INSTALLATION MANUAL

RESIDENTIAL GAS FURNACE

EFFICIENCY

MODELS: TG9S*MP, GG9S*MP RATING

CERTIFIED

ISO 9001
(95.5% AFUE Single Stage Multi-position) Certified Quality
Management System

LIST OF SECTIONS
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 COMBUSTION AIR and VENT SYSTEM . . . . . . . . . . . . . . . . . 22
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . 29
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 NORMAL OPERATION AND DIAGNOSTICS . . . . . . . . . . . . . 35
ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . 37
TWINNING AND STAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 REPLACEMENT PART CONTACT INFORMATION . . . . . . . . 37
CONDENSATE PIPING AND FURNACE WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
VENTING CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . 16

LIST OF FIGURES
Duct Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Typical. Condensate drain, vertical installation . . . . . . . . . . . . . 17
Vertical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Typical. Combustion Pipe Drain Tee . . . . . . . . . . . . . . . . . . . . . 17
Coil Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Upflow Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Horizontal Right Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Downflow Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Horizontal Left Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Horizontal Left Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
PC Series Upflow Coil Installation . . . . . . . . . . . . . . . . . . . . . . . . 7 Horizontal Right Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 21
Horizontal Left or Right application (Right Shown) . . . . . . . . . . . 7 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Combustible Floor Base Accessory . . . . . . . . . . . . . . . . . . . . . . . 7 Home Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Horizontal Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Termination Configuration - 1 Pipe . . . . . . . . . . . . . . . . . . . . . . 25
Typical Attic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Termination Configuration - 2 Pipe . . . . . . . . . . . . . . . . . . . . . . 25
Typical Suspended Furnace / Crawl Space Installation . . . . . . . 8 Termination Configuration - 2 Pipe Basement . . . . . . . . . . . . . 25
Downflow Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Double Horizontal Combustion Air Intake
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 and Vent Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Side Return Cutout Markings . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Double Vertical Combustion Air Intake
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 and Vent Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Direct Vent Air Intake Connection and Vent Connection . . . . . . 26
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Combustion Airflow Path Through The Furnace Casing . . . . . . 26
Thermostat Chart - Single Stage AC with Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . 27
Single Stage PSC Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Attic and Crawl Space Combustion Air Termination . . . . . . . . . 28
Thermostat Chart - Single Stage HP with Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Single Stage PSC Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Typical Twinned Furnace Application . . . . . . . . . . . . . . . . . . . . 15 Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Single Wire Twinning Wiring Diagram . . . . . . . . . . . . . . . . . . . . 16 Furnace Control Event Schedule . . . . . . . . . . . . . . . . . . . . . . . 37
Single Wire Staging Wiring Diagram . . . . . . . . . . . . . . . . . . . . . 16 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

LIST OF TABLES
Unit Clearances to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . 4 Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Coil Projection Dimensions - PC Series Coils . . . . . . . . . . . . . . . 7 Unconfined Space Minimum Area . . . . . . . . . . . . . . . . . . . . . . . 27
Cabinet and Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Recommended Filter Sizes (High Velocity 600 FPM) . . . . . . . . . 9 Gas Rate (CU FT/HR) at Full Input . . . . . . . . . . . . . . . . . . . . . . 30
Nominal Manifold Pressure - High Fire . . . . . . . . . . . . . . . . . . . 11 Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Ratings & Physical / Electrical Data . . . . . . . . . . . . . . . . . . . . . 12 Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Maximum Equivalent Pipe Length . . . . . . . . . . . . . . . . . . . . . . . 22 Blower Performance CFM - Any Position
Elbow Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 (without filter) - Bottom Return . . . . . . . . . . . . . . . . . . . . . . . . . 33
Equivalent Length of Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Blower Performance CFM - Any Position
Combustion Air Intake and Vent Connection (without filter) - Left Side Return . . . . . . . . . . . . . . . . . . . . . . . . 34
Size at Furnace (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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These high efficiency, compact units employ induced combustion, reli- 8. When a furnace is installed so that supply ducts carry air circulated
able hot surface ignition and high heat transfer aluminized tubular heat by the furnace to areas outside the space containing the furnace,
exchangers. The units are factory shipped for installation in upflow or the return air shall also be handled by duct(s) sealed to the fur-
horizontal applications and may be converted for downflow applica- nace casing and terminating outside the space containing the fur-
tions. nace.
These furnaces are designed for residential installation in a basement, 9. It is permitted to use the furnace for heating of buildings or struc-
tures under construction where the application and use must com-
closet, alcove, attic, recreation room or garage and are also ideal for
ply with all manufacturer’s installation instructions including:
commercial applications. All units are factory assembled, wired and
tested to assure safe dependable and economical installation and oper- • Proper vent installation;
ation. • Furnace operating under thermostatic control;
• Return air duct sealed to the furnace;
These units are Category IV listed and may not be common vented with
• Air filters in place;
another gas appliance as allowed by the National Fuel Gas Code.
• Set furnace input rate and temperature rise per rating plate
SECTION I: SAFETY marking;
• Means for providing outdoor air required for combustion;
This is a safety alert symbol. When you see this symbol on • Return air temperature maintained between 55ºF (13ºC) and
labels or in manuals, be alert to the potential for personal 80ºF (27ºC);
injury. • The air filter must be replaced upon substantial completion of
the construction process;
Understand and pay particular attention to the signal words DANGER,
WARNING, or CAUTION. • Clean furnace, duct work and components upon substantial
completion of the construction process, and verify furnace-
DANGER indicates an imminently hazardous situation, which, if not operating conditions including ignition, input rate, temperature
avoided, will result in death or serious injury. rise and venting, according to the manufacturer’s instructions.
WARNING indicates a potentially hazardous situation, which, if not 10. When installed in a non-HUD-Approved Modular Home or building
avoided, could result in death or serious injury. constructed on-site, combustion air shall not be supplied from
occupied spaces.
CAUTION indicates a potentially hazardous situation, which, if not
11. The size of the unit should be based on an acceptable heat loss
avoided may result in minor or moderate injury. It is also used to
calculation for the structure. ACCA, Manual J or other approved
alert against unsafe practices and hazards involving only property dam-
methods may be used.
age.
12. When moving or handling this furnace prior to installation, always
leave the doors on the furnace to provide support and to prevent
damage or warping of the cabinet. When lifting the furnace by the
cabinet, support the ends of the furnace rather than lifting by the
Improper installation may create a condition where the operation of cabinet flanges at the return air openings (bottom or sides) or sup-
the product could cause personal injury or property damage. ply air opening.
Improper installation, adjustment, alteration, service or mainte- 13. When lifting the furnace, it is acceptable to use the primary heat
nance can cause injury or property damage. Failure to carefully exchanger tubes as a lifting point provided that the tubes are lifted
read and follow all instructions in this manual can result in fur- at the front of the heat exchangers where attached to the vestibule
nace malfunction, death, personal injury and/or property dam- panel. Do not use the top return bend of the heat exchangers as
age. Only a qualified contractor, installer or service agency should
lifting points as the tubes may shift out of position or their location
install this product.
brackets/baffles.
SPECIFIC SAFETY RULES AND PRECAUTIONS
1. Only Natural gas or Propane (LP) gas are approved for use with
this furnace.
During installation, doors should remain on the furnace when
2. Install this furnace only in a location and position as specified in moving or lifting.
these instructions.
3. A gas-fired furnace for installation in a residential garage must be SAFETY REQUIREMENTS
installed as specified in these instructions.
4. Provide adequate combustion and ventilation air to the furnace
space as specified in these instructions.
5. Combustion products must be discharged outdoors. Connect this This product must be installed in strict compliance with the installa-
furnace to an approved vent system only, as specified in "COM- tion instructions and any applicable local, state, and national codes
BUSTION AIR and VENT SYSTEM" of these instructions. including, but not limited to building, electrical, and mechanical
6. Test for gas leaks as specified in these instructions. codes.

• Refer to the unit rating plate for the furnace model number, and
then see the dimensions page of this instruction for return air ple-
num dimensions in Figure 13. The plenum must be installed
FIRE OR EXPLOSION HAZARD according to the instructions.
Failure to follow the safety warnings exactly could result in serious • Provide clearances from combustible materials as listed under
injury, death or property damage. Clearances to Combustibles.
Never test for gas leaks with an open flame. Use a commercially • Provide clearances for servicing ensuring that service access is
available soap solution made specifically for detection of leaks to allowed for both the burners and blower.
check all connections. A fire or explosion may result causing prop-
• These models ARE NOT CSA listed or approved for installation
erty damage, personal injury or loss of life.
into a HUD Approved Modular Home or a Manufactured
7. Always install the furnace to operate within the furnace’s intended (Mobile) Home.
temperature rise range. Only connect the furnace to a duct system • This furnace is not approved for installation in trailers or recre-
which has an external static pressure within the allowable range, ational vehicles.
as specified on the furnace rating plate.

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• Furnaces for installation on combustible flooring shall not be When outdoor air is used for combustion, the combustion air intake duct
installed directly on carpeting, tile or other combustible material system termination must be located external to the building and in an
other than wood flooring. area where there will be no exposure to the substances listed above.
• Check the rating plate and power supply to be sure that the elec-
trical characteristics match. All models use nominal 115 VAC, 1 CODES AND STANDARDS
Phase, 60-Hz power supply. DO NOT CONNECT THIS APPLI- Follow all national, local codes and standards in addition to this installa-
ANCE TO A 50-Hz POWER SUPPLY OR A VOLTAGE ABOVE tion manual. The installation must comply with regulations of the serv-
130 VOLTS. ing gas supplier, local building, heating, plumbing, and other codes. In
• Furnace shall be installed so the electrical components are pro- absence of local codes, the installation must comply with the national
tected from water. codes listed below and all authorities having jurisdiction.
• Installing and servicing heating equipment can be hazardous due
In the United States and Canada, follow all codes and standards for the
to the electrical components and the gas fired components. Only
following, using the latest edition available:
trained and qualified personnel should install, repair, or service
gas heating equipment. Untrained service personnel can perform STEP 1 - Safety
basic maintenance functions such as cleaning and replacing the • US: National Fuel Gas Code (NFGC) NFPA 54/ANSI Z223.1 and
air filters. When working on heating equipment, observe precau- the Installation Standards, Warm Air Heating and Air Conditioning
tions in the manuals and on the labels attached to the unit and Systems ANSI/NFPA 90B
other safety precautions that may apply. • CANADA: CAN/CGA-B149.1 National Standard of Canada. Natu-
COMBUSTION AIR QUALITY ral Gas and Propane Installation Codes (NSCNGPIC)
(LIST OF CONTAMINANTS) STEP 2 - General Installation
• US: Current edition of the NFGC and NFPA 90B. For copies, con-
tact the
National Fire Protection Association Inc.
The furnace area must not be used as a broom closet or for any Batterymarch Park
other storage purposes, as a fire hazard may be created. Never Quincy, MA 02269
store items such as the following on, near or in contact with the fur- or for only the NFGC, contact the
nace. American Gas Association,
1. Spray or aerosol cans, rags, brooms, dust mops, vacuum 400 N. Capital, N.W.
cleaners or other cleaning tools. Washington DC 20001
2. Soap powders, bleaches, waxes or other cleaning com-
or www.NFPA.org
pounds; plastic items or containers; gasoline, kerosene, ciga-
rette lighter fluid, dry cleaning fluids or other volatile fluid. • CANADA: NSCNGPIC. For a copy contact:
Standard Sales, CSA International
3. Paint thinners and other painting compounds.
178 Rexdale Boulevard
4. Paper bags, boxes or other paper products
Etobicoke, (Toronto) Ontario Canada M9W 1RS
Never operate the furnace with the blower door removed. To
do so could result in serious personal injury and/or equipment STEP 3 - Combustion and Ventilation Air
damage. • US: Section 5.3 of the NFGC, air for Combustion and Ventilation
• CANADA: Part 7 of NSCNGPIC, Venting Systems and Air Supply
The furnace requires OUTDOOR AIR for combustion when the furnace for Appliances
is located in any of the following environments. STEP 4 - Duct Systems
• Buildings with indoor pools • US and CANADA: Air Conditioning Contractors Association
• Chemical exposure (ACCA) Manual D, Sheet Metal and Air Conditioning Contractors
• Commercial buildings Association National Association (SMACNA), or American Soci-
• Furnaces installed in hobby or craft rooms ety of Heating, Refrigeration, and Air Conditioning Engineers
• Furnaces installed in laundry rooms (ASHRAE) 1997 Fundamentals Handbook Chapter 32.
• Furnaces installed near chemical storage areas STEP 5 - Acoustical Lining and Fibrous Glass Duct
• Restricted Environments • US and CANADA: Current edition of SMACNA and NFPA 90B as
The furnace requires OUTDOOR AIR for combustion when the furnace tested by UL Standard 181 for Class I Rigid Air Ducts
is located in an area where the furnace is being exposed to the follow- STEP 6 - Gas Piping and Gas Pipe Pressure Testing
ing substances and / or chemicals. • US: NFGC; chapters 2, 3, 4, & 9 and National Plumbing Codes
• Antistatic fabric softeners for clothes dryers • CANADA: NSCNGPIC Part 5
• Carbon tetrachloride STEP 7 - Electrical Connections
• Cements and glues • US: National Electrical Code (NEC) ANSI/NFPA 70
• Chlorine based swimming pool chemicals • CANADA: Canadian Electrical Code CSA C22.1
• Chlorinated waxes and cleaners
These instructions cover minimum requirements and conform to exist-
• Cleaning solvents (such as perchloroethylene)
ing national standards and safety codes. In some instances these
• De-icing salts or chemicals instructions exceed certain local codes and ordinances, especially
• Halogen type refrigerants those who have not kept up with changing residential and non-HUD
• Hydrochloric acid modular home construction practices. These instructions are required
• Masonry acid washing materials as a minimum for a safe installation.
• Permanent wave solutions
• Printing inks, paint removers, varnishes, etc.
• Water softening chemicals

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4. Where it will not interfere with proper air circulation in the confined
FOR FURNACES INSTALLED IN THE COMMON- space.
WEALTH OF MASSACHUSETTS ONLY 5. Where the outdoor vent terminal will not be blocked or restricted.
For all side wall horizontally vented gas fueled equipment installed in Refer to “VENT CLEARANCES” located in SECTION VII of these
every dwelling, building or structure used in whole or in part for resi- instructions. These minimum clearances must be maintained in
dential purposes, including those owned or operated by the Com- the installation.
monwealth and where the side wall exhaust vent termination is less 6. Where the unit will be installed in a level position with no more than
than seven (7) feet above finished grade in the area of the venting, 1/4” (6.4 mm) slope side-to-side and front-to-back to provide
including but not limited to decks and porches, the following require- proper condensate drainage.
ments shall be satisfied: Installation in freezing temperatures:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At 1. Furnace shall be installed in an area where ventilation facilities
the time of installation of the side wall horizontal vented gas provide for safe limits of ambient temperature under normal oper-
fueled equipment, the installing plumber or gasfitter shall ating conditions. Ambient temperatures must not fall below 32°F
observe that a hard wired carbon monoxide detector with an (0°C) unless the condensate system is protected from freezing.
alarm and battery back-up is installed on the floor level where
the gas equipment is to be installed. In addition, the installing
plumber or gasfitter shall observe that a battery operated or
hard wired carbon monoxide detector with an alarm is installed Improper installation in an ambient below 32ºF (0° C) could create a
on each additional level of the dwelling, building or structure hazard, resulting in damage, injury or death.
served by the side wall horizontal vented gas fueled equipment.
2. Do not allow return air temperature to be below 55ºF (13°C) for
It shall be the responsibility of the property owner to secure the
extended periods. To do so may cause condensation to occur in
services of qualified licensed professionals for the installation of
the main heat exchanger, leading to premature heat exchanger
hard wired carbon monoxide detectors
failure.
a. In the event that the side wall horizontally vented gas
3. If this furnace is installed in an unconditioned space and an
fueled equipment is installed in a crawl space or an attic, extended power failure occurs, there will be potential damage to
the hard wired carbon monoxide detector with alarm and the internal components. Following a power failure situation, do
battery back-up may be installed on the next adjacent floor not operate the unit until inspection and repairs are performed.
level.
b. In the event that the requirements of this subdivision can
not be met at the time of completion of installation, the
owner shall have a period of thirty (30) days to comply with Liquid anti-freeze will cause damage to internal plastic parts of this
the above requirements; provided, however, that during furnace. DO NOT attempt to winterize the furnace using liquid
said thirty (30) day period, a battery operated carbon mon- anti-freeze.
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
2034 listed and IAS certified. 1. Twenty-four (24) inches (61 cm) between the front of the furnace
and an adjacent wall or another appliance, when access is
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
height of eight (8) feet above grade directly in line with the 2. Eighteen (18) inches (46 cm) at the side where access is required
exhaust vent terminal for the horizontally vented gas fueled for passage to the front when servicing or for inspection or replace-
heating appliance or equipment. The sign shall read, in print ment of flue/vent connections.
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
installation unless, upon inspection, the inspector observes car- A gas-fired furnace for installation in a residential garage must be
bon monoxide detectors and signage installed in accordance installed so the burner(s) and the ignition source are located not less
with the provisions of 248 CMR 5.08(2)(a)1 through 4. than 18” (46 cm) above the floor, and the furnace must be located or
protected to avoid physical damage by vehicles.

INSPECTION Table 1: Unit Clearances to Combustibles

As soon as a unit is received, it should be inspected for possible dam- Application Upflow Downflow Horizontal
age during transit. If damage is evident, the extent of the damage Top 1" 0" 0"
should be noted on the carrier’s freight bill. A separate request for
Vent 0" 0" 0"
inspection by the carrier’s agent should be made in writing. Also, before
installation, the unit should be checked for screws or bolts which may Rear 0" 0" 0"
have loosened in transit. There are no shipping or spacer brackets Side 0" 0" 1"
which need to be removed from the interior of this unit. Front* 0" 0" 0"
FURNACE LOCATION AND CLEARANCES Floor Combustible Combustible1 Combustible
The furnace shall be located using the following guidelines: Closet Yes Yes Yes
1. Where a minimum amount of air intake/vent piping and elbows will Line Contact No No Yes
be required.
1. For combustible floors only when used with special sub-base.
2. As centralized with the air distribution as possible. * 24" clearance in front and 18" on side recommended for service access.
3. Where adequate combustion air will be available (particularly All furnaces approved for alcove and attic installation.
when the appliance is not using outdoor combustion air).

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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
for the furnace size that is being installed.
1. Handle an air volume appropriate for the served space and within
Refer to Table 6 or the furnace rating plate for the correct rise range
the operating parameters of the furnace specifications.
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 FIGURE 1: Duct Attachment
furnace. If the plenum is shorter than 12” (30.5 cm) the turbulent air flow
may cause the limit controls not to operate as designed, or the limit con- DUCTWORK INSTALLATION AND SUPPLY PLENUM
trols may not operate at all. CONNECTION - UPFLOW/HORIZONTAL
The duct system is a very important part of the installation. If the duct Attach the supply plenum to the furnace outlet. The use of
system is improperly sized the furnace will not operate properly. an approved flexible duct connector is recommended on all
The ducts attached to the furnace plenum, should be of sufficient size installations. This connection should be sealed to prevent
so that the furnace operates at the specified external static pressure air leakage. The sheet metal should be crosshatched to
and within the air temperature rise specified on the nameplate. 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 DOWNFLOW
operate properly on a shorter plenum height. The minimum recom-
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 move grom-
On all installations without a coil, a removable access panel is recom- met 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.

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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-
flow applications with no conversion. These upflow coils are designed for installation on top of upflow fur-
naces only.
Position the coil casing over or under the furnace opening as shown in
Figure 2 after configuring coil flanges as required see “Coil Flange” sec- If the coil is used with a furnace of a different size, use a 45° transition
tion below. to allow proper air distribution through the coil.
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

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 364861-UIM-D-1209

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
WARM AIR PLENUM
Upflow WITH 1” FLANGES
Furnace
Alternate FIBERGLASS
Primary INSULATION
Drain Secondary Drain Location
Drain
FIBERGLASS TAPE
FIGURE 6: PC Series Upflow Coil Installation UNDER FLANGE

Table 2: Coil Projection Dimensions - PC Series Coils

COIL SIZE DIMENSION “C” INCH

PC18 3-1/2
COMBUSTIBLE FLOOR
PC24 4-1/2 BASE ACCESSORY
PC30, PC32, PC35 4-1/2
PC42, PC43, PC36, PC37 5-1/2
PC48 6-1/2 FIGURE 8: Combustible Floor Base Accessory
PC60 9
Dimension “C” should be at least 2/3 of dimension “D”. See Figure 6. RESIDENTIAL AND MODULAR HOME UPFLOW
RETURN PLENUM CONNECTION
CRITICAL COIL PROJECTION Return air may enter the furnace through the side(s) or bottom depend-
The coil assembly must be located in the duct such that a minimum dis- ing on the type of application. Return air may not be connected into the
tance is maintained between the top of the coil and the top of the duct. rear panel of the unit.
Refer to Table 2.
BOTTOM RETURN AND ATTIC INSTALLATIONS
COIL / FURNACE ASSEMBLY - HC SERIES COILS Bottom return applications normally pull return air through a base plat-
These coils are supplied ready to be installed in a right hand position or form or return air plenum. Be sure the return platform structure or return
a left hand position. When used in conjunction with a horizontal furnace air plenum is suitable to support the weight of the furnace.
(blow through) application, the coil should be oriented with the opening
The internal bottom panel must be removed for this application.
of the “A” coil closest to the furnace. See Figure 7.
Attic installations must meet all minimum clearances to combustibles

NOTICE
and have floor support with required service accessibility.

HORIZONTAL APPLICATION
Each coil is shipped with an external tie plate that should be used to
secure the coil to the furnace. It should be installed on the back side
of the coil using the dimpled pilot holes. See Figure 7.

Use tie plate

supplied with coil
FIGURE 9: Horizontal Application

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

as shown above. It must not be installed on its back.
Gas Furnace
Air flo
w

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

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ATTIC INSTALLATION All six suspension points must be level to ensure proper and quiet fur-
nace operation. When suspending the furnace, use a secure platform
Line contact only permissible Supply constructed of plywood or other building materials secured to the floor
between lines formed by the Air or ceiling joists. Refer to Figure 11 for details and additional information.
Vent (Maintain
intersection of furnace top
required
and two sides and building
clearances to
joists, studs or framing
combustibles)
Filter rack
must be a minimum
distance Gas Piping
of 18” (45.7 cm) Support
from the Rod
furnace

30” MIN.
Work Area
Support
Angle (x3)
Return Maintain 6” minimum
Air Sediment clearance between support
Trap rods and front of furnace

FIGURE 10: Typical Attic Installation FIGURE 11: Typical Suspended Furnace / Crawl Space 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 During installation, doors should remain on the furnace when
may be in contact with combustible material. Refer to Figure 10. moving or lifting.

When moving or handling this furnace prior to installation it is recom-

mended to leave the doors on the furnace to provide support and to
prevent damage or warping of the cabinet. When lifting the furnace,
When a furnace is installed in an attic or other insulated space, support the ends of the furnace rather than lifting by the cabinet flanges
keep all insulating materials at least 12” (30.5 cm) away from fur- at the return air openings (bottom or sides) or supply air opening.
nace and burner combustion air openings.
It is acceptable to use the primary heat exchanger tubes as a lifting
point provided that the tubes are lifted at the front of the heat exchang-
ers where attached to the vestibule panel. Do not use the top return
bend of the heat exchangers as lifting points as the tubes may shift out
During installation, doors should remain on the furnace when of position or their location brackets/baffles.
moving or lifting.
DOWNFLOW APPLICATION
When moving or handling this furnace prior to installation, always leave
the doors on the furnace to provide support and to prevent damage or To apply the furnace in a downflow position, it will be necessary to
warping of the cabinet. When lifting the furnace, support the ends of the rotate the vent blower 90° left or right so that the vent pipe passes
furnace rather than lifting by the cabinet flanges at the return air open- through the side of the furnace casing. See Figure 12.
ings (bottom or sides) or supply air opening.
It is acceptable to use the primary heat exchanger tubes as a lifting
point provided that the tubes are lifted at the front of the heat exchang-
ers where attached to the vestibule panel. Do not use the top return
bend of the heat exchangers as lifting points as the tubes may shift out
of position or their location brackets/baffles.

SUSPENDED FURNACE / CRAWL SPACE

INSTALLATION
The furnace can be hung from floor joists or installed on suitable blocks Rotate vent
or pads. Blocks or pad installations shall provide adequate height to blower 90°
either way
ensure that the unit will not be subject to water damage.
Units may also be suspended from rafters or floor joists using rods, pipe
angle supports or straps. In all cases, the furnace should be supported
with rods, straps, or angle supports at three locations to properly sup-
port the furnace. Place one support at the supply end of the furnace,
one support located approximately in the center of the furnace near the LEFT SIDE VENT RIGHT SIDE VENT
blower shelf, and the third support should be at the return end of the fur-
FIGURE 12: Downflow Venting
nace. Maintain a 6” (15.2 cm) minimum clearance between the front of
the furnace and the support rods or straps.

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 364861-UIM-D-1209

LEFT SIDE FRONT RIGHT SIDE

Combustion Air Inlet Combustion Air Inlet

Condensate Drain Gas Pipe

(Downflow) Entry Gas Pipe Condensate Drain
Entry (Downflow)
Vent Outlet Electrical
Entry Electrical
Entry Vent Outlet
Condensate
Drain 33 Condensate 23”
Drain
Thermostat
Wiring Thermostat
Wiring Optional Return Air
Cutout (Either side) 14”

1”

28.5” A 1.5”
29.5”
(For Cladded door add appoximately an additional .75”)
.56”
23.8” 3”
Vent
Outlet

B Combustion B
Air Inlet C

.56” .56” 24.25”

20”
SUPPLY END RETURN END

FIGURE 13: Dimensions

Table 3: Cabinet and Duct Dimensions

Approximate
BTUH (kW) Nominal Cabinet Cabinet Dimensions (Inches)
Operating Weights
Input 3 Size
CFM (m /min)
A (in) A (cm) B (in) B (cm) C (in) C (cm) Lbs (kg)
40 (11.7) 800 (22.7) A 14 1/2 36.8 13 3/8 34.0 11 3/4 29.8 113 (51.3)
60 (17.6) 1000 (28.3) A 14 1/2 36.8 13 3/8 34.0 11 3/4 29.8 118 (53.5)
60 (17.6) 1200 (34.0) B 17 1/2 44.4 16 3/8 41.6 13 1/4 33.7 122 (55.3)
80 (23.4) 1200 (34.0) B 17 1/2 44.4 16 3/8 41.6 14 3/4 37.5 126 (57.2)
80 (23.4) 1600 (45.3) C 21 53.3 19 7/8 50.5 16 1/2 41.9 136 (61.7)
80 (23.4) 2200 (62.3) C 21 53.3 19 7/8 50.5 16 1/2 41.9 139 (63.0)
100 (29.3) 1600 (45.3) C 21 53.3 19 7/8 50.5 18 1/4 46.4 142 (64.4)
100 (29.3) 2000 (56.6) C 21 53.3 19 7/8 50.5 18 1/4 46.4 145 (65.8)
120 (35.1) 1600 (45.3) D 24 1/2 62.2 23 3/8 59.4 21 3/4 55.2 153 (69.4)
120 (35.1) 2000 (56.6) D 24 1/2 62.2 23 3/8 59.4 21 3/4 55.2 156 (70.7)
130 (38.1) 2000 (56.6) D 24 1/2 62.2 23 3/8 59.4 No Hole No Hole 160 (72.5)

SECTION III: FILTERS Table 4: Recommended Filter Sizes (High Velocity 600 FPM)
FILTER INSTALLATION CFM (m³/min) Cabinet Size Side (in) Bottom (in)
All applications require the use of a field installed filter. All filters and 800 (22.7) A 16 x 25 14 x 25
mounting provision must be field supplied. 1000 (28.3) A 16 x 25 14 x 25
Filters must be installed external to the furnace cabinet. DO NOT 1200 (34.0) A 16 x 25 14 x 25
attempt to install filters inside the furnace. 1200 (34.0) B 16 x 25 16 x 25
1600 (45.3) B 16 x 25 16 x 25
NOTICE 1600 (45.3)
2000 (56.6)
C
C
16 x 25
(2) 16 x 25
20 x 25
20 x 25
Single side return above 1800 CFM is approved as long as the filter
velocity does not exceed filter manufacturer’s recommendation and 2200 (62.3) C (2) 16 x 25 20 x 25
a transition is used to allow use on a 20x25 filter. 2000 (56.6) D (2) 16 x 25 22 x 25
1. Air velocity through throwaway type filters may not exceed 300 feet per min-
ute (91.4 m/min). All velocities over this require the use of high velocity fil-
ters.
2. Do not exceed 1800 CFM using a single side return and a 16x25 filter. For
CFM greater than 1800, you may use two side returns or one side and the
bottom or one side return with a transition to allow use of a 20x25 filter.

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SIDE RETURN SECTION IV: GAS PIPING

Locate the “L” shaped corner locators. These indicate the size of the cut- GAS SAFETY
out to be made in the furnace side panel. Refer to Figure 14.

Front of An overpressure protection device, such as a pressure regulator,

Furnace must be installed in the gas piping system upstream of the furnace
and must act to limit the downstream pressure to the gas valve so it
Side of does not exceed 0.5 psig [14" w.c. (3.48 kPa)]. Pressures exceed-
Furnace ing 0.5 psig [14” w.c. (3.48 kPa)] at the gas valve will cause damage
to the gas valve, resulting in a fire or explosion or cause damage to
Corner the furnace or some of its components that will result in property
Markings damage and loss of life.

FIGURE 14: Side Return Cutout Markings HIGH STAGE REGULATOR

ADJUSTMENT
Install the side filter rack following the instructions provided with that OUTLET
PRESSURE
accessory. If a filter(s) is provided at another location in the return air PORT VENT
PORT
system, the ductwork may be directly attached to the furnace side
panel. INLET
OUTLET

WRENCH
BOSS

Some accessories such as electronic air cleaners and pleated INLET

PRESSURE
media may require a larger side opening. Follow the instructions PORT
ON OFF LOW STAGE REGULATOR
supplied with that accessory for side opening requirements. Do not SWITCH ADJUSTMENT
cut the opening larger than the dimensions shown in Figure 13.
FIGURE 15: Gas Valve
HORIZONTAL APPLICATION
Horizontal Filters

Plan your gas supply before determining the correct gas pipe entry.
Use 90° service elbow(s), or short nipples and conventional 90°
All filters and mounting provision must be field supplied. All installa- elbow(s) to enter through the cabinet access holes.
tions must have a filter installed.
Any branch duct (rectangular or round duct) attached to the plenum GAS PIPING INSTALLATION
must attach to the vertical plenum before the filter. The use of straps Properly sized wrought iron, approved flexible or steel pipe must be
and/or supports is required to support the weight of the external filter used when making gas connections to the unit. If local codes allow the
box. 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
Downflow Filters
appliance.
Downflow furnaces typically are installed with the filters located above
Some utility companies or local codes require pipe sizes larger than the
the furnace, extending into the return air plenum or duct. Any branch
minimum sizes listed in these instructions and in the codes. The furnace
duct (rectangular or round duct) attached to the plenum must attach to
rating plate and the instructions in this section specify the type of gas
the vertical plenum above the filter height.
approved for this furnace - only use those approved gases. The instal-
Filter(s) may be located in the duct system external to the furnace using lation of a drip leg and ground union is required. Refer to Figure 16.
an external duct filter box attached to the furnace plenum or at the end
of the duct in a return filter grille(s). The use of straps and/or supports is
required to support the weight of the external filter box.

To Gas NOTE: Ground Union maybe installed inside or outside unit.

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

FIGURE 16: Gas Piping

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GAS ORIFICE CONVERSION FOR PROPANE (LP)

This furnace is constructed at the factory for natural gas-fired operation,
but may be converted to operate on propane (LP) gas by using a fac-
An accessible manual shutoff valve must be installed upstream of
the furnace gas controls and within 6 feet (1.8 m) of the furnace. tory-supplied LP conversion kit. Follow the instructions supplied with
the LP kit.
The furnace must be isolated from the gas supply piping system by
closing its individual external manual shutoff valve during any pressure
HIGH ALTITUDE GAS ORIFICE CONVERSION
testing of the gas supply piping system at pressures equal to or less This furnace is constructed at the factory for natural gas-fired operation
than 0.5 psig (3.5 kPa). at 0 –7,999 feet (0 – 2,438 m) above sea level.
The manifold pressure must be changed in order to maintain proper
and safe operation when the furnace is installed in a location where the
altitude is greater than 7,999 feet (2,438 m) above sea level. Refer to
The gas valve body is a very thin casting that cannot take any Table 5 for proper manifold pressure settings.
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- HIGH ALTITUDE PRESSURE SWITCH CONVERSION
gon hub located on the gas inlet side of the valve. Placing a wrench
For installation where the altitude is less than 5,000 feet (1,524m), it is
to the body of the gas valve will damage the valve causing improper
operation and/or the valve to leak. not required that the pressure switch be changed unless you are in an
area subject to low pressure inversions.
Gas piping may be connected from either side of the furnace using any
of the gas pipe entry knockouts on both sides of the furnace. Refer to
Figure 13.

Table 5: Nominal Manifold Pressure - High Fire

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 Gas Heating Value 31.7 0.87 0.87 0.87
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.

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Table 6: Ratings & Physical / Electrical Data

Nominal Max. Outlet Max Min. wire Size
Input Output AFUE Air Temp. Rise Blower Blower Total Unit
Airflow 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
40 11.7 38 11.1 800 22.7 95.5 30-60 17-33 160 71.1 1/3 4.8 11x8 15 8.0 14
60 17.6 57 16.7 1000 28.3 95.5 30-60 19-36 160 71.1 1/2 7.07 11x8 15 10.0 14
60 17.6 57 16.7 1200 34.0 95.5 30-60 19-36 160 71.1 1/2 7.07 11x8 15 10.0 14
80 23.4 76 22.3 1200 34.0 95.5 35-65 19-36 165 73.9 1/2 7.07 11x8 15 10.0 14
80 23.4 76 22.3 1600 45.3 95.5 35-65 19-36 165 73.9 3/4 8.8 11x10 15 11.5 14
80 23.4 76 22.3 2200 62.3 95.5 35-65 19-36 165 73.9 1 14.5 11x11 20 17.0 12
100 29.3 95 27.8 1600 45.3 95.5 35-65 19-36 165 73.9 3/4 8.8 11x10 15 11.5 14
100 29.3 95 27.8 2000 56.6 95.5 35-65 19-36 165 73.9 1 14.5 11x11 20 17.0 12
120 35.1 114 33.4 1600 45.3 95.5 40-70 22-39 170 76.7 3/4 8.8 11x10 15 11.5 14
120 35.1 114 33.4 2000 56.6 95.5 35-65 19-36 165 73.9 1 14.5 11x11 20 17.0 12
130 38.1 123.5 36.2 2000 56.6 95.5 45-75 28-44 175 79.4 1 14.5 11x11 20 17.0 12
Annual Fuel Utilization Efficiency (AFUE) numbers are determined in accordance with DOE Test procedures.
Wire size and over current protection must comply with the National Electrical Code (NFPA-70-latest edition) and all local codes.
The furnace shall be installed so that the electrical components are protected from water.

SUPPLY VOLTAGE CONNECTIONS

The power connection leads and wiring box may be relocated to the
left side of the furnace. Remove the screws and cut wire tie holding
Junction excess wiring. Reposition on the left side of the furnace and fasten
Box using holes provided.
Connect ground LOW VOLTAGE CONTROL WIRING CONNECTIONS
lead to screw
Install the field-supplied thermostat by following the instructions that
Electrical Entry come with the thermostat. With the thermostat set in the OFF position
L1-Hot BLK and the main electrical source disconnected, connect the thermostat
Neutral WHT wiring from the wiring connections on the thermostat to the terminal
board on the ignition module, as shown in Figure 17. Electronic thermo-
stats may require the common wire to be connected. Apply strain relief
to thermostat wires passing through cabinet. If air conditioning equip-
FIGURE 17: Electrical Wiring ment is installed, use thermostat wiring to connect the Y and C termi-
nals on the furnace control board to the proper wires on the condensing
1. Provide a power supply separate from all other circuits. Install unit (unit outside).
overcurrent protection and disconnect switch per local/national
electrical codes. The switch should be close to the unit for conve-
nience in servicing. With the disconnect or fused switch in the OFF
position, check all wiring against the unit wiring label. Refer to the
Set the heat anticipator in the room thermostat to 0.4 amps. Setting
wiring diagram in this instruction. it lower will cause short cycles. Setting it higher will cause the room
2. Remove the wiring box cover screws. Route all power wiring temperature to exceed the set points.
through a conduit connector or other proper bushing that has been
installed into the unit opening and the junction box. In the junction
box there is a black wire, a white wire and a green ground screw.
Connect the power supply as shown on the unit’s wiring label on
the inside of the blower compartment door or the wiring schematic Some electronic thermostats do not have adjustable heat anticipa-
in this section. Connect the black wire to L1 (hot) from the power tors. They should be set to six cycles per hour. Follow the thermo-
supply. Connect the white wired to neutral. Connect the ground stat manufacturer's instructions.
wire (installer-supplied) to the green (equipment ground) screw.
The 24-volt, 40 VA transformer is sized for the furnace components
An alternate wiring method is to use a field-provided 2” (5.1 cm) x
only, and should not be connected to power auxiliary devices such as
4” (10.2 cm) box and cover on the outside of the furnace. Route
humidifiers, air cleaners, etc. The transformer may provide power for an
the furnace leads into the box using a protective bushing where
the wires pass through the furnace panel. After making the wiring air conditioning unit contactor.
connections replace the wiring box cover and screws. Refer to Fig-
ure 17.
3. The furnace's control system requires correct polarity of the power
supply and a proper ground connection. Refer to Figure 17.

12 Johnson Controls Unitary Products

 364861-UIM-D-1209

For additional connection diagrams for all UPG equipment refer to “Low Voltage System Wiring” document available on-line at www.upgnet.com in
the Product Catalog Section.

AC 5D Single Stage Air Conditioner – Single Stage PSC Furnace

ID MODELS
G*(8/9)S GF(8/9)
G*9F LF8
L(Y/M)8S (G,T)G(8/9)S
THERMOSTAT G8C (G/T)GLS

SINGLE STAGE SINGLE STAGE

*PP11C70224 PSC AIR
FURNACE CONDITIONER

SINGLE STAGE PSC 1 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

Other Part Numbers:

1
SAP = Legacy
265901 = 031-09166

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

Johnson Controls Unitary Products 13

364861-UIM-D-1209

HP 2C Single Stage Heat Pump – Single Stage PSC Furnace

ID MODELS OD MODELS
G*(8/9)S GF(8/9) E*R* *RHS
G*9F LF8 E*ZD HP*
L(Y/M)8S (G,T)G(8/9)S E*B* *HGD
THERMOSTAT THERMOSTAT THERMOSTAT G8C (G/T)GLS

*BP21H50124 SINGLE STAGE

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

SINGLE STAGE PSC 2 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

3
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

3 Other Part Numbers: Part Numbers:

Part Number: 2 1
SAP = Legacy SAP = Legacy
S1-2HU16700124
265901 = 031-09166 67297 = 031-01975

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

14 Johnson Controls Unitary Products

 364861-UIM-D-1209

ACCESSORY CONNECTIONS
Vent Pipe
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
air cleaner connections are located on the control board. The terminals
Electrical Gas Supply
provide 115 VAC (1.0 amp maximum) during circulating blower opera-
Supply (Both sides)
tion.
HUMIDIFIER CONNECTION 1 Coil for
Two 1/4” (6.4 mm) spade terminals (HUM and NEUTRAL) for humidifier Each Furnace
connections are located on the control board. The terminals provide 115 Supply
CO
VAC (1.0 amp maximum) during heating system operation. SU MM Air
PL PPL ON
EN Y
A mounting hole is provided on the control panel next to the furnace UM
control board for mounting a humidifier transformer if required.

SECTION VI: TWINNING AND STAGING FIGURE 20: Typical Twinned Furnace Application

In applications where more heating capacity or more airflow capacity is

needed than what one furnace can deliver, twinning can be used to
make two furnaces operate in tandem. When two furnaces are installed
using the same duct system, it is very important that the two furnace cir- When two furnaces are twinned, typical system total airflow will be
culating air blowers operate in unison. If one blower starts before the approximately 85% of additive individual furnaces, i.e., two 2000
second blower, the duct system will become pressurized and the blower CFM units will yield a total 3400 CFM.
on the second furnace will turn backwards causing the second furnace
to overheat, resulting in damage to the furnace. Twinning is used to
make two furnaces operate in tandem, using one duct system, one
room thermostat and causing both furnaces to turn on and off simulta-
If a return duct is connected to only one furnace (with a connection
neously. between the two furnaces) an imbalance in the airflow will occur
and the furnace furthest from the return plenum will overheat.

GAS PIPING
Before installing the relay and wiring, disconnect electrical power to Furnace gas supplies must be provided as specified with these instruc-
both furnaces. Failure to cut power could result in electrical shock tions. Since the furnaces are side by side, with no space between, gas
or equipment damage. supplies must enter on the right and left respectively. All gas piping
must be in accordance with the national fuel gas code, ANSI Z223.1,
latest edition, and/or all local code or utility requirements.
TWINNING
The relay must not be installed in any location where it could be In applications where more heating capacity or more airflow capacity is
exposed to water. If the relay has been exposed to water in any needed than what one furnace can deliver, twinning can be used to
way, it must not be used. make two furnaces operate in tandem, using one duct system and one
room thermostat. When one duct system is used for two furnaces, it is
TWINNING DUCT SYSTEM necessary that the two blowers operate in unison. The twinning function
Twinned furnaces must only be applied on a common duct system. A of the board in this furnace ensures that both blowers turn on and off
single air supply plenum must be used for both furnaces and coil(s). simultaneously, and operate on the same blower speed.
Separate plenums and supply ducts systems cannot be utilized. A sin-
gle return air plenum, common to both furnaces must be used. It is sug- Single-Wire Twinning
gested that a return platform be utilized, with bottom air entrance into The control in the furnace has the single-wire twinning feature. With this
each furnace. If a side entrance returns system is used, the common feature, a single wire is connected between the TWIN terminal on one
return duct must be divided equally so as to supply each furnace with furnace board to the TWIN terminal on the second furnace board. The
an equal amount of return air. board then communicates the blower status from one furnace to the
Both furnaces must be identical models in both heating capacity and other along this wire. This communication makes the second furnace
CFM capacity. Both furnaces must be operated on the same motor blower come on at the same time, and on the same speed, as the first
speed tap. See typical application, Figure 20. furnace blower. To ensure stable communication, the common terminal
of each control must be connected.
If furnace staging is desired with two single stage furnaces on a com-
mon duct, where the gas burner on the first furnace operates on W1 Single-Wire Twinning Instructions
and the gas burner on the second furnace operates on W2, then the Connect the control wiring as shown in Figure 21.
use of an air-mixing device in the plenum to mix the air from both fur- 1. Connect the low voltage wiring from the wall thermostat to the ter-
naces is strongly recommended. The mixing device must be installed minal strip on the control board of Furnace #1.
before any ducts that supply air to occupied spaces. Twinning causes
both indoor fans to operate simultaneously. If a mixing device is not 2. Connect a wire from the TWIN terminal of Furnace #1 to the TWIN
used, any ducts that are connected down stream from the furnace that terminal of Furnace #2.
operates on W2, will be supplying cold air in the Heating mode to the 3. Install a separate 24V relay as shown in the diagram below. Use of
occupied spaces unless W2 is energized. this relay is required, as it ensures that the transformers of the two
furnaces are isolated, thus preventing the possibility of any safety
devices being bypassed.
4. Connect the common wires of furnace #1 to the common terminal
of furnace #2.

Johnson Controls Unitary Products 15

364861-UIM-D-1209

Single-Wire Twinning Operation Single-Wire Staging Operation

Heating - On a call for heat (W signal) from the wall thermostat, both Heating - On a call for first-stage heat (W1 signal) from the wall thermo-
furnaces will start the ignition sequence and the burners on both fur- stat, Furnace #1 will start the ignition sequence and the burners will
naces will light. About thirty seconds after the burners light, the blowers light. About thirty seconds after the burners light, the blowers on both
on both furnaces will come on in heating speed. When the thermostat is furnaces will come on in heating speed. When the thermostat is satis-
satisfied, the burners will all shut off and, after the selected blower off fied, the burners will shut off and, after the selected blower off delay
delay time, both blowers will shut off at the same time. The twinning time, both blowers will shut off at the same time. On a call for second
control ensures that both blowers come on and shut off at the same stage of heat, the burners of Furnace #2 will also light and both blowers
time. will run. The twinning control ensures that both blowers come on and
Cooling - On a call for cooling (Y signal) from the wall thermostat, both shut off at the same time.
furnace blowers will come on at the same time in cooling speed. When
Cooling - On a call for cooling (Y signal) from the wall thermostat, both
the thermostat is satisfied, both blowers will stay on for 60 seconds,
furnace blowers will come on at the same time. When the thermostat is
then will shut off at the same time.
satisfied, both blowers will stay on for 60 seconds, then will shut off at
Continuous Fan - On a thermostat call for continuous fan (G signal),
both furnace blowers will come on at the same time in cooling speed the same time.
and will stay on until the G signal is removed. Continuous Fan - On a thermostat call for continuous fan (G signal),
both furnace blowers will come on at the same time in cooling speed
FURNACE 1 FURNACE 2
CONTROL BOARD CONTROL BOARD and will stay on until the G signal is removed.

W W FURNACE 1 FURNACE 2
CONTROL BOARD CONTROL BOARD
G G
C C W W

R TWIN R TWIN G G
Y ISOLATION Y C C
RELAY R TWIN R TWIN
Y ISOLATION Y
RELAY

TO A/C W G R Y
WALL THERMOSTAT
TO A/C W1 G R Y W2
FIGURE 21: Single Wire Twinning Wiring Diagram
WALL THERMOSTAT
STAGING
FIGURE 22: Single Wire Staging Wiring Diagram
This control can also be used along with a two-stage wall thermostat to
stage two twinned furnaces, making them operate like a single two- SECTION VII: CONDENSATE PIPING AND
stage furnace. This allows only one furnace to supply heat during times FURNACE VENTING CONFIGURATION
when the heat output from one furnace is sufficient to satisfy the
demand. When one duct system is used for two furnaces, it is neces- CONDENSATE DRAIN LOCATION
sary that the two blowers operate in unison. The twinning function of As shipped from the factory:
this board ensures that both blowers turn on and off simultaneously,
and operate on the same blower speed. Even when only one furnace is • For all 040, 060, & 080K input furnaces the main drain is plumbed
supplying heat, both furnace blowers must run. through the casing right-side opening when viewed from the front
of the furnace.
Single-Wire Staging • For all 100, 120, & 130K input furnaces the main drain is plumbed
The single-wire twinning feature of this board can also be used for stag- through the casing left-side opening when viewed from the front
ing of two furnaces. With this feature, a single wire is connected of the furnace.
between the TWIN terminal on one furnace board to the TWIN terminal
on the second furnace board. The board then communicates the blower
status from one furnace to the other along this wire. This communica-
NOTICE
tion makes the second furnace blower come on at the same time, and The Figures 25 - 28 show the condensate drain arrangement for the
on the same speed, as the first furnace blower. To ensure stable com- various possible furnace and vent blower positions.
munication, the common terminal of each control must be connected. The condensate hoses must slope downwards at all points.
Single-Wire Staging Instructions
Connect the control wiring as shown in Figure 22.
1. Connect the low voltage wiring from the wall thermostat to the ter-
The furnace condensate pan is self priming and contains an internal
minal strip on the control board of Furnace #1. For staging applica- trap to prevent flue gas leaking. Do not install an external conden-
tions, the wire from thermostat W1 is connected to the W sate trap.
connection on the board on Furnace #1. The wire from thermostat
W2 is connected to Furnace #2 through a separate relay, as When drain hose routing changes are required (shown in Figures 25 -
described below. 28), be sure to cap all un-used openings.
2. Connect a wire from the TWIN terminal of Furnace #1 to the TWIN If rerouting hoses - excess length should be cut off so that no sagging
terminal of Furnace #2. loops will collect and hold condensate - which will cause the furnace to
3. Install a separate 24V relay as shown in the diagram below. Use of not operate.
this relay is required, as it ensures that the transformers of the two No hose clamps are needed for connecting to the condensate pan.
furnaces are isolated, thus preventing the possibility of any safety
devices being bypassed.
4. Connect the common between furnace #1 and furnace #2.

16 Johnson Controls Unitary Products

 364861-UIM-D-1209

The furnace, evaporator coil, and humidifier drains may be com-

It is possible for condensation to form inside the combustion air
bined and drained together. The evaporator coil drain may have an
(intake) pipe in the summer months if significant length of combus-
external, field-supplied trap prior to the furnace drain connection to
tion air pipe passes through conditioned space. This problem can
prevent conditioned air leakage. All drain connections (furnace,
be averted by the addition of a simple drain tee, or a drain tee with a
evaporator coil, or humidifier) must be terminated into an open or
drain on the combustion air pipe as close to the furnace as possi-
vented drain as close to the respective equipment as possible.
ble, as shown in Figure 24. This is true for all long horizontal vent-
Regular maintenance is required on condensate drainage system.
ing in any furnace configuration. This will prevent the condensate
from entering the furnace.

Exhaust Pipe
Condensate must be disposed of properly. Follow local plumbing
or wastewater codes. The drain line must maintain a 1/4" per foot
(20 mm/m) downward slope to the drain.
Combustion Air Pipe

Tee with Drain Trap

If an external vent tee is being installed, then it must have its own
condensate trap before it is disposed into an open or vented drain. Trap
This is not to be considered as a second trap as referenced
elsewhere in this document.
Connect to Drain

Open Stand Pipe

(Anti-siphon air vent)

FIGURE 24: Typical. Combustion Pipe Drain Tee

5” Min.
CONDENSATE DRAIN TERMINATION
A condensate sump pump MUST be used if required by local codes, or
if no indoor floor drain is available. The condensate sump pump must
Tee
be approved for use with acidic condensate.

To Open Or DO NOT terminate the condensate drain in a chimney, or where the

Vented Drain drain line may freeze. If the drain line will be exposed to tempera-
tures below freezing, adequate measures must be taken to prevent
the drain line from freezing. Failure to provide proper protection
from freezing can result in improper operation or damage to the
equipment and possible property damage. When exposed to tem-
FIGURE 23: Typical. Condensate drain, vertical installation peratures below freezing, use of a 3 to 6 watt per foot at 115 VAC,
40°F (4.4°C) self-regulating, shielded and waterproof heat tape is
The condensate will flow to the drain better if an open stand pipe is recommended on the drain line outside the furnace.
installed in the drain line. See Figure 23. DO NOT trap the drain line at any other location than at the conden-
sate drain trap supplied with the furnace.
If evaporator coil or humidifier drains are combined with the furnace
drain, then the open stand pipe could be raised higher, above the 5”
minimum.

NOTICE
Liquid anti-freeze will cause damage to internal plastic parts of this
furnace. DO NOT attempt to winterize the furnace using liquid
anti-freeze.
A loop has been added to the pressure switch vacuum hose. How-
ever, ensure that all pressure switch hoses are routed such that
they prevent any condensate from entering the pressure switch.

Johnson Controls Unitary Products 17

18
When drain hose routing changes are required, be sure to cap all un-used openings.
If rerouting hoses - excess length should be cut off so that no sagging loops will collect
and hold condensate, which will cause the furnace to not operate.
130 K Model does not have provisions for top venting, it must be vented through a side opening.
364861-UIM-D-1209

FIGURE 25: Upflow Configuration

1 Shorten 1 Shorten
pressure rain gutter
switch hose hose
2 2 Re-route and
Move rain
gutter hose shorten

For 100, 120 & 130K input furnaces, the condensate

drain is plumbed toward the left casing outlet from the factory.
to this position pressure
switch hose
For 040, 060 & 080K input furnaces, the condensate
drain is plumbed toward the right casing outlet from the factory.

INDUCER ROTATED FOR UPFLOW INDUCER ROTATED FOR

LEFT SIDE VENTING AS RECEIVED RIGHT SIDE VENTING
(As required for 130K model) (Except for 130K Model)
Condensate drain may exit cabinet on either side.

Johnson Controls Unitary Products

 When drain hose routing changes are required, be sure to cap all un-used openings.
If rerouting hoses - excess length should be cut off so that no sagging loops will collect
and hold condensate, which will cause the furnace to not operate.

AIRFLOW
AIRFLOW

FIGURE 26: Downflow Configuration

Johnson Controls Unitary Products

Move rain
gutter hose
to this position

1 Move pressure switch

hose to this position.
NOTE: May require
the longer hose that
is provided with
wider cabinets

2
Move rain gutter
hose to this position

3
Move condensate drain
hose to this position
(May exit either side
DOWNFLOW - INDUCER ROTATED of the cabinet) DOWNFLOW - INDUCER ROTATED
FOR LEFT SIDE VENTING FOR RIGHT SIDE VENTING
364861-UIM-D-1209

19
20
When drain hose routing changes are required, be sure to cap all un-used openings.
If rerouting hoses - excess length should be cut off so that no sagging loops will collect
and hold condensate, which will cause the furnace to not operate.
364861-UIM-D-1209

HORIZONTAL - LEFT
INDUCER ROTATED

FIGURE 27: Horizontal Left Configuration

AIRFLOW 1
Move rain gutter hose to
this position
2 Move pressure switch hose NOTE: May require hose
to this position. extension that is
NOTE: May require the longer provided with wider
hose that is provided with cabinets
wider cabinets
1
Move rain gutter
hose to this position 4
3 Change condensate
Move drain connection to
condensate the 90° fitting provided
drain hose to
this position
2
Move pressure switch
AIRFLOW hose to this position.
NOTE: May require
the longer hose that
is provided with
wider cabinets HORIZONTAL - LEFT
INDUCER AS RECEIVED
(Except for 130K Model)

3 5 Change condensate drain

Move rain gutter hose to this position 4 connection to the 90° fitting provided
NOTE: May require hose extension Move condensate
that is provided with wider cabinets drain hose to this position

Johnson Controls Unitary Products

 When drain hose routing changes are required, be sure to cap all un-used openings.
If rerouting hoses - excess length should be cut off so that no sagging loops will collect
and hold condensate, which will cause the furnace to not operate.

HORIZONTAL - RIGHT
INDUCER ROTATED

Johnson Controls Unitary Products

FIGURE 28: Horizontal Right Configuration
1 AIRFLOW
Move pressure
switch hose to
this position.
4
Move rain gutter
hose to this position
2 Change condensate
drain connection to
the 90° fitting
provided 3 Move condensate
drain hose to AIRFLOW
this position

1
Move pressure
HORIZONTAL - RIGHT switch hose to
INDUCER AS RECEIVED this position.
(Except for 130K Model)

2 Change condensate drain

connection to the 90° 4
3 Move condensate Move rain gutter
fitting provided drain hose to this position hose to this position
364861-UIM-D-1209

21
364861-UIM-D-1209

SECTION VIII: COMBUSTION AIR AND 4. All combustion air and vent pipe must conform to American
VENT SYSTEM National Standards Institute (ANSI) and American Society for Test-
ing and Materials (ASTM) standards D1785 (Schedule 40 PVC),
COMBUSTION AIR AND VENT SAFETY D2665 (PVC-DWV), F891 (PVC-DWV Cellular Core), D2261
This Category IV, dual certified direct vent furnace is designed for resi- (ABS-DWV) or F628 (Schedule 40 ABS). Pipe cement and primer
dential application. It may be installed without modification to the con- must conform to ASTM Standard D2546 (PVC) or D2235 (ABS). If
ABS pipe is to be used, any joint where ABS pipe is joined to PVC
densate system in a basement, garage, equipment room, alcove, attic
pipe must be glued with cement that is approved for use with
or any other indoor location where all required clearance to combusti-
BOTH materials. Metallic materials must not be used for venting or
bles and other restrictions are met. The combustion air and the venting
air intake.
system must be installed in accordance with Section 5.3, Air for Com-
5. If a flexible connector is used in the vent system, it must be made
bustion and Ventilation, of the National Fuel Gas Code Z223.1/NFPA 54
of a material that is resistant to acidic exposure and to at least
(latest edition), or Sections 7.2, 7.3 or 7.4 of CSA B149.1, National Gas
225°F (107°C) temperature. Flexible connectors are also allowed
and Propane Codes (latest edition) or applicable provisions of the local
in the combustion air pipe.
building code and these instructions.
6. All models are supplied with 2" (5.1 cm) vent connections. When
the pipe must be increased to 3" (7.6 cm) diameter, the transition
from 2" to 3" must be done as close to the furnace as possible. For
upflow models, the transition from 2" to 3" should be done immedi-
The “VENT SYSTEM” must be installed as specified in these
ately above the furnace. For downflow or horizontal models, the
instructions for Residential and non-HUD Modular Homes. The
transition from 2" to 3" pipe should be done immediately after exit-
direct vent system is the only configuration that can be installed in a
non-HUD Modular Home. ing the furnace.
7. In Canada, vents shall be certified to ULC S636, Standard for Type
BH Gas Venting Systems.
8. In Canada, the first three feet (91.4 cm) of the vent must be readily
accessible for inspection.
This furnace may not be common vented with any other appliance,
since it requires separate, properly sized air intake and vent lines. 9. For single pipe systems it is recommended to install the combus-
The furnace shall not be connected to any type of B, BW or L vent tion air coupling provided and install approximately 18” (46 cm) of
or vent connector, and not connected to any portion of a factory- PVC pipe on the furnace.
built or masonry chimney 10. Minimum vent length for all models is 5 feet (1.5 m).
The furnace shall not be connected to a chimney flue serving a sep-
arate appliance designed to burn solid fuel. TABLE 7: Maximum Equivalent Pipe Length

Maximum
Model Input Pipe Size
Equivalent
BTUH (kW) Inches (cm)
length feet (m)
When combustion air pipe is installed above a suspended ceiling or
40,000 (11.7) 2 (5.1) 65 (19.8)
when it passes through a warm and humid space, the pipe must be
insulated with 1/2” Armaflex or other heat resistant type insulation if 40,000 (11.7) 3 (7.6) 90 (27.4)
two feet or more of pipe is exposed. 60,000 (17.6) 2 (5.1) 65 (19.8)
Vent piping must be insulated if it will be subjected to freezing tem- 60,000 (17.6) 3 (7.6) 90 (27.4)
peratures such as routing through unheated areas or through an 80,000 (23.4) 2 (5.1) 65 (19.8)
unused chimney.
80,000 (23.4) 3 (7.6) 90 (27.4)
COMBUSTION AIR/VENT PIPE SIZING 100,000 (29.3) 2 (5.1) 30 (9.2)
The size of pipe required will be determined by the furnace model, the 100,000 (29.3) 3 (7.6) 90 (27.4)
total length of pipe required and the number of elbows required. 120,000 (35.1) 2 (5.1) 30 (9.2)
Table 7 lists the maximum equivalent length of pipe allowed for each 120,000 (35.1) 3 (7.6) 90 (27.4)
model of furnace. The equivalent length of elbows is shown in Table 9. 130,000 (38.1) 3 (7.6) 85 (25.9)
The equivalent length of the vent system is the total length of straight
pipe PLUS the equivalent length of all of the elbows.
A
The following rules must also be followed: A

1. Long radius (sweep) elbows are recommended. Standard elbows

may be used, but since they have a longer equivalent length, they
will reduce the total length of pipe that will be allowed. Short radius
(plumbing vent) elbows are not allowed. The standard dimensions
A
A

of the acceptable elbows are shown below.

2. The maximum equivalent length listed in Table 7 is for the vent pip-
ing and the air intake piping separately. For example, if the table
allows 65 equivalent feet for a particular model, then the vent can STANDARD ELBOW LONG (SWEEP) ELBOW
have 65 equivalent feet of pipe, AND the combustion air intake can
have another 65 equivalent feet of pipe. FIGURE 29: Dimensions
3. Three vent terminal elbows (two for the vent and one for the com-
bustion air intake) are already accounted for and need not be TABLE 8: Elbow Dimensions
included in the equivalent length calculation.
Elbow "A" Dimension
2" Standard 2-5/16"
3" Standard 3-1/16"
2" Sweep 3-1/4"
3" Sweep 4-1/16"
Dimensions are those required in Standard ASTM D-3311.

22 Johnson Controls Unitary Products

 364861-UIM-D-1209

TABLE 9: Equivalent Length of Fittings

Fitting Equivalent Length

2" 90º sweep elbow 5 feet of 2" pipe Furnace vent pipe connections are sized for 2” (5.1 cm). pipe. Any
pipe size change must be made outside the furnace casing in a ver-
2" 45º sweep elbow 2-1/2 feet of 2" pipe tical pipe section to allow proper drainage of condensate. An offset
2" 90º standard elbow 7 feet of 2" pipe using two 45º (degree) elbows will be required for plenum clear-
2" 45º standard elbow 3-1/2 feet of 2" pipe ance when the vent is increased to 3” (7.6 cm).
3" 90º sweep elbow 5 feet of 3" pipe
3" 45º sweep elbow 2-1/2 feet of 3" pipe
3" 90º standard elbow 7 feet of 3" pipe
Accessory concentric vent / intake termination kits 1CT0302 and
3" 45º standard elbow 3-1/2 feet of 3" pipe 1CT0303, and for Canadian applications 1CT0302-636 and
2" corrugated connector 10 feet of 2" pipe 1CT0303-636 are available and approved for use with these fur-
3" corrugated connector 10 feet of 3" pipe naces. Horizontal sidewall vent terminations kits 1HT0901 &
1HT0902 are also approved for use with these furnaces.
Example:
COMBUSTION AIR AND VENT PIPING ASSEMBLY
An 80,000 BTUH furnace requires 32 feet of pipe and five 90º elbows.
Using 2" pipe and standard elbows, the total equivalent length will be: The final assembly procedure for the combustion air and vent piping is
as follows:
32 feet of 2" pipe = 32 equivalent feet 1. Cut piping to the proper length beginning at the furnace.
5 - 90º standard 2" elbows = (5 x 7) = 35 equivalent feet
2. Deburr the piping inside and outside.
Total = 67 equivalent feet of 2" pipe
3. Chamfer (bevel) the outer edges of the piping.
This exceeds the 65 foot maximum equivalent length of 2" pipe allowed 4. Dry-fit the vent piping assembly from the furnace to the outside ter-
for that model and is thus not acceptable. mination checking for proper fit support and slope.
By using sweep elbows, the total equivalent length will be: 5. Dry-fit the combustion air piping assembly checking for proper fit,
support and slope on the following systems:
32 feet of 2" pipe = 32 equivalent feet
a. Sealed combustion air systems from the furnace to the out-
5 - 90º sweep 2" elbows = (5 x 5) = 25 equivalent feet side termination.
Total = 57 equivalent feet of 2" pipe
b. Ventilated combustion air systems from the furnace to the
This is less than the 65 foot maximum equivalent length of 2" pipe attic or crawl space termination.
allowed for that model and is thus acceptable.
Alternatively, using 3" pipe and standard elbows, the total equivalent
length will be:
Solvent cements are flammable and must be used in well-ventilated
32 feet of 3" pipe = 32 equivalent feet areas only. Keep them away from heat, sparks and open flames.
5 - 90º standard 3" elbows = (5 x 7) = 35 equivalent feet Do not breathe vapors and avoid contact with skin and eyes.
Total = 67 equivalent feet of 3" pipe
6. Disassemble the combustion air and vent piping, apply cement
This is less than the 90 foot maximum equivalent length of 3" pipe primer and the cement per the manufactures instructions. Primer
allowed for that model and is thus acceptable. and cement must conform to ASTM D2564 for PVC, or ASTM
D2235 for ABS piping.
TABLE 10: Combustion Air Intake and Vent Connection Size at Furnace
7. All joints must provide a permanent airtight and watertight seal.
(All Models)
8. Support the combustion air and vent piping such that it is angled a
FURNACE VENT CONNECTION SIZES minimum of 1/4” per foot (21 mm/m) so that condensate will flow
Furnace Input All back towards the furnace. Piping should be supported with pipe
hangers to prevent sagging.
Intake Pipe Size 2” (5.1 cm)
9. Seal around the openings where the combustion air and / or vent
Vent Pipe Size 2” (5.1 cm)
piping pass through the roof or sidewalls.

COMBUSTION AIR / VENTING

The vent must be installed with the minimum required clearances,

and must comply with local codes and requirements.

Johnson Controls Unitary Products 23

364861-UIM-D-1209

VENT CLEARANCES

G
V

A
V VENT TERMINAL

D FIXED H
X AIR SUPPLY
E CLOSED B
V B
B I
B X AREA WHERE TERMINAL IS NOT PERMITTED
L V C V M V
V K
X
V V
J FIXED
F V B
CLOSED
B
OPERABLE

FIGURE 30: Home Layout

Direct Vent Terminal Clearances Canadian Installations1,3 US Installation2,3

A. Clearance above grade, veranda, porch, deck, or
12” (30.5 cm) 12” (30.5 cm)
balcony
12” (30.5 cm) for models 100,000 BTUH (30 kW), Two-pipe (direct vent) applications: 12” (30.5 cm)††
B. Clearance to window or door that may be opened
36” (91.4 cm) for models >100,000 BTUH (30 kW). Single-pipe applications: 4 feet (1.2 m).
C. Clearance to permanently closed window 12” (30.5 cm) 12” (30.5 cm)
D. Vertical clearance to ventilated soffit located
12” (30.5 cm) or in accordance with local installation 12” (30.5 cm) or in accordance with local installation
above the terminal within a horizontal distance
codes and the requirements of the gas supplier. codes and the requirements of the gas supplier.
of 2 feet (61 cm) from the center line of the terminal
12” (30.5 cm) or in accordance with local installation 12” (30.5 cm) or in accordance with local installation
E. Clearance to unventilated soffit
codes and the requirements of the gas supplier. codes and the requirements of the gas supplier.
12” (30.5 cm) or in accordance with local installation 12” (30.5 cm) or in accordance with local installation
F. Clearance to outside corner
codes and the requirements of the gas supplier. codes and the requirements of the gas supplier.
G. Clearance to inside corner 3 feet (91.4 cm) 3 feet (91.4 cm)
Above a meter/regulator assembly within 3 feet Above a meter/regulator assembly within 3 feet
H. Clearance to each side of center line (91.4 cm) horizontally of the vertical center-line of the (91 cm) horizontally of the vertical center-line of the
extended above meter/regulator assembly regulator vent outlet to a maximum vertical distance of regulator vent outlet to a maximum vertical distance of
15 feet (4.5 m) above the meter/regulator assembly. 15 feet (4.5 m) above the meter/regulator assembly.
3 feet (91.4 cm) or in accordance with local installation
I. Clearance to service regulator vent outlet 3 feet (91.4 cm)
codes and the requirements of the gas supplier.
J. Clearance to non-mechanical air supply inlet to
12” (30.5 cm) for models 100,000 BTUH (30 kW), Two-pipe (direct vent) applications: 12” (30.5 cm)
building or the combustion air inlet to any other
36” (91 cm) for models >100,000 BTUH (30 kW). Single-pipe applications: 4 feet (1.2 m).
appliance
3 feet (91.4 cm) above if within 10 feet (3 m)
K. Clearance to a mechanical supply inlet 6 feet (1.83 m)
horizontally.
L. Clearance above paved sidewalk or paved 7 feet (2.13 m) or in accordance with local installation
7 feet (2.13 m)†
driveway located on public property codes and the requirements of the gas supplier.
12” (30.5 cm) or in accordance with local installation
M. Clearance under veranda, porch, deck, or balcony 12” (30.5 cm)‡
codes and the requirements of the gas supplier.

1. In accordance with the current CSA B149.1-00, Natural Gas and Propane Installation Code.
2. In accordance with the current ANSI Z223.1 / NFPA 54, National Gas Code.
3. In accordance with the current ANSI Z21.47 * CSA 2.3 American National Standard.
† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.
†† 12” (30.5 cm) up from the bottom edge of the structure for Two-pipe (direct vent) applications per ANSI Z223.1 / NFPA 54, National Gas Code.
‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor and the distance between the top of the vent termina-
tion and the underside of the veranda, porch, or deck is greater than 12” (30.5 cm) as specified in CSA B149.1-00.
A vent shall not terminate less than 12” (30.5 cm) above a grade level.
Any fresh air or make up inlet for dryer or furnace area is considered to be forced air inlet.
Avoid areas where condensate drippage may cause problems such as above planters, patios, or adjacent to windows where steam may cause fogging.
A terminus of a vent shall be fitted with a cap in accordance with the vent manufacturer’s installation instructions, or in accordance with the installation instructions for a
special venting system.
Responsibility for the provision of proper adequate venting and air supply for application shall rest with the installer.
Vent shall extend high enough above building, or a neighboring obstruction, so that wind from any direction will not create a positive pressure in the vicinity of the vent.

Consideration must be given for degradation of building materials by flue gases. Sidewall termination may require sealing or shielding of building
surfaces with a corrosion resistant material to protect against combustion product corrosion. Consideration must be given to wind direction in
order to prevent flue products and/or condensate from being blown against the building surfaces. If a metal shield is used it must be a stainless
steel material at a minimum dimension of 20 inches (51 cm). It is recommended that a retaining type collar be used that is attached to the build-
ing surface to prevent movement of the vent pipe.

24 Johnson Controls Unitary Products

 364861-UIM-D-1209

VENT SYSTEM 12” vertical separation

This furnace is certified to be installed with one of two possible vent Maintain 12” minimum between combustion air
12” minimum
clearance above intake and vent.
configurations. below overhang
highest anticipated
1. Horizontal vent system. This vent system can be installed com- snow level. 12” minimum
separation between
pletely horizontal or combinations of horizontal, vertical, or offset bottom of
using elbows. combustion air pipe
2. Vertical vent system. This vent system can be installed completely and bottom of vent.
vertical or a combination of horizontal, vertical, or offset using
Maintain 12”
elbows.
minimum clearance
above highest

NOTICE anticipated snow

level or grade,
whichever is higher.
On 130K BTU models, there is no provision for the vent to exit
the top of the cabinet, the vent must always exit one of the
sides.

VENT APPLICATIONS AND TERMINATION

When selecting the location for a combustion air / vent termination, the FIGURE 32: Termination Configuration - 2 Pipe
following should be considered:
1. Observe all clearances listed in vent clearances in these instruc-
tions.
12” MIN.
2. Termination should be positioned where vent vapors will not dam-
age plants or shrubs or air conditioning equipment.
12” Minimum
3. Termination should be located where it will not be affected by wind below overhang
gusts, light snow, airborne leaves or allow recirculation of flue 12” MIN.
G 12” Minimum
gases. AN
H separation between
R
4. Termination should be located where it will not be damaged or VE bottom of
O
exposed to flying stones, balls, etc. combustion air
intake and
5. Termination should be positioned where vent vapors are not objec- bottom of vent
tionable.
6. Horizontal portions of the vent system must slope upwards and be Maintain 12”
minimumclearance
supported to prevent sagging. above highest
7. Direct vent systems must be installed so the vent and the combus- anticipated snow
tion air pipes terminate in the same atmospheric zone. Refer to level or grade,
whichever is higher
Figures 32 or 33.

Maintain 12” minimum clearance FIGURE 33: Termination Configuration - 2 Pipe Basement
above highest anticipated snow level.
Maximum 24” above roof. VENTING MULTIPLE UNITS
Multiple units can be installed in a space or structure as either a single
pipe configuration or a two-pipe configuration.
12” Min.
The combustion air side of the single pipe configuration shown in Figure
12” Min. 31 is referred to in these instructions as ambient combustion air supply.
Follow the instructions for ambient combustion air installations, paying
particular attention to the section on air source from inside the building.
The vent for a single pipe system must be installed as specified in the
venting section of these instructions with the vent terminating as shown
in Figure 31. Each furnace must have a separate vent pipe. Under NO
circumstances can the two vent pipes be tied together.
The combustion air side of the two-pipe configuration shown in Figure
32 can be installed so the combustion air pipe terminates as described
FIGURE 31: Termination Configuration - 1 Pipe in outdoor combustion air or ventilated combustion air sections in these
instructions. Follow the instructions for outdoor combustion air or venti-
lated combustion air and the instructions for installing the vent system
with the vent terminating as shown in Figures 34 or 35. The two-pipe
system must have a separate combustion air pipe and a separate vent
pipe for each furnace. Under NO circumstances can the two combus-
tion air or vent pipes be tied together. The combustion air and vent
pipes must terminate in the same atmospheric zone.

Johnson Controls Unitary Products 25

364861-UIM-D-1209

The combustion air intake pipe should be located either through the
wall (horizontal or side vent) or through the roof (vertical vent). Care
VENT should be taken to locate side vented systems where trees or shrubs
will not block or restrict supply air from entering the terminal.
Also, the terminal assembly should be located as far as possible from a
swimming pool or a location where swimming pool chemicals might be
stored. Be sure the terminal assembly follows the outdoor clearances
listed in Section #1 “Outdoor Air Contaminants.”
COMBUSTION AIR

2” Connects to Vent pipe cements

MIN.
collar on top into socket just
FIGURE 34: Double Horizontal Combustion Air Intake and Vent of burner box above top panel
Termination

Or vent pipe may be

clamped into outlet
MIN.
of drain coupling
6”

FIGURE 36: Direct Vent Air Intake Connection and Vent Connection
FIGURE 35: Double Vertical Combustion Air Intake and Vent
Termination Ambient Combustion Air Supply
This type installation will draw the air required for combustion from
COMBUSTION AIR SUPPLY within the space surrounding the appliance and from areas or rooms
All installations must comply with Section 5.3, Air for Combustion and adjacent to the space surrounding the appliance. This may be from
Ventilation of the National Fuel Gas Code, ANSI Z223.1 or Sections within the space in a non-confined location or it may be brought into the
7.2, 7.3 or 7.4 of CAN/CGA B149.1 or .2 Installation Code - latest edi- furnace area from outdoors through permanent openings or ducts. It is
tions. not piped directly into the furnace. A single, properly sized pipe from the
This furnace is certified to be installed with one of three possible com- furnace vent connector to the outdoors must be provided. It is recom-
bustion air intake configurations. mended that the supplied intake coupling & 18” of pipe be attached to
1. OUTDOOR COMBUSTION AIR: This is a direct vent configuration the furnace to prevent accidental blockage of the combustion air intake.
where the combustion air is supplied through a PVC or ABS pipe
that is connected to the PVC coupling attached to the furnace and Vent pipe cements
COMBUSTION AIR
is terminated in the same atmospheric zone as the vent. This type into socket just
of installation is approved on all models. Refer to Figure 36. above top panel
2. AMBIENT COMBUSTION AIR: Combustion air is supplied from
the area surrounding the furnace through openings in the furnace
casing. The combustion air and the vent pipes are not terminated
in the same atmospheric zone. Refer to Figure 31 for vent termina- Or vent pipe may be
tions. Refer to "Ambient Combustion Air Supply" for proper instal- clamped into outlet
lation. Refer to Figure 37. of drain coupling
3. VENTILATED COMBUSTION AIR: Combustion air is supplied
through a PVC or ABS pipe that is connected to the PVC coupling
attached to the burner box and is terminated in a ventilated attic or
crawl space. The combustion air and the vent pipes are not termi-
nated in the same atmospheric zone. Refer to Figure 39 for attic
and crawl space termination. Only the combustion air intake may
terminate in the attic. The vent must terminate outside.
Outdoor Combustion Air FIGURE 37: Combustion Airflow Path Through The Furnace Casing
Combustion Air Intake/Vent Connections
This installation requires combustion air to be brought in from outdoors.
This requires a properly sized pipe (Shown in Figure 36) that will bring
air in from the outdoors to the furnace combustion air intake collar on This type of installation requires that the supply air to the appli-
the burner box. The second pipe (Shown in Figure 36) is the furnace ance(s) be of a sufficient amount to support all of the appliance(s)
in the area. Operation of a mechanical exhaust, such as an exhaust
vent pipe.
fan, kitchen ventilation system, clothes dryer or fireplace may cre-
ate conditions requiring special attention to avoid unsatisfactory
NOTICE operation of gas appliances. A venting problem or a lack of supply
air will result in a hazardous condition, which can cause the appli-
An optional plastic birdscreen is shipped in the loose parts bag with ance to soot and generate dangerous levels of CARBON MONOX-
every furnace. This may be installed in the intake collar to prevent IDE, which can lead to serious injury, property damage and / or
any small objects from entering the furnace. death.

26 Johnson Controls Unitary Products

 364861-UIM-D-1209

An unconfined space is not less than 50 cu.ft (1.42 m3) per 1,000 Btu/
hr (0.293 kW/h) input rating for all of the appliances installed in that
area.
When a Category I furnace is removed or replaced, the original
Rooms communicating directly with the space containing the appli- venting system may no longer be correctly sized to properly vent
ances are considered part of the unconfined space, if doors are fur- the attached appliances.
nished with openings or louvers. An improperly sized vent system can cause CARBON MONOXIDE
A confined space is an area with less than 50 cu.ft (1.42 m3) per 1,000 to spill into the living space causing personal injury, and or death.
Btu/hr (0.293 kW/h) input rating for all of the appliances installed in that
area. The following must be considered to obtain proper air for combus- Table 12: Unconfined Space Minimum Area
tion and ventilation in confined spaces. Minimum Free Area
BTUH Input Rating
Combustion Air Source From Outdoors Required for Each Opening
The blocking effects of louvers, grilles and screens must be given con- 40,000 40 in2 (258 cm2)
sideration in calculating free area. If the free area of a specific louver or 60,000 60 in2 (387 cm2)
grille is not known, Refer to Table11, to estimate free area.
80,000 80 in2 (516 cm2)
Table 11: Estimated Free Area 100,000 100 in2 (645 cm2)
Wood or Metal Wood 20-25%* 120,000 120 in2 (742 cm2)
Louvers or Grilles Metal 60-70% *
130,000 130 in2 (838 cm2)
1/4” (6.4 mm)
Screens+
mesh or larger 100% Table 13: Free Area
* Do not use less than 1/4” (6.4 mm) mesh
+ Free area of louvers and grille varies widely; the installer should follow Minimum Free Area Required for Each Opening
louver or grille manufacturer’s instructions. BTUH Input Vertical Duct or
Horizontal Duct Round Duct
Rating Opening to Outside
Dampers, Louvers and Grilles (Canada Only) (2,000 BTUH) (4,000 BTUH)
(4,000 BTUH)
1. The free area of a supply air opening shall be calculated by sub- 40,000 20 in2 (129 cm2) 10 in2 (64 cm2) 4” (10 cm)
tracting the blockage area of all fixed louvers grilles or screens
2
from the gross area of the opening. 60,000 30 in (193 cm2) 15 in2 (97 cm2) 5” (13 cm)
2. Apertures in a fixed louver, a grille, or screen shall have no dimen- 80,000 2 2 2 2 5” (13 cm)
40 in (258 cm ) 20 in (129 cm )
sion smaller than 1/4” (6.4 mm). 2 2 2 2
100,000 50 in (322 cm ) 25 in (161 cm ) 6” (15 cm)
3. A manually operated damper or manually adjustable louvers are
not permitted for use. 120,000 60 in2 (387 cm2) 30 in2 (193 cm2) 7” (18 cm)
130,000 2 cm2) in2
7” (18 cm) cm2)
4. A automatically operated damper or automatically adjustable lou- 65 in (419 33 (213
vers shall be interlocked so that the main burner cannot operate EXAMPLE: Determining Free Area.
unless either the damper or the louver is in the fully open position. Appliance 1 Appliance 2 Total Input
100,000 + 30,000 = (130,000  4,000) = 32.5 Sq. In. Vertical
Appliance 1 Appliance 2 Total Input
100,000 + 30,000 = (130,000  2,000) = 65 Sq. In. Horizontal

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 38: Outside and Ambient Combustion Air

Air Supply Openings and Ducts 4. The duct shall terminate within 12” (30.5 cm) above, and within
1. An opening may be used in lieu of a duct to provide to provide the 24” (61 cm) horizontally from, the burner level of the appliance
outside air supply to an appliance unless otherwise permitted by having the largest input.
the authority having jurisdiction. The opening shall be located 5. A square or rectangular shaped duct shall only be used when the
within 12” (30.5 cm) horizontally from, the burner level of the appli- required free area of the supply opening is 9 in2 (58.06 cm2) or
ance. Refer to “AIR SOURCE FROM OUTDOORS AND VENT larger. When a square or rectangular duct is used, its small dimen-
AND SUPPLY AIR SAFETY CHECK” in these instructions for sion shall not be less than 3” (7.6 cm).
additional information and safety check procedure. 6. An air inlet supply from outdoors shall be equipped with a means
2. The duct shall be either metal, or a material meeting the class 1 to prevent the direct entry of rain and wind. Such means shall not
requirements of CAN4-S110 Standard for Air Ducts. reduce the required free area of the air supply opening.
3. The duct shall be least the same cross-sectional area as the free 7. An air supply inlet opening from the outdoors shall be located not
area of the air supply inlet opening to which it connects. less than 12” (30.5 cm) above the outside grade level.

Johnson Controls Unitary Products 27

364861-UIM-D-1209

Combustion Air Source from Outdoors Ventilated Combustion Air

1. Two permanent openings, one within 12” (30.5 cm) of the top and The ventilated attic space or a crawl space from which the combustion
one within 12” (30.5 cm) of bottom of the confined space, Two per- air is taken must comply with the requirements specified in “AIR
manent openings, shall communicate directly or by means of ducts SOURCE FROM OUTDOORS” in this instruction or in Section 5.3, Air
with the outdoors, crawl spaces or attic spaces. for Combustion and Ventilation of the National Fuel Gas Code, ANSI
2. One permanent openings, commencing within 12” (30.5 cm) of the Z223.1 (latest edition). This type installation requires two properly sized
top of the enclosure shall be permitted where the equipment has pipes. One brings combustion air from a properly ventilated attic space
clearances of at least 1” (2.54 cm) from the sides and back and 6” or crawl space and a second pipe that extends from the furnace vent
(15.2 cm) from the front of the appliance. The opening shall com- connection (top right of unit) to the exterior of the building. Refer to
municate directly with the outdoors and shall have a minimum free Table 7 for intake pipe sizing, allowable length and elbow usage. Follow
area of: all notes, procedures and required materials in the "COMBUSTION
a. 1 square inch per 3000 BTU per hour (322 cm2 per 0.879 AIR/VENT PIPE SIZING" section in these instructions when installing
kW) of the total input rating of all equipment located in the the combustion air pipe from the unit and into a ventilated attic space or
enclosure. crawl space. DO NOT terminate vent pipe in an Attic or Crawl Space.
b. Not less than the sum of all vent connectors in the confined Ventilated Combustion Air Termination
space.
Refer to Figure 39 for required attic termination for the combustion air
3. The duct shall be least the same cross-sectional area as the free intake pipe. For attic termination, use two 90 elbows with the open end
area of the air supply inlet opening to which it connects.
in a downward position. Be sure to maintain 12” (30.5 cm) clearance
4. The blocking effects of louvers, grilles and screens must be given above any insulation, flooring or other material.
consideration in calculating free area. If the free area of a specific
louver or grille is not known. Refer to Table 11. A crawl space combustion air installation consists of a straight pipe from
the PVC coupling on the burner box that extends into the crawl space
and terminates with a 1/4” (6.4 mm) mesh screen and no elbows.

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 and all doors.
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.

Specially Engineered Installations

The above requirements shall be permitted to be waived where special
12” minimum
between bottom engineering, approved by the authority having jurisdiction, provides an
of air intake and adequate supply of air for combustion and ventilation.
any material below.
12” Min.

Be sure to instruct the owner not to block this intake pipe.

VENT BLOWER ROTATION

For ease of venting, the vent blower may be rotated 90° in either direc-
tion. For upflow installations the vent may exit through the top or either
side of the cabinet. For downflow installations, the vent blower must be
rotated so that the vent exits through either side of the cabinet. See Fig-
ures 25-28 for details.
FIGURE 39: Attic and Crawl Space Combustion Air Termination

28 Johnson Controls Unitary Products

 364861-UIM-D-1209

SECTION IX: START-UP AND 3. System start-up will occur as follows:

ADJUSTMENTS a. The induced draft blower motor will start and come up to
The initial start-up of the furnace requires the following additional speed. Shortly after inducer start-up, the hot surface igniter
procedures: will glow for about 17 seconds.
b. After this warm up, the ignition module will energize (open)
the main gas valve.
c. After flame is established, the supply air blower will start in
All electrical connections made in the field and in the factory should about 30 seconds.
be checked for proper tightness.

When the gas supply is initially connected to the furnace, the gas piping
may be full of air. In order to purge this air, it is recommended that the HOT SURFACE IGNITION SYSTEM
ground union be loosened until the odor of gas is detected. When gas is Do not attempt to light this furnace by hand (with a match or
detected, immediately retighten the union and check for leaks. Allow any other means). There may be a potential shock hazard from
five minutes for any gas to dissipate before continuing with the start-up the components of the hot surface ignition system. The fur-
procedure. Be sure proper ventilation is available to dilute and carry nace can only be lit automatically by its hot surface ignition
away any vented gas. system.

GAS PIPING LEAK CHECK CALCULATING THE FURNACE INPUT (NAT. GAS)
Burner orifices are sized to provide proper input rate using natural gas
with a heating value of 1030 BTU/Ft3 (38.4 MJ/m3). If the heating value
of your gas is significantly different, it may be necessary to replace the
FIRE OR EXPLOSION HAZARD orifices.
Failure to follow the safety warnings exactly could result in serious

NOTICE
injury, death or property damage.
Never test for gas leaks with an open flame. Use a commercially
available soap solution made specifically for the detection of leaks DO NOT set manifold pressure less than 3.2” w.c. or more than 3.8”
to check all connections. A fire or explosion may result causing w.c. for natural gas at sea level. If manifold pressure is outside this
property damage, personal injury or loss of life. range, change main burner orifices.

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

NOTICE
If orifice hole appears damaged or it is suspected to have been
ual air in the gas line or until gas manifold pressure is adjusted. The redrilled, check orifice hole with a numbered drill bit of correct size.
ignition control will make three attempts to light before locking out. Never redrill an orifice. A burr-free and squarely aligned orifice hole
is essential for proper flame characteristics.
It is recommended that when the gas supply is first connected to the
furnace, the ground union be loosened until the odor of gas is detected.
When gas is detected, immediately tighten the union and check for gas
leaks. Allow five minutes for any gas to dissipate before continuing with
the startup procedure. Be sure that proper ventilation is available to
DO NOT bottom out gas valve regulator adjusting screw. This can
dilute and carry away any vented gas. result in unregulated manifold pressure and result in excess over-
With furnace in operation, check all of the pipe joints, gas valve connec- fire and heat exchanger failures.
tions and manual valve connections for leakage using an approved gas
detector, a non-corrosive leak detection fluid or other leak detection Verify natural gas input rate by clocking meter.
methods. Take appropriate action to stop any leak. If a leak persists, 1. Turn off all other gas appliances and pilots.
replace the faulty component. 2. Run furnace for a minimum of 3 minutes in heating operation.
The furnace and its equipment shutoff valve must be disconnected from 3. Measure time (in sec) for gas meter to complete 1 revolution and
the gas supply during any pressure testing of that system at test pres- note reading. The 2 cubic feet dial provides a more accurate mea-
sures in excess of 0.5 psig (3.45 kPa). surement of gas flow.
The furnace must be isolated from the gas supply piping system by 4. Refer to Table 14 for cubic feet of gas per hour.
closing the equipment shutoff valve during any pressure testing of the 5. Multiply cubic feet per hour by heating valve (BTU/cu ft) to obtain
gas supply system. input.
If clocked rate does not match the input rate from the unit nameplate.
IGNITION SYSTEM SEQUENCE follow steps in next section to adjust the manifold pressure. Repeat
1. Turn the gas supply ON at external valve and main gas valve. steps 2 - 5 until correct input is achieved.
2. Set the thermostat above room temperature to call for heat.

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

Johnson Controls Unitary Products 29

364861-UIM-D-1209

Table 14: Gas Rate (CU FT/HR) at Full Input

Seconds For Size of Test Dial Seconds For Size of Test Dial
1 Revolution 1 Cu Ft 2 Cu Ft 5 Cu Ft 1 Revolution 1 Cu Ft 2 Cu Ft 5 Cu Ft
10 360 720 1800 55 65 131 327
11 327 655 1636 56 64 129 321
12 300 600 1500 57 63 126 316
13 277 555 1385 58 62 124 310
14 257 514 1286 59 61 122 305
15 240 480 1200 60 60 120 300
16 225 450 1125 62 58 116 290
17 212 424 1059 64 56 112 281
18 200 400 1000 66 54 109 273
19 189 379 947 68 53 106 265
20 180 360 900 70 51 103 257
21 171 343 857 72 50 100 250
22 164 327 818 74 48 97 243
23 157 313 783 76 47 95 237
24 150 300 750 78 46 92 231
25 144 288 720 80 45 90 225
26 138 277 692 82 44 88 220
27 133 267 667 84 43 86 214
28 129 257 643 86 42 84 209
29 124 248 621 88 41 82 205
30 120 240 600 90 40 80 200
31 116 232 581 92 39 78 196
32 113 225 563 94 38 76 192
33 109 218 545 96 38 75 188
34 106 212 529 98 37 74 184
35 103 206 514 100 36 72 180
36 100 200 500 102 35 71 178
37 97 195 486 104 35 69 173
38 95 189 474 106 34 68 170
39 92 185 462 108 33 67 167
40 90 180 450 110 33 65 164
41 88 176 439 112 32 64 161
42 86 172 429 116 31 62 155
43 84 167 419 120 30 60 150
44 82 164 409 124 29 58 145
45 80 160 400 128 28 56 141
46 78 157 391 133 27 54 135
47 76 153 383 138 26 52 130
48 75 150 375 144 25 50 125
49 73 147 367 150 24 48 120
50 72 144 360 157 23 46 115
51 71 141 355 164 22 44 110
52 69 138 346 171 21 42 105
53 68 136 340 180 20 40 100
54 67 133 333

30 Johnson Controls Unitary Products

 364861-UIM-D-1209

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 entirely to gain
“U” tube manometer to the gas valve with a piece of tubing. Follow the access to the adjustment screw. Loosening or tightening the cap
appropriate section in the instructions below. Refer to Figure 40 for a does not adjust the flow of gas.
drawing of the locations of the pressure ports on the gas valve.

NOTICE
Turn gas off at the ball valve or gas cock on gas supply line
before the gas valve. Find the pressure ports on the gas
valve marked Out P and In P. The regulated outlet pressure has been calibrated at the factory.
1. The manifold pressure must be taken at the port marked OUT P. Additional pressure adjustment should not be necessary. If adjust-
ment is necessary, set to the following specifications. After adjust-
2. The gas line pressure must be taken at the port marked IN P.
ment, 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 40 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
instructions to place the unit back in operation.
Connect the positive side of the manometer to the IN P Tap on the gas
valve. Do not connect any tubing to the negative side of the manometer, 3. Adjust manifold pressure by adjusting gas valve regulator screw
as it will reference atmospheric pressure. Refer to Figure 41 for connec- for the appropriate gas per the following:
tion details. Table 16: Nominal Manifold Pressure
1. Turn gas and electrical supplies on and follow the operating NOMINAL MANIFOLD PRESSURE
instructions to place the unit back in operation.
Natural Gas 3.5" w.c. (0.87 kPa)
Table 15: Inlet Gas Pressure Range Propane (LP) Gas 10.0" w.c. (2.488 kPa)
INLET GAS PRESSURE RANGE
Natural Gas Propane (LP)
OUTLET VENT PORT
Minimum 4.5” w.c. (1.12 kPa) 8.0” w.c. (1.99 kPa) PRESSURE
Maximum 10.5” w.c. (2.61 kPa) 13.0” w.c. (3.24 kPa). PORT
INLET OUTLET
FF
WRENCH O
BOSS
The inlet gas pressure operating range table specifies what the INLET N MAIN REGULATOR
O
minimum and maximum gas line pressures must be for the furnace PRESSURE ADJUSTMENT
to operate safely. The gas line pressure MUST BE a minimum of: PORT ON/OFF SWITCH
(Shown in ON position)
• 7” w.c. (1.74 kPA) for Natural Gas
• 11” w.c. (2.74 kPA) for Propane (LP) Gas FIGURE 40: Gas Valve
in order to obtain the BTU input specified on the rating plate and/or
the nominal manifold pressure specified in these instructions and
on the rating plate.

2. Once the correct gas inlet pressure has been established, see If gas valve regulator is turned in (clockwise), manifold pressure is
Table 15, turn the gas valve to OFF and turn the electrical supply increased. If screw is turned out (counterclockwise), 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
gas valve to OFF and turn the electrical supply switch to OFF; then
Read the manifold gas pressure 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 6. Turn the electrical and gas supplies back on, and with the burners
pressure. Refer to Figure 41 for connection details. in operation, check for gas leakage around the gas valve pressure
port for leakage using an approved non-corrosive gas leak detec-
tion fluid, or other non-flammable leak detection methods.

Johnson Controls Unitary Products 31

364861-UIM-D-1209

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
PRESSURE TAP
about six feet (1.8 m) from the furnace where they will not be affected
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
SENSOR speed taps are located on the furnace control board in the blower com-
partment. Refer to Figure 42, 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
3.5 IN and connected to the desired motor lead. Place all unused motor leads
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

FIGURE 41: Reading Gas Pressure the motor will result.

ADJUSTMENT OF TEMPERATURE RISE ADJUSTMENT OF FAN CONTROL SETTINGS

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 Table 6.
four pins as shown in Figure 42.
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.

TWIN
PARK PARK
Blower Off Delay Timer
Adjustment Jumper
120 DELAY
180

90 BLOWER
60

(in seconds) HI COOL

OFF
Y/Y2

HEAT
W

EAC-H
R
G

L1
C

XFMR
NEUTRALS

HUM

FIGURE 42: Furnace Control Board

32 Johnson Controls Unitary Products

 364861-UIM-D-1209

Table 17: Blower Performance CFM - Any Position (without filter) - Bottom Return

Bottom Airflow Data (SCFM)

Models
Speed Ext. Static Pressure (in. H2O)
Input/Airflow/Cabinet
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
High 1128 1077 1035 996 950 891 842 781 708 646
Medium High 934 909 867 834 818 780 745 696 631 584
40/800/A
Medium Low 746 735 714 679 653 629 596 585 547 494
Low 676 652 627 601 581 542 516 474 441 383
High 1360 1290 1230 1165 1103 1043 983 925 820 776
Medium High 1251 1198 1140 1089 1038 979 916 854 790 718
60/1000/A
Medium Low 1081 1062 1015 964 917 871 819 767 710 634
Low 909 900 852 812 769 739 712 662 612 547
High 1492 1442 1378 1325 1243 1176 1075 966 849 655
Medium High 1236 1201 1161 1139 1082 1011 919 830 715 590
60/1200/B
Medium Low 986 950 961 916 872 831 757 703 600 510
Low 824 795 783 744 713 659 624 554 489 389
High 1597 1537 1484 1435 1370 1286 1230 1155 1075 925
Medium High 1338 1307 1273 1223 1179 1123 1065 998 928 812
80/1200/B
Medium Low 1113 1094 1077 1043 1008 972 924 868 803 798
Low 937 916 900 877 854 817 775 718 639 560
High 1919 1865 1802 1738 1671 1600 1517 1414 1322 1201
Medium High 1532 1533 1513 1499 1465 1416 1352 1283 1198 1084
80/1600/C
Medium Low 1232 1313 1291 1280 1250 1209 1207 1148 1055 937
Low 826 821 853 858 838 817 794 776 760 711
High 2529 2435 2338 2256 2162 2041 1920 1794 1654 1501
Medium High 2166 2111 2070 2001 1927 1849 1719 1614 1499 1344
80/2200/C
Medium Low 1697 1685 1664 1631 1586 1531 1466 1393 1315 1185
Low 1383 1377 1358 1336 1285 1244 1199 1147 1048 925
High 1909 1880 1823 1776 1706 1637 1562 1474 1375 1252
Medium High 1465 1463 1469 1485 1477 1416 1386 1324 1250 1114
100/1600/C
Medium 1190 1222 1216 1215 1224 1189 1158 1145 1087 996
Low 787 834 819 836 819 810 790 761 690 707
High 2284 2205 2114 2021 1934 1848 1752 1653 1505 1397
Medium High 1967 1905 1824 1763 1712 1628 1551 1473 1379 1213
100/2000/C
Medium Low 1610 1563 1513 1480 1430 1367 1319 1261 1101 1012
Low 1326 1304 1267 1232 1183 1143 1080 1003 871 798
High 2020 1994 1958 1878 1805 1740 1647 1560 1445 1294
Medium High 1551 1559 1549 1520 1494 1451 1383 1334 1253 1145
120/1600/D
Medium Low 1270 1267 1269 1269 1254 1227 1185 1121 1051 985
Low 932 916 905 894 876 828 803 725 754 696
High 2341 2245 2153 2072 1977 1876 1769 1642 1506 1306
Medium High 2002 1952 1878 1823 1739 1657 1563 1458 1322 1185
120/2000/D
Medium Low 1615 1579 1533 1473 1430 1368 1282 1186 1091 953
Low 1352 1295 1259 1245 1190 1141 1076 998 938 820
High 2412 2329 2247 2173 2047 1980 1887 1777 1655 1511
Medium High 2040 2004 1948 1876 1786 1738 1656 1562 1461 1314
130/2000/D
Medium Low 1614 1591 1549 1531 1459 1400 1335 1267 1180 1061
Low 1327 1294 1257 1224 1198 1171 1124 1036 944 848
NOTES:
1.Airflow expressed in standard cubic feet per minute (CFM).
2.Motor voltage at 115 V.

Johnson Controls Unitary Products 33

364861-UIM-D-1209

Table 18: Blower Performance CFM - Any Position (without filter) - Left Side Return

Left Side Airflow Data (SCFM)

Models
Speed Ext. Static Pressure (in. H2O)
Input/Airflow/Cabinet
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
High 1131 1091 1053 1003 965 921 862 800 733 659
Medium High 982 959 935 887 846 795 745 675 628 595
40/800/A
Medium Low 772 736 715 689 661 642 599 568 531 493
Low 636 618 585 569 546 522 486 460 455 370
High 1431 1375 1304 1244 1178 1109 1040 963 861 805
Medium High 1280 1226 1171 1117 1059 1004 930 865 781 731
60/1000/A
Medium Low 1099 1050 1008 970 919 866 814 759 710 626
Low 914 876 842 812 770 728 694 661 612 545
High 1470 1406 1361 1309 1241 1155 1060 920 775 628
Medium High 1211 1186 1139 1101 1042 980 896 796 681 545
60/1200/B
Medium Low 970 957 927 889 853 796 745 660 568 450
Low 793 781 756 724 694 653 585 530 469 382
High 1605 1562 1514 1454 1393 1330 1251 1169 1073 940
Medium High 1372 1318 1280 1255 1205 1161 1093 1023 943 849
80/1200/B
Medium Low 1087 1073 1052 1003 993 953 897 843 775 709
Low 916 896 881 854 831 802 757 708 642 574
High 1956 1907 1846 1778 1717 1647 1573 1483 1353 1209
Medium High 1543 1543 1516 1504 1477 1446 1382 1309 1202 1099
80/1600/C
Medium Low 1238 1241 1243 1241 1252 1242 1201 1140 1074 967
Low 906 902 903 910 888 866 859 829 795 743
High 2585 2492 2405 2321 2232 2137 2015 1902 1745 1577
Medium High 2098 2067 2036 1982 1928 1860 1767 1670 1549 1331
80/2200/C
Medium Low 1619 1628 1614 1584 1545 1488 1424 1339 1216 1121
Low 1338 1347 1327 1301 1262 1199 1138 1078 1019 938
High 1828 1829 1789 1768 1727 1671 1601 1505 1390 1272
Medium High 1422 1444 1437 1424 1396 1326 1301 1253 1200 1100
100/1600/C
Medium 1224 1229 1243 1234 1219 1193 1168 1135 1088 977
Low 813 819 818 814 783 762 756 732 690 642
High 2391 2286 2165 2079 2004 1934 1839 1692 1560 1366
Medium High 1945 1878 1838 1782 1694 1642 1565 1451 1334 1163
100/2000/C
Medium Low 1549 1530 1495 1430 1431 1365 1284 1192 1097 1022
Low 1256 1229 1189 1159 1089 1033 1008 950 871 784
High 1998 1987 1914 1858 1798 1721 1629 1530 1417 1303
Medium High 1512 1506 1492 1467 1441 1406 1342 1280 1206 1097
120/1600/D
Medium Low 1217 1219 1210 1185 1174 1148 1112 1063 1012 937
Low 892 870 859 843 814 798 790 745 740 677
High 2343 2253 2167 2071 1979 1881 1785 1668 1473 1351
Medium High 1954 1892 1846 1781 1714 1637 1548 1429 1238 1171
120/2000/D
Medium Low 1596 1539 1511 1458 1399 1341 1254 1180 942 988
Low 1299 1261 1229 1177 1111 1053 993 937 882 782
High 2425 2336 2255 2157 2046 1966 1865 1758 1615 1420
Medium High 1979 1959 1899 1825 1773 1686 1619 1516 1376 1225
130/2000/D
Medium Low 1582 1567 1540 1488 1443 1406 1336 1252 1146 1033
Low 1305 1287 1239 1194 1159 1126 1062 1003 943 831
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 motor side (right side) may be slightly less than the data shown above.

34 Johnson Controls Unitary Products

 364861-UIM-D-1209

SECTION X: SAFETY CONTROLS Intermittent Blower - Cooling

CONTROL CIRCUIT FUSE Cooling/heating thermostats have a fan switch that has an ON and
AUTO position. In the AUTO position the thermostat circuit is completed
A 3-amp fuse is provided on the control circuit board to protect the 24- between terminals R and G when there is a call for cooling. The motor
volt transformer from overload caused by control circuit wiring errors. will operate on the speed tap wire that is connected to the “HI COOL”
This is an ATO 3, automotive type fuse and is located on the control cooling terminal on the control board. The fan off setting is fixed at 60
board. seconds to improve cooling efficiency.

BLOWER DOOR SAFETY SWITCH Heating Cycle

When the thermostat switch is set on HEAT and the fan is set on AUTO,
and there is a call for heat, a circuit is completed between terminals R
and W of the thermostat. When the proper amount of combustion air is
being provided, the pressure switch will close, the ignition control pro-
Main power to the unit must still be interrupted at the main power
disconnect switch before any service or repair work is to be done to vides a 17-second ignitor warm-up period, the gas valve then opens,
the unit. Do not rely upon the interlock switch as a main power dis- the gas starts to flow, ignition occurs and the flame sensor begins its
connect. sensing function. The blower motor will energize 30 seconds after the
Blower and burner must never be operated without the blower gas valve opens, if a flame is detected. Normal furnace operation will
panel in place. continue until the thermostat circuit between R and W is opened, which
causes the ignition system and gas valve to de-energize and the burner
This unit is equipped with an electrical interlock switch mounted in the flames to be extinguished. The vent motor will operate for 15 seconds
burner compartment. This switch interrupts all power at the unit when and the blower motor will operate for the amount of time set by the fan-
the panel covering the blower compartment is removed. off delay jumper located on the control board. See Figure 42. The heat-
Electrical supply to this unit is dependent upon the panel that covers the ing cycle is now complete, and ready for the start of the next heating
blower compartment being in place and properly positioned. cycle.
If the flame is not detected within 7 seconds of the gas valve opening,
ROLLOUT SWITCH CONTROLS the gas valve is shut off and a retry operation begins. Also, if the flame
These controls are mounted on the burner assembly. If the temperature is lost for 2 seconds during the 10-second stabilization period, the gas
in the area surrounding burner exceeds its set point, the gas valve is valve is shut off and a retry operation begins. During a retry operation,
de-energized. The operation of this control indicates a malfunction in the vent motor starts a 15 second inter-purge and the ignitor warm-up
the combustion air blower, heat exchanger or a blocked vent pipe con- time is extended to 27 seconds. If the flame is established for more than
nection. Corrective action is required. These are manual reset controls 10 seconds after ignition during a retry, the control will clear the ignition
that must be reset before operation can continue. attempt (retry) counter. If three retries occur during a call for heat, the
furnace will shut down for one hour. If at the end of the one hour shut
PRESSURE SWITCHES down there is a call for heat, the furnace will initiate a normal start cycle.
This furnace is supplied with two pressure switches, which monitor the If the problem has not been corrected the furnace will again lockout
flow through the combustion air/vent piping and condensate drain sys- after three retries.
tem. These switches de-energize the gas valve if any of the following A momentary loss of gas supply, flame blowout, or a faulty flame probe
conditions are present. Refer to "CONDENSATE PIPING AND FUR- circuit will result in a disruption in the flame and be sensed within 1.0
NACE VENTING CONFIGURATION" for tubing connections. seconds. The gas valve will de-energize and the control will begin a
1. Blockage of vent piping or terminal. recycle operation. A normal ignition sequence will begin after a 15 sec-
ond inter-purge. If during the five recycles the gas supply does not
2. Failure of combustion air blower motor.
return, or the fault condition is not corrected the ignition control will lock-
3. Blockage of combustion air piping or terminals. out for 60 minutes.
4. Blockage of condensate drain piping. During burner operation, a momentary loss of power for 50 milliseconds
LIMIT CONTROLS 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
There is a high temperature limit control located on the furnace vesti- immediately restart.
bule panel near the gas valve. This is an automatic reset control that
provides over temperature protection due to reduced airflow. This may TROUBLESHOOTING
be caused by: The following visual checks should be made before troubleshooting:
1. A dirty filter. 1. Check to see that the power to the furnace and the ignition control
2. If the indoor fan motor should fail. module is ON.
3. Too many supply or return registers closed or blocked off. 2. The manual shut-off valves in the gas line to the furnace must be
The control module will lockout if the limit trips 5 consecutive times. If open.
this occurs, control will reset & try ignition again after 1 hour. 3. Make sure all wiring connections are secure.
4. Review the sequence of operation. Start the system by setting the
SECTION XI: NORMAL OPERATION AND thermostat above the room temperature. Observe the system’s
DIAGNOSTICS response. Then use the troubleshooting section in this manual to
check the system’s operation.
NORMAL OPERATION SEQUENCE
The following describes the sequence of operation of the furnace. Refer
to Owners Manual for component location.
Continuous Blower Never bypass any safety control to allow furnace operation. To
do so will allow furnace to operate under potentially hazardous
Cooling/heating thermostats have a fan switch that has an ON and conditions.
AUTO position. In the ON position the thermostat circuit is completed Do not try to repair controls. Replace defective controls with
between terminals R and G. The motor will operate continuously on the UPG Source 1 Parts.
speed tap wire that is connected to the “HI COOL” cooling terminal on Never adjust pressure switch to allow furnace operation.
the control board. To obtain a constant air circulation at lower flow rate,
change the high-speed wire to another lower speed wire.

Johnson Controls Unitary Products 35

364861-UIM-D-1209

FURNACE CONTROL DIAGNOSTICS 9 RED FLASHES: Indicates reversed line voltage polarity or grounding
problem. Both heating and cooling operations will be affected. Check
The furnace has built-in, self-diagnostic capability. If a system problem
occurs, a blinking LED can flash red, green or amber to indicate various polarity at furnace and branch. Check furnace grounding. Check that
flame probe is not shorted to chassis.
conditions.
10 RED FLASHES: Flame sensed with no call for heat. Check gas
The control continuously monitors its own operation and the operation
valve and gas valve wiring.
of the system. If a failure occurs, the LED will indicate the failure code. If
the failure is internal to the control, the light will stay on continuously. In 11 RED FLASHES: This indicates that a primary or auxiliary limit switch
this case, the entire control should be replaced, as the control is not has opened its normally-closed contacts and has remained open for
field repairable. more than five minutes. This condition is usually caused by a failed
blower motor or blower wheel. Cycle power (24 VAC) to the control to
Flash sequence codes 1 through 11 are as follows: LED will turn ON for
reset the hard lockout condition after correcting the failure condition.
1/4 second and OFF for 1/4 second. This pattern will be repeated the
number of times equal to the code. For example, six ON flashes equals 12 RED FLASHES: This code indicates an open igniter circuit, which
could be a disconnected or loose wire or a cracked or broken igniter.
a number 6 fault code. All flash code sequences are broken by a 2 sec-
ond OFF period. STEADY ON RED: Control failure. Replace control board.
SLOW GREEN FLASH: Normal operation. 60-MINUTE AUTOMATIC RESET FROM LOCKOUT: This control
includes a “watchdog” type circuit that will reset from a lockout condition
SLOW AMBER FLASH: Normal operation with call for heat.
after 60 minutes. Operational faults 6,7,8 will be reset. This provides
RAPID RED FLASH: Twinning error, incorrect 24V phasing. Check protection to an unoccupied structure if a temporary condition exists
twinning wiring.
causing a furnace malfunction. An example would be a low incoming
RAPID AMBER FLASH: Flame sense current is below 1.5 microamps. gas supply pressure preventing unit operation. When the gas pressure
Check and clean flame sensor. Check for proper gas flow. Verify that is restored, at some point the “watchdog” would restart the unit and pro-
current is greater than 1.5 microamps at flame current test pad. vide heat for the house.
4 AMBER FLASHES: The control is receiving a “Y” signal from the
thermostat without a “G” signal, indicating improper thermostat wiring.
1 RED FLASH: This indicates that flame was sensed when there was
NOTICE
not a call for heat. The control will turn on both the inducer motor and If a flame is detected the control flashes the LED for 1/8 of a second
supply air blower. A gas valve that leaks or is slow closing would typi- and then enters a flame stabilization period.
cally cause this fault.
IGNITION CONTROL FLAME SENSE LEVELS
2 RED FLASHES: This indicates that the normally open pressure
Normal flame sense current is approximately
switch contacts are stuck in the closed position. The control confirms
3.7 microamps DC (µa)
these contacts are open at the beginning of each heat cycle. This would
Low flame signal warning starts at 1.5 microamps.
indicate a faulty pressure switch or miswiring.
Low flame signal control lockout point is
3 RED FLASHES: This indicates the normally open pressure switch 0.1 microamps DC (µa)
contact did not close after the inducer was energized. This could be
caused by a number of problems: faulty inducer, blocked vent pipe, bro- DIAGNOSTIC FAULT CODE STORAGE AND
ken pressure switch hose or faulty pressure switch. RETRIEVAL
4 RED FLASHES: This indicates that the main limit switch has opened The control in this furnace is equipped with memory that will store up to
its normally closed contacts. The control will operate the supply air five error codes to allow a service technician to diagnose problems
blower and inducer. This condition may be caused by: dirty filter, more easily. This memory will be retained even if power to the furnace
improperly sized duct system, incorrect blower speed setting, incorrect is lost. This feature should only be used by a qualified service tech-
firing rate or faulty blower motor. Also, this fault code could be caused nician.
by a blown fuse located on the control board.
If more than five error codes have occurred since the last reset, only the
5 RED FLASHES: This fault is indicated if the normally closed contacts five most recent will be retained. The furnace control board has a but-
in the rollout switch opens. The rollout control is manually reset. If it has ton, labeled "LAST ERROR" that is used to retrieve error codes. This
opened, check for proper combustion air, proper inducer operation, and function will only work if there are no active thermostat signals. So any
primary heat exchanger failure or burner problem. Be sure to reset the call for heating, cooling or continuous fan must be terminated before
switch and cycle power (24 VAC) to the control after correcting the fail- attempting to retrieve error codes.
ure condition. Also, this fault code could be caused by a blown fuse
located on the control board. To retrieve the error codes, push the LAST ERROR button. The LED on
the control will then flash the error codes that are in memory, starting
6 RED FLASHES: This indicates that after the unit was operating, the
with the most recent. There will be a two-second pause between each
pressure switch opened 4 times during the call for heat. If the main
flash code. After the error codes have all been displayed, the LED will
blower is in a “Delay on” mode, it will complete it, and any subsequent
resume the normal slow green flash after a five second pause. To
delay off period. The furnace will lock out for one hour and then restart.
repeat the series of error codes, push the button again.
7 RED FLASHES: This fault code indicates that the flame could not be
If there are no error codes in memory, the LED will flash two green
established. This no-light condition occurred 3 times (2 retries) during
flashes. To clear the memory, push the LAST ERROR button and hold it
the call for heat before locking out. Low gas pressure, faulty gas valve,
for more than five seconds. The LED will flash three green flashes when
dirty or faulty flame sensor, faulty hot surface ignitor or burner problem
the memory has been cleared, then will resume the normal slow green
may cause this. The furnace will lock out for one hour and then restart.
flash after a five-second pause.
8 RED FLASHES: This fault is indicated if the flame is lost 5 times (4
recycles) during the heating cycle. This could be caused by low gas
pressure, dirty or faulty flame sensor or faulty gas valve. The furnace
will lock out for one hour and then restart.

36 Johnson Controls Unitary Products

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Thermostat Calling for Heat Thermostat Satisfied

(Seconds) 02 17 22 52 0

Fan on Delay
30 Seconds
ON
THERMOSTAT
OFF OFF
ON
INDUCER
OFF 15 OFF
Sec.
ON Post
IGNITOR OFF OFF Purge OFF
ON
MAIN VALVE
OFF OFF
ON
HUMIDIFIER
OFF OFF OFF
ELECTRONIC ON
AIR CLEANER OFF OFF OFF
CIRCULATING ON
BLOWER OFF OFF OFF
60, 90, 120, 180 SEC.
Selectable Fan Off Delay

FIGURE 43: Furnace Control Event Schedule

SECTION XII: REPLACEMENT PARTS LIST

DESCRIPTION DESCRIPTION
MOTOR FABRICATED PARTS Continued
MOTOR, DIRECT DRIVE BLOWER MANIFOLD, GAS
BLOWER, COMBUSTION PAN, BOTTOM
ELECTRICAL PANEL, TOP
CAPACITOR, RUN PANEL, DOOR (2 Req’d)
SWITCH, LIMIT PANEL, BLOCKOFF
CONTROL, FURNACE MISCELLANEOUS
IGNITER ORIFICE, BURNER (Natural #45)
SENSOR, FLAME SIGHT GLASS, OVAL (2 Req’d)
SWITCHES, PRESSURE GASKET, FOAM (Door) (1.5 ft req’d)
SWITCH, DOOR PAN, CONDENSATE
TRANSFORMER BRACKET, DOOR
VALVE, GAS HARNESS, WIRING
CONTROL, TEMPERATURE FERRULE (3 Req’d)
AIR MOVING GROMMET (3 Req’d)
HOUSING, BLOWER MOTOR MOUNT
WHEEL, BLOWER TUBING, SILICON
FABRICATED PARTS HOSE, RAIN GUTTER
RESTRICTOR, COMBUSTION BLOWER HOSE, CONDENSATE
BURNER, MAIN GAS PLUG, SEAL, 7/8”
BRACKET, IGNITER PLUG, SEAL, 2-3/8”
SHELF, BLOWER PLUG, VENT PIPE
RAIL, BLOWER (2 Req’d) BAG, PARTS
BRACKET, BLOWER TRACK (2 Req’d) KNOB, QUARTER TURN (4 Req’d)
HEAT EXCHANGER ASS’Y DIAGRAM, WIRING

REPLACEMENT PART CONTACT INFORMATION

This is a generic parts list. To request a complete parts list, refer to the contact information below:
• Visit our website at www.source1parts.com for the following information:
1. Search for a part or browse the catalog.
2. Find a dealer or distributor.
3. Customer Service contact information.
a. Click on the “Brand Links” button
b. Click on the “Customer Service” buttont
• You can contact us by mail. Just send a written request to:
Johnson Controls Unitary Products
Consumer Relations
5005 York Drive
Norman, OK 73069

Johnson Controls Unitary Products 37

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SECTION XIII: WIRING DIAGRAM

FIGURE 44: Wiring Diagram

38 Johnson Controls Unitary Products

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NOTES

Johnson Controls Unitary Products 39

 NOTES

Subject to change without notice. Published in U.S.A. 364861-UIM-D-1209

Copyright © 2009 by Johnson Controls, Inc. All rights reserved. Supersedes: 364861-UIM-C-0709

Johnson Controls Unitary Products

5005 York Drive
Norman, OK 73069