Johnson Controls Furnace CP8C CPLCMP User Manual

INSTALLATION MANUAL

RESIDENTIAL GAS FURNACE

WITH ECM MOTOR

EFFICIENCY

RATING

CERTIFIED

MODELS:

TP8C/TPLC*MP, YP8C/YPLC*MP,

CP8C/CPLC*MP, LP8C/LPLC*MP

ISO 9001

Certified Quality

Management System

(80% Modulating Multi-position / Low NOx)

LIST OF SECTIONS

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

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

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

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

VENT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . 22

SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

NORMAL OPERATION AND DIAGNOSTICS . . . . . . . . . . . . . 29

REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . 30

REPLACEMENT PART CONTACT INFORMATION . . . . . . . . 30

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

LIST OF FIGURES

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

Combustible Floor Base Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Horizontal Application (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Typical Attic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Typical Suspended Furnace / Crawl Space Installation . . . . . . . . . . . 7

Downflow Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Downflow Installation - Gas Valve Rotation . . . . . . . . . . . . . . . . . . . . 7

Vertical Applications (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Coil Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Horizontal Right Application (Typical) . . . . . . . . . . . . . . . . . . . . . . . . 8

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

PC Series Upflow Coil Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Horizontal Left or Right application (Right Shown) . . . . . . . . . . . . . . 8

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

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

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

Upflow/Downflow Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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

Thermostat Chart - Single Stage Air Conditioner –

Variable Speed or PSC Modulating Furnace . . . . . . . . . . . . . . . . . .13

Thermostat Chart - Two Stage Air Conditioner –

Variable Speed or PSC Modulating Furnace . . . . . . . . . . . . . . . . . .14

Thermostat Chart - Two Stage Air Conditioner with Single Stage

Thermostat – Variable Speed or PSC Modulating Furnace . . . . . . .15

Thermostat Chart - Single Stage Heat Pump –

Variable Speed or PSC Modulating Furnace . . . . . . . . . . . . . . . . . .16

Thermostat Chart - Single Stage Heat Pump –

Variable Speed or PSC Modulating Furnace . . . . . . . . . . . . . . . . . .17

Thermostat Chart - Two Stage Heat Pump –

Variable Speed or PSC Modulating Furnace . . . . . . . . . . . . . . . . . .18

Combustion Air Inducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Combustion Airflow Path Through The Furnace Casing

to the Burner Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . .21

Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

LIST OF TABLES

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

Coil Projection Dimensions - PC Series Coils . . . . . . . . . . . . . . . . . . 8

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

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

High Altitude Orifices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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

Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Unconfined Space Minimum Area in Square Inch . . . . . . . . . . . . . .20

Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Gas Rate (CU FT/HR) at Full Input . . . . . . . . . . . . . . . . . . . . . . . . . .24

Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Blower Performance CFM - Any Position . . . . . . . . . . . . . . . . . . . . .27

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.

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.

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.

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.

These units are Category I listed and may be common vented with

another gas appliance as allowed by the National Fuel Gas Code.

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.

368262-UIM-B-1008

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

368262-UIM-B-1008

COMBUSTION AIR QUALITY

CODES AND STANDARDS

(LIST OF CONTAMINANTS)

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.

The furnace requires OUTDOOR AIR for combustion when the furnace

is located in any of the following environments.

•

Restricted Environments

Commercial buildings

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

following, using the latest edition available:

Buildings with indoor pools

Furnaces installed in laundry rooms

Furnaces installed in hobby or craft rooms

Furnaces installed near chemical storage areas

Chemical exposure

STEP 1 -Safety

•

US: National Fuel Gas Code (NFGC) NFPA 54/ANSI Z223.1 and

the Installation Standards, Warm Air Heating and Air Conditioning

Systems ANSI/NFPA 90B

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.

•

CANADA: CAN/CGA-B149.1 National Standard of Canada. Natu-

ral Gas and Propane Installation Codes (NSCNGPIC)

STEP 2 -General Installation

•

Permanent wave solutions

•

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

tact the

Chlorinated waxes and cleaners

Chlorine based swimming pool chemicals

Water softening chemicals

National Fire Protection Association Inc.

Batterymarch Park

Quincy, MA 02269

De-icing salts or chemicals

or for only the NFGC, contact the

American Gas Association,

400 N. Capital, N.W.

Carbon tetrachloride

Halogen type refrigerants

Cleaning solvents (such as perchloroethylene)

Printing inks, paint removers, varnishes, etc.

Hydrochloric acid

Washington DC 20001

or www.NFPA.org

•

CANADA: NSCNGPIC. For a copy contact:

Standard Sales, CSA International

178 Rexdale Boulevard

Cements and glues

Antistatic fabric softeners for clothes dryers

Masonry acid washing materials

Etobicoke, (Toronto) Ontario Canada M9W 1RS

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.

STEP 3 -Combustion and Ventilation Air

•

US: Section 5.3 of the NFGC, air for Combustion and Ventilation

CANADA: Part 7 of NSCNGPIC, Venting Systems and Air Supply

for Appliances

STEP 4 -Duct Systems

US and CANADA: Air Conditioning Contractors Association

•

The furnace area must not be used as a broom closet or for any

other storage purposes, as a fire hazard may be created. Never

store items such as the following on, near or in contact with the fur-

nace.

1. Spray or aerosol cans, rags, brooms, dust mops, vacuum

cleaners or other cleaning tools.

(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.

STEP 5 -Acoustical Lining and Fibrous Glass Duct

•

US and CANADA: Current edition of SMACNA and NFPA 90B as

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

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

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

3. Paint thinners and other painting compounds.

tested by UL Standard 181 for Class I Rigid Air Ducts

STEP 6 -Gas Piping and Gas Pipe Pressure Testing

•

US: NFGC; chapters 2, 3, 4, & 9 and National Plumbing Codes

CANADA: NSCNGPIC Part 5

4. Paper bags, boxes or other paper products

STEP 7 -Electrical Connections

Never operate the furnace with the blower door removed. To

do so could result in serious personal injury and/or equipment

damage.

•

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.

Johnson Controls Unitary Products

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

368262-UIM-B-1008

INSPECTION

FOR FURNACES INSTALLED IN THE COMMON-

WEALTH OF MASSACHUSETTS ONLY

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.

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:

FURNACE LOCATION AND CLEARANCES

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

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.

4. Where it will not interfere with proper air circulation in the confined

space.

5. Where the outdoor vent terminal will not be blocked or restricted.

Refer to “VENT CLEARANCES” located in SECTION VII of these

instructions. These minimum clearances must be maintained in

the installation.

6. Where the unit will be installed in a level position with no more than

1/4” (6.4 mm) slope side-to-side and front-to-back.

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.

Installation in freezing temperatures:

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

provide for safe limits of ambient temperature under normal oper-

ating conditions.

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 mon-

oxide detector with an alarm shall be installed.

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.

Clearances for access/service:

Ample clearances should be provided to permit easy access to the unit.

The following minimum clearances are recommended:

2. APPROVED CARBON MONOXIDE DETECTORS. Each car-

bon monoxide detector as required in accordance with the

above provisions shall comply with NFPA 720 and be ANSI/UL

2034 listed and IAS certified.

1. Twenty-four (24) inches (61 cm) between the front of the furnace

and an adjacent wall or another appliance, when access is

required for servicing and cleaning.

3. SIGNAGE. A metal or plastic identification plate shall be perma-

nently mounted to the exterior of the building at a minimum

height of eight (8) feet above grade directly in line with the

exhaust vent terminal for the horizontally vented gas fueled

heating appliance or equipment. The sign shall read, in print

size no less than one-half (1/2) inch in size, "GAS VENT

DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUC-

TIONS".

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

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

ment of flue/vent connections.

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

ances for combustible materials where accessibility clearances are

greater.

Installation in a residential garage:

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.

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 inches (46 cm) above the floor, and the furnace must be located

or protected to avoid physical damage by vehicles.

Table 1: Unit Clearances to Combustibles (All Dimensions in Inches, and All Surfaces Identified with the Unit in an Upflow Configuration)

Top

Front

Rear

Left Side

In. (cm)

0 (0.0)

Right Side

In. (cm)

0 (0.0)

Flue

Floor/

Bottom

Line

Contact

Application

Closet

Alcove

Attic

In. (cm) In. (cm) In. (cm)

In. (cm)

Upflow B-Vent

1 (2.5)

3 (7.6)

0 (0.0)

1 (2.5) Combustible

Yes

1 (25.4)¹

1 (2.5)

Downflow B-Vent

Horizontal B-Vent

0 (0.0)

Yes²

0 (0.0)

1 (2.5) Combustible

1. Special floor base or air conditioning coil required for use on combustible floor.

2. Line contact only permitted between lines formed by the intersection of the rear panel and side panel (top in horizontal position) of the furnace jacket and building

joists, studs or framing.

Johnson Controls Unitary Products

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

368262-UIM-B-1008

DUCT FLANGES

SECTION II: DUCTWORK

Four flanges are provided to attach ductwork to the furnace. These

flanges are rotated down for shipment. In order to use the flanges,

remove the screw holding an individual flange, rotate the flange so it is

in the upward position and reinstall the screw then repeat this for all 4

flanges.

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.

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

tion as shipped.

2. Be installed in accordance of National Fire Protection Association

as outlined in NFPA standard 90B (latest editions) or applicable

national, provincial, state, and local fire and safety codes.

Factory

installed

For duct attachment,

if needed.

3. Create a closed duct system. For residential and Non-HUD Modu-

lar Home installations, when a furnace is installed so that the sup-

ply ducts carry air circulated by the furnace to areas outside the

space containing the furnace, the return air shall also be handled

by a duct(s) sealed to the furnace casing and terminating outside

the space containing the furnace.

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

air conditioning and heating equipment and to and from the condi-

tioned space.

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

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

exchanger.

FIGURE 1: Duct Attachment

DUCTWORK INSTALLATION AND SUPPLY PLENUM

CONNECTION - UPFLOW/HORIZONTAL

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

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

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

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

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

ated, the damper must be equipped with means to prevent the furnace

or the air conditioner from operating unless the damper is in full heat or

cool position.

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

When replacing an existing furnace, if the existing plenum is not the

same size as the new furnace then the existing plenum must be

removed and a new plenum installed that is the proper size for the new

furnace. If the plenum is shorter than 12” (30.5 cm) the turbulent air flow

may cause the limit controls not to operate as designed, or the limit con-

trols may not operate at all.

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 cooling coil, properly sealed to

prevent leaks. Follow the instructions supplied with the

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

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

move grommet to desired vent side exit.

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.

Downflow Air Conditioning Coil Cabinet

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

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

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

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

requirements, refer to the installation instructions supplied with the coil

cabinet.

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

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

mended rectangular duct height is 4 inches (10 cm) attached to the

plenum.

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

nace outlet and sealed to prevent leakage. If thermoplastic evaporator

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

tion, then extra 2” minimum spacing may be needed to ensure against

drain pan distortion.

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

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

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

must be sealed to prevent air leakage.

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

for the furnace size that is being installed.

Refer to Table 6 or the furnace rating plate for the correct rise range

and static pressures.

If the ducts are undersized, the result will be high duct static pres-

sures and/or high temperature rises which can result in a heat

exchanger OVERHEATING CONDITION. This condition can result

in premature heat exchanger failure, which can result in personal

injury, property damage, or death.

Johnson Controls Unitary Products

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

368262-UIM-B-1008

DOWNFLOW DUCT CONNECTORS

ATTIC INSTALLATION

All downflow installations must use a suitable duct connector approved

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

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

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

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

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

nectors.

This appliance is certified for line contact when the furnace is installed

in the horizontal left or right position. The line contact is only permissi-

ble between lines that are formed by the intersection of the top and the

two sides of the furnace and the building joists, studs, or framing. This

line may be in contact with combustible material. Refer to Figure 10 for

details and additional information.

Vent Pipe

(Maintain required

clearances to combustible

materials)

FURNACE

Supply

Air

WARM AIR PLENUM

WITH 1” FLANGES

Return

Air

FIBERGLASS

INSULATION

FIBERGLASS TAPE

UNDER FLANGE

FIGURE 4: Typical Attic Installation

This appliance is certified for line contact when the furnace is installed

in the horizontal left or right position. The line contact is only permissible

between lines that are formed by the intersection of the top and two

sides of the furnace and the building joists, studs or framing. This line

may be in contact with combustible material. Refer to Figure 4.

COMBUSTIBLE FLOOR

BASE ACCESSORY

When a furnace is installed in an attic or other insulated space,

keep all insulating materials at least 12 inches (30.5 cm) away from

furnace and burner combustion air openings.

FIGURE 2: Combustible Floor Base Accessory

RESIDENTIAL AND MODULAR HOME UPFLOW

RETURN PLENUM CONNECTION

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

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

rear panel of the unit.

During installation, doors must remain on the furnace when

moving or lifting.

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.

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

openings (bottom or sides) or supply air opening.

The internal bottom panel must be removed for this application.

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.

Attic installations must meet all minimum clearances to combustibles

and have floor support with required service accessibility.

HORIZONTAL APPLICATION

SUSPENDED FURNACE / CRAWL SPACE

INSTALLATION

The furnace can be hung from floor joists or installed on suitable blocks

or pads. Blocks or pad installations shall provide adequate height to

ensure that the unit will not be subject to water damage.

FIGURE 3: Horizontal Application (Typical)

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” minimum clearance between the front of the fur-

nace and the support rods or straps.

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

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

Johnson Controls Unitary Products

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

368262-UIM-B-1008

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

nace operation. When suspending the furnace, use a secure platform

constructed of plywood or other building materials secured to the floor

or ceiling joists. Refer to Figure 11 for details and additional informa-

tion.

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

openings (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.

Support

Rod

DOWNFLOW APPLICATION

To apply the furnace in a downflow position, it will be necessary to

rotate the vent blower 90° left or right so that the vent pipe passes

through the side of the furnace casing rather than the end. See Figure

Support

Angle (x3)

Maintain 6” minimum

clearance between support

rods and front of furnace

For modulating furnaces to be used in the downflow position, it is

necessary to rotate the gas valve so that it is upright when the fur-

nace is installed. Loosen the pipe union between the gas valve and

manifold, rotate the valve as far upward as it will go, and tighten the

union. See Figure 7.

FIGURE 5: Typical Suspended Furnace / Crawl Space Installation

During installation, doors must remain on the furnace when

moving or lifting.

For downflow

installation,rotate

gas valve upwards,

as shown

Rotate vent

blower 90°

either way

LEFT SIDE VENT

RIGHT SIDE VENT

FIGURE 6: Downflow Venting

FIGURE 7: Downflow Installation - Gas Valve Rotation

COIL INSTALLATION

COIL/FURNACE ASSEMBLY - MC/FC/PC SERIES

COILS

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

ommended in the outlet duct such that smoke or reflected light

would be observable inside the casing to indicate the presence of

leaks in the heat exchanger. This access cover shall be attached in

such a manner as to prevent leaks.

UPFLOW

FIGURE 8: Vertical Applications (Typical)

DOWNFLOW

Johnson Controls Unitary Products

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

368262-UIM-B-1008

FURNACE ASSEMBLY - MC & FC SERIES COILS

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

flow applications with no conversion.

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

flange on the coil in order to prevent damaging coil tubing. See

Figure 12.

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

Figure 8 after configuring coil flanges as required see “Coil Flange” sec-

tion below.

COIL FLANGE INSTALLATION

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

having various inlet and outlet flange configurations. The two flanges

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

proper configuration of flanges refer to Figure 9.

(Min)

ALTERNATE

Flexible

Duct Collar

FLANGE LOCATION

(Used for downflow or

horizontal left

Field

Fabricated

Ductwork

installations)

Do not drill

or Screw

this flange

Upflow

Coil

Upflow

Furnace

FACTORY

FLANGE

LOCATION

Alternate

Drain Location

Primary

Drain

Secondary

Drain

(Used for upflow

or horizontal

right installations)

FIGURE 12: PC Series Upflow Coil Installation

Table 2: Coil Projection Dimensions - PC Series Coils

FIGURE 9: Coil Flange

FURNACE ASSEMBLY - MC SERIES COILS ONLY

MC coils are supplied ready to be installed in a horizontal position. A

horizontal pan is factory installed. MC coils should be installed in all hor-

izontal applications with the horizontal drain pan side down.

COIL SIZE

DIMENSION “C” INCH

PC18

PC24

3-1/2

4-1/2

5-1/2

6-1/2

PC30, PC32, PC35

PC42, PC43, PC36, PC37

PC48

Mounting Plate

PC60

Furnace

NOTE: Dimension “C” should be at least 2/3 of dimension “D”. See Fig-

ure 12.

CRITICAL COIL PROJECTION

FIGURE 10: Horizontal Right Application (Typical)

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

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

Refer to Table 2.

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

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

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

nated as top side. See Figures 10 & 11.

COIL / FURNACE ASSEMBLY - HC SERIES COILS

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

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

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

of the “A” coil closest to the furnace. See Figure 13.

Mounting Plate

Furnace

NOTE: Each coil is shipped with an external tie plate that should be

used to secure the coil to the furnace. It should be installed on the back

side of the coil using the dimpled pilot holes. See Figure 13.

FIGURE 11: Horizontal Left Application

Use tie plate

supplied with coil

FURNACE ASSEMBLY - PC SERIES COILS

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

naces only.

If the coil is used with a furnace of a different size, use a 45° transition

to allow proper air distribution through the coil.

1. Position the coil casing over the furnace opening as shown in Fig-

ure 12.

Gas Furnace

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

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

seal appropriately.

FIGURE 13: Horizontal Left or Right application (Right Shown)

Johnson Controls Unitary Products

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

368262-UIM-B-1008

RIGHT SIDE

FRONT

LEFT SIDE

Vent Connection

Outlet

Electrical

Entry

Vent

Connection

Outlet

Electrical

Entry

Gas Pipe

Entry

Gas Pipe

Entry

33”

23”

Thermostat

Wiring

Thermostat

Wiring

14”

28.5”

29.5”

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

1”

1.5”

4” Diameter

Vent Connection

Outlet

.5”

24.38”

.5”

20”

24.25”

SUPPLY END

RETURN END

FIGURE 14: Dimensions

Table 3: Cabinet and Duct Dimensions

Approximate

Operating Weights

Cabinet Dimensions (Inches)

Nominal

CFM (m³/min)

BTUH (kW)

Input

Cabinet

Size

14 1/2

17 1/2

A (cm)

36.8

44.4

53.3

13 1/2

16 1/2

B (cm)

34.3

41.9

50.8

C (cm)

26.2

29.9

34.5

40.1

Lbs

60 (17.6)

80 (23.4)

100 (29.3)

120 (35.1)

1200 (34.0)

1600 (45.3)

2000 (56.6)

10.3

11.8

13.6

15.8

103

114

118

122

129

SIDE RETURN

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

out to be made in the furnace side panel. Refer to Figure 15.

SECTION III: FILTERS

FILTER INSTALLATION

All applications require the use of a field installed filter. All filters and

mounting provision must be field supplied.

Filters must be installed external to the furnace cabinet. DO NOT

attempt to install filters inside the furnace.

Front of

Furnace

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

Side of

Furnace

CFM

(m³/min)

Cabinet

Size

Side

(in)

Bottom

(in)

Corner

Markings

1200 (34.0)

1600 (45.3)

2000 (56.6)

16 x 25

14 x 25

16 x 25

20 x 25

FIGURE 15: Side Return Cutout Markings

16 x 25

(2) 16 x 25

Install the side filter rack following the instructions provided with that

accessory. If a filter(s) is provided at another location in the return air

system, the ductwork may be directly attached to the furnace side

panel.

NOTES:

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

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

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.

Some accessories such as electronic air cleaners and pleated

media may require a larger side opening. Follow the instructions

supplied with that accessory for side opening requirements. Do not

cut the opening larger than the dimensions shown in Figure 14.

Johnson Controls Unitary Products

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

368262-UIM-B-1008

HORIZONTAL APPLICATION

Horizontal Filters

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

tions must have a filter installed.

Main

Regulator

Adjustment

On/Off

Knob

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.

Outlet

Pressure

Tap

Inlet

Pressure

Tap

Downflow Filters

Downflow furnaces typically are installed with the filters located above

the furnace, extending into the return air plenum or duct. Any branch

duct (rectangular or round duct) attached to the plenum must attach to

the vertical plenum above the filter height.

FIGURE 16: Gas Valve

Filter(s) may be located in the duct system external to the furnace using

an external duct filter box attached to the furnace plenum or at the end

of the duct in a return filter grille(s). The use of straps and/or supports is

required to support the weight of the external filter box.

Plan your gas supply before determining the correct gas pipe entry.

Use 90-degree service elbow(s), or short nipples and conventional

90-degree elbow(s) to enter through the cabinet access holes.

GAS PIPING INSTALLATION

SECTION IV: GAS PIPING

Properly sized wrought iron, approved flexible or steel pipe must be

used when making gas connections to the unit. If local codes allow the

use of a flexible gas appliance connection, always use a new listed con-

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

appliance.

GAS SAFETY

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 PSI (14" w.c. (3.48 kPa). Pressures exceeding

0.5 PSI (14” w.c. (3.48 kPa) at the gas valve will cause damage to

the gas valve, resulting in a fire or explosion or cause damage to

the furnace or some of its components that will result in property

damage and loss of life.

Some utility companies or local codes require pipe sizes larger than the

minimum sizes listed in these instructions and in the codes. The furnace

rating plate and the instructions in this section specify the type of gas

approved for this furnace - only use those approved gases. The instal-

lation of a drip leg and ground union is required. Refer to Figure 17.

NOTE: Ground Union maybe installed inside or outside unit.

External

Manual

Shut-off

Valve

To Gas

Supply

To Gas

Supply

Ground

Union

External

Manual

Shut-off

Valve

To Gas

Supply

To Gas

Supply

To Gas

Supply

Gas

Valve

Ground

Union

Ground

Union

Drip Leg

Ground

Union

Gas

Valve

External

Gas

Valve

Manual

Shut-off

Valve

Gas

Pipe

Drip

Leg

Drip

Leg

Drip

Leg

Drip

Leg

To Gas

Supply

Gas

Pipe

Ground

Union

Upflow

Downflow

Horizontal

Drip

Leg

Configuration

FIGURE 17: Upflow/Downflow Gas Piping

An accessible manual shutoff valve must be installed upstream of

the furnace gas controls and within 6 feet (1.8 m) of the furnace.

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

external pressure. Never apply a pipe wrench to the body of the gas

valve when installing piping. A wrench must be placed on the octa-

gon hub located on the gas inlet side of the valve. Placing a wrench

to the body of the gas valve will damage the valve causing improper

operation and/or the valve to leak.

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

closing its individual external manual shutoff valve during any pressure

testing of the gas supply piping system at pressures equal to or less

than 1/2 psig (3.5 kPa).

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

of the gas pipe entry on both sides of the furnace. Refer to Figure 14.

Johnson Controls Unitary Products

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

368262-UIM-B-1008

3. Read down the left-hand “Actual Rate” column to find the closest

number to your actual de-ration percent.

GAS 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 fac-

tory-supplied LP conversion kit which includes a LP gas valve. Follow

the instructions supplied with the LP kit.

4. Read across that row to the column for the elevation at your loca-

tion. The number listed there is the orifice size that is proper for

your unit.

Example – You have a 100,000 BTU/H furnace installed at an elevation

of 6,000 feet. You clock the gas meter and find that the furnace is actu-

ally fired at 64,000 BTU/H. Divide 64,000 by 100,000, which gives 0.64

(64%). The closest number to 64% in the left-hand “Actual Rate” col-

umn is 65. Read across that row to the column for 6,000 feet elevation,

which shows “#43”. You should change from the factory #45 orifices to

larger #43 orifices, which will bring the input rate back up to approxi-

mately 76,000 BTU/H, which is what it should be for that furnace at

6,000 feet.

LoNOx furnaces requiring propane (LP) gas must have the LoNOx

screens removed prior to installation and operation. See propane

instructions.

HIGH ALTITUDE NATURAL GAS ORIFICE

CONVERSION

The National Fuel Gas Code requires that gas appliances installed

above 2,000 feet elevation have their inputs de-rated by 4% per 1,000

feet above sea level. The modulating furnaces automatically de-rate for

altitude by measuring the inducer blower pressure and using that to

determine if there is adequate air to support good combustion. If there

is not enough combustion air to properly support 100% of the furnace

nameplate input rate, the control will reduce the input to the point that

there will be good combustion.

Table 5: High Altitude Orifices

Elevation in Feet Above Sea Level

Actual Rate

(percent of

nameplate)

4,000 5,000 6,000 7,000 8,000 9,000 10,000

84% 80% 76% 72% 68% 64%

Orifice Drill Size

60%

100

The factory gas orifice sizes are based on a gas heating value of

1030 BTU/Cu.ft., so if your gas value is significantly higher or

lower than that, it may be necessary to change to smaller or larger

gas orifices.

The chart below shows recommended gas orifice sizes to use at vari-

ous altitudes and at various de-ration levels. To use the chart, follow

these instructions:

1. Clock the gas meter and calculate the actual input rate using your

local gas heating value. See "CALCULATING THE FURNACE

INPUT (NATURAL GAS)" in this manual.

2. Divide that input rate by the input rate shown on the furnace rating

plate to get the actual de-ration percent.

PROPANE 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.

Propane (LP) conversions are required in order for the appliance to satisfactory meet the application.

An authorized distributor or dealer must make all gas conversions.

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

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

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

causing premature heat exchanger burnout, high levels of carbon monoxide, excessive sooting, a fire hazard, personal injury, property damage

and/or death.

SECTION V: ELECTRICAL POWER

ELECTRICAL POWER CONNECTIONS

Field wiring to the unit must be grounded. Electric wires that are field

installed shall conform to the temperature limitation for 63°F (35°C) rise

wire when installed in accordance with instructions. Refer to Table 6 in

these instructions for specific furnace electrical data.

Use copper conductors only.

Johnson Controls Unitary Products

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

368262-UIM-B-1008

Table 6: Ratings & Physical / Electrical Data

Input

Max/Min

Output

Max/Min

Nominal

Airflow

Air Temp. Rise

Max Input

Air Temp. Rise

Min Input

m³/min

MBH

60/30

MBH

47/24

62/32

78/40

95/48

CFM

1200

1600

2000

°F

°C

°F

°C

17.6/8.8

23.5/11.8

29.3/14.7

33.7/16.9

13.8/7.0

18.2/9.4

22.8/11.7

27.8/14.1

34.0

45.3

56.6

30-60

40-70

35-65

45-75

17-33

22-39

19-36

25-42

20-50

25-55

11-28

13-31

80/40

100/50

120/60

Max. Outlet

Air Temp

Blower

Wheel

size

Max

Over-Current

Protect

Min. wire Size

(awg) @ 75 ft

one way

Blower

AFUE

Total Unit

Amps

°F

°C

1/2

3/4

Amps

4.8

160

170

165

175

71.1

76.7

73.9

79.4

11 x 8

80.0

7.0

7.5

4.8

7.5

11 x 10

11 x 11

10.0

12.0

7.5

14.5

Annual Fuel Utilization Efficiency (AFUE) numbers are determined in accordance with DOE Test procedures.

Wire size and over current protection must comply with the National Electrical Code (NFPA-70-latest edition) and all local codes.

SUPPLY VOLTAGE CONNECTIONS

LOW VOLTAGE CONTROL WIRING CONNECTIONS

Install the field-supplied thermostat by following the instructions that

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

and the main electrical source disconnected, connect the thermostat

wiring from the wiring connections on the thermostat to the terminal

board on the ignition module, as shown in Figures 19-24, Thermostat

Charts. Electronic thermostats may require the common wire to be con-

nected as shown in Figure 16. Apply strain relief to thermostat wires

passing through cabinet.

Junction

Box

Connect ground

lead to screw

Electrical Entry

BLK

L1-Hot

WHT

Neutral

Set the heat anticipator in the room thermostat to 0.1 amps. Setting

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

temperature to exceed the set points.

FIGURE 18: Electrical Wiring

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

overcurrent protection and disconnect switch per local/national

electrical codes. The switch should be close to the unit for conve-

nience in servicing. With the disconnect or fused switch in the OFF

position, check all wiring against the unit wiring label. Refer to the

wiring diagram in this instruction.

Some electronic thermostats do not have adjustable heat anticipa-

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

stat manufacturer's instructions.

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

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

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

air conditioning unit contactor.

2. Remove the screws retaining the wiring box cover. Route the

power wiring through the opening in the unit into the junction box

with a conduit connector or other proper connection. In the junc-

tion box there will be 3 wires, a Black Wire, a White Wire. Connect

the power supply as shown on the unit-wiring label on the inside of

the blower compartment door or the wiring schematic in this sec-

tion. The black furnace lead must be connected to the L1 (hot)

wire from the power supply. The white furnace screw must be con-

nected to neutral. Connect the power supply ground to the green

screw (equipment ground) An alternate wiring method is to use a

field provided 2” (5.1 cm) x 4” (10.2 cm) box and cover on the out-

side of the furnace. Route the furnace leads into the box using a

protective bushing where the wires pass through the furnace

panel. After making the wiring connections replace the wiring box

cover and screws. Refer to Figure 18.

AIR CONDITIONER CONNECTIONS

This furnace may be used with single-stage or two-stage air condition-

ing units.

For Single-Stage A/C - Connect the low voltage wiring as shown in

Figure 19, Thermostat Chart.

For Two-Stage A/C - Use a two-stage thermostat, connect the low volt-

age wiring as shown in Figure 20, Thermostat Chart.

For Two-Stage A/C using a Single-Stage Thermostat - connect the

low voltage wiring as shown in Figure 20, Thermostat Chart.

This furnace control board can control a two-stage A/C using only a sin-

gle-stage thermostat. In this case, the furnace control switches between

high cool and low cool based on the calculated cooling load.

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

supply and a proper ground connection. Refer to Figure 18.

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

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

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

using holes provided.

Johnson Controls Unitary Products

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

368262-UIM-B-1008

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.

ID MODELS

TP(8,L)C

YP(8,L)C

CP(8,L)C

THERMOSTAT

LP(8,L)C

SINGLE STAGE

AIR

MODULATING

FURNACE

*PP11C70224

AIR CONDITIONER

CONDITIONER

MODULATING

FURNACE CONTROL

24 – Volt Common

Single

Stage Compressor

Full Stage Compressor

CompCroemssporresCsoonrtactor

24 – Volt Hot

(Heat XFMR)

24 – Volt Hot

Fan

Modulating Heat

Y/Y2

24 – Volt Hot

(Cool XFMR)

Second or Full

Stage Compressor

Reversing Valve

Energized in Cool

LO COMP

Single Stage

Compressor (OUT)

HI COMP

Second Stage

Compressor (OUT)

Full Stage Heat

DHUM

Dehumidification-

Open on Humidity Rise

HM1

Humidistat

External Humidistat

(Optional)

Open on Humidity Rise

Clipping Jumper W914 for

electric heat on thermostat

is not necessary

Move HUMIDISTAT

jumper to “YES”

if humidistat is to be used.

Part Number:

Part Numbers:

S1-2HU16700124

SAP

Legacy

FIGURE 19: Thermostat Chart - Single Stage Air Conditioner – Variable Speed or PSC Modulating Furnace

Johnson Controls Unitary Products

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

368262-UIM-B-1008

ID MODELS

TP(8,L)C

YP(8,L)C

CP(8,L)C

LP(8,L)C

THERMOSTAT

*PP32U70124

TWO STAGE

AIR

CONDITIONER

MODULATING

FURNACE

*DN22U00124

MODULATING

FURNACE CONTROL

24 – Volt Common

Single

Stage Compressor

First Stage Compressor

24 – Volt Hot

(Heat XFMR)

24 – Volt Hot

(Heat XFMR)

24 – Volt Hot

Fan

E/W1

First Stage Heat

Emergency Heat

Modulating Heat

AUX

Second Stage Heat

Auxiliary Heat

Y/Y2

24 – Volt Hot

(Cool XFMR)

24 – Volt Hot

(Cool XFMR)

Second or Full

Stage Compressor

Reversing Valve

Energized in Cool

LO COMP

Single Stage

Compressor (OUT)

HI COMP

Second Stage

Compressor

Second Stage

Compressor

Second Stage

Compressor (OUT)

Second Stage

Compressor

DHUM

Dehumidification-

Open on Humidity Rise

External Humidistat

(Optional)

Open on Humidity Rise

Move HUMIDISTAT

jumper to “YES”

if humidistat is to be used.

Connection of the “C”

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

is optional when used with is optional when used with

Connection of the “C”

batteries

Thermostat Installer Setup Thermostat Installer Setup

1-System Type-must

0170-System Type-must

batteries

be set to 6-2 Heat/2 Cool be set to 8-2 Heat/2 Cool

Multistage Conventional Multistage Conventional

Thermostat Installer Setup

15-Compressor Protection

-must be set to 5

Part Numbers:

Part Number:

S1-2HU16700124

SAP

Legacy

FIGURE 20: Thermostat Chart - Two Stage Air Conditioner – Variable Speed or PSC Modulating Furnace

Johnson Controls Unitary Products

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

368262-UIM-B-1008

ID MODELS

TP(8,L)C

YP(8,L)C

CP(8,L)C

LP(8,L)C

THERMOSTAT

TWO STAGE

AIR

CONDITIONER

MODULATING

FURNACE

*PP11C70224

MODULATING

FURNACE CONTROL

24 – Volt Common

Single

Stage Compressor

Full Stage Compressor

First Stage Compressor

24 – Volt Hot

(Heat XFMR)

24 – Volt Hot

Fan

Modulating Heat

Y/Y2

24 – Volt Hot

(Cool XFMR)

Second or Full

Stage Compressor

Reversing Valve

Energized in Cool

LO COMP

Single Stage

Compressor (OUT)

HI COMP

Second Stage

Compressor (OUT)

Second Stage

Compressor

Full Stage Heat

DHUM

Dehumidification-

Open on Humidity Rise

HM1

Humidistat

External Humidistat

(Optional)

Open on Humidity Rise

Clipping Jumper W914 for

electric heat on thermostat

is not necessary

Move HUMIDISTAT

jumper to “YES”

if humidistat is to be used.

Part Number:

Part Numbers:

S1-2HU16700124

SAP

Legacy

FIGURE 21: Thermostat Chart - Two Stage Air Conditioner with Single Stage Thermostat – Variable Speed or PSC Modulating Furnace

Johnson Controls Unitary Products

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

368262-UIM-B-1008

ID MODELS

OD MODELS

TP(8,L)C

E*R*

*RHS

YP(8,L)C

CP(8,L)C

LP(8,L)C

E*ZD

E*B*

HP*

*HGD

THERMOSTAT

*BP21H50124

*BN21H00124

*DP21H40124

*DN21H00124

MODULATING

FURNACE

SINGLE STAGE

HEAT PUMP

*DP32H70124

*DN22U00124

MODULATING

FURNACE CONTROL

DEMAND DEFROST

CONTROL

24 – Volt Common

Single

Stage Compressor

First Stage Compressor

Compressor

24 – Volt Hot

Fan

W1/66(out)

Heat

Emergency Heat

Modulating Heat

N/A

Third Stage Heat

Y/Y2

Second or Full

Stage Compressor

Reversing Valve

Energized in Cool

Reversing Valve

Energized in Cool

LO COMP

Single Stage

Compressor (OUT)

HI COMP

Reversing Valve

Energized in Cool

X/L

Malfunction Light

Second Stage

Compressor (OUT)

Second Stage Compressor

Second Stage Aux. Heat

Auxiliary Heat

DHUM

Dehumidification-

Open on Humidity Rise

External Humidistat

(Optional)

Open on Humidity Rise

Move HUMIDISTAT

jumper to “YES”

if humidistat is to be used.

Step 1 of Thermostat

Installer / Configuration

Menu must be set to

Heat Pump 1

Step 9 of Thermostat

Installer / Configuration

Menu must be set to

Pump OFF

Part Numbers:

Part Number:

S1-2HU16700124

SAP

Legacy

SAP

Legacy

67297 = 031-01975

FIGURE 22: Thermostat Chart - Single Stage Heat Pump – Variable Speed or PSC Modulating Furnace

Johnson Controls Unitary Products

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

368262-UIM-B-1008

ID MODELS

OD MODELS

YZB

TP(8,L)C

YMB

H*3

YP(8,L)C

CP(8,L)C

LP(8,L)C

THERMOSTAT

*BP21H50124

*BN21H00124

*DP21H40124

*DN21H00124

MODULATING

FURNACE

SINGLE STAGE

HEAT PUMP

*DN22U00124

*DP32H70124

YORKGUARD VI

CONTROL

MODULATING

FURNACE CONTROL

24 – Volt Common

Single

Stage Compressor

Single

Stage Compressor

First Stage Compressor

First Stage Compressor First Stage Compressor

24 – Volt Hot

(Heat XFMR)

24 – Volt Hot

Fan

W1 OUT

Emergency Heat

Modulating Heat

First Stage Heat

W2 OUT

Third Stage Heat

Second Stage Heat

Y/Y2

Y2 OUT

Second

Stage Compressor

Reversing Valve

Energized in Cool

24 – Volt Hot

(Cool XFMR)

Second or Full

Stage Compressor

Reversing Valve

Energized in Cool

LO COMP

Single Stage

Compressor (OUT)

HI COMP

O/B

Reversing Valve

Energized in Cool

Reversing Valve

Energized in Cool

Reversing Valve

X/L

Malfunction Light

Second

Stage Compressor

Second

Stage Compressor

Second

Stage Compressor

Second Stage

Compressor (OUT)

Second

Stage Compressor

AUX

Auxiliary Heat

Second Stage Heat

Second Stage Aux. Heat

Auxiliary Heat

DHUM

Dehumidification-

Open on Humidity Rise

BSG

Bonnet Sensor

(Optional)

External Humidistat

(Optional)

Open on Humidity Rise

Bonnet Sensor

Step 1 of Thermostat

Installer / Configuration

Menu must be set to

Heat Pump 1

Thermostat Installer Setup

1-System Type-must be set

to 5 – 2 Heat/1 Heat Pump

Move HUMIDISTAT

jumper to “YES”

if humidistat is to be used.

Change FFuel jumper

on the heat pump control

to “ON”

Change Hot Heat Pump

jumper on the heat

pump control to “ON” if

Hot Heat Pump

B/O Switch on Thermostat

must be in the O position

Thermostat Installer Setup

2-Changeover Valve-must

be set to 0 – O/B terminal

Energized in Cooling

Operation is desired.

Part Numbers:

Part Number:

S1-2HU16700124

Part Numbers:

SAP

Legacy

SAP

Legacy

126768 = 031-09137

18395 = 031-01996

340512 = 031-09178

FIGURE 23: Thermostat Chart - Single Stage Heat Pump – Variable Speed or PSC Modulating Furnace

Johnson Controls Unitary Products

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

368262-UIM-B-1008

ID MODELS

OD MODELS

YZE

TP(8,L)C

YZH

H*5

H*8

YP(8,L)C

CP(8,L)C

LP(8,L)C

THERMOSTAT

*DN22H00124

*DP22U70124

MODULATING

FURNACE

TWO STAGE

HEAT PUMP

*PP32U70124

YORKGUARD VI

CONTROL

MODULATING

FURNACE CONTROL

24 – Volt Common

Single

Stage Compressor

Single

Stage Compressor

First Stage Compressor First Stage Compressor

24 – Volt Hot

(Heat XFMR)

24 – Volt Hot

Fan

W1 OUT

Emergency Heat

Modulating Heat

First Stage Heat

W2 OUT

Second Stage Aux. Heat

Second Stage Heat

Y/Y2

Y2 OUT

Second

Stage Compressor

Reversing Valve

Energized in Cool

24 – Volt Hot

(Cool XFMR)

Second or Full

Stage Compressor

Reversing Valve

Energized in Cool

LO COMP

Single Stage

Compressor (OUT)

HI COMP

O/B

Reversing Valve

Energized in Cool

Reversing Valve

X/L

Malfunction Light

Second

Stage Compressor

Second

Stage Compressor

Second Stage

Compressor (OUT)

Second

Stage Compressor

AUX

E/W1

Auxiliary Heat

First Stage Aux. Heat

Auxiliary Heat

DHUM

Dehumidification-

Open on Humidity Rise

BSG

Bonnet Sensor

(Optional)

External Humidistat

(Optional)

Open on Humidity Rise

Bonnet Sensor

Thermostat Installer Setup

0170-System Type-

must be set to 12

3 Heat/2 Heat Pump

Thermostat Installer Setup

0190-Changeover Valve-

must be set to 0

Step 1 of Thermostat

Installer/Configuration

Menu must be set to “HP2”

Selection of GAS/ELEC

switch on thermostat

not necessary

Move HUMIDISTAT

jumper to “YES”

if humidistat is to be used.

Change FFuel jumper

on the heat pump control

to “ON”

Change Hot Heat Pump

jumper on the heat

pump control to “ON” if

Hot Heat Pump

O/B terminal

Operation is desired.

Energized in Cooling

Thermostat Installer Setup

0200-Backup Heat Source-

must be set to 1

Heat Pump Backup Heat

Source is Fossil Fuel

Thermostat Installer Setup

0210-External Fossil Fuel

Kit- must be set to 1

Heat Pump Control

Part Numbers:

SAP

Legacy

SAP

Legacy

126768 = 031-09137

18395 = 031-01996

340512 = 031-09178

is Controlling Heat Pump

Backup Heat

FIGURE 24: Thermostat Chart - Two Stage Heat Pump – Variable Speed or PSC Modulating Furnace

Johnson Controls Unitary Products

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

368262-UIM-B-1008

ACCESSORY CONNECTIONS

The furnace control will allow power-switching control of various acces-

sories.

SECTION VI: VENT SYSTEM

VENT CONNECTIONS

Figure 25 shows the furnace as it is shipped from the factory. To convert

to a horizontal or downflow position, remove the four screws that secure

the inducer assembly and rotate 90° being careful not to damage the

gasket. Reinstall screws. Remove cap from appropriate vent outlet

location on the cabinet cut insulation in cabinet to same size as the hole

provided and reinstall cap in the hole in the top panel.

ELECTRONIC AIR CLEANER CONNECTION

Two 1/4” (0.64 cm) spade terminals (EAC and NEUTRAL) for electronic

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

provide 115 VAC (1.0 amp maximum) during circulating blower opera-

tion.

HUMIDIFIER CONNECTION

Two 1/4” (0.64 cm) 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.

In downflow applications, do not block the combustion air inlet. The

furnace must be installed on a coil cabinet or subbase to allow com-

bustionair to enter the burner compartment.

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

control board for mounting a humidifier transformer if required.

COMBUSTION AIR INDUCER

HUMIDISTAT CONNECTION

90°

Mounting Screw

(Remove)

90°

For better humidity control during cooling operation, an external humi-

distat may be used. When using a external humidistat, put the HUMI-

DISTAT jumper in the “YES” position. Connect the low voltage wiring as

shown in Figures 19-24, Thermostat Charts.

ZONING OPERATION

This furnace may be used in zoning systems, using a separate after-

market zoning control. For use in zoned systems, put the ZONE CON-

TROL jumper on the furnace control board in the “YES” position.

Pressure Switch

Tube Routing

Flue Transition

(Do Not Remove)

If the Zone jumper is put in the “Yes” position, the heating load logic

switches to a special algorithm for multi-zone homes.

Pressure

Switch

1. This algorithm operates at the “low demand” firing rate for 10 min-

utes and then ramps to high fire within 20 minutes (30 minutes

maximum to get to 100% firing rate).

Mounting Screw

(Remove)

2. The special zoning algorithm does not have the Run 2 function, so

the burners will stop firing as soon as there is no call for heating.

FIGURE 25: Combustion Air Inducer

CATEGORY 1 - 450 F. MAX. VENT TEMP.

HEAT PUMP OPERATION

The venting system must be installed in accordance with Section 5.3,

Air for Combustion 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.

This furnace may be used in conjunction with a heat pump in dual fuel

applications. For heat pump applications, put the HEAT PUMP jumper

on the furnace control board in the “YES” position. Connect the low volt-

age wiring as shown in Figures 19-24, Thermostat Charts. If a two-

stage heat pump is to be used, a two-stage thermostat is required.

The furnace shall be connected to a type B vent connector, and

shall be connected to a type B vent only. The furnace shall not be

If the Heat Pump jumper is in the “Yes” position, it indicates that there is

a heat pump present and the furnace is used as a secondary heat

source. In addition, the “Yes” Heat Pump jumper allows the system to

read the presence of the “O” terminal signal. In heat pump operation,

the following special algorithm logic applies:

connected to

chimney flue serving

separate appliance

designed to burn solid fuel. Single-wall vent pipe is not allowed.

It is recommended that the appliance is installed in a location where the

space temperature is 32 °F (0°C) or higher. If the appliance is installed

in a location where the ambient temperature is below 32 °F (0°C), the

combustion byproducts could condense causing damage to the appli-

ance heat exchanger.

1. Supplemental Heating - When both a “W” signal and a “Y1” signal

are present, the modulating firing rate will operate as normal,

except there will be no Run 2 function, so the burners will stop fir-

ing as soon as the “W” signal is removed.

2. Defrost Cycle - When both a “W” signal and a “Y2” signal are

present, the modulating firing rate will operate at a constant 80%

firing rate and there will be no Run 2 function, so the burners will

stop firing as soon as the “W” signal is removed..

This appliance may be common vented with another gas appliance for

residential installations as allowed by the codes and standards listed in

these instructions.

VENTING

3. Hot Heat Pump - The “hot” heat pump feature will work when the

control is wired to a 2-stage thermostat and a 2-stage heat pump.

Category I venting consists of vertically venting one or more appliances

in B-vent or B-vent connectors. Type B-vent system extends in a gen-

eral vertical direction and does not contain offsets exceeding 45°. A

vent system having not more than one 60° offset is permitted.

4. Hot Heat Pump - The “hot” heat pump feature will not work when

the control is wired to a single-stage thermostat and a 2-stage heat

pump.

VENTING INTO AN EXISTING CHIMNEY

TWINNING

This furnace may not be vented directly into an unlined or clay tile-lined

masonry chimney. This furnace may be vented into a masonry chimney

if a double-wall metal chimney liner is used and the liner is properly

sized according to the requirements of the National Fuel Gas Code or

in Canada, the B-149 Installation Codes.

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.

Johnson Controls Unitary Products

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

368262-UIM-B-1008

FAN-ASSISTED COMBUSTION SYSTEM

Combustion Air Source From Outdoors

This appliance is equipped with an integral mechanical means to draw

products of combustion through the heat exchanger.

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 7, to estimate free area.

Ambient Combustion Air Supply

Table 7: Estimated Free Area

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. A

single, properly sized pipe from the furnace vent connector to the out-

doors must be provided. For upflow models combustion air is brought

into the furnace through the unit top panel opening.

Wood or Metal

Louvers or Grilles

Wood 20-25%*

Metal 60-70% *

1/4” (0.635 cm)

mesh or larger 100%

Screens+

* Do not use less than 1/4”(0.635 cm) 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)

COMBUSTION

AIR

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 0.25” (0.64 cm).

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.

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

venting system may no longer be correctly sized to properly vent

the attached appliances.

FIGURE 26: Combustion Airflow Path Through The Furnace Casing to

the Burner Compartment

An improperly sized vent system can cause CARBON MONOXIDE

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

This type of installation requires that the supply air to the appli-

ance(s) be of a sufficient amount to support all of the appliance(s)

in the area. Operation of a mechanical exhaust, such as an exhaust

fan, kitchen ventilation system, clothes dryer or fireplace may cre-

ate conditions requiring special attention to avoid unsatisfactory

operation of gas appliances. A venting problem or a lack of supply

air will result in a hazardous condition, which can cause the appli-

ance to soot and generate dangerous levels of CARBON MONOX-

IDE, which can lead to serious injury, property damage and / or

death.

Table 8: Unconfined Space Minimum Area in Square Inch

Minimum Free Area in Square Feet

BTUH Input Rating

Required for Each Opening

60 (387 cm²)

60,000

80 (516 cm²)

80,000

100 (645 cm²)

100,000

120 (742 cm²)

120,000

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

hr (0.2928 kW) input rating for all of the appliances installed in that

area.

Table 9: Free Area

Minimum Free Area Required for Each Opening

BTUH Input

Rating

Vertical Duct or

Opening to Outside

(4,000 BTUH)

15 in²(97 cm²)

20 in²(129 cm²)

25 in²(161 cm²)

30 in²(193 cm²)

Horizontal Duct

(2,000 BTUH)

Round Duct

(4,000 BTUH)

Rooms communicating directly with the space containing the appli-

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

nished with openings or louvers.

30 in²(193 cm²)

40 in²(258 cm²)

50 in²(322 cm²)

60 in²(387 cm²)

60,000

80,000

5” (13 cm)

6” (15 cm)

7” (18 cm)

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

Btu/hr (0.2928 kW) input rating for all of the appliances installed in that

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

tion and ventilation in confined spaces.

100,000

120,000

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

Johnson Controls Unitary Products

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

368262-UIM-B-1008

Gas

Vent

Gas

Vent

Gas

Vent

Gable

Vent

Gable

Vent

Ventilated

Attic

Ventilated

Attic

Optional

Inlet (a)

Top Above

Insulation

Top Above

Insulation

Outlet

Air (a)

Soffit

Vent

Soffit

Vent

Outlet

Air (b)

Outlet

Air (a)

Gas

Water

Heater

Gas

Water

Heater

Gas

Water

Heater

Inlet

Air (b)

Inlet

Air (b)

Inlet

Air (a)

Inlet

Air (a)

Ventilated

Crawl Space

FIGURE 27: Outside and Ambient Combustion Air

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.

Air Supply Openings and Ducts

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

supply to an appliance unless otherwise permitted by the authority

having jurisdiction. The opening shall be located within 12” (30.5

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

“COMBUSTION AIR SOURCE FROM OUTDOORS and VENT

AND SUPPLY AIR SAFETY CHECK” in these instructions for

additional information and safety check procedure.

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 a grille is not known. Refer to Table 7 to estimate free

area.

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.

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

Vent and Supply (Outside) Air Safety Check Procedure

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-

sionshall not be less than 3 in (7.6 cm).

For Category I furnaces, vent installations shall be in accordance with

Parts 7 and 11 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54,

and or Section 7 and Appendix B of the CSA B149.1, Natural Gas and

Propane Installation Codes, the local building codes, furnace and vent

manufacture's instructions.

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.

Multi-story or common venting systems are permitted and must be

installed in accordance with the National Fuel Gas Code, ANSI Z223.1/

NFPA 54 and / or the CSA B149.1, Natural Gas and Propane Installa-

tion Codes, local codes, and the manufacture's instructions.

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

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

Combustion Air Source from Outdoors

1. Two permanent openings, one within 12 in (30.5 mm) of the top

and one within 12 in (30.5 mm) 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.

Vent connectors serving Category I furnaces shall not be connected

into any portion of mechanical draft systems operating under positive

pressure.

Horizontal portions of the venting system shall be supported to prevent

sagging using hangers or perforated straps and must slope upwards

not less than 1/4" per foot (0.635 cm/m) from the furnace to the vent ter-

minal.

2. One permanent openings, commencing within 12 in (30.5 mm)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 (15.24 cm) from the front of the appliance. The opening

shall communicate directly with the outdoors and shall have a min-

imum free area of:

It is recommended that you follow the venting safety procedure below.

This procedure is designed to detect an inadequate ventilation system

that can cause the appliances in the area to operate improperly causing

unsafe levels of Carbon Monoxide or an unsafe condition to occur.

a. 1 square in per 3000 Btu per hour (6.45 cm3 per 0.879 kW) of

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

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

space.

Johnson Controls Unitary Products

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

368262-UIM-B-1008

CARBON MONOXIDE POISONING HAZARD

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

monxide poisoning or death.

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

connected to the venting system are not in operation:

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

deficiencies, which could cause an unsafe condition

2. Close all building doors and windows.

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

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

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

uously.

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

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

appliance as possible. Use a combustion analyzer to check the CO2 and CO levels of each appliance. Use a draft gauge to check for a

downdraft or inadequate draft condition.

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

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

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

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

function safely.

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

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

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

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

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

GAS PIPING LEAK CHECK

SECTION VII: START-UP AND

ADJUSTMENTS

NOTE: In order that this furnace will operate properly, it is required that

all of the startup procedures in this section be followed.

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.

NOx SCREEN REMOVAL (Lo-NOx Models Only)

If the furnace is equipped with NOx screens and is to be used with LP

(propane) gas, the screens must be removed prior to start-up.

1. Make sure that the electrical power to the unit is turned off and that

the gas supply is turned off at the shut-off valve.

2. Remove the blower compartment and burner compartment access

doors.

3. Disconnect the gas supply piping at the union to permit removal of

the entire burner and gas control assembly from the vestibule

panel. Use the wrench boss on the gas valve when removing or

installing the piping.

Burner ignition may not be satisfactory on first startup due to resid-

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

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

4. Unplug the igniter from the wire harness. Disconnect the flame

sensor wires located on top of the air shield. Unplug the gas valve

from the wiring harness.

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

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

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

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

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

dilute and carry away any vented gas.

5. Remove the screws holding the burner assembly to the vestibule

panel.

6. Remove the burner assembly. It should be possible to swing the

burner assembly out of the way without disconnecting the remain-

ing wires.

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.

7. With the burner assembly out of the way, simply slide the NOx

screens out of the heat exchanger tubes and discard the screens.

8. Replace all components in reverse order. Reconnect all wiring.

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 1/2 PSI (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.

Johnson Controls Unitary Products

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

368262-UIM-B-1008

SETUP TEST MODE

During normal operation, the furnace input rate can vary between 50%

and 100% of full nameplate input, making it difficult to check for proper

operation. To help with the furnace startup process, the control has a

TEST MODE available that allows the furnace input rate to stay at a

constant input rate. To access this TEST MODE perform the following

sequence:

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

result in unregulated manifold pressure and result in excess over-

fire and heat exchanger failures.

NOTE: 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 sqaurely aligned orifice hole is

essential for proper flame characteristics.

1. With power to the board on and with no thermostat calls (no call for

heating, cooling or continuous fan), push and hold the TEST but-

ton on the board for one second. The LED on the board will glow

red.

Verify natural gas input rate by clocking meter.

2. Release the TEST button. The LED on the board will flash a rapid

green signal, indicating that TEST MODE is activated.

1. Turn off all other gas appliances and pilots.

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

3. Turn the thermostat to call for heat (R & W signal).

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

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

surement of gas flow.

4. The furnace will light and operate at high (100%) firing rate. The

furnace firing rate should be checked at this level to confirm that

the furnace is not overfired or underfired.

4. Refer to Table 10 for cubic feet of gas per hour.

5. To run the furnace at minimum rate (50%), press the ERROR but-

ton once. The LED will flash one green flash to confirm.

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

input.

6. To run the furnace at a middle rate (70%), press the ERROR but-

ton twice within a five-second period. The LED will flash green two

times to confirm.

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.

7. To again operate the furnace at maximum (100%) rate, press the

ERROR button three times within a five-second period. The LED

will flash green three times to confirm.

8. If the thermostat call for heat is removed, the LED will flash a rapid

green signal, indicating that the furnace is still in TEST MODE.

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

start of this input check.

9. When startup tests are completed, turning off power to the board

will take the furnace out of TEST MODE and will restore normal

operation. The furnace will automatically return to normal opera-

tion after 150 minutes if power is not cycled.

HIGH ALTITUDE NATURAL GAS ORIFICE

CONVERSION

The National Fuel Gas Code requires that gas appliances installed

above 2,000 feet elevation have their inputs de-rated by 4% per 1,000

feet above sea level. The modulating furnaces automatically de-rate for

altitude by measuring the inducer blower pressure and using that to

determine if there is adequate air to support good combustion. If there

is not enough combustion air to properly support 100% of the furnace

nameplate input rate, the control will reduce the input to the point that

there will be good combustion.

CALCULATING THE FURNACE INPUT

(NATURAL GAS)

NOTE: Burner orifices are sized to provide proper input rate using natu-

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

ing value of your gas is significantly different, it may be necessary to

replace the orifices.

NOTE: DO NOT set manifold pressure less than 3.2 in wc or more than

3.8 in wc for natural gas at sea level. If manifold pressure is outside this

range, change main burner orifices.

Johnson Controls Unitary Products

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

368262-UIM-B-1008

Table 10: Gas Rate (CU FT/HR) at Full Input

Size of Test Dial

Seconds For

1 Revolution

Seconds For

1 Revolution

1 Cu Ft

360

327

300

277

257

240

225

212

200

189

180

171

164

157

150

144

138

133

129

124

120

116

113

109

106

103

100

2 Cu Ft

720

655

600

555

514

480

450

424

400

379

360

343

327

313

300

288

277

267

257

248

240

232

225

218

212

206

200

195

189

185

180

176

172

167

164

160

157

153

150

147

144

141

138

136

133

5 Cu Ft

1800

1636

1500

1385

1286

1200

1125

1059

1000

947

900

857

818

783

750

720

692

667

643

621

600

581

563

545

529

514

500

486

474

462

450

439

429

419

409

400

391

383

375

367

360

355

346

340

333

1 Cu Ft

2 Cu Ft

131

129

126

124

122

120

116

112

109

106

103

100

5 Cu Ft

327

321

316

310

305

300

290

281

273

265

257

250

243

237

231

225

220

214

209

205

200

196

192

188

184

180

178

173

170

167

164

161

155

150

145

141

135

130

125

120

115

110

105

100

102

104

106

108

110

112

116

120

124

128

133

138

144

150

157

164

171

180

Johnson Controls Unitary Products

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

368262-UIM-B-1008

ADJUSTMENT OF MANIFOLD GAS PRESSURE

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

start of this input check.

Main

Regulator

Adjustment

On/Off

Knob

Table 11: Inlet Gas Pressure Range

INLET GAS PRESSURE RANGE

Outlet

Pressure

Tap

Inlet

Pressure

Tap

Natural Gas

Propane (LP)

Minimum*

Maximum

4.5” W.C. (1.12 kPa)

10.5” W.C. (2.61 kPa)

8.0” W.C. (1.99 kPa)

13.0” (3.24 kPa) W.C.

FIGURE 28: Gas Valve

* The gas line pressure MUST BE

•

7” W.C. (1.74 kPA) for Natural Gas

11” W.C. (2.74 kPA) for Propane (LP) Gas

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

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

sure will decrease.

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.

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

furnace input to make sure you have not exceeded the specified

input on the rating plate. Refer to "CALCULATING THE FURNACE

INPUT (NATURAL GAS)".

The inlet gas pressure operating range table specifies what the

minimum and maximum gas line pressures must be for the furnace

to operate safely.

8. 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 and fittings from the gas valve pressure

tap and the pressure reference hose from the burner box and

replace the pressure tap plugs. Replace the burner box front cover

(if it was removed) and place the pressure reference hose back on

the gas valve.

Follow the appropriate section in the instructions below. Refer to Figure

28 for a drawing of the locations of the pressure ports on the gas valve.

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

before the gas valve.

9. 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 gas detector, a non-corrosive

leak detection fluid, or other leak detection methods.

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

PRESS TAP.

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

PRESS TAP.

ADJUSTMENT OF TEMPERATURE RISE

3. Using a 3/16” allen wrench, remove the plugs from the inlet and

outlet pressure ports. Connect a 1/8” UPT barbed hose fitting to

each pressure port.

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.

The supply air temperature cannot exceed the “Maximum Supply

Air Temperature” specified in these instructions and on the fur-

nace rating plate. Under NO circumstances can the furnace be

allowed to operate above the Maximum Supply Air Temperature.

Operating the furnace above the Maximum Supply Air Temperature

will cause premature heat exchanger failure, high levels of Carbon

Monoxide, a fire hazard, personal injury, property damage, and/or

death.

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

access to the adjustment screw. Loosening or tightening the cap

does not adjust the flow of gas.

4. Refer to Figure 28 for location of pressure regulator adjustment

cap and adjustment screws on main gas valve.

5. Turn gas and electrical supplies on and follow the operating

instructions to place the unit back in operation.

6. Adjust manifold pressure by adjusting gas valve regulator screw

for the appropriate gas per the following:

After about 5 minutes of operation, determine the furnace temperature

rise. Take temperature readings of both the return air and the heated air

in the ducts about six feet away from the furnace, where they will not be

affected by radiant heat. Increase or decrease the temperature rise by

changing the ATR jumper on the furnace control board. The jumper is

factory-set to deliver an air temperature rise near the midpoint of the

nameplate temperature rise range. If more air is desired (lower temper-

ature rise), move the jumper to the -10 position. If less air is desired

(higher temperature rise), move the jumper to the +10 position.

TABLE 12: Nominal Manifold Pressure

NOMINAL MANIFOLD PRESSURE

Natural Gas (Max)

Natural Gas (Min)

3.5" w.c. (0.87 kPa)

0.9" w.c. (0.22 kPa)

10.0" w.c. (2.49 kPa)

2.5" w.c. (0.62 kPa)

Propane (LP) Gas (Max)

Propane (LP) Gas (Min)

Johnson Controls Unitary Products

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

368262-UIM-B-1008

Continuous Fan Operation - The airflow delivered by the furnace dur-

ing continuous fan operation can be adjusted as desired. This is done

my moving the control fan jumper on the control board to give the

desired airflow.

ADJUSTMENT OF FAN CONTROL SETTINGS

Cooling - The airflow delivered by the furnace during cooling operation

can be adjusted to match the cooling capacity of the A/C condensing

unit. This is done by moving the COOL and ADJ jumper on the control

board to give the desired airflow.

The jumper has three positions. The "H" position delivers maximum air-

flow, 100% of the blower capacity. Position "M" delivers approximately

70% of the blower capacity. And Position "L" delivers minimum airflow,

approximately 40% of the blower capacity.

The COOL jumper has four positions, which will deliver sufficient airflow

in cooling mode for the cooling capacities shown in Table 13.

the ADJ jumper has three positions which can be used to make further

adjustments to the cooling blower airflow.

EAC

Terminals

Humidifier

Terminals

Zoning

Jumper

Heat Pump

Jumper

Cooling

Speed

Jumper

Humidistat

Jumper

Continuous

Fan Speed

Jumper

Test

Button

Last

Error

Button

Low

Voltage

Terminals

Diagnostic

Light

FIGURE 29: Furnace Control Board

Johnson Controls Unitary Products

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

368262-UIM-B-1008

Table 13: Blower Performance CFM - Any Position

High / Low Speed Cooling CFM

080B12

060A12

Jumper Settings

Hi Cool

1340

1125

1225

1050

1100

890

Lo Cool

900

750

820

680

740

600

615

450

545

440

499

440

Hi Cool

1290

1065

1165

960

Lo Cool

790

660

720

600

590

525

540

395

495

380

430

380

COOL Jumper

ADJ Jumper

1050

855

920

875

675

640

815

775

600

580

720

700

540

525

High / Low Speed Cooling CFM

100C16

080C16

Jumper Settings

Hi Cool

1715

1520

1575

1395

1430

1320

1260

1100

1200

1000

1080

900

Lo Cool

1165

1020

1060

930

Hi Cool

1600

1450

1500

1345

1315

1265

1210

1080

1165

980

Lo Cool

1120

980

COOL Jumper

ADJ Jumper

1020

900

950

930

875

845

840

805

730

700

795

765

665

635

715

1050

885

695

600

585

High / Low Speed Cooling CFM

120C20

100C20

Jumper Settings

Hi Cool

2110

1670

1900

1515

1710

1465

1370

1255

1330

1140

1195

1025

Lo Cool

1360

1085

1235

990

Hi Cool

1990

1760

1900

1510

1800

1540

1440

1320

1400

1200

1260

1080

Lo Cool

1290

1030

1210

935

COOL Jumper

ADJ Jumper

1130

950

1095

900

890

845

815

790

865

835

740

725

780

750

665

650

All CFM’s are shown at 0.5” w.c. external static pressure.These units have variable speed motors that automatically adjust to provide constant CFM from 0.0”

to 0.6” w.c. static pressure. From 0.6” to 1.0” static pressure, CFM is reduced by 2% per 0.1” increase in static. Operation on duct systems with greater than

1.0” w.c. external static pressure is not recommended.

NOTE: At some settings, LOW COOL airflow may be lower that what is required to operate an airflow switch on certain models of electronic air cleaners. Con-

sult the instructions for the electronic air cleaner for further details.

Johnson Controls Unitary Products

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

368262-UIM-B-1008

Delay Taps Selection

ROLLOUT SWITCH CONTROLS

These controls are mounted on the burner assembly. If the temperature

in the burner area exceeds its set point, the ignition control and the gas

valve are de-energized. The operation of this control indicates a mal-

function in the combustion air blower, heat exchanger or a blocked vent

pipe connection. Corrective action is required. These are manual reset

controls that must be reset before operation can continue.

The set of jumper pins on the control board labeled "DELAY" are used

to set the delay profiles for the furnace. These can be chosen so as to

maximize the comfort and sound levels for various regions of the coun-

try.

Tap A is the default profile. It provides a 30-second ramp-up from zero

airflow to full capacity and a 30-second ramp-down from full capacity

back to zero airflow. Whenever there is a change in airflow mode, such

as from low heat to high heat, the motor will take 30 seconds to ramp

from one speed to the other.

PRESSURE CONTROLS

Pressure Sensor - This furnace is equipped with a pressure sensor in

the burner compartment near the combustion blower. This sensor mon-

itors combustion airflow through furnace and piping systems. If any of

the conditions listed below are detected by the pressure sensor, the

control board will prevent a hazardous condition from occurring by

speeding up the combustion blower motor in order to maintain ade-

quate combustion airflow. If the combustion blower is already turning at

full speed, the furnace control will then start reducing the input to the

furnace in order to maintain proper combustion with the amount of com-

bustion airflow available. If there is not enough combustion air available

to give proper combustion even at the minimum input rate (50%), the

control will close the gas valve and shut off the burners. The sensor will

detect the following conditions.

Tap B is the humid profile. This profile is best-suited for installations

where the humidity is frequently very high during cooling season, such

as in the southern part of the country. On a call for cooling, the blower

will ramp up to 50% of full capacity and will stay there for two minutes,

then will ramp up to 82% of full capacity and will stay there for five min-

utes, and then will ramp up to full capacity, where it will stay until the

wall thermostat is satisfied. In every case, it will take the motor 30 sec-

onds to ramp from one speed to another.

Tap C is the dry profile. This profile is best suited to parts of the country

where excessive humidity is not generally a problem, where the sum-

mer months are usually dry. On a call for cooling the motor will ramp up

to full capacity and will stay there until the thermostat is satisfied. At the

end of the cooling cycle, the blower will ramp down to 50% of full capac-

ity where it will stay for 60 seconds. Then it will ramp down to zero. In

every case, it will take the motor 30 seconds to ramp from one speed to

another.

1. Blockage of vent piping or vent terminal

2. Failure of combustion air blower motor or blower wheel.

Pressure Switch - This furnace is equipped with a pressure switch

mounted on the furnace vestibule panel. This switch monitors the flow

through the vent system. The switch will close at the beginning of each

cycle when adequate combustion airflow is established. However, this

switch may be open under certain conditions when the burners are lit.

The pressure sensor is the primary flow sensor.

Tap D is the normal profile, best suited for most of the country, where

neither excessive humidity nor extremely dry conditions are the norm.

On a call for cooling, the motor will ramp up to 63% of full capacity and

will stay there for 90 seconds, then will ramp up to full capacity. At the

end of the cooling cycle, the motor will ramp down to 63% of full capac-

ity and will stay there for 30 seconds, then will ramp down to zero. In

every case, it will take the motor 30 seconds to ramp from one speed to

another.

LIMIT CONTROLS

Limit Switch - This furnace is equipped with a high temperature limit

control mounted to the left side of the furnace vestibule panel. This limit

switch will open and shut off gas to the burners if it detects excessive air

temperature in the furnace, which can be caused by any of the following

conditions:

Humidistat

When a humidistat is installed in the system, the “Humidistat” jumper on

the control board should be moved to the “YES” position. The cooling

airflow will then be reduced by 15% whenever the humidistat indicates

high humidity.

1. Dirty filter

2. Failure of the circulating blower motor or wheel

3. Too many supply or return registers closed or blocked.

Temperature Sensor - This furnace is also equipped with a tempera-

ture sensor mounted to the left side of the vestibule panel, near the limit

switch. This sensor monitors the temperature of the air being supplied

to the home. If the sensor detects air temperature higher than normal,

the furnace control will first speed up the circulating blower motor in

order to try to increase the amount of airflow being delivered, thereby

reducing the air temperature. If the blower motor is already turning at

full speed, the control will then start reducing the input to the furnace to

try to reduce the air temperature. If the supply air temperature is too

high even at the minimum input rate (50%), the control will close the

gas valve and shut off the furnace.

SECTION VIII: SAFETY CONTROLS

CONTROL CIRCUIT FUSE

A 3-amp fuse is provided on the control circuit board to protect the 24-

volt transformer from overload caused by control circuit wiring errors.

This is an ATO 3, automotive type fuse and is located on the control

board.

BLOWER DOOR SAFETY SWITCH

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.

Main power to the unit must still be interrupted at the main power

disconnect switch before any service or repair work is to be done to

the unit. Do not rely upon the interlock switch as a main power dis-

connect.

Blower and burner must never be operated without the blower

panel in place.

Johnson Controls Unitary Products

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

368262-UIM-B-1008

Three Amber flashes - Normal operation, burner is on at end of heat-

ing cycle after wall thermostat has been satisfied.

SECTION IX: NORMAL OPERATION AND

DIAGNOSTICS

NORMAL OPERATION SEQUENCE

Four Amber Flashes - Heating capacity is reduced due to restriction in

the circulating air system. Check for dirty filter or closed registers.

The furnace control calculates the optimum firing rate each time the

wall thermostat R and W contacts close or open (at the beginning and

at the end of each call for heat) based on information from the thermo-

stat and past demand. UNLIKE CONVENTIONAL SYSTEMS, THE

WALL THERMOSTAT DOES NOT SIMPLY TURN THE FURNACE ON

AND OFF. THE FURNACE CONTROL CALCULATES THE DEMAND

AND MAY CONTINUE TO FIRE THE FURNACE DURING PORTIONS

OF THE THERMOSTAT "OFF" CYCLE.

Five Amber Flashes - Heating capacity is reduced due to restriction in

the combustion air or vent system. Check for blocked vent/air pipe or

clogged condensate drain. Above 4,000 feet altitude, this may also indi-

cate automatic, normal derating for altitude. See page 7 for additional

high altitude information.

Six Amber Flashes - (Heat Pump applications only) Normal operation

with call for heat pump heating.

Rapid Amber Flash - Low flame sense current. Check for dirty or mis-

located flame sensor rod.

When the wall thermostat R and W contacts close, indicating a call for

heat, the following sequence occurs:

One Red Flash - Flame is present with no power being supplied to gas

valve. This can be caused by a gas valve that is slow to close or that

leaks gas through to the burners.

1. The inducer is energized and ramps up its speed until airflow is

proven by the pressure switch and by the pressure sensor on the

control board.

2. The hot surface ignitor is energized.

Two Red Flashes - Pressure switch closed with inducer pressure

below pressure switch setpoint (switch is closed when it should be

open). Check pressure switch.

3. After a 17-20 second igniter heat-up, the gas valve opens and the

burners light.

4. When the control senses that flame is present, the circulating

blower starts at low speed.

Three Red Flashes - Pressure switch open with inducer pressure

above pressure switch setpoint (switch is open when it should be

closed). Check pressure switch.

5. The furnace fires at 70% of full rate for 30-45 seconds, then drops

to the minimum (50%) firing rate.

Four Red Flashes - High limit switch open or defective temperature

sensor or 24 volt fuse is open. This may be caused by a dirty air filter,

improperly sized duct system, faulty blower motor, restricted circulating

airflow an open fuse on the control board.

6. The firing rate is automatically adjusted to meet demand, increas-

ing gradually to maximum (100%) firing rate if the thermostat is not

satisfied within a defined time.

7. When the thermostat R and W contacts open (thermostat is satis-

fied) the furnace control recalculates the demand and a new firing

rate.

Five Red Flashes - Rollout switch or condensate pressure switch

open. Check the rollout switch(es) on the burner assembly. It is a man-

ual reset switch. To reset, push the small button in the center of the

switch. If it cannot be reset or if the switch trips again, contact a quali-

fied serviceman.

a. If demand exceeds the minimum firing rate, the burners will

continue to fire at a recalculated reduced firing rate, decreas-

ing if the thermostat remains off for a defined time.

Six Red Flashes - Current failure on modulating gas valve.

b. If demand does not exceed the minimum firing rate, the burn-

ers will shut off immediately.

Seven Red Flashes - Lockout due to no ignition. The control will try

three times for ignition. If flame cannot be established in three tries, the

control will lockout for one hour and then will try again to light. Check

gas supply, ignitor, gas valve, flame sensor.

8. After the burners shut off, the circulating blower will continue to run

until the temperature sensor detects that the supply air tempera-

ture has dropped to the desired level, which should take from 30 to

90 seconds.

Eight Red Flashes - Lockout due to too many flame recycles. This

flash code occurs if flame is lost five times during a single heating cycle.

This could be caused by a faulty gas valve, low gas pressure, or dirty

flame sensor. The control will lock out for one hour and then will try

again.

FURNACE CONTROL DIAGNOSTICS

This furnace has built-in self-diagnostic capability. If a system problem

occurs, a flashing LED shows a fault code. The LED can flash red,

green or amber to indicate various conditions. The LED is located on

the furnace control board and can be seen through the clear view port

in the lower door of the furnace. To indicate an error condition, the LED

will turn on for 1/4 second and off for 1/4 second. The pattern will be

repeated the number of times equal to the flash code. For instance, a

"six flash code" will be indicated by the LED turning on and off six times.

There will be a two second off period between each set of flashes. The

flash codes and an indication of their likely causes are listed below:

Nine Red Flashes - Reversed line polarity or improper grounding.

Check polarity of the incoming power to the furnace. Check the ground-

ing of the furnace, including the transformer ground and the L1 and

neutral connections.

Ten Red Flashes - Gas valve circuit shorted. Check gas valve wiring. If

correct, replace gas valve.

Eleven Red Flashes - Main blower failure - This flash code occurs

when the main limit opens and fails to reclose within five minutes, indi-

cating that the blower motor or blower wheel has failed.

STEADY OFF - No 24V power to board. Check the 24 volt control cir-

cuit fuse on the board. Check the circuit breaker or fuse on the 115 volt

supply power to the furnace. Check that the 24 volt transformer.

Twelve Red Flashes - ID plug is not present or not connected properly,

check for loose plug or loose wires in plug.

One Green Flash - Normal Operation with no call for heat.

Steady On Red - Control fault has been detected or there is 24 volts

present without 115 volts. Check that there is 24 volts and 115 volts

being supplied to the board. If so, then the board should be replaced.

Two Green Flashes - Indicator for "No error codes in memory". See

Diagnostic Fault Code Storage and Retrieval section below.

Three Green Flashes - Indicator for "Error codes cleared from mem-

ory". See Diagnostic Fault Code Storage and Retrieval section below.

IGNITION CONTROL FLAME SENSE LEVELS

Normal flame sense current is approximately

3.7 microamps DC (µa)

Low flame signal warning starts at 1.5 microamps.

Low flame signal control lockout point is

0.1 microamps DC (µa)

Rapid Green Flash - Control is in "Factory Speed-up" mode. This

mode is used only during factory run-testing of the furnace. To stop this

mode, cycle power to the furnace off and then back on.

One Amber Flash - Normal operation with call for cooling.

Two Amber Flashes - Normal operation with call for heat.

Johnson Controls Unitary Products

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

368262-UIM-B-1008

To retrieve the error codes, push the LAST ERROR button. The LED on

the control will then flash the error codes that are in memory, starting

with the most recent. There will be a two-second pause between each

flash code. After the error codes have all been displayed, the LED will

resume the normal slow green flash after a five second pause. To

repeat the series of error codes, push the button again.

DIAGNOSTIC FAULT CODE STORAGE AND

RETRIEVAL

The control in this furnace is equipped with memory that will store up to

five error codes to allow a service technician to diagnose problems

more easily. This memory will be retained even if power to the furnace

is lost. Only a qualified service technician should use this feature.

If there are no error codes in memory, the LED will flash two green

flashes. To clear the memory, push the LAST ERROR button and hold it

for more than five seconds. The LED will flash three green flashes

when the memory has been cleared, then will resume the normal slow

green flash after a five-second pause.

The control stores up to five separate error codes. If more than five

error codes have occurred since the last reset, only the five most recent

will be retained. The furnace control board has a button, labeled "LAST

ERROR" that is used to retrieve error codes. This function will only

work if there are no active thermostat signals. So any call for heating,

cooling or continuous fan must be terminated before attempting to

retrieve error codes.

SECTION X: REPLACEMENT PARTS LIST

DESCRIPTION

FABRICATED PARTS Continued

BRACKET, BLOWER TRACK (2 Req’d)

HEAT EXCHANGER ASS’Y

MANIFOLD, GAS

DESCRIPTION

MOTOR

MOTOR, DIRECT DRIVE BLOWER

BLOWER, COMBUSTION

ELECTRICAL

PAN, BOTTOM

CAPACITOR, RUN

SWITCH, LIMIT

PANEL, TOP

PANEL, DOOR (2 Req’d)

VENT PAN, COMBUSTION (w/Gasket)

PANEL, BLOCKOFF

CONTROL, FURNACE

IGNITER

SENSOR, FLAME

LO-NOX SCREEN (L-Models Only)

MISCELLANEOUS

SWITCH, PRESSURE

SWITCH, DOOR

ORIFICE, BURNER (Natural #45)

SIGHT GLASS, OVAL (2 Req’d)

GASKET, FOAM (Door) (1.5 ft req’d)

GASKET, INTAKE PAN

PLUG, VENT HOLE

TRANSFORMER

VALVE, GAS

CONTROL, TEMPERATURE

SENSOR, PRESSURE

SENSOR, THERMISTOR

AIR MOVING

BRACKET, DOOR

WIRING HARNESS

HOUSING, BLOWER

WHEEL, BLOWER

FABRICATED PARTS

BAFFLE, FLUE

FERRULE (3 Req’d)

GROMMET (3 Req’d)

MOTOR MOUNT

HOSE ASSY, VACUUM

PLUG, ID (Control Board)

KNOB, QUARTER TURN (4 Req’d)

UNION

BURNER, MAIN GAS

BRACKET, IGNITER

SHELF, BLOWER

RAIL, BLOWER (2 Req’d)

DIAGRAM, WIRING

REPLACEMENT PART CONTACT INFORMATION

This is a generic parts list. To request a complete parts list, refer to the contact information below:

• Visit our website at www.source1parts.com for the following information:

1. Search for a part or browse the catalog.

2. Find a dealer or distributor.

3. Customer Service contact information.

a. Click on the “Brand Links” button

b. Click on the “Customer Service” button

• You can contact us by mail. Just send a written request to:

Johnson Controls Unitary Products

Consumer Relations

5005 York Drive

Norman, OK 73069

Johnson Controls Unitary Products

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

368262-UIM-B-1008

SECTION XI: WIRING DIAGRAM

FIGURE 30: Wiring Diagram

Johnson Controls Unitary Products

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

Subject to change without notice. Printed in U.S.A.

368262-UIM-B-1008

Supersedes: 368262-UIM-A-0508

Johnson Controls Unitary Products

5005 York Drive

Norman, OK 73069

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

Indesit Washer PWE 9168 S User Manual
Intel Switch 510T User Manual
Invacare Mobility Aid 1130213 User Manual
Jensen Marine Radio MSR3007 User Manual
JVC Car Stereo System GET0063 001A User Manual
JVC CD Player KD DV6101 User Manual
JVC Security Camera VN H217U User Manual
JVC Speaker System UX L30 User Manual
Kenwood Marine Radio TK 5910 User Manual
Konica Minolta Drums CM 2500d User Manual