)Pipe Size (in)Max. equivalent Length (ft) 40,000 2 50 40,000 2 30 40,000 3 75 40,000 3 55 40,000 4 140 40,000 4 120 60,000 2 50 60,000 2 30 60,000 3 75 60,000 3 55 60,000 4 140 60,000 4 120 80,000 2 50 80,000 2 20 80,000 3 75 80,000 3 55 80,000 4 140 80,000 4 120 100,000 2 15 100,000 2 NA 100,000 3 75 100,000 3 55 100,000 4 140 100,000 4 120 120,000 3 75 120,000 3 55 120,000 4 140 120,000 4 120 Elevation 5001 - 6000 Elevation 9001-10000 Model Input (Btu/h)Pipe Size (in)Max. equivalent Length (ft)Model Input (Btu/h)Pipe Size (in)Max. equivalent Length (ft) 40,000 2 45 40,000 2 25 40,000 3 70 40,000 3 50 40,000 4 135 40,000 4 115 60,000 2 45 60,000 2 25 60,000 3 70 60,000 3 50 60,000 4 135 60,000 4 115 80,000 2 35 80,000 2 15 80,000 3 70 80,000 3 50 80,000 4 135 80,000 4 115 100,000 2 10 100,000 2 NA 100,000 3 70 100,000 3 50 100,000 4 135 100,000 4 115 120,000 3 70 120,000 3 50 120,000 4 135 120,000 4 115 5750144-UIM-H-0423 Johnson Controls Ducted Systems 21 Dimensions are those required in Standard ASTM D-3311. Example: An 80,000 Btu/h furnace requires 32 ft of pipe and five 90º elbows. Using 2 in. pipe and standard elbows, the total equivalent length will be: This exceeds the 65 ft maximum equivalent length of 2 in. pipe allowed for that model and is thus not acceptable. By using sweep elbows, the total equivalent length will be: This is less than the 65 ft maximum equivalent length of 2 in. pipe allowed for that model and is thus acceptable. Alternatively, using 3 in. pipe and standard elbows, the total equivalent length will be: This is less than the 90 ft maximum equivalent length of 3 in. pipe allowed for that model and is thus acceptable. 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. 3.Chamfer (bevel) the outer edges of the piping. 4.Dry-fit the 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 outside termination. b.Ventilated combustion air systems from the furnace to the attic or crawl space termination. 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, ASTM D2235 for ABS piping, or ASTM F493 for CPVC. 7.All joints must provide a permanent airtight and watertight seal. 8.Install the combustion air and vent piping such that it has a 1/4 in./ft (21 mm/m) grade so that condensate flows back toward the fur- nace. Piping should be supported with pipe hangers to prevent sag- ging. 9.Seal around the openings where the combustion air and / or vent piping pass through the roof or sidewalls. Table 8: High altitude pressure switches High Altitude Pressure Switches required for all installations above 5000 ft Part Number Models S1-1PS3308 All Figure 21: Dimensions Table 9: Elbow dimensions Elbow “A” Dimension 2 in. Standard 2 5/16 in. 3 in. Standard 3 1/16 in. 2 in. Sweep 3 1/4 in. 3 in. Sweep 4 1/16 in. Table 10: Equivalent length of fittings Fitting Equivalent Length 2 in. 90° sweep elbow 5 ft of 2 in. pipe 2 in. 45° sweep elbow 2 1/2 ft of 2 in. pipe 2 in. 90° standard elbow 7 ft of 2 in. pipe 2 in. 45° standard elbow 3 1/2 ft of 2 in. pipe 3 in. 90° sweep elbow 5 ft of 3 in. pipe 3 in. 45° sweep elbow 2 1/2 ft of 3 in. pipe 3 in. 90° standard elbow 7 ft of 3 in. pipe 3 in. 45° standard elbow 3 1/2 ft of 3 in. pipe 4 in. 90° elbow (sweep or stan- dard)5 ft of 4 in. pipe 4 in. 45° elbow (sweep or stan- dard)2 1/2 ft of 4 in. pipe 32 ft of 2 in. pipe =32 equivalent ft 5 - 90º standard 2 in. elbows = (5 x 7) = 35 equivalent ft Total = 67 equivalent ft of 2 in. pipe 32 ft of 2 in. pipe =32 equivalent ft 5 - 90º sweep 2 in. elbows = (5 x 5) = 25 equivalent ft Total = 57 equivalent ft of 2 in. pipe 32 ft of 3 in. pipe =32 equivalent ft A A A A STANDARD ELBOW LONG (SWEEP) ELBOW 5 - 90º standard 3 in. elbows = (5 x 7) = 35 equivalent ft Total = 67 equivalent ft of 3 in. pipe Table 11: Combustion air intake and vent connection size at furnace (all models) Furnace vent connection sizes Furnace Input All Intake Pipe Size 2 in. (5.1 cm) Vent Pipe Size 2 in. (5.1 cm) Important: Furnace vent pipe connections are sized for 2 in. (5.1 cm). pipe. Any pipe size change must be made outside the furnace casing in a vertical pipe section to allow proper drainage of conden- sate. An offset using two 45º elbows will be required for plenum clear- ance when the vent is increased to 3 in. (7.6 cm) or 4 in. (10.16 cm). Important: Accessory concentric vent / intake termination kits 1CT0302 and 1CT0303, and for Canadian applications 1CT0302-636 and 1CT0303-636 are available and approved for use with these fur- naces. Horizontal sidewall vent terminations kits 1HT0901 & 1HT0902 are also approved for use with these furnaces. The above listed termination kits are not to be used with CPVC vent piping. 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. ! 5750144-UIM-H-0423 22 Johnson Controls Ducted Systems Combustion air/venting Vent clearances †A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings. ††12 in. (30.5 cm) up from the bottom edge of the structure for Two-pipe (direct vent) applications per ANSI Z223.1 / NFPA 54, National Gas Code. ‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor and the distance between the top of the vent termina- tion and the underside of the veranda, porch, or deck is greater than 12 in. (30.5 cm) as specified in CSA B149.1-00. A vent shall not terminate less than 12 in. (30.5 cm) above a grade level. Any fresh air or make up inlet for dryer or furnace area is considered to be forced air inlet. Avoid areas where condensate drippage may cause problems such as above planters, patios, or adjacent to windows where steam may cause fogging. A terminus of a vent shall be fitted with a cap in accordance with the vent manufacturer’s installation instructions, or in accordance with the installation instructions for a special venting system. Responsibility for the provision of proper adequate venting and air supply for application shall rest with the installer. Vent shall extend high enough above building, or a neighboring obstruction, so that wind from any direction will not create a positive pressure in the vicinity of the vent. Important: The vent must be installed with the minimum required clearances, and must comply with local codes and requirements. Figure 22: Home layout L E D B V V V XV B V J X B B B V VF V C B X V I V G H A M K OPERABLE FIXED CLOSED VENT TERMINAL AIR SUPPLY AREA WHERE TERMINAL IS NOT PERMITTED FIXED CLOSED Direct Vent Terminal Clearances Canadian Installations1,3 US Installation2,3 A.Clearance above grade, veranda, porch, deck, or balcony 12 in. (30.5 cm)12 in. (30.5 cm) B.Clearance to window or door that may be opened 12 in. (30.5 cm) for models £100,000 Btu/h (30 kW), 36 in. (91.4 cm) for models >100,000 Btu/h (30 kW). Two-pipe (direct vent) applications: 9 in. (23 cm) for models £50,000 Btu/h (15 kW), 12 in. (30.5 cm) for models >50,000 Btu/h (15 kW). †† Single-pipe applications: 4 ft (1.2 m). C.Clearance to permanently closed window 12 in. (30.5 cm)12 in. (30.5 cm) D.Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 ft (61 cm) from the center line of the terminal 12 in. (30.5 cm) or in accordance with local installation codes and the requirements of the gas supplier. 12 in. (30.5 cm) or in accordance with local installation codes and the requirements of the gas supplier. E.Clearance to unventilated soffit 12 in. (30.5 cm) or in accordance with local installation codes and the requirements of the gas supplier. 12 in. (30.5 cm) or in accordance with local installation codes and the requirements of the gas supplier. F.Clearance to outside corner 12 in. (30.5 cm) or in accordance with local installation codes and the requirements of the gas supplier. 12 in. (30.5 cm) or in accordance with local installation codes and the requirements of the gas supplier. G.Clearance to inside corner 3 ft (91.4 cm)3 ft (91.4 cm) H.Clearance to each side of center line extended above meter/regulator assembly Above a meter/regulator assembly within 3 ft (91.4 cm) horizontally of the vertical center-line of the regulator vent outlet to a maximum vertical distance of 15 ft (4.5 m) above the meter/regulator assembly. Above a meter/regulator assembly within 3 ft (91.4 cm) horizontally of the vertical center-line of the regulator vent outlet to a maximum vertical distance of 15 ft (4.5 m) above the meter/regulator assembly. I.Clearance to service regulator vent outlet 3 ft (91.4 cm)3 ft (91.4 cm) or in accordance with local installation 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 12 in. (30.5 cm) for models £100,000 Btu/h (30 kW), 3 ft (91.4 cm) for models >100,000 Btu/h (30 kW). Two-pipe (direct vent) applications: 9 in. (23 cm) for models £50,000 Btu/h (15 kW), 12 in. (30.5 cm) for models >50,000 Btu/h (15 kW). Single-pipe applications: 4 ft (1.2 m). K.Clearance to a mechanical supply inlet 6 ft (1.83 m)3 ft (91.4 cm) above if within 10 ft (3 m) horizontally. L.Clearance above paved sidewalk or paved driveway located on public property 7 ft (2.13 m)†7 ft (2.13 m) or in accordance with local installation codes and the requirements of the gas supplier. M.Clearance under veranda, porch, deck, or balcony 12 in. (30.5 cm)‡12 in. (30.5 cm) or in accordance with local installation 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.In accordance with the current ANSI Z223.1 / NFPA 54, National Gas Code. 3.In accordance with the current ANSI Z21.47 * CSA 2.3 American National Standard. 5750144-UIM-H-0423 Johnson Controls Ducted Systems 23 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 objec- tionable. 6.Horizontal portions of the vent system must slope upwards and be supported to prevent sagging. 7.Direct vent systems must be installed so the vent and the combus- tion air pipes terminate in the same atmospheric zone. See Figures 24 or 25. 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 both vents terminating as shown in Figure 23. 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 configuration shown in Figure 25 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 26 or 27. 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. Important: Consideration must be given for degradation of building materials by flue gases. Sidewall termination may require sealing or shielding of building surfaces with a corrosion resistant material to protect against combustion product corrosion. Consideration must be given to wind direc- tion 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 stain- less steel material at a minimum dimension of 20 in. (51 cm). It is recommended that a retaining type collar be used that is attached to the building surface to prevent movement of the vent pipe. Figure 23: Termination configuration - one pipe WARNING Condensation in Intake Pipe Installations where the furnace and intake pipe are to be located in a conditioned space and in a region that may have hot, humid weather extending several consecutive days will have condensate form in the intake pipe. Use of the supplied intake drain will ensure that any con- densate will be safely diverted away from the internal components of the furnace. Proper venting installation (of both intake and exhaust) and sealing any equipment air leaks that might contact the intake pipe will help reduce condensation. 12” Min. 12” Min. Maintain 12” minimum clearance above highest anticipated snow level. Maximum 24” above roof. ! Figure 24: Termination configuration - two pipe Figure 25: Termination configuration - two pipe basement Maintain 12” minimum clearance above highest anticipated snow level. 12” vertical separation between combustion air intake and vent.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. ´0,1 ´0,1 29( 5 + $ 1 * ´0LQLPXP EHORZRYHUKDQJ ´0LQLPXP VHSDUDWLRQEHWZHHQ ERWWRPRI FRPEXVWLRQDLU LQWDNHDQG ERWWRPRIYHQW 0DLQWDLQ´ PLQLPXPFOHDUDQFH DERYHKLJKHVW DQWLFLSDWHGVQRZ OHYHORUJUDGH ZKLFKHYHULVKLJKHU $ 5750144-UIM-H-0423 24 Johnson Controls Ducted Systems Downward venting In some applications, it may be necessary to run the vent pipe and air intake downwards. If this is to be done, the following rules must be fol- lowed. •A condensate trap hose must be connected to both the air intake pipe and the vent pipe at the lowest part of the horizontal run. •The condensate drain trap must have a trap of a minimum of six inches. •The total vertical downward distance must not exceed 16 ft. •The condensate drain hose must be connected to a condensate drain pump, a open or vented drain or into the condensate drain line from the furnace. •The condensate drain lines must not pass through unconditioned spaces where the temperature may fall below freezing. •The condensate drain line must be primed at the initial start-up prior to the start of heating season. 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 B149.2 Installation Code - latest editions. 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, CPVC, or ABS pipe that is connected to the coupling attached to the furnace and is terminated in the same atmospheric zone as the vent. This type of installation is approved on all models. See Figure 29. 2.Ambient combustion air: Combustion air is supplied from the area surrounding the furnace through openings in the furnace cas- ing. The combustion air and the vent pipes are not terminated in the same atmospheric zone. See Figure 23 for vent terminations. See “Ambient Combustion air Supply” for proper installation. See Fig- ures 29 and 30. 3.Ventilated combustion air: Combustion air is supplied through a PVC, CPVC, or ABS pipe that is connected to the 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 terminated in the same atmospheric zone. See Figure 32 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 28) 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 29) is the furnace vent pipe. 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.” Figure 26: Double horizontal combustion air intake and vent termination Figure 27: Double vertical combustion air intake and vent termination Figure 28: Downward venting VENT 2” MIN. COMBUSTION AIR MIN. 6” 16’ MAX 6” MIN. 6” MIN. 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. Figure 29: Direct vent air intake connection and vent connection Connects to collar on top of burner box Vent pipe clamps into outlet of drain coupling 5750144-UIM-H-0423 Johnson Controls Ducted Systems 25 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 in. (46 cm) of pipe be attached to the furnace to prevent accidental blockage of the combus- tion air intake. An unconfined space is not less than 50 cu.ft (1.42 m3) per 1,000 Btu/ h (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 m3) per 1,000 Btu/h (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 louvers, grilles and screens must be given con- sideration in calculating free area. If the free area of a specific louver or grille is not known, refer to Table 12, to estimate free area. *Do not use less than 1/4 in. (6.4 mm) mesh +Free area of louvers and grille varies widely; the installer should follow louver or grille manufacturer’s instructions. Dampers, louvers and grilles (Canada only) 1.The free area of a supply air opening shall be calculated by sub- tracting the blockage area of all fixed louvers grilles or screens from the gross area of the opening. 2.Apertures in a fixed louver, a grille, or screen shall have no dimen- sion smaller than 1/4 in. (6.4 mm). 3.A manually operated damper or manually adjustable louvers are not permitted for use. 4.A automatically operated damper or automatically adjustable lou- vers shall be interlocked so that the main burner cannot operate unless either the damper or the louver is in the fully open position. Figure 30: Combustion airflow path through the furnace casing WARNING This type of installation requires that the supply air to the appliance(s) be of a sufficient amount to support all of the appliance(s) in the area. Operation of a mechanical exhaust, such as an exhaust fan, kitchen ventilation system, clothes dryer or fireplace may create conditions requiring special attention to avoid unsatisfactory operation of gas appliances. A venting problem or a lack of supply air will result in a hazardous condition, which can cause the appliance to soot and gen- erate dangerous levels of CARBON MONOXIDE, which can lead to serious injury, property damage and / or death. COMBUSTION AIR Vent pipe clamps into outlet of drain coupling ! Table 12: Estimated free area Wood or Metal Louvers or Grilles Wood 20-25%* Metal 60-70% * Screens+1/4 in. (6.4 mm) mesh or larger 100% WARNING When a Category I furnace is removed or replaced, the original vent- ing system may no longer be correctly sized to properly vent the attached appliances. An improperly sized vent system can cause CARBON MONOXIDE to spill into the living space causing personal injury, and or death. Table 13: Unconfined space minimum area Btu/h Input Rating Minimum Free Area Required for Each Opening 40,000 40 in2 (258 cm2) 60,000 60 in2 (387 cm2) 80,000 80 in2 (516 cm2) 100,000 100 in2 (645 cm2) 120,000 120 in2 (742 cm2) Table 14: Free area Btu/h Input Rating Minimum Free Area Required for Each Opening Horizontal Duct (2,000 Btu/h) Vertical Duct or Opening to Outside (4,000 Btu/h) Round Duct (4,000 Btu/h) 40,000 20 in2 (129 cm2)10 in2 (64 cm2) 4 in. (10 cm) 60,000 30 in2 (193 cm2)15 in2 (97 cm2)5 in. (13 cm) 80,000 40 in2 (258 cm2)20 in2 (129 cm2)5 in. (13 cm) 100,000 50 in2 (322 cm2)25 in2 (161 cm2)6 in. (15 cm) 120,000 60 in2 (387 cm2)30 in2 (193 cm2)7 in. (18 cm) 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 ! 5750144-UIM-H-0423 26 Johnson Controls Ducted Systems Air supply openings and ducts 1.An opening may be used in lieu of a duct to provide to provide the outside air supply to an appliance unless otherwise permitted by the authority having jurisdiction. The opening shall be located within 12 in. (30.5 cm) horizontally from, the burner level of the appliance. See “AIR SOURCE FROM OUTDOORS AND VENT AND SUPPLY AIR SAFETY CHECK” in these instructions for additional informa- tion and safety check procedure. 2.The duct shall be either metal, or a material meeting the class 1 requirements of CAN4-S110 Standard for Air Ducts. 3.The duct shall be least the same cross-sectional area as the free area of the air supply inlet opening to which it connects. 4.The duct shall terminate within 12 in. (30.5 cm) above, and within 24 in. (61 cm) horizontally from, the burner level of the appliance having the largest input. 5.A square or rectangular shaped duct shall only be used when the required free area of the supply opening is 9 in2 (58.06 cm2) or larger. When a square or rectangular duct is used, its small dimen- sion shall not be less than 3 in. (7.6 cm). 6.An air inlet supply from outdoors shall be equipped with a means to prevent the direct entry of rain and wind. Such means shall not reduce the required free area of the air supply opening. 7.An air supply inlet opening from the outdoors shall be located not less than 12 in. (30.5 cm) above the outside grade level. Combustion air source from outdoors 1.Two permanent openings, one within 12 in. (30.5 cm) of the top and one within 12 in. (30.5 cm) of bottom of the confined space, Two permanent openings, shall communicate directly or by means of ducts with the outdoors, crawl spaces or attic spaces. 2.One permanent openings, commencing within 12 in. (30.5 cm) of the top of the enclosure shall be permitted where the equipment has clearances of at least 1 in. (2.54 cm) from the sides and back and 6 in. (15.2 cm) from the front of the appliance. The opening shall communicate directly with the outdoors and shall have a mini- mum free area of: a.1 in.2 / 3,000 Btu/h (700mm2/kW) of the total input rating of all equipment located in the enclosure. b.Not less than the sum of all vent connectors in the confined space. 3.The duct shall be least the same cross-sectional area as the free area of the air supply inlet opening to which it connects. 4.The blocking effects of louvers, grilles and screens must be given consideration in calculating free area. If the free area of a specific louver or grille is not known. See Table 12. 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 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. See Table 7 for intake pipe sizing, allowable length and elbow usage. Follow all notes, procedures and required materials in the “COMBUSTION AIR/ VENT PIPE SIZING” section in these instructions when installing the combustion air pipe from the unit and into a ventilated attic space or crawl space. DO NOT terminate vent pipe in an Attic or Crawl Space. Ventilated combustion air termination See Figure 32 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 in. (30.5 cm) clearance 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 in. (6.4 mm) mesh screen and no elbows. Figure 31: Ambient combustion air Gable Vent Gas Vent Soffit Vent Ventilated Attic Top Above Insulation Optional Inlet (a) Outlet Air (a) Ventilated Crawl Space Gas Water Heater Fu r n a c e Soffit Vent Gas Water Heater Inlet Air (a) Inlet Air (b)Fu r n a c e Gas Vent Outlet Air (a) Outlet Air (b) Inlet Air (a) Inlet Air (b) Gas Water Heater Fu r n a c e Gable Vent Gas Vent Ventilated Attic Top Above Insulation 5750144-UIM-H-0423 Johnson Controls Ducted Systems 27 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. 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 17 - 20 for illustrations of different inducer rotation positions. Section IX: Start-up and adjustments The following start-up checks MUST be performed by the furnace installer on every new furnace installation. 1.Gas piping leak check. 2.Furnace input rate check. 3.Air temperature rise check. Instructions on how to perform each of these required installation checks are listed in the sections below. When the gas supply is initially connected to the furnace, the gas piping may be full of air. In order to purge this air, it is recommended that the ground union be loosened until the odor of gas is detected. When gas is detected, immediately retighten the union and check for leaks. Allow 5 min for any gas to dissipate before continuing with the start-up proce- dure. Be sure proper ventilation is available to dilute and carry away any vented gas. Gas piping leak check 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: 1.Inspect the venting system for proper size and horizontal pitch. Determine that there is no blockage, restriction, leakage, corrosion or other defi- ciencies, which could cause an unsafe condition 2.Close all building doors and windows. 3.Turn on clothes dryers and TURN ON any exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum speed. Open the fireplace dampers. Do not operate a summer exhaust fan. 4.Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so the appliance shall operate continu- ously. 5.Test each appliance (such as a water heater) equipped with a draft hood for spillage (down-draft or no draft) at the draft hood relief opening after 5 min 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 CO2 and CO levels of each appliance. Use a draft gauge to check for a downdraft or inade- quate draft condition. 6.After it has been determined that each appliance properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their normal condition. 7.If improper venting is observed during any of the above tests, a problem exists with either the venting system or the appliance does not have enough combustion air (Supply Air from outside) to complete combustion. This condition must be corrected before the appliance can function safely. 8.Any corrections to the venting system and / or to the supply (outside) air system must be in accordance with the National Fuel Gas Code Z223.1 or CAN/CGA B149.1 Natural Gas and Propane Installation Code (latest editions). If the vent system must be resized, follow the appro- priate tables in Appendix G of the above codes or for this appliance. ! Figure 32: Attic and crawl space combustion air termination WARNING Be sure to instruct the owner not to block this intake pipe. 12” Min. 12” minimum between bottom of air intake and any material below. ! Important: All electrical connections made in the field and in the fac- tory should be checked for proper tightness. 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 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 residual air in the gas line or until gas manifold pressure is adjusted. The ignition control will make three attempts to light before locking out. ! 5750144-UIM-H-0423 28 Johnson Controls Ducted Systems 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 5 min 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 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. 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 s. 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 s. Calculating the furnace input (natural gas) Burner orifices are sized to provide proper input rate using natural gas with a heating value of 1030 Btu/Ft3 (38.4 MJ/m3). If the heating value of your gas is significantly different, it may be necessary to replace the orifices. Verify natural gas input rate by clocking meter. 1.Turn off all other gas appliances and pilots. 2.Run furnace for a minimum of 3 min in heating operation. 3.Measure time (in sec) for gas meter to complete 1 revolution and note reading. The 2 cu ft dial provides a more accurate measure- ment of gas flow. 4.See Table 15 for cubic feet of gas per hour. 5.Multiply cubic feet per hour by heating value (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. WARNING HOT SURFACE IGNITION SYSTEM Do not attempt to light this furnace by hand (with a match or any other means). There may be a potential shock hazard from the components of the hot surface ignition system. The furnace can only be lit auto- matically by its hot surface ignition system. ! NOTICE DO NOT set manifold pressure less than 3.2 in. W.C. or more than 3.8 in. W.C. for natural gas at sea level. If manifold pressure is out- side this range, change main burner orifices. NOTICE If orifice hole appears damaged or it is suspected to have been redrilled, check orifice hole with a numbered drill bit of correct size. Never redrill an orifice. A burr-free and squarely aligned orifice hole is essential for proper flame characteristics. CAUTION DO NOT bottom out gas valve regulator adjusting screw. This can result in unregulated manifold pressure and result in excess overfire and heat exchanger failures. CAUTION Be sure to relight any gas appliances that were turned off at the start of this input check. ! ! 5750144-UIM-H-0423 Johnson Controls Ducted Systems 29 Adjustment of manifold gas pressure and 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. See Figure 33 for the loca- tions 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.The manifold pressure must be taken at the port marked OUT P. 2.The gas line pressure must be taken at the port marked IN P. 3.Using a 3/32 in. (2.4 mm) hex head wrench, loosen the set screw by turning 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 reference atmospheric pressure. See Figure 34 for connection details. 1.Turn gas and electrical supplies on and follow the operating instruc- tions to place the unit back in operation. Table 15: Gas rate (cu ft/h) at full input Seconds For 1 Revolution Size of Test Dial Seconds For 1 Revolution Size of Test Dial 1 cu ft 2 cu ft 5 cu ft 1 cu ft 2 cu ft 5 cu ft 10 360 720 1800 55 65 131 327 11 327 655 1636 56 64 129 321 12 300 600 1500 57 63 126 316 13 277 555 1385 58 62 124 310 14 257 514 1286 59 61 122 305 15 240 480 1200 60 60 120 300 16 225 450 1125 62 58 116 290 17 212 424 1059 64 56 112 281 18 200 400 1000 66 54 109 273 19 189 379 947 68 53 106 265 20 180 360 900 70 51 103 257 21 171 343 857 72 50 100 250 22 164 327 818 74 48 97 243 23 157 313 783 76 47 95 237 24 150 300 750 78 46 92 231 25 144 288 720 80 45 90 225 26 138 277 692 82 44 88 220 27 133 267 667 84 43 86 214 28 129 257 643 86 42 84 209 29 124 248 621 88 41 82 205 30 120 240 600 90 40 80 200 31 116 232 581 92 39 78 196 32 113 225 563 94 38 76 192 33 109 218 545 96 38 75 188 34 106 212 529 98 37 74 184 35 103 206 514 100 36 72 180 36 100 200 500 102 35 71 178 37 97 195 486 104 35 69 173 38 95 189 474 106 34 68 170 39 92 185 462 108 33 67 167 40 90 180 450 110 33 65 164 41 88 176 439 112 32 64 161 42 86 172 429 116 31 62 155 43 84 167 419 120 30 60 150 44 82 164 409 124 29 58 145 45 80 160 400 128 28 56 141 46 78 157 391 133 27 54 135 47 76 153 383 138 26 52 130 48 75 150 375 144 25 50 125 49 73 147 367 150 24 48 120 50 72 144 360 157 23 46 115 51 71 141 355 164 22 44 110 52 69 138 346 171 21 42 105 53 68 136 340 180 20 40 100 54 67 133 333 Table 16: Inlet gas pressure range Inlet gas pressure range Natural Gas Propane (LP) Minimum 4.5 in. W.C. (1.12 kPa)8.0 in. W.C. (1.99 kPa) Maximum 10.5 in. W.C. (2.61 kPa)13.0 in. W.C. (3.24 kPa) 5750144-UIM-H-0423 30 Johnson Controls Ducted Systems 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 in. (2.4 mm) hex head 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 OUT P Tap on the gas valve. Do not connect any tubing to the negative side of the manometer, as it will reference atmospheric pressure. See Figures 33 and 34 for connection details. This gas valve has separate regulator adjustment screws for high fire and low fire, as shown in Figure 33. The procedure below is used to adjust either the high fire manifold pressure or the low fire manifold pressure. 1.See Figure 33 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 instruc- tions to place the unit back in operation. 3.Place jumper wire from W1 to W2 to R on the furnace control board for the furnace to operate HIGH fire. Once correct manifold pres- sure is set (HI), remove jumper from W2 for the furnace to operate on low fire. Set the manifold pressure (LO) to correct manifold pres- sure. 4.After the manifold pressure has been adjusted, re-calculate the fur- nace input to make sure you have not exceeded the specified input on the rating plate. See “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 in. (2.4 mm) hex head 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. Adjustment of temperature rise After about 5 min of operation, determine the furnace temperature rise. Take readings of both the return air and the heated air in the ducts, about 6 ft (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. See furnace rating plate for minimum or maximum temperature rise, and adjust blower speed accordingly. Airflow settings Cooling airflow settings This unit is equipped with a five-speed blower motor. The desired cooling airflow may be selected by connecting the desired motor speed tap wire to the HI COOL terminal on the control board. The speed should be selected so as to deliver approximately 350-400 CFM per ton of A/C cooling capacity. Use of airflow outside of this range may result in diminished air conditioning performance and may result in lower overall energy efficiency and higher electric utility bills. Important: The inlet gas pressure operating range table specifies what the minimum and maximum gas line pressures must be for the furnace to operate correctly. The gas line pressure MUST BE a mini- mum of: •7 in. W.C. (1.74 kPA) for Natural Gas •11 in. W.C. (2.74 kPA) for Propane (LP) Gas in order to obtain the Btu input specified on the rating plate and/or the nominal manifold pressure specified in these instructions and on the rating plate. Important: The cap for the pressure regulator must be removed entirely to gain access to the adjustment screw. Loosening or tighten- ing the cap does not adjust the flow of gas. NOTICE Gas manifold pressure must be set on high fire before adjusting low fire pressure. Table 17: Nominal manifold pressure Nominal manifold pressure Natural Gas (High Fire)3.5 in. W.C. (0.87 kPa) Natural Gas (Low Fire)1.6 in. W.C. (0.40 kPa) Propane (LP) Gas (High Fire)9.8 in. W.C. (2.488 kPa) Propane (LP) Gas (Low Fire)4.0 in. W.C. (0.99 kPa) Figure 33: Gas valve INLET WRENCH BOSS INLET PRESSURE PORT ON OFF SWITCH LOW STAGE REGULATOR ADJUSTMENT OUTLET OUTLET PRESSURE PORT VENT PORT HIGH STAGE REGULATOR ADJUSTMENT Important: If gas valve regulator is turned in (clockwise), manifold pressure is increased. If screw is turned out (counterclockwise), man- ifold pressure will decrease. MANIFOLD PRESSURE “U” TUBE CONNECTION Figure 34: Reading gas pressure DANGER The temperature rise, or temperature difference between the return air and the supply (heated) air from the furnace, must be within the range shown on the furnace rating plate and within the application limitations shown in Table 6 “RATINGS & PHYSICAL / ELECTRICAL DATA”. The supply air temperature cannot exceed the “Maximum Supply Air Temperature” specified in these instructions and on the furnace rating plate. Under NO circumstances can the furnace be allowed to operate above the Maximum Supply Air Temperature. Operating the furnace above the Maximum Supply Air Temperature will cause pre- mature heat exchanger failure, high levels of Carbon Monoxide, a fire hazard, personal injury, property damage, and/or death. U-TUBE MANOMETER 3.5 IN WATER COLUMN GAS PRESSURE SHOWN GAS BURNERS OUTLET PRESSURE TAP GAS VALVE FLAME SENSOR 1/4” TUBING MAINIFOLD PIPE ! 5750144-UIM-H-0423 Johnson Controls Ducted Systems 31 Continuous fan airflow settings The default blower speed for continuous fan operation is LO HT (Low Heat) speed. This furnace may be operated in continuous fan mode by setting the wall thermostat FAN switch to ON. To select the desired continuous fan airflow, set the CONT SPEED dip switches on the control board to the desired position. There are four options: 1.With the FAN SPEED dip switches in the “HI CL” position the blower will run during continuous fan operation at the motor speed connected to the “HI COOL” terminal on the control board. 2.With the FAN SPEED dip switches in the “LO CL” position the blower will run during continuous fan operation at the motor speed connected to the “LO COOL” terminal on the control board. 3.With the FAN SPEED dip switches in the “HI HT” position the blower will run during continuous fan operation at the motor speed connected to the “HI HEAT” terminal on the control board. 4.With the FAN SPEED dip switches in the “LO HT” position the blower will run during continuous fan operation at the motor speed connected to the “LO HEAT” terminal on the control board. The default position is with the dip switches in the “LO HT” position and the LOW speed motor wire on the LO HEAT terminal. In certain circum- stances, it may be necessary to move the continuous fan speed to a dif- ferent speed tap. However, doing so is not recommended since it will result in higher than normal electrical energy usage and higher than normal electric utility bills. Gas heating airflow settings The default heating blower speed is shown in Table 18. This unit is equipped with a five-speed blower motor. The heating blower speed is set at the factory to the default blower speed, which is the blower speed that will deliver the correct airflow for proper heating operation in most applications. In certain circumstances, it may be necessary to move the heating blower speed to a different motor speed tap. Not all five motor speeds are appropriate for gas heating operation. The use of heating airflow on a speed other than the default speed will result in diminished heating performance and may cause the furnace temperature limit controls to shut down the furnace. Measurement of temperature rise After about 5 min of operation, determine the furnace temperature rise. Measure the temperature of both the return air and the heated air in the ducts, about 6 ft (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. The blower speed taps are located on the furnace control board in the blower compartment. See Figure 36, and the unit-wiring label to change the blower speed. To use the same speed tap for heating and cooling, the heat terminal and cool terminal must be connected using a jumper wire and connected to the desired motor lead. Place the unused motor leads on the PARK terminal. Taking a flue gas sample If it becomes necessary to obtain a flue gas sample for analysis, it is permissible to drill a small hole in the plastic flue pipe for a sample probe, provided that the vent piping is PVC and the hole is properly sealed afterwards. If using a polypropylene vent system, the vent sys- tems manufacturer test port fitting must be used. DONOT drill a test port hole in polypropylene piping. Use the following procedure: 1.Drill a 11/32 in. hole in the side wall of the PVC vent pipe. If the hole is in a horizontal section of the vent pipe, ensure that it is located away from the bottom where condensation may be flowing back toward the furnace. 2.Operate the furnace a minimum of (10 min) to ensure stable opera- tion of the combustion process. 3.Sample the flue gas as necessary to obtain CO readings. 4.Using a 1/8 in. pipe tap, cut threads into the sampling hole of the PVC pipe. 5.Use high temp RTV as a sealant on the threads of a 1/8 in. brass MPT plug and insert it 3 turns into the hole to correctly seal it. External static pressure setup Set appropriate airflow per temperature rise for gas heating. Set appro- priate airflow per Table 19 for cooling/heat pump heating operating based on outdoor unit size. Table 18: Default blower speeds Model Number Default blower speeds Hi Heat LO Heat HI Cool LO Cool Continuous Fan 040A10 Medium High (2)Low (5)High (1)Medium (3)LO Heat 060B12 Medium High (2)Low (5)High (1)Medium (3)LO Heat 080B12 Medium High (2)Medium Low (4)High (1)Medium (3)LO Heat 080C16 Medium High (2)Medium Low (4)High (1)Medium (3)LO Heat 100C16 Medium High (2)Medium (3)High (1)Medium Low (4)LO Heat 100C20 Medium High (2)Medium Low (4)High (1)Medium (3)LO Heat 120D20 Medium High (2)Medium Low (4)High (1)Medium (3)LO Heat DANGER The temperature rise, or temperature difference between the return air and the supply (heated) air from the furnace, must be within the range shown on the furnace rating plate and within the application limitations shown in SECTION V. The supply air temperature cannot exceed the “Maximum Supply Air Temperature” specified in these instructions and on the furnace rating plate. Under NO circumstances can the furnace be allowed to operate above the Maximum Supply Air Temperature. Operating the furnace above the Maximum Supply Air Temperature will cause pre- mature heat exchanger failure, high levels of Carbon Monoxide, a fire hazard, personal injury, property damage, and/or death. ! Figure 35: Measuring external duct static Supply Duct Return Duct 5750144-UIM-H-0423 32 Johnson Controls Ducted Systems To measure external static pressure: •Measure the supply air static pressure •Record this positive number •Measure the return air static pressure •Record this negative number •Treat the negative number as a positive and add the two numbers together •This is total system static Figure 36: Furnace control board &219(17,21$//2: 92/7$*(7+(50267$7 &211(&7,216 ',$*1267,&/,*+7',$*1267,&(5525 &2'(5(75,(9$/ %87721 &217,18286)$1 63(('',36:,7&+(6 %/2:(52))'(/$< 6(77,1*',36:,7&+(6 +,*+/2:),5( 67$*,1*',36:,7&+(6 (/(&7521,& $,5&/($1(5 7(50,1$/ +80,',),(5 7(50,1$/ $ %/2:(5 02725 /2:92/7$*( &211(&7256 &21752/ %2$5' )86( 5750144-UIM-H-0423 Johnson Controls Ducted Systems 33 NOTES: 1.Airflow expressed in standard cubic feet per minute (SCFM). 2.Motor voltage at 115 V. Section X: Safety controls Control circuit fuse A 3 A fuse is provided on the control circuit board to protect the 24 V 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 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 malfunction in the combustion air blower, heat exchanger or a blocked vent pipe con- nection. Corrective action is required. These are manual reset controls that must be reset before operation can continue. Table 19: Blower performance CFM - any position (without filter) Models Speed Bottom Airflow Data (SCFM) External Static Pressure (in. H2O) 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 40A High 1290 1260 1220 1160 1100 1040 960 840 750 660 Medium High 1170 1140 1110 1070 1040 990 930 820 730 650 Medium 990 980 940 900 860 830 790 730 680 630 Medium Low 900 880 850 810 770 730 670 630 600 560 Low 730 710 690 650 620 590 540 510 480 450 60B High 1402 1374 1354 1328 1299 1262 1222 1167 1107 1036 Medium High 1252 1233 1203 1182 1150 1125 1095 1064 1031 980 Medium 1076 1059 1029 1007 973 946 908 883 843 800 Medium Low 988 967 936 903 875 838 806 765 737 685 Low 798 769 727 695 650 619 574 517 485 443 80B High 1445 1423 1397 1365 1339 1311 1283 1250 1204 1140 Medium High 1282 1266 1232 1211 1182 1157 1128 1097 1069 1013 Medium 1098 1084 1059 1027 998 967 939 910 879 822 Medium Low 1012 993 953 930 894 851 828 773 752 692 Low 865 810 763 730 689 628 594 520 496 448 80C High 1713 1682 1643 1600 1558 1519 1480 1436 1385 1333 Medium High 1554 1519 1485 1439 1404 1368 1327 1280 1176 1130 Medium 1380 1351 1302 1263 1224 1171 1128 1085 1030 943 Medium Low 1177 1142 1083 1050 988 922 890 819 798 687 Low 951 841 650 588 457 418 355 227 203 N / A 100C High 1734 1694 1650 1611 1570 1536 1485 1438 1392 1335 Medium High 1568 1537 1492 1453 1414 1373 1327 1279 1230 1118 Medium 1420 1380 1332 1294 1249 1196 1152 1100 981 938 Medium 1218 1169 1124 1067 1015 965 894 845 754 679 Low 979 846 647 580 464 427 345 220 195 N / A 100C High 2143 2102 2065 2028 1989 1944 1892 1825 1733 1625 Medium High 1788 1749 1718 1672 1629 1587 1541 1500 1447 1355 Medium 1575 1539 1500 1456 1410 1363 1305 1246 1095 1030 Medium Low 1372 1325 1276 1225 1170 1111 1044 972 884 812 Low 1031 921 810 728 660 615 518 474 391 355 120D High 2214 2173 2132 2086 2036 1994 1952 1907 1849 1777 Medium High 1841 1799 1749 1699 1659 1611 1567 1520 1471 1372 Medium 1605 1562 1514 1470 1416 1361 1310 1180 1119 1045 Medium Low 1405 1362 1303 1244 1189 1125 1054 986 876 826 Low 1135 1020 844 758 671 557 511 464 387 N / A CAUTION Main power to the unit must still be interrupted at the main power dis- connect switch before any service or repair work is to be done to the unit. Do not rely upon the interlock switch as a main power discon- nect. Blower and burner must never be operated without the blower panel in place. ! 5750144-UIM-H-0423 34 Johnson Controls Ducted Systems 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. See "Condensate piping and furnace venting configuration" for tubing connections. 1.Blockage of combustion air piping or terminals. 2.Blockage of condensate drain piping. 3.Blockage of vent piping or terminal. 4.Failure of combustion air blower motor. 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.If the indoor fan motor should fail. 3.Too many supply or return registers closed or blocked off. 4.Improperly sized duct system. The control module will lockout if the limit trips 5 consecutive times. If this occurs, control will reset & try ignition again after 1 hour. Section XI: Normal operation and diagnostics Normal operation sequence The following describes the sequence of operation of the furnace. Refer to Owners Manual for component location. Continuous blower Cooling/heating thermostats have a fan switch that has an ON and AUTO position. In the ON position the thermostat circuit is completed between terminals R and G. The motor will operate continuously on the speed tap that is selected through dipswitches on the furnace control board. To obtain a different constant air circulation change dipswitches to assign another speed tap. Intermittent blower - cooling Cooling/heating thermostats have a fan switch that has an ON and AUTO position. In the AUTO position the thermostat circuit is completed between terminals R and G when there is a call for cooling. The motor will operate on the speed tap wire that is connected to the HI COOL or LO COOL cooling terminal on the control board depending on 24V ther- mostat input on Y1 or Y/Y2. The fan off setting is fixed at 60 s to improve cooling efficiency. Heating cycle When the thermostat switch is set on HEAT and the fan is set on AUTO, and there is a call for heat, a circuit is completed between terminals R and W of the thermostat. When the proper amount of combustion air is being provided, the pressure switch will close, the ignition control pro- vides a 17 s 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 furnace fires on high fire for 10 s, then it switches to low fire unless there is a heating call present on W2. The blower motor energizes 30 s after the gas valve opens if a flame is detected. Normal furnace operation continues 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 operates for 15 s, and the blower motor operates for the amount of time set by the fan-off delay dip switches located on the control board. See Figure 36. The heating cycle is now complete and ready for the start of the next heating cycle. If the flame is not detected within 7 s of the gas valve opening, the gas valve is shut off and a retry operation begins. During a retry operation, the vent motor starts a 15 s inter-purge and the ignitor warm-up time is extended to 27 s. If the flame is established for more than 10 s after ignition during a retry, the control will clear the ignition attempt (retry) counter. If three retries occur during a call for heat, the furnace will shut down for one hour. If at the end of the one hour shut down there is a call for heat, the furnace will initiate a normal start cycle. If the problem has not been corrected the furnace will again lockout after three retries. 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 s. The gas valve will de-energize and the control will begin a recycle oper- ation. A normal ignition sequence will begin after a 15 s inter-purge. If during the five recycles the gas supply does not return, or the fault con- dition is not corrected the ignition control will lockout for 60 min. 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. Furnace control diagnostics The furnace has built-in, self-diagnostic capability. A blinking LED light on the control board can flash red, green or amber to indicate various conditions. The control continuously monitors its own operation and the operation of the system. If a failure occurs, the LED light will indicate the failure code. The SLOW flash speed is 2 s on and 2 s off. The other flash codes listed below have the following timing: LED light will turn on for 1/3 s and off for 1/3 s. This pattern will be repeated the number of times equal to the code. There will be a 2 s pause between codes. For example, the six red flash code will flash the LED light on and off six times, then will be off for 2 s. This pattern will repeat as long as the fault condition remains. SLOW GREEN FLASH: Normal operation, no thermostat calls. SLOW AMBER FLASH: Normal operation with call for heat. LED STEADY OFF – If the LED light does not flash at all, check for power to the board and check for a blown fuse on the board. If the board is properly powered and the fuse is not blown, the control board may need to be replaced. STEADY ON ANY COLOR: Possible control failure. Remove and check the control voltage fuse. An open fuse will result in a steady on red LED. Turn power to the furnace off and back on. If the fault code returns, the control board must be replaced. The control board is not field-repairable. WARNING Never bypass any safety control to allow furnace operation. To do so will allow furnace to operate under potentially hazardous conditions. Do not try to repair controls. Replace defective controls with UPG Source 1 Parts. Never adjust pressure switch to allow furnace operation. ! 5750144-UIM-H-0423 Johnson Controls Ducted Systems 35 CONTINUOUS AMBER FLASH: Flame sense current is below 0.35 micro amps. Check and clean flame sensor. Check for proper gas flow. Verify that current is greater than 0.35 micro amps at the flame current test pad. 1 RED FLASH: This indicates that flame was sensed when there was not a call for heat. The control will turn on both the inducer motor and supply air blower. Check for a leaking or slow-closing gas valve. 2 RED FLASHES: This indicates that the pressure switch is closed when it should be open. The control confirms that the pressure switch contacts are open at the beginning of each heat cycle and will not let the ignition sequence continue if the pressure switch contacts are closed when they should be open. Check for a faulty pressure switch or miswiring. 3 RED FLASHES: This indicates the pressure switch contacts are open when they should be closed. Check for faulty inducer, blocked vent pipe, broken pressure switch hose, disconnected pressure switch or inducer wires or faulty pressure switch. 4 RED FLASHES: This indicates that the main limit switch has opened its normally closed contacts. The control will operate the supply air blower and inducer while the open limit condition exists. Check for a dirty filter, improperly sized duct system, incorrect blower speed setting, incorrect firing rate, loose limit switch wiring or faulty blower motor. If the limit switch has not closed within 5 min, the control will assume that the blower is not functioning, will start a hard lockout and will begin to flash the 11 Red Flashes error code. Power will have to be cycled off and on to reset the control after the problem has been corrected. See “11 Red Flashes” description below. If the main limit switch opens five times within a single call for heat, the control will also indicate 4 Red Flashes and will enter a one-hour soft lockout. 5 RED FLASHES: This fault is indicated if the normally closed rollout switch opens or if the limit switch has been open longer than 15 min. The rollout control is manually reset. Check for proper combustion air, proper inducer operation, and primary heat exchanger failure or burner problem. The control will enter a hard lockout and power will have to be cycled off and on to reset the control after the problem has been cor- rected. 6 RED FLASHES: This indicates that while the unit was operating, the pressure switch opened four times during the call for heat. Check for faulty inducer, blocked vent pipe or faulty pressure switch. The furnace will lock out for one hour and then restart. 7 RED FLASHES: This fault code indicates that the flame could not be established during three trials for ignition. Check that the gas valve switch is in the ON position. Check for low or no gas pressure, faulty gas valve, dirty or faulty flame sensor, faulty hot surface ignitor, loose wires or a burner problem. The furnace will lock out for one hour and then restart. 8 RED FLASHES: This fault is indicated if the flame is lost five times (four recycles) during the heating cycle. Check for low gas pressure, dirty or faulty flame sensor or faulty gas valve. The furnace will lock out for one hour and then restart. 9 RED FLASHES: Indicates reversed line voltage polarity, grounding problem or reversed low voltage transformer wires. Both heating and cooling operations will be affected. Check polarity at furnace and branch. Check furnace grounding. Check that flame probe is not shorted to chassis. The furnace will not start the ignition sequence until this problem is corrected. 10 RED FLASHES: Gas valve energized with no call for heat. The main blower and inducer blower will run and no ignition sequence will be started as long as this condition exists. Check gas valve and gas valve wiring. 11 RED FLASHES: This indicates that the main limit switch has opened its normally-closed contacts and has remained open for more than 5 min. This condition is usually caused by a failed blower motor or blower wheel. The control will enter a hard lockout and power will have to be cycled off and on to reset the control after the problem has been cor- rected. 13 RED FLASHES: This fault code indicates that the second stage (high) pressure switch is open with a call for second stage heating (high fire) present. Check for faulty inducer, blocked vent pipe, broken or dis- connected pressure switch hoses, disconnected pressure switch or inducer wiring or faulty pressure switch. 4 AMBER FLASHES: The control is receiving a “Y” signal from the thermostat without a “G” signal. The furnace will operate normally in both heating and cooling, but this fault code will be displayed in order to alert the user that there is a wiring problem. Verify that the “G” wire from the thermostat is connected properly. SOFT LOCKOUT: This control includes a soft lockout that will reset automatically after one hour. This provides protection to an unoccupied structure if a temporary condition exists causing a furnace malfunction. An example of this is a temporary interruption in gas supply that would prevent the furnace from lighting. The control will keep trying to light each hour and will resume normal operation if the gas supply is restored. HARD LOCKOUT: Some fault conditions result in a hard lockout, which requires power to the control to be turned off and then back on to reset the control. The control will not automatically restart. Diagnostic fault code storage and retrieval The control in this furnace is equipped with memory that will store up to five error codes to allow a service technician to diagnose problems more easily. This memory will be retained even if power to the furnace is lost. This feature should only be used by a qualified service tech- nician. If more than five error codes have occurred within last 30 days, 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 and release LAST ERROR button. The LED on the control will then flash the error codes that are in mem- ory, starting with the most recent. There will be a 2 s pause between each flash code. After the error codes have all been displayed, the LED will resume the normal slow green flash after a 5 s 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 5 s. The LED will flash three green flashes when the memory has been cleared, then will resume the normal slow green flash after a 5 s pause. IGNITION CONTROL FLAME SENSE LEVELS Normal flame sense current is approximately 3.7 microamps DC (a) Low flame signal warning starts at 0.35 microamps. Low flame signal control lockout point is 0.24 microamps DC (a) 5750144-UIM-H-0423 36 Johnson Controls Ducted Systems Section XII: Replacement parts list DESCRIPTION MOTOR BLOWER, COMBUSTION MOTOR, DIRECT DRIVE BLOWER ELECTRICAL CONTROL, FURNACE CONTROL, TEMPERATURE IGNITER SENSOR, FLAME SWITCH, DOOR SWITCH, LIMIT SWITCHES, PRESSURE TRANSFORMER VALVE, GAS AIR MOVING HOUSING, BLOWER WHEEL, BLOWER FABRICATED PARTS BRACKET, BLOWER TRACK (2 req’d) BURNER, MAIN GAS HEAT EXCHANGER ASS’Y MANIFOLD, GAS PANEL, BLOCKOFF PANEL, DOOR (2 req’d) FABRICATED PARTS Continued PANEL, TOP RAIL, BLOWER (2 req’d) SHELF, BLOWER MISCELLANEOUS BAG, PARTS BRACKET, DOOR DIAGRAM, WIRING FERRULE (3 req’d) GASKET, FOAM (Door) (1.5 ft req’d) GROMMET (3 req’d) HARNESS, WIRING HOSE, CONDENSATE HOSE, RAIN GUTTER KNOB, QUARTER TURN (4 req’d) MOTOR MOUNT ORIFICE, BURNER (Natural #45) PAN, CONDENSATE PLUG, SEAL, 7/8 in. PLUG, SEAL, 2-3/8 in. PLUG, VENT PIPE SIGHT GLASS, OVAL (2 req’d) TUBING, SILICON DESCRIPTION Replacement part contact information This is a generic parts list. To request a complete parts list, refer to the contact information below: •Visit our website at www.source1parts.com for the following information: 1.Search for a part or browse the catalog. 2.Find a dealer or distributor. 3.Customer Service contact information. a.Click on the “Brand Links” button b.Click on the “Customer Service” button •You can contact us by mail. Just send a written request to: Johnson Controls Ducted Systems Consumer Relations 5005 York Drive Norman, OK 73069 Third-Party Trademarks Notice: For information about third-party trademarks, refer to the relevant company websites. 5750144-UIM-H-0423 Johnson Controls Ducted Systems 37 Section XIII: Wiring diagram Figure 37: Wiring diagram POWER SUPPLY 115-1-60 Refer to Installation Manual for more detailed information. 1 2 3 4 5 6 7 8 9 10 11 12 3 2 1 5 4 ROS1 HI C M GAS VALVE CONTROLS TO AIR CONDITIONER ROOM THERMOSTAT 2-STAGE COOLING 2-STAGE HEATING COMMON THERMOSTAT CONNECTION Y2 Y W1 W R C G Y1 W2 W2 Y1 G C R W W1 Y Y2 HIGH LOW IDM EAC HUMIDIFIER GND CNO HS1 DS C PS2 NO COM115V 24V SEC PRI 1T (40VA) 2ND STAGE LS ROS2 GRY 3 2 1 WHT RED BLK GRN IDM GRY BRN WHT RED 2 1 WHT WHT HSI GND Wiring Diagram - 95% Two-Stage Standard ECM Furnace Flashes Diagnostic Fault Codes Fault Condition Power Off or blown fuse Normal Operation Normal Operation with call for heat Open 24V control fuse OR Control Failure Low flame sense current Y signal with no G from thermostat Flame present with gas off Check pressure switch wiring Vent, intake, OR termination problem Airflow problem Flame Rollout Repeated 3 Red Failed to light burners Loss of flame during call for heat Hot/Neutral reversed OR poor ground/neutral Gas valve shorted "ON" Check blower motor/wiring Vent, intake, OR termination problem None Slow Green Slow Amber Steady on Red Rapid Amber 4 Amber 1 Red 2 Red 3 Red 4 Red 5 Red 6 Red 7 Red 8 Red 9 Red 10 Red 11 Red 13 Red SERVICING THIS UNIT OPEN ALL DISCONNECTS BEFORE CAUTION PRECAUTION OUVREZ LES DISJONCTEURS AVANT DE PROCEDER AVEC LE SERVICE 5111807-UWD-D-0519 Fault Code Retrieval To retrieve fault codes, push and release ERROR button on control board. The LED will flash the last five error codes, beginning with the most recent. If there are no fault codes in memory, the LED will give two green flashes. To clear the fault code memory, push and hold the ERROR button for at least five seconds. The LED will give three green flashes when the memory has been cleared. Notice - Only a qualified service technician should use this feature. Fault code retrieval functions will work only if there are no active thermostat signals. NOTES: 1. Si l'un des fils d'origine fourni avec ce four doit être remplacé, il doit être remplacé avec le fil ayant un degré de température d'au moins 221 degrés F (105 degrés C ). 2. Les connexions à grande vitesse du moteur du ventilateur indiqués sont typiques, mais peuvent varier selon le modèle et par application. NOTES: 1. If any of the original wire as supplied with the furnace must be replaced, it must be replaced with wiring material having a temperature rating of at least 221 degrees F (105 degrees C ). 2. Blower motor speed connections shown are typical, but may vary by model and application. DS - ROS - TST - PS1 - PS2 - PS3 - MOT - IDM - HSI - LS - HUM - XFMR - GV - EAC - PF - Legend Door Switch Rollout Switch Wall Thermostat Pressure Switch 1 Stage Pressure Switch 2 Stage Pressure Switch Condensate Circulating Motor Inducer Motor Hot Surface Igniter Limit Switch Humidifier Transformer Gas Valve Electronic Air Cleaner Power Factor Choke DS - ROS - XFMR - LS - HSI - PS1 - PS2 - PS3 - MOT - IDM - GV - HUM - TST - EAC - PF - Legende Commutateur de porte Commutateur de roulement Transformeur Commutateur de limite Ignition de surface chaud Commutateur de pression, premier stage Commutateur de pression, deuxieme stage Commutateur de pression, condensation Moteur soufflerie D'induct moteur Soupape de gaz Humidificateur Thermostat Filtre électrique Transformeur e facteur de puissnace XFMR MOT 1 2 3 4 5 C L G N PA R K CO M LO H E A T HI H E A T LO C O O L HI C O O L EA C - H CI R C - H L1 XF M R HU M NEUTRALS Y1 Y / Y 2 W / W 1 W2 R G C PF 2000 CFM MODELS ONLY RED - LOW BLU/WHT YEL- MED LO GRY - MED BLU - MED HI BLK - HI BLK/WHT WHTEAC HUM GRN GND NO C DS 115VAC LINEBLK 115VAC NEUT BLK WHT BRN BLU 24V SEC LOAD 115V PRI LINE BLK GND TRANSFORMER WHT CONTROL BOARD CNO GAS VALVE BLK WHT BLK ORG PS2 M C HI YEL PRPFLAME SENSOR MOT L N G PF 2000 CFM MODELS ONLY RED/GRN ORG/BLK NO C WHT PS1 PS3 NOC RED LS RED/BLK ROS1 RED ROS2 RED/WHT MOT C GND TERMINAL 1,2,3,4,5 CONDENSATE C PS3 NONO PS1 C 1ST STAGE 5750144-UIM-H-0423 38 Johnson Controls Ducted Systems Notes 5750144-UIM-H-0423 Johnson Controls Ducted Systems 39 Section XIV: Start-up sheet 33" 96% AFUE Two Stage Standard ECM Gas Furnace Start Up Sheet Proper furnace start up is critical to customer comfort and equipment longevity Name Address City State or Province Zip or Postal Code Furnace Model Furnace Serial Indoor Coil Model Indoor Coil Serial Upflow Downflow Horizontal Left Horizontal Right Unit is level or tilted slightly forward Filter Type Thermostat Type Other System Equipment and Accessories Owner Information Equipment Data Furnace Configuration Outdoor Unit Model Outdoor Unit Serial Filter, Thermostat, Accessories Filter Location(s) Connections -- All Per Installation Instructions and Local Code Gas piping is connected (including drip leg) Supply plenum and return air are connected Filter Size Vent system is connected Technician Performing Start-Up Installing Contractor Name Start-Up Date Continued on next PageOFF10 MIN 15 AUTO 20 MINThermostat Staging: Staging: Venting system is the proper size, within the limitations of the chart in the installation instructions, properly connected to the furnace, and properly pitched Condensate drain is connected Intake Size Exhaust Size # of 90 Degree Ells # of 45 Degree Ells Length Length # of 45 Degree Ells# of 90 Degree Ells Polarity is correct (black is L1 (hot), white is N (neutral)Ground wire is connected from the furnace to electrical panel Line voltage value to furnace (volts AC) Low voltage value between "R" and "C" on furnace control board (volts AC) Condensate Management Venting Electrical: Line Voltage Thermostat wiring is complete Electrical: Low Voltage Condensate tubing is correctly installed for the furnace position Sidewall Roof Sidewall Roof Attic Exhaust Termination Intake Termination Thermostat heat anticipator set to .4 or (6 cycles per hour for electronic thermostats) Subject to change without notice. Published in U.S.A 5750144-UIM-H-0423 Copyright © 2023 by Johnson Controls. All rights reserved.Supersedes: 5750144-UIM-G-1122 York International Corp. 5005 York Drive Norman, OK 73069 Natural Gas LP Gas (Requires LP conversion kit) LP Conversion Kit Installed By Supply static after indoor coil (in w.c.") Return Static (in w.c.") before filter Total External Static Pressure Temperature rise in degrees F measured in low fire Installation debris disposed of and furnace area cleaned up? Explain operation of system to equipment owner Low Heat Blower Speed Selected 1 2 3 4 5 Explain the importance of regular filter replacement and equipment maintenance Gas Side Air Side: System External Static Pressure Owner Education Supply static before indoor coil (in w.c.") Calculated input in btuh - clock the gas meter in high fire (Nat Gas Only) Low Fire Manifold Gas Pressure (in. w.c.")Inlet Gas Pressure (in. w.c.") LP Gas Conversion Kit Part # Used Burner flame inspected -- flames are blue and extending directly into the primary heat exchanger cells Return Static (in w.c.") after filter (furnace side) Air Side: Heating (STD ECM) Air Side: Cooling (STD ECM) Air Side: Continuous Fan (STD ECM) Clean Up Give owner the owner's manual provided Gas Type Explain thermostat use and programming (if applicable) to owner Cycle Test Operate the furnace through several heating cycles from the thermostat, noting and correcting any problems Operate the furnace through continuous fan cycles from the thermostat, noting and correcting any problems Operate the furnace through cooling cycles (as applicable), noting and correcting any problems High Heat Blower Speed Selected 1 2 3 4 5 Blower Speed Selected Lo Heat HI Heat Lo Cool Hi Cool High Fire Manifold Gas Pressure (in. w.c.") Low Cool Blower Speed Selected 1 2 3 4 5High Cool Blower Speed Selected 1 2 3 4 5 Temperature rise in degrees F measured in high fire Cooling CFM delivery (use Blower Performance Data Chart)Hi Low