INSTALLATION MANUAL

RESIDENTIAL GAS FURNACE MODELS

TM8X*MP, TMLX*MP EFFICIENCY
RATING
CERTIFIED

(Single Stage Multi-position / Low NOx with ISO 9001

Certified Quality
High-Efficiency Motors) Management System

LIST OF SECTIONS
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 REPLACEMENT PART CONTACT INFORMATION . . . . . . . . . . . . 26
ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
VENT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

LIST OF FIGURES
Duct Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Vertical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Coil Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Combustion Air Inducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Horizontal Right Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Thermostat Chart - Single Stage AC with
Horizontal Left Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Single Stage Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
PC Series Upflow Coil Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Thermostat Chart - Single Stage HP with
Horizontal Left or Right application (Right Shown) . . . . . . . . . . . . . . 7 Single Stage Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Combustible Floor Base Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Combustion Airflow Path Through The
Horizontal Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Furnace Casing to the Burner Compartment . . . . . . . . . . . . . . . . . . 15
Typical Attic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . 16
Typical Suspended Furnace / Crawl Space Installation . . . . . . . . . . . 8 Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Side Return Cutout Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

LIST OF TABLES
Unit Clearances to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Coil Projection Dimensions - PC Series Coils . . . . . . . . . . . . . . . . . . 7 Gas Rate (CU FT/HR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cabinet and Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Recommended Filter Sizes (High Velocity 600 FPM) . . . . . . . . . . . . 9 Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Blower Performance CFM - Any Position
Ratings & Physical / Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . 11 (without filter) - Bottom Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Blower Performance CFM - Any Position
Unconfined Space Minimum Area . . . . . . . . . . . . . . . . . . . . . . . . . . 16 (without filter) - Left Side Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

These high efficiency, compact units employ induced combustion, reli- DANGER indicates an imminently hazardous situation, which, if not
able hot surface ignition and high heat transfer aluminized tubular heat avoided, will result in death or serious injury.
exchangers. The units are factory shipped for installation in upflow or WARNING indicates a potentially hazardous situation, which, if not
horizontal applications and may be converted for downflow applica- avoided, could result in death or serious injury.
tions.
CAUTION indicates a potentially hazardous situation, which, if not
These furnaces are designed for residential installation in a basement, avoided may result in minor or moderate injury. It is also used to
closet, alcove, attic, recreation room or garage and are also ideal for alert against unsafe practices and hazards involving only property dam-
commercial applications. All units are factory assembled, wired and age.
tested to assure safe dependable and economical installation and oper-
ation.
These units are Category I listed and may be common vented with
another gas appliance as allowed by the National Fuel Gas Code.
Improper installation may create a condition where the operation of
SECTION I: SAFETY the product could cause personal injury or property damage.
Improper installation, adjustment, alteration, service or mainte-
This is a safety alert symbol. When you see this symbol on nance can cause injury or property damage. Failure to carefully
labels or in manuals, be alert to the potential for personal read and follow all instructions in this manual can result in fur-
injury. nace malfunction, death, personal injury and/or property dam-
age. Only a qualified contractor, installer or service agency should
Understand and pay particular attention to the signal words DANGER,
install this product.
WARNING, or CAUTION.

437642-UIM-C-0210
437642-UIM-C-0210

SPECIFIC SAFETY RULES AND PRECAUTIONS 12. When moving or handling this furnace prior to installation it is rec-
1. Only Natural gas or Propane (LP) gas are approved for use with ommended to leave the doors on the furnace to provide support
this furnace. and to prevent damage or warping of the cabinet. When lifting the
furnace by the cabinet, support the ends of the furnace rather than
2. Install this furnace only in a location and position as specified in
lifting by the cabinet flanges at the return air openings (bottom or
these instructions.
sides) or supply air opening.
3. A gas-fired furnace for installation in a residential garage must be
13. When lifting the furnace, it is acceptable to use the primary heat
installed as specified in these instructions.
exchanger tubes as a lifting point provided that the tubes are lifted
4. Provide adequate combustion and ventilation air to the furnace at the front of the heat exchangers where attached to the vestibule
space as specified in these instructions. panel. Do not use the top return bend of the heat exchangers as
5. Combustion products must be discharged outdoors. Connect this lifting points as the tubes may shift out of position or their location
furnace to an approved vent system only, as specified in SEC- brackets/baffles.
TION VI of these instructions.
6. Test for gas leaks as specified in these instructions.

During installation, doors should remain on the furnace when

moving or lifting.

FIRE OR EXPLOSION HAZARD SAFETY REQUIREMENTS

Failure to follow the safety warnings exactly could result in serious
injury, death or property damage.
Never test for gas leaks with an open flame. Use a commercially
available soap solution made specifically for detection of leaks to
check all connections. A fire or explosion may result causing prop- This product must be installed in strict compliance with the installa-
erty damage, personal injury or loss of life. tion instructions and any applicable local, state, and national codes
including, but not limited to building, electrical, and mechanical
7. Always install the furnace to operate within the furnace’s intended codes.
temperature rise range. Only connect the furnace to a duct system
which has an external static pressure within the allowable range, • Refer to the unit rating plate for the furnace model number, and
as specified on the furnace rating plate. then see the dimensions page of this instruction for return air ple-
8. When a furnace is installed so that supply ducts carry air circulated num dimensions in Figure 12. The plenum must be installed
by the furnace to areas outside the space containing the furnace, according to the instructions.
the return air shall also be handled by duct(s) sealed to the fur- • Provide clearances from combustible materials as listed under
nace casing and terminating outside the space containing the fur- Clearances to Combustibles.
nace. • Provide clearances for servicing ensuring that service access is
9. It is permitted to use the furnace for heating of buildings or struc- allowed for both the burners and blower.
tures under construction where the application and use must com- • These models ARE NOT CSA listed or approved for installation
ply with all manufacturer’s installation instructions including: into a HUD Approved Modular Home or a Manufactured
• Proper vent installation; (Mobile) Home.
• Furnace operating under thermostatic control; • This furnace is not approved for installation in trailers or recre-
• Return air duct sealed to the furnace; ational vehicles.
• Air filters in place; • Furnaces for installation on combustible flooring shall not be
• Set furnace input rate and temperature rise per rating plate installed directly on carpeting, tile or other combustible material
marking; other than wood flooring.
• Means for providing outdoor air required for combustion; • Check the rating plate and power supply to be sure that the elec-
• Return air temperature maintained between 55ºF (13ºC) and trical characteristics match. All models use nominal 115 VAC, 1
80ºF (27ºC); Phase, 60 Hz power supply. DO NOT CONNECT THIS APPLI-
• The air filter must be replaced upon substantial completion of ANCE TO A 50 Hz POWER SUPPLY OR A VOLTAGE ABOVE
the construction process; 130 VOLTS.
• Clean furnace, duct work and components upon substantial • Furnace shall be installed so the electrical components are pro-
completion of the construction process, and verify furnace- tected from water.
operating conditions including ignition, input rate, temperature • Installing and servicing heating equipment can be hazardous due
rise and venting, according to the manufacturer’s instructions. to the electrical components and the gas fired components. Only
10. When installed in a non-HUD-Approved Modular Home or building trained and qualified personnel should install, repair, or service
constructed on-site, combustion air shall not be supplied from gas heating equipment. Untrained service personnel can perform
occupied spaces. basic maintenance functions such as cleaning and replacing the
air filters. When working on heating equipment, observe precau-
11. The size of the unit should be based on an acceptable heat loss
tions in the manuals and on the labels attached to the unit and
calculation for the structure. ACCA, Manual J or other approved
other safety precautions that may apply.
methods may be used.

2 Johnson Controls Unitary Products

 437642-UIM-C-0210

COMBUSTION AIR QUALITY CODES AND STANDARDS

(LIST OF CONTAMINANTS) Follow all national, local codes and standards in addition to this installa-
The furnace requires OUTDOOR AIR for combustion when the furnace tion manual. The installation must comply with regulations of the serv-
is located in any of the following environments. ing gas supplier, local building, heating, plumbing, and other codes. In
• Restricted Environments absence of local codes, the installation must comply with the national
codes listed below and all authorities having jurisdiction.
• Commercial buildings
• Buildings with indoor pools In the United States and Canada, follow all codes and standards for the
following, using the latest edition available:
• Furnaces installed in laundry rooms
• Furnaces installed in hobby or craft rooms STEP 1 -Safety
• Furnaces installed near chemical storage areas • US: National Fuel Gas Code (NFGC) NFPA 54/ANSI Z223.1 and
the Installation Standards, Warm Air Heating and Air Conditioning
• Chemical exposure
Systems ANSI/NFPA 90B
The furnace requires OUTDOOR AIR for combustion when the furnace • CANADA: CAN/CGA-B149.1 National Standard of Canada. Natu-
is located in an area where the furnace is being exposed to the follow- ral Gas and Propane Installation Codes (NSCNGPIC)
ing substances and / or chemicals.
STEP 2 -General Installation
• Permanent wave solutions
• US: Current edition of the NFGC and NFPA 90B. For copies, con-
• Chlorinated waxes and cleaners tact the
• Chlorine based swimming pool chemicals National Fire Protection Association Inc.
• Water softening chemicals Batterymarch Park
• De-icing salts or chemicals Quincy, MA 02269
• Carbon tetrachloride or for only the NFGC, contact the
• Halogen type refrigerants American Gas Association,
• Cleaning solvents (such as perchloroethylene) 400 N. Capital, N.W.
• Printing inks, paint removers, varnishes, etc. Washington DC 20001
• Hydrochloric acid or www.NFPA.org
• Cements and glues • CANADA: NSCNGPIC. For a copy contact:
Standard Sales, CSA International
• Antistatic fabric softeners for clothes dryers
178 Rexdale Boulevard
• 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 STEP 3 -Combustion and Ventilation Air
area where there will be no exposure to the substances listed above. • 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
The furnace area must not be used as a broom closet or for any • US and CANADA: Air Conditioning Contractors Association
other storage purposes, as a fire hazard may be created. Never (ACCA) Manual D, Sheet Metal and Air Conditioning Contractors
store items such as the following on, near or in contact with the fur- Association National Association (SMACNA), or American Soci-
nace. ety of Heating, Refrigeration, and Air Conditioning Engineers
1. Spray or aerosol cans, rags, brooms, dust mops, vacuum (ASHRAE) 1997 Fundamentals Handbook Chapter 32.
cleaners or other cleaning tools. STEP 5 -Acoustical Lining and Fibrous Glass Duct
2. Soap powders, bleaches, waxes or other cleaning com- • US and CANADA: Current edition of SMACNA and NFPA 90B as
pounds; plastic items or containers; gasoline, kerosene, ciga- tested by UL Standard 181 for Class I Rigid Air Ducts
rette lighter fluid, dry cleaning fluids or other volatile fluid.
STEP 6 -Gas Piping and Gas Pipe Pressure Testing
3. Paint thinners and other painting compounds.
4. Paper bags, boxes or other paper products • US: NFGC; chapters 2, 3, 4, & 9 and National Plumbing Codes
• CANADA: NSCNGPIC Part 5
Never operate the furnace with the blower door removed. To
do so could result in serious personal injury and/or equipment STEP 7 -Electrical Connections
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 3

437642-UIM-C-0210

INSPECTION
FOR FURNACES INSTALLED IN THE COMMON-
As soon as a unit is received, it should be inspected for possible dam-
WEALTH OF MASSACHUSETTS ONLY
age during transit. If damage is evident, the extent of the damage
For all side wall horizontally vented gas fueled equipment installed in should be noted on the carrier’s freight bill. A separate request for
every dwelling, building or structure used in whole or in part for resi- inspection by the carrier’s agent should be made in writing. Also, before
dential purposes, including those owned or operated by the Com- installation, the unit should be checked for screws or bolts which may
monwealth and where the side wall exhaust vent termination is less have loosened in transit. There are no shipping or spacer brackets
than seven (7) feet above finished grade in the area of the venting, which need to be removed from the interior of this unit.
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 furnace shall be located using the following guidelines:
the time of installation of the side wall horizontal vented gas 1. Where a minimum amount of air intake/vent piping and elbows will
fueled equipment, the installing plumber or gasfitter shall be required.
observe that a hard wired carbon monoxide detector with an
2. As centralized with the air distribution as possible.
alarm and battery back-up is installed on the floor level where
the gas equipment is to be installed. In addition, the installing 3. Where adequate combustion air will be available (particularly
plumber or gasfitter shall observe that a battery operated or when the appliance is not using outdoor combustion air).
hard wired carbon monoxide detector with an alarm is installed 4. Where it will not interfere with proper air circulation in the confined
on each additional level of the dwelling, building or structure space.
served by the side wall horizontal vented gas fueled equipment. Installation in freezing temperatures:
It shall be the responsibility of the property owner to secure the
1. Furnace shall be installed in an area where ventilation facilities
services of qualified licensed professionals for the installation of
hard wired carbon monoxide detectors provide for safe limits of ambient temperature under normal oper-
ating conditions.
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. Improper installation in an ambient below 32ºF (0° C) could create a
hazard, resulting in damage, injury or death.
b. In the event that the requirements of this subdivision can
not be met at the time of completion of installation, the 2. Do not allow return air temperature to be below 55ºF (13°C) for
owner shall have a period of thirty (30) days to comply with extended periods. To do so may cause condensation to occur in
the above requirements; provided, however, that during the main heat exchanger, leading to premature heat exchanger
said thirty (30) day period, a battery operated carbon mon- failure.
oxide detector with an alarm shall be installed. Clearances for access/service:
2. APPROVED CARBON MONOXIDE DETECTORS. Each car- Ample clearances should be provided to permit easy access to the unit.
bon monoxide detector as required in accordance with the The following minimum clearances are recommended:
above provisions shall comply with NFPA 720 and be ANSI/UL
1. Twenty-four (24) inches (61 cm) between the front of the furnace
2034 listed and IAS certified.
and an adjacent wall or another appliance, when access is
3. SIGNAGE. A metal or plastic identification plate shall be perma- required for servicing and cleaning.
nently mounted to the exterior of the building at a minimum
2. Eighteen (18) inches (46 cm) at the side where access is required
height of eight (8) feet above grade directly in line with the
for passage to the front when servicing or for inspection or replace-
exhaust vent terminal for the horizontally vented gas fueled
ment of flue/vent connections.
heating appliance or equipment. The sign shall read, in print
size no less than one-half (1/2) inch in size, "GAS VENT In all cases, accessibility clearances shall take precedence over clear-
DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUC- ances for combustible materials where accessibility clearances are
TIONS". greater.
4. INSPECTION. The state or local gas inspector of the side wall Installation in a residential garage:
horizontally vented gas fueled equipment shall not approve the A gas-fired furnace for installation in a residential garage must be
installation unless, upon inspection, the inspector observes car- installed so the burner(s) and the ignition source are located not less
bon monoxide detectors and signage installed in accordance than 18” (46 cm) above the floor, and the furnace must be located or
with the provisions of 248 CMR 5.08(2)(a)1 through 4. 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 Right Side Flue Floor/ Line
Application Closet Alcove Attic
In. (cm) In. (cm) In. (cm) In. (cm) In. (cm) In. (cm) Bottom Contact
Upflow 1 (2.5) 1 (2.5) 0 (0.0) 0 (0.0) 0 (0.0) 6 (15.2) Combustible Yes Yes Yes No
Upflow B-Vent 1 (2.5) 1 (2.5) 0 (0.0) 0 (0.0) 0 (0.0) 1 (2.5) Combustible Yes Yes Yes No
Downflow 1 (2.5) 1 (2.5) 0 (0.0) 0 (0.0) 0 (0.0) 6 (15.2) 1 (25.4)1 Yes Yes Yes No
Downflow B-Vent 1 (2.5) 1 (2.5) 0 (0.0) 0 (0.0) 0 (0.0) 1 (2.5) 1 Yes Yes Yes No
1 (25.4)
Horizontal 1 (2.5) 1 (2.5) 0 (0.0) 0 (0.0) 0 (0.0) 6 (15.2) Combustible No Yes Yes Yes2
Horizontal B-Vent 1 (2.5) 1 (2.5) 0 (0.0) 0 (0.0) 0 (0.0) 1 (2.5) Combustible No Yes Yes Yes2
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.

4 Johnson Controls Unitary Products

 437642-UIM-C-0210

SECTION II: DUCTWORK

DUCTWORK GENERAL INFORMATION
The duct system’s design and installation must: The duct system must be properly sized to obtain the correct airflow
1. Handle an air volume appropriate for the served space and within for the furnace size that is being installed.
the operating parameters of the furnace specifications. Refer to Table 6 or the furnace rating plate for the correct rise range
and static pressures.
2. Be installed in accordance of National Fire Protection Association
If the ducts are undersized, the result will be high duct static pres-
as outlined in NFPA standard 90B (latest editions) or applicable
sures and/or high temperature rises which can result in a heat
national, provincial, state, and local fire and safety codes.
exchanger OVERHEATING CONDITION. This condition can result
3. Create a closed duct system. For residential and non-HUD Modu- in premature heat exchanger failure, which can result in personal
lar Home installations, when a furnace is installed so that the sup- injury, property damage, or death.
ply ducts carry air circulated by the furnace to areas outside the
space containing the furnace, the return air shall also be handled DUCT FLANGES
by a duct(s) sealed to the furnace casing and terminating outside Four flanges are provided to attach ductwork to the furnace. These
the space containing the furnace. flanges are rotated down for shipment. In order to use the flanges,
4. Complete a path for heated or cooled air to circulate through the remove the screw holding an individual flange, rotate the flange so it is
air conditioning and heating equipment and to and from the condi- in the upward position and reinstall the screw then repeat this for all 4
tioned space. flanges.
If the flanges are not used, they must remain in the rotated down posi-
tion as shipped.
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 For duct attachment, Factory
exchanger. if needed. installed
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.
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 FIGURE 1: Duct Attachment
may cause the limit controls not to operate as designed, or the limit con-
trols may not operate at all. DUCTWORK INSTALLATION AND SUPPLY PLENUM
The duct system is a very important part of the installation. If the duct
CONNECTION - UPFLOW/HORIZONTAL
system is improperly sized the furnace will not operate properly. Attach the supply plenum to the furnace outlet. The use of
The ducts attached to the furnace plenum, should be of sufficient size an approved flexible duct connector is recommended on all
so that the furnace operates at the specified external static pressure installations. This connection should be sealed to prevent
and within the air temperature rise specified on the nameplate. 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 -

The minimum plenum height is 12” (30.5 cm). The furnace will not
operate properly on a shorter plenum height. The minimum recom- DOWNFLOW
mended rectangular duct height is 4” (10.1 cm) attached to the ple- Installations on combustible material or directly on any
num. floors must use a combustible floor base shown in Figure 8.
Follow the instructions supplied with the combustible floor
If a matching cooling coil is used, it may be placed directly on the fur- base accessory. This combustible floor base can be
nace outlet and sealed to prevent leakage. If thermoplastic evaporator replaced with a matching cooling coil, properly sealed to
‘A’ coil drain pans are to be installed in the upflow/horizontal configura- prevent leaks. Follow the instructions supplied with the
tion, then extra 2” minimum spacing may be needed to ensure against cooling coil cabinet for installing the cabinet to the duct con-
drain pan distortion. nector. Plug intake and vent pipe holes in bottom panel and
On all installations without a coil, a removable access panel is recom- move grommet to desired vent side exit.
mended in the outlet duct such that smoke or reflected light would be
Downflow Air Conditioning Coil Cabinet
observable inside the casing to indicate the presence of leaks in the
heat exchanger. This access cover shall be attached in such a manner The furnace should be installed with coil cabinet part number specifi-
as to prevent leaks. cally intended for downflow application. If a matching cooling coil is
used, it may be placed directly on the furnace outlet and sealed to pre-
vent leakage. For details of the coil cabinet dimensions and installation
requirements, refer to the installation instructions supplied with the coil
cabinet.
Attach the air conditioning 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.

Johnson Controls Unitary Products 5

437642-UIM-C-0210

COIL INSTALLATION 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.
On all installations without a coil, a removable access panel is rec-
ommended in the outlet duct such that smoke or reflected light Mounting Plate
would be observable inside the casing to indicate the presence of
leaks in the heat exchanger. This access cover shall be attached in
such a manner as to prevent leaks.

COIL/FURNACE ASSEMBLY - MC/FC/PC SERIES Furnace

COILS

FIGURE 4: Horizontal Right Application

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

coil when used with a downflow/horizontal furnace. A mounting plate,
supplied with every coil should always be installed on the side desig-
Furnace

nated as top side. See Figures 4 & 5.

Mounting Plate
Furnace

Furnace

UPFLOW DOWNFLOW

FIGURE 2: Vertical Applications FIGURE 5: Horizontal Left Application

FURNACE ASSEMBLY - MC & FC SERIES COILS FURNACE ASSEMBLY - PC SERIES COILS
These coils are factory shipped for installation in either upflow or down- These upflow coils are designed for installation on top of upflow fur-
flow applications with no conversion.
naces only.
Position the coil casing over or under the furnace opening as shown in
If the coil is used with a furnace of a different size, use a 45° transition
Figure 2 after configuring coil flanges as required see “Coil Flange” sec-
to allow proper air distribution through the coil.
tion below.
1. Position the coil casing over the furnace opening as shown in Fig-
COIL FLANGE INSTALLATION ure 6.
The coils include removable flanges to allow proper fit up with furnaces 2. Place the ductwork over the coil casing flange and secure.
having various inlet and outlet flange configurations. The two flanges 3. Check for air leakage between the furnace and coil casing and
are attached to the top of the coil in the factory during production. For seal appropriately.
proper configuration of flanges refer to Figure 3.

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 6

FACTORY
FLANGE
LOCATION
(Used for upflow
or horizontal
right installations)
ALTERNATE
FLANGE LOCATION
(Used for downflow or
horizontal left installations)

FIGURE 3: Coil Flange

6 Johnson Controls Unitary Products

 437642-UIM-C-0210

DOWNFLOW DUCT CONNECTORS

All downflow installations must use a suitable duct connector approved
C by the furnace manufacturer for use with this furnace. The duct connec-
D (Min) 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
Flexible at the end of these instructions for the approved accessory duct con-
Duct Collar nectors.

Field
Fabricated
Ductwork Do not drill
or Screw FURNACE
Upflow this flange
Coil

Upflow WARM AIR PLENUM

Furnace WITH 1” FLANGES

Primary Alternate
Drain Secondary Drain Location FIBERGLASS
Drain
INSULATION

FIGURE 6: PC Series Upflow Coil Installation

FIBERGLASS TAPE
Table 2: Coil Projection Dimensions - PC Series Coils UNDER FLANGE

COIL SIZE DIMENSION “C” INCH

PC18 3-1/2
PC24 4-1/2
PC30, PC32, PC35 4-1/2
PC42, PC43, PC36, PC37 5-1/2 COMBUSTIBLE FLOOR
BASE ACCESSORY
PC48 6-1/2
PC60 9
Dimension “C” should be at least 2/3 of dimension “D”. See Figure 6
FIGURE 8: Combustible Floor Base Accessory
CRITICAL COIL PROJECTION
The coil assembly must be located in the duct such that a minimum dis-
RESIDENTIAL AND MODULAR HOME UPFLOW
tance is maintained between the top of the coil and the top of the duct. RETURN PLENUM CONNECTION
Refer to Table 2. 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
COIL / FURNACE ASSEMBLY - HC SERIES COILS
rear panel of the unit.
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 BOTTOM RETURN AND ATTIC INSTALLATIONS
(blow through) application, the coil should be oriented with the opening Bottom return applications normally pull return air through a base plat-
of the “A” coil closest to the furnace. See Figure 7. form or return air plenum. Be sure the return platform structure or return
air plenum is suitable to support the weight of the furnace.

NOTICE The internal bottom panel must be removed for this application.
Attic installations must meet all minimum clearances to combustibles
Each coil is shipped with an external tie plate that should be used to and have floor support with required service accessibility.
secure the coil to the furnace. It should be installed on the back side
of the coil using the dimpled pilot holes. See Figure 7. HORIZONTAL APPLICATION

Use tie plate

supplied with coil

FIGURE 9: Horizontal Application

Gas Furnace
This furnace may be installed in a horizontal position on either side
Air flo
w as shown above. It must not be installed on its back.

FIGURE 7: Horizontal Left or Right application (Right Shown)

Johnson Controls Unitary Products 7

437642-UIM-C-0210

TTIC INSTALLATION SUSPENDED FURNACE / CRAWL SPACE

INSTALLATION
Line contact only permissible Supply
between lines formed by the Air
The furnace can be hung from floor joists or installed on suitable blocks
Vent (Maintain or pads. Blocks or pad installations shall provide adequate height to
intersection of furnace top
required
and two sides and building ensure that the unit will not be subject to water damage.
clearances to
joists, studs or framing Units may also be suspended from rafters or floor joists using rods, pipe
combustibles)
Filter rack angle supports or straps. In all cases, the furnace should be supported
must be a minimum Sheet metal in
front of furnace with rods, straps, or angle supports at three locations to properly sup-
distance Gas Piping
combustion air port the furnace. Place one support at the supply end of the furnace,
of 18” (45.7 cm) 12”
from the Openings is one support located approximately in the center of the furnace near the
furnace Recommended blower shelf, and the third support should be at the return end of the fur-
12” nace. Maintain a 6” (15.2 cm) minimum clearance between the front of
30” MIN. the furnace and the support rods or straps.
Work Area
All six suspension points must be level to ensure proper and quiet fur-
Return nace operation. When suspending the furnace, use a secure platform
Air Sediment constructed of plywood or other building materials secured to the floor
Trap or ceiling joists. Refer to Figure 11 for details and additional information.

FIGURE 10: Typical Attic Installation

This appliance is certified for line contact when the furnace is installed
in the horizontal left or right position. The line contact is only permissible
between lines that are formed by the intersection of the top and two
sides of the furnace and the building joists, studs or framing. This line Support
may be in contact with combustible material. Refer to Figure 10. Rod

Support
When a furnace is installed in an attic or other insulated space, Angle (x3)
keep all insulating materials at least 12 inches (30.5 cm) away from Maintain 6” minimum
furnace and burner combustion air openings. clearance between support
rods and front of furnace

FIGURE 11: Typical Suspended Furnace / Crawl Space Installation

During installation, doors should remain on the furnace when

moving or lifting.
During installation, doors should remain on the furnace when
When moving or handling this furnace prior to installation, always leave
moving or lifting.
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 When moving or handling this furnace prior to installation it is recom-
the furnace rather than lifting by the cabinet flanges at the return air mended to leave the doors on the furnace to provide support and to
openings (bottom or sides) or supply air opening. prevent damage or warping of the cabinet. When lifting the furnace,
It is acceptable to use the primary heat exchanger tubes as a lifting support the ends of the furnace rather than lifting by the cabinet flanges
point provided that the tubes are lifted at the front of the heat exchang- at the return air openings (bottom or sides) or supply air opening.
ers where attached to the vestibule panel. Do not use the top return It is acceptable to use the primary heat exchanger tubes as a lifting
bend of the heat exchangers as lifting points as the tubes may shift out point provided that the tubes are lifted at the front of the heat exchang-
of position or their location brackets/baffles. 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.

8 Johnson Controls Unitary Products

 437642-UIM-C-0210

LEFT SIDE Vent Connection FRONT RIGHT SIDE

Electrical
Outlet Entry
Vent
Electrical Connection
Entry Outlet
Gas Pipe
Gas Pipe Entry
Entry 33”
23”
Thermostat
Thermostat
Wiring
Wiring
14”

28.5” A 1.5” 1”
29.5”
4” Diameter
.5” 24.38” Vent Connection .5”
Outlet
.5”

B B
C

.5” 20” 24.25”

SUPPLY END RETURN END

FIGURE 12: Dimensions

Table 3: Cabinet and Duct Dimensions

Approximate
BTUH (kW) Nominal Cabinet Cabinet Dimensions (Inches)
Operating Weights
Input 3/min) Size
CFM (m
A A (cm) B B (cm) C C (cm) Lbs
60 (17.6) 1200 (34.0) A 14 1/2 36.8 13 3/8 34.0 10.3 26.2 94
80 (23.4) 1200 (34.0) B 17 1/2 44.4 16 3/8 41.6 11.8 29.9 103
80 (23.4) 1600 (45.3) C 21 53.3 19 7/8 50.5 13.6 34.5 114
100 (29.3) 1600 (45.3) C 21 53.3 19 7/8 50.5 13.6 34.5 118
100 (29.3) 2000 (56.6) C 21 53.3 19 7/8 50.5 13.6 34.5 122
120 (35.1) 2000 (56.6) C 21 53.3 19 7/8 50.5 15.8 40.1 129

SECTION III: FILTERS SIDE RETURN

Locate the “L” shaped corner locators. These indicate the size of the cut-
FILTER INSTALLATION
out to be made in the furnace side panel. Refer to Figure 13.
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 Front of
attempt to install filters inside the furnace. Furnace

Side of
NOTICE Furnace
Single side return above 1800 CFM is approved as long as the filter
velocity does not exceed filter manufacturer’s recommendation. Corner
Markings
Table 4: Recommended Filter Sizes (High Velocity 600 FPM)
FIGURE 13: Side Return Cutout Markings
CFM Cabinet Side Bottom
Install the side filter rack following the instructions provided with that
(m³/min) Size (in) (in)
accessory. If a filter(s) is provided at another location in the return air
1200 (34.0) A 16 x 25 14 x 25 system, the ductwork may be directly attached to the furnace side
1200 (34.0) B 16 x 25 16 x 25 panel.
1600 (45.3) C 16 x 25 20 x 25
2000 (56.6) C (2) 16 x 25 20 x 25
1. Air velocity through throwaway type filters may not exceed 300 feet per min- Some accessories such as electronic air cleaners and pleated
ute (91.4 m/min). All velocities over this require the use of high velocity fil- media may require a larger side opening. Follow the instructions
ters.
2. Do not exceed 1800 CFM using a single side return and a 16x25 filter. For
supplied with that accessory for side opening requirements. Do not
CFM greater than 1800, you may use two side returns or one side and the cut the opening larger than the dimensions shown in Figure 12.
bottom or one return with a transition to allow use of a 20x25 filter.

Johnson Controls Unitary Products 9

437642-UIM-C-0210

HORIZONTAL APPLICATION
Outlet
Horizontal Filters Pressure Vent Port
Port
Inlet Outlet
FF
Wrench O
All filters and mounting provision must be field supplied. All installa- Boss
tions must have a filter installed. Inlet N
O Main Regulator
Pressure Adjustment
Any branch duct (rectangular or round duct) attached to the plenum Port On/Off Switch
must attach to the vertical plenum before the filter. Use of straps and/or (Shown in ON position)
supports is required to support the weight of the external filter box.
FIGURE 14: Gas Valve
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 Plan your gas supply before determining the correct gas pipe entry.
the vertical plenum above the filter height. Use 90-degree service elbow(s), or short nipples and conventional
90-degree elbow(s) to enter through the cabinent access holes.
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 GAS PIPING INSTALLATION
of the duct in a return filter grille(s). The use of straps and/or supports is
Properly sized wrought iron, approved flexible or steel pipe must be
required to support the weight of the external filter box.
used when making gas connections to the unit. If local codes allow the
SECTION IV: GAS PIPING 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
GAS SAFETY
appliance.
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
An overpressure protection device, such as a pressure regulator, approved for this furnace - only use those approved gases. The instal-
must be installed in the gas piping system upstream of the furnace lation of a drip leg and ground union is required. Refer to Figure 15.
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.

NOTE: Ground Union maybe installed inside or outside unit.

To Gas
To Gas To Gas External Supply Ground
To Gas External Union
Supply Supply Supply Manual
Manual Gas
Shut-off Valve To Gas
Shut-off Valve Supply
Valve
Ground Ground Drip Leg
Union Union

Ground External
Union Gas Gas Manual
Pipe Valve Shut-off
Valve
Gas
Drip Valve Drip
Drip Leg Drip Leg
Leg Leg Gas Pipe To Gas
Supply
Upflow Downflow Horizontal Ground
Union
Configuration Configuration Configuration Drip Leg

FIGURE 15: Gas Piping

An accessible manual shutoff valve must be installed upstream of The gas valve body is a very thin casting that cannot take any
the furnace gas controls and within 6 feet (1.8 m) of the furnace. 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-
The furnace must be isolated from the gas supply piping system by gon hub located on the gas inlet side of the valve. Placing a wrench
closing its individual external manual shutoff valve during any pressure to the body of the gas valve will damage the valve causing improper
testing of the gas supply piping system at pressures equal to or less operation and/or the valve to leak.
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 12.

10 Johnson Controls Unitary Products

 437642-UIM-C-0210

GAS ORIFICE CONVERSION FOR PROPANE (LP) HIGH ALTITUDE GAS ORIFICE CONVERSION
This furnace is constructed at the factory for natural gas-fired operation, 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- at 0 – 5,000 feet (0 – 1,524 m) above sea level.
tory-supplied LP conversion kit. Follow the instructions supplied with The manifold pressure must be changed in order to maintain proper
the LP kit. and safe operation when the furnace is installed in a location where the
altitude is greater than 5,000 feet (1,524 m) above sea level. Refer to
Table 5 for proper manifold pressure settings.

LoNOx furnaces requiring propane (LP) gas must have the LoNOx HIGH ALTITUDE PRESSURE SWITCH CONVERSION
screens removed prior to installation and operation. See propane For installation where the altitude is less than 5,000 feet (1,524 m), it is
instructions. not required that the pressure switch be changed unless you are in an
area subject to low pressure inversions.

Table 5: Nominal Manifold Pressure

Manifold Pressures (in w.c.) Manifold Pressures (kpa)

Altitude (feet) Altitude (m)
0-7999 8000-8999 9000-9999 0-2437 2438-2742 2743-3048
800 3.5 3.5 3.5 29.8 0.87 0.87 0.87
850 3.5 3.5 3.5 31.7 0.87 0.87 0.87
Gas Heating Value

Gas Heating Value

900 3.5 3.5 3.5 33.5 0.87 0.87 0.87
(BTU/cu ft.)

(MJ/cu m)
950 3.5 3.5 3.3 35.4 0.87 0.87 0.81
1000 3.5 3.2 2.9 37.3 0.87 0.80 0.73
1050 3.5 2.9 2.7 39.1 0.87 0.73 0.67
1100 3.2 2.7 2.4 41.0 0.80 0.66 0.61
2500 (LP) 9.8 8.2 7.5 93.2 (LP) 2.44 2.03 1.86

PROPANE AND HIGH ALTITUDE CONVERSION KITS

It is very important to choose the correct kit and/or gas orifices for the altitude and the type of gas for which the furnace is being installed.
Only use natural gas in furnaces designed for natural gas. Only use propane (LP) gas for furnaces that have been properly converted to use pro-
pane (LP) gas. Do not use this furnace with butane gas.
Incorrect gas orifices or a furnace that has been improperly converted will create an extremely dangerous condition resulting in premature heat
exchanger failure, excessive sooting, high levels of carbon monoxide, personal injury, property damage, a fire hazard and/or death.
High altitude and propane (LP) conversions are required in order for the appliance to satisfactory meet the application.
An authorized distributor or dealer must make all gas conversions.
In Canada, a certified conversion station or other qualified agency, using factory specified and/or approved parts, must perform the conversion.
The installer must take every precaution to insure that the furnace has been converted to the proper gas orifice size when the furnace is installed.
Do not attempt to drill out any orifices 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 Use copper conductors only.
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.
The residential supply must have a bonded neutral.

Table 6: Ratings & Physical / Electrical Data

Nominal Air Temp. Max. Outlet Max Min. wire Size

Input Output Blower Blower Total Unit
Airflow AFUE Rise Air Temp Over-Current (awg) @ 75 ft
Size Amps
MBH kW MBH kW CFM m3/min °F °C °F °C HP Amps Protect one way
60 17.6 48 14.1 1200 34.0 80.0 30-60 17-33 170 76.7 1/2 6.8 11 x 8 15 9.3 14
80 23.5 64 18.8 1200 34.0 80.0 35-65 19-36 165 73.9 1/2 6.8 11 x 8 15 9.3 14
80 23.5 64 18.8 1600 45.3 80.0 25-55 14-31 155 68.3 1/2 6.8 11 x 10 15 9.3 14
100 29.3 80 23.4 1600 45.3 80.0 35-65 19-36 165 73.9 1/2 6.8 11 x 10 15 9.3 14
100 29.3 80 23.4 2000 56.6 80.0 25-55 14-31 155 68.3 3/4 8.4 11 x 11 15 10.9 14
120 33.7 96 26.9 2000 56.6 80.0 35-65 19-36 165 73.9 3/4 8.4 11 x 11 15 10.9 14
Annual Fuel Utilization Efficiency (AFUE) numbers are determined in accordance with DOE Test procedures.
Wire size and over current protection must comply with the National Electrical Code (NFPA-70-latest edition) and all local codes.
The furnace shall be installed so that the electrical components are protected from water.

Johnson Controls Unitary Products 11

437642-UIM-C-0210

SUPPLY VOLTAGE CONNECTIONS

Some electronic thermostats do not have adjustable heat anticipa-

tors. They should be set to six cycles per hour. Follow the thermo-
Junction stat manufacturer's instructions.
Box
Connect ground The 24-volt, 40 VA transformer is sized for the furnace components
lead to screw only, and should not be connected to power auxiliary devices such as
Electrical Entry humidifiers, air cleaners, etc. The transformer may provide power for an
L1-Hot BLK air conditioning unit contactor.
Neutral WHT
ACCESSORY CONNECTIONS
The furnace control will allow power-switching control of various acces-
sories.

ELECTRONIC AIR CLEANER CONNECTION

Two 1/4” (6.4 mm) spade terminals (EAC and NEUTRAL) for electronic
FIGURE 16: Electrical Wiring air cleaner connections are located on the control board. The terminals
1. Provide a power supply separate from all other circuits. Install provide 115VAC (1.0 Amp maximum) during circulating blower opera-
overcurrent protection and disconnect switch per local/national tion.
electrical codes. The switch should be close to the unit for conve- HUMIDIFIER CONNECTION
nience in servicing. With the disconnect or fused switch in the OFF
position, check all wiring against the unit wiring label. Refer to the Two 1/4” (6.4 mm) spade terminals (HUM and NEUTRAL) for humidifier
wiring diagram in this instruction. connections are located on the control board. The terminals provide
115VAC (1.0 Amp maximum) during heating system operation.
2. Remove the screws retaining the wiring box cover. Route the
power wiring through the opening in the unit into the junction box A mounting hole is provided on the control panel next to the furnace
with a conduit connector or other proper connection. In the junc- control board for mounting a humidifier transformer if required.
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 SECTION VI: VENT SYSTEM
the blower compartment door or the wiring schematic in this sec-
tion. The black furnace lead must be connected to the L1 (hot) VENT CONNECTIONS
wire from the power supply. The white furnace screw must be con- All models are provided with a flue transition that is sized for 4” diame-
nected to neutral. Connect the power supply ground to the green ter vent connections. If a larger size vent connector is required, that
screw (equipment ground) An alternate wiring method is to use a connection must be installed external to the furnace. Figure 17 shows
field provided 2” (5.1 cm) x 4” (10.1 cm) box and cover on the out- the furnace as it is shipped from the factory. To convert to a horizontal
side of the furnace. Route the furnace leads into the box using a or downflow position, remove the four screws that secure the inducer
protective bushing where the wires pass through the furnace assembly and rotate 90° being careful not to damage the gasket. Rein-
panel. After making the wiring connections replace the wiring box
stall screws. Remove cap from appropriate vent outlet location on the
cover and screws. Refer to Figure 16.
cabinet, cut insulation in cabinet to same size as the hole provided and
3. The furnace's control system requires correct polarity of the power reinstall cap in the hole in the top panel.
supply and a proper ground connection. Refer to Figure 16

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

The power connection leads and wiring box may be relocated to the furnace must be installed on a coil cabinet or subbase to allow com-
left side of the furnace. Remove the screws and cut wire tie holding bustion air to enter the burner compartment.
excess wiring. Reposition on the left side of the furnace and fasten
using holes provided.
COMBUSTION AIR INDUCER
LOW VOLTAGE CONTROL WIRING CONNECTIONS 90° Mounting Screw 90°
(Remove)
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 Figure 18 or 19. Electronic Pressure Switch
thermostats may require the common wire to be connected. Apply Tube Routing Flue Transition
strain relief to thermostat wires passing through cabinet. If air condition- (Do Not Remove)
ing equipment is installed, use thermostat wiring to connect the Y and C
terminals on the furnace control board to the proper wires on the con- Pressure
densing unit (unit outside). Switch
Mounting Screw
(Remove)
FIGURE 17: Combustion Air Inducer
Set the heat anticipator in the room thermostat to 0.4 amps. Setting
it lower will cause short cycles. Setting it higher will cause the room
temperature to exceed the set points.

12 Johnson Controls Unitary Products

 437642-UIM-C-0210
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.

Single Stage Air Conditioner – Single Stage Furnace with Hi-Efficiency Motor

ID MODELS
TM8X TMLX

THERMOSTAT

SINGLE STAGE SINGLE STAGE

*PP11C70224 AIR
FURNACE
CONDITIONER

SINGLE STAGE SINGLE

SINGLE STAGE
STAGE
FURNACE AIR
AIR CONDITIONER
CONDITIONER

C C
24 – Volt Common 24 – Volt Common

Y Y/Y2 YY
Full Stage Compressor Full Stage Compressor Compressor
Compressor Contactor
RH
R
24 – Volt Hot
24 – Volt Hot
(Heat XFMR)
G G
Fan Fan

W
Full Stage Heat

RC
24 – Volt Hot
(Cool XFMR)

W
Full Stage Heat

HM1 24VAC Humidifier

Humidistat (Optional)

Clipping Jumper W914 for

electric heat on thermostat
is not necessary

FIGURE 18: Thermostat Chart - Single Stage AC with Single Stage Furnaces

Johnson Controls Unitary Products 13

437642-UIM-C-0210

Single Stage Heat Pump – Single Stage Furnace with Hi-Efficiency Motor

ID MODELS OD MODELS
TM8X TMLX E*R* *RHS
E*ZD HP*
E*B* *HGD
THERMOSTAT THERMOSTAT THERMOSTAT

*BP21H50124
SINGLE STAGE SINGLE STAGE
*DN22U00124 *BN21H00124 *DP32H70124 FURNACE HEAT PUMP
*DP21H40124
*DN21H00124

SINGLE STAGE DEMAND DEFROST 1

FURNACE CONTROL

C C C
24 – Volt Common 24 – Volt Common 24 – Volt Common

Y1 Y/Y2 Y
First Stage Compressor Full Stage Compressor Compressor

R R R
24 – Volt Hot 24 – Volt Hot 24 – Volt Hot

G G
Fan Fan

E W W1/66(out)
Emergency Heat Full Stage Heat Heat

W2
N/A N/A Third Stage Heat

O O
Reversing Valve Reversing Valve
Energized in Cool Energized in Cool
L X/L
Malfunction Light Malfunction Light

Y2
Second Stage Compressor

W1 W
Second Stage Aux. Heat Auxiliary Heat

2
External Humidistat
(Optional)
Open on Humidity Rise

24VAC Humidifier
(Optional)

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

2 Part Number: Part Numbers: 1

S1-2HU16700124 SAP = Legacy
67297 = 031-01975

FIGURE 19: Thermostat Chart - Single Stage HP with Single Stage Furnaces

14 Johnson Controls Unitary Products

 437642-UIM-C-0210

CATEGORY 1 - 450 F. MAX. VENT TEMP.

The venting system must be installed in accordance with Section 5.3, COMBUSTION
Air for Combustion and Ventilation, of the National Fuel Gas Code AIR
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.
The furnace shall be connected to any type of B, BW or L vent connec-
tor, and shall be connected to a factory-built or masonry chimney. The
furnace shall not be connected to a chimney flue serving a sepa-
rate appliance designed to burn solid fuel.
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 com-
bustion byproducts could condense causing damage to the appliance
heat exchanger.
This appliance may be common vented with another gas appliance for FIGURE 20: Combustion Airflow Path Through The Furnace Casing to
residential installations as allowed by the codes and standards listed in the Burner Compartment
these instructions.
Non-HUD approved Modular Homes must be vented with an approved
roof jack and may not be common vented with other appliances.

VENTING 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)
Category I venting consists of vertically venting one or more appliances in the area. Operation of a mechanical exhaust, such as an exhaust
in B-vent or masonry chimney (as allowed), using single wall metal pipe fan, kitchen ventilation system, clothes dryer or fireplace may cre-
or B-vent connectors. Type B-vent system extends in a general vertical ate conditions requiring special attention to avoid unsatisfactory
direction and does not contain offsets exceeding 45°. A vent system operation of gas appliances. A venting problem or a lack of supply
having not more than one 60° offset is permitted. air will result in a hazardous condition, which can cause the appli-
ance to soot and generate dangerous levels of CARBON MONOX-
VENTING INTO AN EXISTING CHIMNEY IDE, which can lead to serious injury, property damage and / or
For Category I installations, the furnace shall be connected to a factory death.
built chimney or vent complying with a recognized standard, or a
masonry or concrete chimney lined with a material acceptable to the An unconfined space is not less than 50 cu.ft (1.42 m3) per 1,000 Btu/
authority having jurisdiction. Venting into an unlined masonry chimney hr (0.2928 kW) input rating for all of the appliances installed in that
or concrete chimney is prohibited. area.
Where use of an existing chimney is unavoidable, the following rules Rooms communicating directly with the space containing the appli-
must be followed: ances are considered part of the unconfined space, if doors are fur-
nished with openings or louvers.
1. The masonry chimney must be built and installed in accordance
with nationally recognized building codes or standards and must A confined space is an area with less than 50 cu.ft (1.42 m3) per 1,000
be lined with approved fire clay tile flue liners or other approved Btu/hr (0.2928 kW) input rating for all of the appliances installed in that
liner material that will resist corrosion, softening, or cracking from area. The following must be considered to obtain proper air for combus-
flue gases. THIS FURNACE IS NOT TO BE VENTED INTO AN tion and ventilation in confined spaces.
UNLINED MASONRY CHIMNEY.
Combustion Air Source From Outdoors
2. This furnace must be vented into a fire clay tile lined masonry
chimney only if a source of dilution air is provided, such as by com- The blocking effects of louvers, grilles and screens must be given con-
mon venting with a draft hood equipped water heater. If no source sideration in calculating free area. If the free area of a specific louver or
of dilution air is available, Type B vent must be used, or masonry grille is not known, refer to Table 7, to estimate free area.
chimney vent kit 1CK0603 or 1CK0604 must be used. Refer to the
Table 7: Estimated Free Area
instructions with the kit to properly apply these masonry chimney
kits. Wood or Metal Wood 20-25%*
3. The chimney must extend at least 3 ft (91 cm) above the highest Louvers or Grilles Metal 60-70% *
point where it passes through a roof of a building and at least two 1/4” (0.635 cm)
feet higher than any portion of the building with a horizontal dis- Screens+
mesh or larger 100%
tance of ten feet.
* Do not use less than 1/4” (6.4 mm) mesh
4. The chimney must extend at least 5 ft (1.5 m) above the highest + Free area of louvers and grille varies widely; the installer should follow
equipment draft hood or flue collar. louver or grille manufacturer’s instructions.

FAN-ASSISTED COMBUSTION SYSTEM Dampers, Louvers and Grilles (Canada Only)

This appliance is equipped with an integral mechanical means to either 1. The free area of a supply air opening shall be calculated by sub-
draw products of combustion through the heat exchanger. tracting the blockage area of all fixed louvers grilles or screens
from the gross area of the opening.
Ambient Combustion Air Supply
2. Apertures in a fixed louver, a grille, or screen shall have no dimen-
This type installation will draw the air required for combustion from sion smaller than 1/4” (6.4 mm).
within the space surrounding the appliance and from areas or rooms 3. A manually operated damper or manually adjustable louvers are
adjacent to the space surrounding the appliance. This may be from not permitted for use.
within the space in a non-confined location or it may be brought into the
4. A automatically operated damper or automatically adjustable lou-
furnace area from outdoors through permanent openings or ducts. A
vers shall be interlocked so that the main burner cannot operate
single, properly sized pipe from the furnace vent connector to the out- unless either the damper or the louver is in the fully open position.
doors must be provided. Combustion air is brought into the furnace
through the unit top panel opening.

Johnson Controls Unitary Products 15

437642-UIM-C-0210

Table 9: Free Area

Minimum Free Area Required for Each Opening

When a Category I furnace is removed or replaced, the original BTUH Input Vertical Duct or
Horizontal Duct Round Duct
venting system may no longer be correctly sized to properly vent Rating Opening to Outside
(2,000 BTUH) (4,000 BTUH)
the attached appliances. (4,000 BTUH)
An improperly sized vent system can cause CARBON MONOXIDE 60,000 30 in2 (193 cm2) 15 in2 (97 cm2) 5” (13 cm)
to spill into the living space causing personal injury, and or death. 2
80,000 40 in (258 cm2) 20 in2 (129 cm2) 5” (13 cm)
Table 8: Unconfined Space Minimum Area 100,000 50 in2 (322 cm2) 25 in2 (161 cm2) 6” (15 cm)

Minimum Free Area 120,00060 in2 (387 cm2) 30 in2 (193 cm2) 7” (18 cm)
BTUH Input Rating EXAMPLE: Determining Free Area.
Required for Each Opening
Appliance 1 Appliance 2 Total Input
60,000 60 in2 (387 cm2)
100,000 + 30,000 = (130,000  4,000) = 32.5 Sq. In. Vertical
80,000 80 in2 (516 cm2) Appliance 1 Appliance 2 Total Input
100,000 100 in2 (645 cm2) 100,000 + 30,000 = (130,000  2,000) = 65 Sq. In. Horizontal
120,000 120 in2 (742 cm2)

Gas Gas Gas

Gable Vent Gable Vent Vent
Vent Vent
Ventilated Ventilated
Attic Attic
Optional Top Above
Inlet (a) Insulation Top Above
Insulation

Soffit Outlet
Vent Air (a) Soffit Outlet Outlet
Vent Air (b) Air (a)
Furnace

Gas
Water

Furnace
Furnace

Gas Gas
Heater Water Water
Inlet Heater Inlet Inlet Heater
Ventilated Inlet
Air (b) Air (a) Air (b)
Crawl Space Air (a)

FIGURE 21: Outside and Ambient Combustion Air

Air Supply Openings and Ducts municate directly with the outdoors and shall have a minimum free
1. An opening may be used in lieu of a duct to provide the outside air area of:
supply to an appliance unless otherwise permitted by the authority a. 1 square in per 3000 Btu per hour (6.45 cm3 per 0.879 kW) of
having jurisdiction. The opening shall be located within 12” (30.5 the total input rating of all equipment located in the enclosure.
cm) horizontally from, the burner level of the appliance. Refer to b. Not less than the sum of all vent connectors in the confined
“COMBUSTION AIR SOURCE FROM OUTDOORS and VENT
space.
AND SUPPLY AIR SAFETY CHECK” in these instructions for
additional information and safety check procedure. 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.
2. The duct shall be either metal, or a material meeting the class 1
requirements of CAN4-S110 Standard for Air Ducts. 4. The blocking effects of louvers, grilles and screens must be given
consideration in calculating free area. If the free area of a specific
3. The duct shall be least the same cross-sectional area as the free
louver or grille is not known. Refer to Table 7 to estimate free area.
area of the air supply inlet opening to which it connects.
4. The duct shall terminate within 12” (30.5 cm) above, and within 24” Ventilated Combustion Air
(61 cm) horizontally from, the burner level of the appliance having The ventilated attic space or a crawl space from which the combustion
the largest input. air is taken must comply with the requirements specified in “AIR
5. A square or rectangular shaped duct shall only be used when the SOURCE FROM OUTDOORS” in this instruction or in Section 5.3, Air
required free area of the supply opening is 9 in2 (58.06 cm2) or for Combustion and Ventilation of the National Fuel Gas Code, ANSI
larger. When a square or rectangular duct is used, its small dimen- Z223.1 (latest edition). This type installation requires two properly sized
sion shall not be less than 3” (7.6 cm). pipes. One brings combustion air from a properly ventilated attic space
6. An air inlet supply from outdoors shall be equipped with a means or crawl space and a second pipe that extends from the furnace vent
to prevent the direct entry of rain and wind. Such means shall not connection (top right of unit) to the exterior of the building.
reduce the required free area of the air supply opening.
Vent and Supply (Outside) Air Safety Check Procedure
7. An air supply inlet opening from the outdoors shall be located not
For Category I furnaces, vent installations shall be in accordance with
less than 12” (30.5 cm) above the outside grade level.
Parts 7 and 11 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54,
Combustion Air Source from Outdoors and or Section 7 and Appendix B of the CSA B149.1, Natural Gas and
1. Two permanent openings, one within 12” (30.5 mm) of the top and Propane Installation Codes, the local building codes, furnace and vent
one within 12” (30.5 mm) of bottom of the confined space, Two manufacture's instructions.
permanent openings, shall communicate directly or by means of Multi-story or common venting systems are permitted and must be
ducts with the outdoors, crawl spaces or attic spaces. installed in accordance with the National Fuel Gas Code, ANSI Z223.1/
2. One permanent openings, commencing within 12” (30.5 cm) of the NFPA 54 and / or the CSA B149.1, Natural Gas and Propane Installa-
top of the enclosure shall be permitted where the equipment has tion Codes, local codes, and the manufacture's instructions.
clearances of at least 1” (2.54 cm) from the sides and back and 6”
Vent connectors serving Category I furnaces shall not be connected
(15.24 cm) from the front of the appliance. The opening shall com-
into any portion of mechanical draft systems operating under positive
pressure.

16 Johnson Controls Unitary Products

 437642-UIM-C-0210

Horizontal portions of the venting system shall be supported to prevent It is recommended that you follow the venting safety procedure below.
sagging using hangers or perforated straps and must slope upwards This procedure is designed to detect an inadequate ventilation system
not less than 1/4” per foot (21 mm/m) from the furnace to the vent termi- that can cause the appliances in the area to operate improperly causing
nal. unsafe levels of Carbon Monoxide or an unsafe condition to occur.

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” 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.

SECTION VII: START-UP AND 4. Unplug the igniter from the wire harness. Disconnect the flame
ADJUSTMENTS sensor wires located on top of the air shield. Unplug the gas valve
from the wiring harness.
The initial start-up of the furnace requires the following additional
procedures: 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-
All electrical connections made in the field and in the factory should ing wires.
be checked for proper tightness. 7. With the burner assembly out of the way, simply slide the NOx
screens out of the heat exchanger tubes and discard the screens.
When the gas supply is initially connected to the furnace, the gas piping
8. Replace all components in reverse order. Reconnect all wiring.
may be full of air. In order to purge this air, it is recommended that the
ground union be loosened until the odor of gas is detected. When gas is GAS PIPING LEAK CHECK
detected, immediately retighten the union and check for leaks. Allow
five minutes for any gas to dissipate before continuing with the start-up
procedure. Be sure proper ventilation is available to dilute and carry
away any vented gas.
FIRE OR EXPLOSION HAZARD
NOx SCREEN REMOVAL (Lo-NOx Models Only) Failure to follow the safety warnings exactly could result in serious
injury, death or property damage.
If the furnace is equipped with NOx screens and is to be used with LP
Never test for gas leaks with an open flame. Use a commercially
(propane) gas, the screens must be removed prior to start-up.
available soap solution made specifically for the detection of leaks
1. Make sure that the electrical power to the unit is turned off and that to check all connections. A fire or explosion may result causing
the gas supply is turned off at the shut-off valve. property damage, personal injury or loss of life.
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 Burner ignition may not be satisfactory on first startup due to resid-
panel. Use the wrench boss on the gas valve when removing or ual air in the gas line or until gas manifold pressure is adjusted. The
installing the piping. ignition control will make three attempts to light before locking out.

Johnson Controls Unitary Products 17

437642-UIM-C-0210

It is recommended that when the gas supply is first connected to the CALCULATING THE FURNACE INPUT
furnace, the ground union be loosened until the odor of gas is detected. (NATURAL GAS)
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 start-up procedure. Be sure that proper ventilation is available to NOTICE
dilute and carry away any vented gas. Burner orifices are sized to provide proper input rate using natural
With furnace in operation, check all of the pipe joints, gas valve connec- gas with a heating value of 1030 BTU/Ft3 (38.4 MJ/m3). If the heat-
tions and manual valve connections for leakage using an approved gas ing value of your gas is significantly different, it may be necessary
detector, a non-corrosive leak detection fluid or other leak detection to replace the orifices.
methods. Take appropriate action to stop any leak. If a leak persists,
replace the faulty component.
The furnace and its equipment shut-off valve must be disconnected NOTICE
from the gas supply during any pressure testing of that system at test DO NOT set manifold pressure less than 3.2 in wc or more than 3.8
pressures in excess of 1/2” psig (3.45 kPa). in wc for natural gas at sea level. If manifold pressure is outside this
range, change main burner orifices.
The furnace must be isolated from the gas supply piping system by
closing the equipment shut-off valve during any pressure testing of the
gas supply system.

IGNITION SYSTEM SEQUENCE

DO NOT bottom out gas valve regulator adjusting screw. This can
1. Turn the gas supply ON at external valve and main gas valve.
result in unregulated manifold pressure and result in excess over-
2. Set the thermostat above room temperature to call for heat. fire and heat exchanger failures.
3. System start-up will occur as follows:
a. The induced draft blower motor will start and come up to
speed. Shortly after inducer start-up, the hot surface igniter
will glow for about 17 seconds.
NOTICE
If orifice hole appears damaged or it is suspected to have been
b. After this warm up, the ignition module will energize (open) redrilled, check orifice hole with a numbered drill bit of correct size.
the main gas valve. Never redrill an orifice. A burr-free and sqaurely aligned orifice hole
c. After flame is established, the supply air blower will start in is essential for proper flame characteristics.
about 30 seconds.
Verify natural gas input rate by clocking meter.
1. Turn off all other gas appliances and pilots.
2. Run furnace for a minimum of 3 minutes in heating operation.
Burner ignition may not be satisfactory on first startup due to resi- 3. Measure time (in sec) for gas meter to complete 1 revolution and
dential air in the gas line or until gas manifold pressure is adjusted. note reading. The 2 cubic feet dial provides a more accurate mea-
The ignition control will make 3 attempts to light before locking out. surement of gas flow.
4. Refer to Table 10 for cubic feet of gas per hour.
With furnace in operation, check all of the pipe joints, gas valve connec-
tions and manual valve connections for leakage using an approved gas 5. Multiply cubic feet per hour by heating valve (BTU/cu. ft.) to obtain
detector, a non-corrosive leak detection fluid, or other leak detection input.
methods. Take appropriate steps to stop any leak. If a leak persists, If clocked rate does not match the input rate from the unit nameplate.
replace the component. follow steps in next section to adjust the manifold pressure. Repeat
steps 2 - 5 until correct input is achieved.

Be sure to relight any gas appliances that were turned off at the
start of this input check.

18 Johnson Controls Unitary Products

 437642-UIM-C-0210

Table 10: Gas Rate (CU FT/HR)

Seconds For Size of Test Dial Seconds For Size of Test Dial
1 Revolution 1 Cu Ft 2 Cu Ft 5 Cu Ft 1 Revolution 1 Cu Ft 2 Cu Ft 5 Cu Ft
10 360 720 1800 50 72 144 360
11 327 655 1636 51 71 141 355
12 300 600 1500 52 69 138 346
13 277 555 1385 53 68 136 340
14 257 514 1286 54 67 133 333
15 240 480 1200 55 65 131 327
16 225 450 1125 56 64 129 321
17 212 424 1059 57 63 126 316
18 200 400 1000 58 62 124 310
19 189 379 947 59 61 122 305
20 180 360 900 60 60 120 300
21 171 343 857 62 58 116 290
22 164 327 818 64 56 112 281
23 157 313 783 66 54 109 273
24 150 300 750 68 53 106 265
25 144 288 720 70 51 103 257
26 138 277 692 72 50 100 250
27 133 267 667 74 48 97 243
28 129 257 643 76 47 95 237
29 124 248 621 78 46 92 231
30 120 240 600 80 45 90 225
31 116 232 581 82 44 88 220
32 113 225 563 84 43 86 214
33 109 218 545 86 42 84 209
34 106 212 529 88 41 82 205
35 103 206 514 90 40 80 200
36 100 200 500 92 39 78 196
37 97 195 486 94 38 76 192
38 95 189 474 96 38 75 188
39 92 185 462 98 37 74 184
40 90 180 450 100 36 72 180
41 88 176 439 102 35 71 178
42 86 172 429 104 35 69 173
43 84 167 419 106 34 68 170
44 82 164 409 108 33 67 167
45 80 160 400 110 33 65 164
46 78 157 391 112 32 64 161
47 76 153 383 116 31 62 155
48 75 150 375 120 30 60 150
49 73 147 367

Johnson Controls Unitary Products 19

437642-UIM-C-0210

ADJUSTMENT OF MANIFOLD GAS PRESSURE &

INPUT RATE
Inlet and manifold gas pressure may be measured by connecting the
The cap for the pressure regulator must be removed to gain access
“U” tube manometer to the gas valve with a piece of tubing. Follow the to the adjustment screw. Loosening or tightening the cap does not
appropriate section in the instructions below. Refer to Figure 22 for a adjust the flow of gas.
drawing of the locations of the pressure ports on the gas valve.
Turn gas off at the ball valve or gas cock on gas supply line
before the gas valve. Find the pressure ports on the gas NOTICE
valve marked Out P and In P. The regulated outlet pressures, both low and high, have been cali-
1. The manifold pressure must be taken at the port marked OUT P. brated at the factory. Additional pressure adjustment should not be
2. The gas line pressure must be taken at the port marked IN P. necessary. If adjustment is necessary, set to the following specifica-
tions. After adjustment, check for gas leakage.
3. Using a 3/32” (2.4 mm) Allen wrench, loosen the set screw by turn-
ing it 1 turn counter clockwise. DO NOT REMOVE THE SET 1. Refer to Figure 22 for location of pressure regulator adjustment
SCREW FROM THE PRESSURE PORT. cap and adjustment screws on main gas valve.
Read the inlet gas pressure 2. Turn gas and electrical supplies on and follow the operating
Connect the positive side of the manometer to the IN P Tap on the gas instructions to place the unit back in operation.
valve. Do not connect any tubing to the negative side of the manometer, 3. Adjust manifold pressure by adjusting gas valve regulator screw
as it will reference atmospheric pressure. Refer to Figure 23 for connec- for the appropriate gas per the following:
tion details. Table 12: Nominal Manifold Pressure
1. Turn gas and electrical supplies on and follow the operating
instructions to place the unit back in operation. NOMINAL MANIFOLD PRESSURE

Table 11: Inlet Gas Pressure Range Natural Gas 3.5" w.c. (0.87 kPa)
Propane (LP) Gas 10.0" w.c. (2.488 kPa)
INLET GAS PRESSURE RANGE
Natural Gas Propane (LP)
Minimum* 4.5” w.c. (1.12 kPa) 8.0” w.c. (1.99 kPa) OUTLET VENT PORT
PRESSURE
Maximum 10.5” w.c. (2.61 kPa) 13.0” w.c. (3.24 kPa) PORT
INLET OUTLET
FF
WRENCH O

The inlet gas pressure operating range table specifies what the BOSS
INLET N MAIN REGULATOR
minimum and maximum gas line pressures must be for the furnace O
to operate safely. The gas line pressure MUST BE a minimum of: PRESSURE ADJUSTMENT
PORT ON/OFF SWITCH
• 7” w.c. (1.74 kPA) for Natural Gas (Shown in ON position)
• 11” w.c. (2.74 kPA) for Propane (LP) Gas
in order to obtain the BTU input specified on the rating plate and/or FIGURE 22: Gas Valve
the nominal manifold pressure specified in these instructions and
on the rating plate.

2. Once the correct gas inlet pressure has been established, see
If gas valve regulator is turned in (clockwise), manifold pressure is
Table 11, turn the gas valve to OFF and turn the electrical supply
increased. If screw is turned out (counter clockwise), manifold pres-
switch to OFF; then remove the flexible tubing from the gas valve
sure will decrease.
pressure tap and tighten the pressure tap plug using the 3/32” (2.4
mm) allen wrench. 4. After the manifold pressure has been adjusted, re-calculate the
3. Turn the electrical and gas supplies back on, and with the burners furnace input to make sure you have not exceeded the specified
in operation, check for gas leakage around the gas valve pressure input on the rating plate. Refer to “CALCULATING THE FURNACE
port for leakage using an approved non-corrosive gas leak detec- INPUT (NATURAL GAS)”.
tion fluid, or other non-flammable leak detection methods. 5. Once the correct BTU (kW) input has been established, turn the
Read the manifold gas pressure gas valve to OFF and turn the electrical supply switch to OFF; then
remove the flexible tubing from the gas valve pressure tap and
Connect the positive side of the manometer to the adapter previously
tighten the pressure tap plug using the 3/32” (2.4 mm) Allen
installed in the OUT P Tap on the gas valve. Do not connect any tubing
wrench.
to the negative side of the manometer, as it will reference atmospheric
pressure. Refer to Figure 23 for connection details. 6. Turn the electrical and gas supplies back on, and with the burners
in operation, check for gas leakage around the gas valve pressure
port for leakage using an approved non-corrosive gas leak detec-
tion fluid, or other non-flammable leak detection methods.

20 Johnson Controls Unitary Products

 437642-UIM-C-0210

After about 5 minutes of operation, determine the furnace temperature

MANIFOLD PRESSURE “U” TUBE CONNECTION
rise. Take readings of both the return air and the heated air in the ducts,
OUTLET about six feet (1.83 m) from the furnace where they will not be affected
PRESSURE TAP by radiant heat. Increase the blower speed to decrease the temperature
GAS VALVE 1/4” TUBING rise; decrease the blower speed to increase the rise.
MAINIFOLD All direct-drive blowers have multi-speed motors. The blower motor
FLAME PIPE speed taps are located on the furnace control board in the blower com-
SENSOR
partment. Refer to Figure 24, and the unit-wiring label to change the
blower speed. To use the same speed tap for heating and cooling, the
heat terminal and cool terminal must be connected using a jumper wire
and connected to the desired motor lead. Place all unused motor leads
3.5 IN
WATER on park terminals. Two park terminals are provided.
COLUMN
GAS GAS
BURNERS U-TUBE PRESSURE
MANOMETER SHOWN
Do not energize more than one motor speed at a time or damage to
the motor will result.
FIGURE 23: Reading Gas Pressure
ADJUSTMENT OF FAN CONTROL SETTINGS
ADJUSTMENT OF TEMPERATURE RISE
This furnace is equipped with a time-on/time-off heating fan control. The
fan on delay is fixed at 30 seconds. The fan off delay has 4 settings (60,
90, 120 and 180 seconds). The fan off delay is factory set to 120 sec-
The temperature rise, or temperature difference between the return onds. The fan-off setting must be long enough to adequately cool the
air and the supply (heated) air from the furnace, must be within the furnace, but not so long that cold air is blown into the heated space. The
range shown on the furnace rating plate and within the application fan-off timing may be adjusted by positioning the jumper on two of the
limitations shown in SECTION V. four pins as shown in Figure 24.
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.

DIAGNOSTIC ERROR CODE

RETRIEVAL BUTTON

BLOWER OFF DELAY JUMPER

ELECTRONIC AIR
CLEANER TERMINAL
CONTINUOUS FAN SPEED
JUMPER

HUMIDIFIER TERMINAL

FIGURE 24: Furnace Control Board

Johnson Controls Unitary Products 21

437642-UIM-C-0210

Table 13: Blower Performance CFM - Any Position (without filter) - Bottom Return

Bottom Airflow Data (SCFM)

Models Speed Ext. Static Pressure (in. H2O)
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
High 966 923 874 804 717 566 386 121 NA NA
Medium High 813 782 743 687 605 464 280 118 NA NA
040A08
Medium Low 745 706 667 619 545 413 205 NA NA NA
Low 684 655 614 565 489 342 171 NA NA NA
High 1292 1230 1160 1088 1004 891 760 476 129 129
Medium High 1203 1157 1105 1035 942 846 728 485 133 129
060A10
Medium Low 1043 1010 962 905 823 705 491 305 124 123
Low 869 845 811 772 708 579 438 178 145 125
High 1358 1341 1319 1303 1275 1238 1190 1130 1062 943
Medium High 1097 1083 1075 1064 1042 1024 997 962 906 821
060A12
Medium Low 935 928 920 899 872 840 809 771 731 659
Low 800 779 763 736 711 687 657 622 584 529
High 1329 1307 1285 1247 1195 1143 1091 1027 927 806
Medium High 994 1004 1008 984 970 941 893 839 773 669
080B12
Medium Low 786 790 782 781 761 743 726 685 630 540
Low 655 654 647 629 620 594 560 524 469 399
High 1881 1822 1783 1696 1602 1539 1465 1394 1267 1130
Medium High 1553 1535 1492 1456 1408 1343 1279 1226 1113 1014
080C16
Medium Low 1312 1286 1288 1260 1205 1143 1091 1029 966 841
Low 1169 1166 1128 1098 1069 1032 987 909 835 747
High 2811 2725 2638 2540 2448 2339 2224 2111 1974 1831
Medium High 2234 2233 2147 2092 2042 1974 1907 1820 1705 1575
080C22
Medium Low 1722 1716 1690 1681 1603 1553 1489 1426 1335 1241
Low 1396 1375 1348 1325 1263 1200 1150 1120 1052 965
High 1314 1318 1292 1265 1223 1177 1119 1051 971 890
Medium High 1010 1004 1003 995 992 956 914 857 798 721
100B12
Medium Low 812 805 796 786 777 754 727 685 626 560
Low 661 659 644 623 614 605 568 532 482 399
High 2069 2014 1956 1885 1820 1748 1668 1577 1468 1362
Medium High 1662 1656 1639 1608 1586 1544 1491 1421 1338 1204
100C16
Medium 1368 1371 1377 1376 1367 1334 1295 1250 1188 1104
Low 1016 1014 1018 1030 1012 996 975 944 898 852
High 2893 2774 2687 2589 2478 2376 2255 2120 1978 1824
Medium High 2272 2243 2204 2169 2086 2018 1940 1842 1743 1602
100C20
Medium Low 1765 1752 1737 1718 1674 1619 1561 1493 1437 1312
Low 1425 1380 1409 1378 1307 1274 1226 1180 1113 1025
High 1752 1724 1702 1664 1600 1542 1454 1372 1264 1119
Medium High 1469 1449 1453 1420 1382 1344 1269 1197 1118 1022
120C16
Medium Low 1248 1235 1226 1207 1179 1133 1077 992 922 841
Low 1076 1076 1046 1025 1002 968 927 869 784 707
High 2701 2620 2533 2429 2338 2227 2112 1993 1861 1706
Medium High 2125 2083 2046 1994 1955 1901 1857 1737 1621 1497
120C20
Medium Low 1664 1664 1647 1619 1580 1555 1468 1392 1332 1226
Low 1358 1339 1330 1318 1286 1235 1185 1141 1060 938
High 2823 2714 2613 2507 2399 2282 2170 2042 1908 1761
Medium High 2242 2188 2154 2102 2045 1970 1887 1792 1673 1537
130D20
Medium Low 1805 1791 1738 1725 1675 1623 1567 1487 1394 1256
Low 1425 1427 1403 1335 1324 1280 1236 1176 1103 996
NOTES:
1. Airflow expressed in standard cubic feet per minute (CFM).
2. Motor voltage at 115 V.

22 Johnson Controls Unitary Products

 437642-UIM-C-0210

Table 14: Blower Performance CFM - Any Position (without filter) - Left Side Return

Left Side Airflow Data (SCFM)

Models Speed Ext. Static Pressure (in. H2O)
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
High 994 971 942 899 829 725 419 120 NA NA
Medium High 824 804 777 739 675 489 350 361 NA NA
040A08
Medium Low 757 733 694 659 575 444 399 NA NA NA
Low 707 684 641 604 495 397 282 NA NA NA
High 1371 1323 1251 1169 1086 971 843 521 NA NA
Medium High 1249 1207 1158 1098 1018 921 669 503 NA NA
060A10
Medium Low 1059 1026 997 949 889 793 582 420 NA NA
Low 854 836 809 775 717 576 464 216 NA NA
High 1406 1401 1394 1379 1338 1304 1261 1202 1135 1040
Medium High 1129 1126 1107 1094 1076 1047 1010 966 921 843
060A12
Medium Low 970 947 933 916 890 863 827 789 741 668
Low 834 809 797 768 740 710 677 634 586 534
High 1274 1285 1255 1239 1207 1158 1111 1049 979 830
Medium High 975 974 968 960 948 923 879 823 756 672
080B12
Medium Low 777 771 772 762 752 734 695 651 604 529
Low 647 634 623 610 602 588 552 506 457 381
High 1825 1781 1746 1695 1641 1587 1521 1429 1330 1184
Medium High 1516 1493 1482 1464 1442 1411 1343 1275 1192 1035
080C16
Medium 1294 1297 1271 1238 1187 1120 1083 1028 979 851
Low 1126 1115 1095 1049 1027 996 957 929 840 742
High 2972 2863 2769 2671 2571 2465 2352 2227 2095 1950
Medium High 2173 2146 2103 2082 2036 1966 1904 1827 1738 1621
080C22
Medium Low 1670 1667 1647 1618 1585 1549 1492 1408 1350 1238
Low 1371 1339 1317 1284 1259 1199 1147 1085 1024 928
High 1258 1278 1283 1259 1240 1204 1149 1073 1015 897
Medium High 986 995 1011 1003 962 935 913 861 808 738
100B12
Medium Low 793 786 786 783 780 750 733 702 627 567
Low 667 653 640 629 604 583 558 519 469 427
High 2009 1994 1933 1893 1836 1763 1691 1606 1508 1389
Medium High 1523 1506 1521 1490 1466 1435 1393 1326 1241 1119
100C16
Medium Low 1230 1249 1245 1230 1218 1195 1161 1120 1039 949
Low 1126 1115 1095 1049 1027 996 957 929 840 742
High 2964 2886 2794 2707 2623 2522 2415 2281 2149 2012
Medium High 2192 2178 2150 2109 2098 2007 1956 1888 1795 1671
100C20
Medium Low 1699 1695 1706 1632 1612 1568 1519 1460 1392 1293
Low 1361 1356 1337 1304 1267 1243 1191 1149 1077 994
High 1789 1774 1738 1702 1665 1608 1514 1431 1343 1205
Medium High 1451 1445 1431 1413 1394 1362 1312 1235 1149 1037
120C16
Medium 1202 1210 1266 1252 1226 1191 1082 1028 950 852
Low 1063 1050 1033 1010 1007 982 941 889 845 778
High 2828 2768 2699 2612 2524 2423 2308 2219 2118 1982
Medium High 2085 2073 2042 2029 1967 1896 1893 1816 1717 1635
120C20
Medium Low 1620 1631 1636 1593 1567 1557 1520 1476 1407 1263
Low 1322 1311 1302 1271 1241 1201 1162 1101 1042 979
High 2958 2862 2758 2662 2553 2447 2328 2203 2056 1893
Medium High 2191 2182 2157 2092 2085 1997 1932 1844 1741 1608
130D20
Medium Low 1737 1738 1713 1691 1675 1590 1531 1467 1389 1276
Low 1404 1394 1380 1355 1327 1276 1220 1163 1095 1013
NOTES:
1. Airflow expressed in standard cubic feet per minute (CFM).
2. Return air is through side opposite motor (left side).
3. Motor voltage at 115 V.
4. Airflow through across motor side (right side) may be slightly less than the data shown above.

Johnson Controls Unitary Products 23

437642-UIM-C-0210

SECTION VIII: SAFETY CONTROLS Intermittent Blower - Cooling

On cooling/ heating thermostats with a fan switch, when the fan switch
CONTROL CIRCUIT FUSE
is set in the auto position and the thermostat calls for cooling, a circuit is
A 3-amp fuse is provided on the control circuit board to protect the 24- completed between the R, Y and G terminals. The motor is energized
volt transformer from overload caused by control circuit wiring errors. through the Y1 cool terminal and runs on the speed selected on the
This is an ATO 3, automotive type fuse and is located on the control COOL tap of the CFM Timer board. The fan off setting is fixed at 60
board. seconds for SEER enhancement. The control board can accommodate
BLOWER DOOR SAFETY SWITCH two-stage cooling. When a two-stage cool thermostat is connected to
the Y1 and Y2 terminals on the board, the blower will operate on LOW
COOL speed when Y1 is energized and on HI COOL speed when Y1
and Y2 are energized.

Main power to the unit must still be interrupted at the main power Heating Cycle
disconnect switch before any service or repair work is to be done to When the thermostat switch is set on HEAT and the fan is set on AUTO,
the unit. Do not rely upon the interlock switch as a main power dis- and there is a call for heat, a circuit is completed between terminals R
connect. Blower and burner must never be operated without the and W of the thermostat. When the proper amount of combustion air is
blower panel in place. being provided, the pressure switch will close, the ignition control pro-
vides a 17-second ignitor warm-up period, the gas valve then opens,
This unit is equipped with an electrical interlock switch mounted in the the gas starts to flow, ignition occurs and the flame sensor begins its
burner compartment. This switch interrupts all power at the unit when sensing function. The blower motor will energize 30 seconds after the
the panel covering the blower compartment is removed. gas valve opens, if a flame is detected. Normal furnace operation will
Electrical supply to this unit is dependent upon the panel that covers the continue until the thermostat circuit between R and W is opened, which
blower compartment being in place and properly positioned. causes the ignition system and gas valve to de-energize and the burner
flames to be extinguished. The vent motor will operate for 15 seconds
ROLLOUT SWITCH CONTROLS
and the blower motor will operate for the amount of time set by the fan-
These controls are mounted on the burner assembly. If the temperature off delay jumper located on the control board. See Figure 24. The heat-
in the area surrounding the burner exceeds its set point, the gas valve ing cycle is now complete, and ready for the start of the next heating
is de-energized. The operation of this control indicates a malfunction in cycle.
the combustion air blower, heat exchanger or a blocked vent pipe con-
If the flame is not detected within 7 seconds of the gas valve opening,
nection. Corrective action is required. These are manual reset controls
the gas valve is shut off and a retry operation begins. Also, if the flame
that must be reset before operation can continue.
is lost for 2 seconds during the 10-second stabilization period, the gas
PRESSURE SWITCHES valve is shut off and a retry operation begins. During a retry operation,
the vent motor starts a 15 second inter-purge and the ignitor warm-up
This furnace is supplied with a pressure switch, which monitors the flow
time is extended to 27 seconds. If the flame is established for more than
through the combustion air/vent piping system. This switch de-ener-
10 seconds after ignition during a retry, the control will clear the ignition
gizes the gas valve if any of the following conditions are present.
attempt (retry) counter. If three retries occur during a call for heat, the
1. Blockage of vent piping or terminal. furnace will shut down for one hour. If at the end of the one hour shut
2. Failure of combustion air blower motor. down there is a call for heat, the furnace will initiate a normal start cycle.
If the problem has not been corrected the furnace will again lockout
LIMIT CONTROLS
after three retries.
There is a high temperature limit control located on the furnace vesti-
A momentary loss of gas supply, flame blowout, or a faulty flame probe
bule panel near the gas valve. This is an automatic reset control that
circuit will result in a disruption in the flame and be sensed within 1.0
provides over temperature protection due to reduced airflow. This may
seconds. The gas valve will de-energize and the control will begin a
be caused by:
recycle operation. A normal ignition sequence will begin after a 15 sec-
1. A dirty filter. ond inter-purge. If during the five recycles the gas supply does not
2. If the indoor fan motor should fail. return, or the fault condition is not corrected the ignition control will lock-
3. Too many supply or return registers closed or blocked off. out for 60 minutes.
The control module will lockout if the limit trips 5 consecutive times. If During burner operation, a momentary loss of power for 50 milliseconds
this occurs, control will reset & try ignition again after 1 hour. or longer will de-energize the gas valve. When the power is restored,
the gas valve will remain de-energized and the ignition sequence will
SEQUENCE OF OPERATION immediately restart.
The following describes the sequence of operation of the furnace. Refer
to Owners Manual for component location. Hot Surface Ignition System
Continuous Blower
Cooling/heating thermostats have a fan switch that has an ON and
AUTO position. In the ON position the thermostat circuit is completed HOT SURFACE IGNITION SYSTEM
between terminals R and G. The motor will operate continuously on the Do not attempt to light this furnace by hand (with a match or any
speed selected on the “FAN SPEED” jumper on the main control board. other means). There may be a potential shock hazard from the
components of the hot surface ignition system. The furnace can
only be lit automatically by its hot surface ignition system.

24 Johnson Controls Unitary Products

 437642-UIM-C-0210

TROUBLESHOOTING 2 RED FLASHES: This indicates that the normally open pressure
The following visual checks should be made before troubleshooting: switch contacts are stuck in the closed position. The control confirms
these contacts are open at the beginning of each heat cycle. This would
1. Check to see that the power to the furnace and the ignition control
indicate a faulty pressure switch or miswiring.
module is ON.
2. The manual shut-off valves in the gas line to the furnace must be 3 RED FLASHES: This indicates the normally open pressure switch
open. contact did not close after the inducer was energized. This could be
caused by a number of problems: faulty inducer, blocked vent pipe, bro-
3. Make sure all wiring connections are secure.
ken pressure switch hose or faulty pressure switch.
4. Review the sequence of operation. Start the system by setting the
thermostat above the room temperature. Observe the system’s 4 RED FLASHES: This indicates that the main limit switch has opened
response. Then use the troubleshooting section in this manual to its normally closed contacts. The control will operate the supply air
check the system’s operation. blower and inducer. This condition may be caused by: dirty filter,
improperly sized duct system, incorrect blower speed setting, incorrect
firing rate or faulty blower motor. Also, this fault code could be caused
by a blown fuse located on the control board.
Never bypass any safety control to allow furnace operation. To do 5 RED FLASHES: This fault is indicated if the normally closed contacts
so will allow furnace to operate under potentially hazardous condi- in the rollout switch opens. The rollout control is manually reset. If it has
tions. opened, check for proper combustion air, proper inducer operation, and
Do not try to repair controls. Replace defective controls with UPG primary heat exchanger failure or burner problem. Be sure to reset the
Source 1 Parts. switch and cycle power (24VAC) to the control after correcting the fail-
Never adjust pressure switch to allow furnace operation. ure condition. Also, this fault code could be caused by a blown fuse
located on the control board.
FURNACE CONTROL DIAGNOSTICS
6 RED FLASHES: This indicates that after the unit was operating, the
The furnace has built-in, self-diagnostic capability. If a system problem pressure switch opened 4 times during the call for heat. If the main
occurs, a blinking LED can flash red, green or amber to indicate various blower is in a “Delay on” mode, it will complete it, and any subsequent
conditions. delay off period. The furnace will lock out for one hour and then restart.
The control continuously monitors its own operation and the operation 7 RED FLASHES: This fault code indicates that the flame could not be
of the system. If a failure occurs, the LED will indicate the failure code. If established. This no-light condition occurred 3 times (2 retries) during
the failure is internal to the control, the light will stay on continuously. In the call for heat before locking out. Low gas pressure, faulty gas valve,
this case, the entire control should be replaced, as the control is not dirty or faulty flame sensor, faulty hot surface ignitor or burner problem
field repairable. may cause this. The furnace will lock out for one hour and then restart.
Flash sequence codes 1 through 12 are as follows: LED will turn “on” 8 RED FLASHES: This fault is indicated if the flame is lost 5 times (4
for 1/4 second and “off” for 1/4 second. This pattern will be repeated the recycles) during the heating cycle. This could be caused by low gas
number of times equal to the code. For example, six “ON” flashes pressure, dirty or faulty flame sensor or faulty gas valve. The furnace
equals a number 6 fault code. All flash code sequences are broken by a will lock out for one hour and then restart.
2 second “OFF” period.
9 RED FLASHES: Indicates reversed line voltage polarity or grounding
SLOW GREEN FLASH: Normal operation. problem. Both heating and cooling operations will be affected. Check
SLOW AMBER FLASH: Normal operation with call for heat. polarity at furnace and branch. Check furnace grounding. Check that
RAPID RED FLASH: Twinning error, incorrect 24V phasing. Check flame probe is not shorted to chassis.
twinning wiring. 10 RED FLASHES: Flame sensed with no call for heat. Check gas
RAPID AMBER FLASH: Flame sense current is below 1.5 microamps. valve and gas valve wiring.
Check and clean flame sensor. Check for proper gas flow. Verify that 11 RED FLASHES: This indicates that a primary or auxiliary limit switch
current is greater than 1.5 microamps at flame current test pad. has opened its normally-closed contacts and has remained open for
4 AMBER FLASHES: The control is receiving a “Y” signal from the more than five minutes. This condition is usually caused by a failed
thermostat without a “G” signal, indicating improper thermostat wiring. blower motor or blower wheel. Cycle power (24VAC) to the control to
1 RED FLASH: This indicates that flame was sensed when there was reset the hard lockout condition after correcting the failure condition.
not a call for heat. The control will turn on both the inducer motor and
supply air blower. A gas valve that leaks or is slow closing would typi-
cally cause this fault.

Johnson Controls Unitary Products 25

437642-UIM-C-0210

SECTION IX: REPLACEMENT PARTS LIST

DESCRIPTION DESCRIPTION (Continued)
MOTOR FABRICATED PARTS
MOTOR, DIRECT DRIVE BLOWER BRACKET, BLOWER TRACK (2 Req’d)
BLOWER, COMBUSTION HEAT EXCHANGER ASS’Y
ELECTRICAL MANIFOLD, GAS
CAPACITOR, RUN PAN, BOTTOM
SWITCH, LIMIT PANEL, TOP
CONTROL, FURNACE PANEL, DOOR (2 Req’d)
IGNITER VENT PAN, COMBUSTION (w/Gasket)
SENSOR, FLAME PANEL, BLOCKOFF
SWITCH, PRESSURE LO-NOX SCREEN (L-Models Only)
SWITCH, DOOR MISCELLANEOUS
TRANSFORMER ORIFICE, BURNER (Natural #45)
VALVE, GAS SIGHT GLASS, OVAL (2 Req’d)
CONTROL, TEMPERATURE GASKET, FOAM (Door) (1.5 ft req’d)
AIR MOVING GASKET, INTAKE PAN
HOUSING, BLOWER PLUG, VENT HOLE
HOUSING, BLOWER w/WHEEL BRACKET, DOOR
WHEEL, BLOWER WIRING HARNESS
FABRICATED PARTS FERRULE (3 Req’d)
BAFFLE, FLUE GROMMET (3 Req’d)
BURNER, MAIN GAS MOTOR MOUNT
BRACKET, IGNITER TUBING, SILICON
SHELF, BLOWER DIAGRAM, WIRING
RAIL, BLOWER (2 Req’d) KNOB, QUARTER TURN (4 Req’d)

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

26 Johnson Controls Unitary Products

 437642-UIM-C-0210

SECTION X: WIRING DIAGRAM

FIGURE 25: Wiring Diagram

Johnson Controls Unitary Products 27

Subject to change without notice. Published in U.S.A. 437642-UIM-C-0210
Copyright © 2010 by Johnson Controls, Inc. All rights reserved. Supersedes: 437642-UIM-B-0109

Johnson Controls Unitary Products

5005 York Drive
Norman, OK 73069