Installation Guide

ManualsBrandsWinchester ManualsForced Air Furnaces80,000 BTU 80% Efficient Residential Forced-Air Multi-Positional Single Stage Gas Furnace with ECM Blower Motor

Johnson Controls Ducted Systems 5594752-UIM-B-0419

SINGLE STAGE ECM

RESIDENTIAL GAS FURNACES

MODELS: TM8E, TMLE

(80% Multi-Position/Standard & Low NOx)

INSTALLATION MANUAL

LIST OF SECTIONS

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

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

FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

VENT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . 16

SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . 25

REPLACEMENT PART CONTACT INFORMATION . . . . . . . . 25

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

START UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

LIST OF FIGURES

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

Furnace and Coil Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

Horizontal Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Typical Attic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Thermostat Chart - Single Stage AC with

Single Stage Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Thermostat Chart - Single Stage HP with

Single Stage Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Combustion Air Inducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Combustion Airflow Path Through The Furnace Casing to the Burner

Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . .15

Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

LIST OF TABLES

Unit Clearances to Combustibles (All Dimensions in

Inches and cm, and All Surfaces Identified with the

Unit in an Upflow Configuration) . . . . . . . . . . . . . . . . . . . . . . . . . 4

Cabinet and Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Recommended Filter Sizes (High Velocity 600 FPM) . . . . . . . . . 8

Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Ratings & Physical / Electrical Data . . . . . . . . . . . . . . . . . . . . . 11

Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Unconfined Space Minimum Area . . . . . . . . . . . . . . . . . . . . . . . 14

Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Gas Rate (CU FT/HR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Default Blower Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Blower Performance CFM - Any Position (without filter) . . . . . . 21

These high efficiency, compact units employ induced combustion, reli-

able hot surface ignition and high heat transfer aluminized tubular heat

exchangers. The units are factory shipped for installation in upflow or

horizontal applications and may be converted for downflow applica-

tions.

These furnaces are designed for residential installation in a basement,

closet, alcove, attic, recreation room or garage and are also ideal for

commercial applications. All units are factory assembled, wired and

tested to assure safe dependable and economical installation and oper-

ation.

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

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

SECTION I: SAFETY

This is a safety alert symbol. When you see this symbol on

labels or in manuals, be alert to the potential for personal

injury.

Understand and pay particular attention to the signal words DANGER,

WARNING, or CAUTION.

DANGER indicates an imminently hazardous situation, which, if not

avoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation, which, if not

avoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation, which, if not

avoided may result in minor or moderate injury. It is also used to

alert against unsafe practices and hazards involving only property dam-

age.

WARNING

Improper installation may create a condition where the operation of

the product could cause personal injury or property damage.

Improper installation, adjustment, alteration, service or maintenance

can cause injury or property damage. Failure to carefully read and

follow all instructions in this manual can result in furnace mal-

function, death, personal injury and/or property damage. Only a

qualified contractor, installer or service agency should install this

product.

Summary of content (28 pages)

PAGE 1
INSTALLATION MANUAL SINGLE STAGE ECM RESIDENTIAL GAS FURNACES MODELS: TM8E, TMLE (80% Multi-Position/Standard & Low NOx) LIST OF SECTIONS SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 2
5594752-UIM-B-0419 SPECIFIC SAFETY RULES AND PRECAUTIONS 1. Only Natural gas or Propane (LP) gas are approved for use with this furnace. 2. Install this furnace only in a location and position as specified in these instructions. 3. A gas-fired furnace for installation in a residential garage must be installed as specified in these instructions. 4. Provide adequate combustion and ventilation air to the furnace space as specified in these instructions. 5. Combustion products must be discharged outdoors.
PAGE 3
5594752-UIM-B-0419 COMBUSTION AIR QUALITY (LIST OF CONTAMINANTS) The furnace requires OUTDOOR AIR for combustion when the furnace is located in any of the following environments.
PAGE 4
5594752-UIM-B-0419 INSPECTION FOR FURNACES INSTALLED IN THE COMMONWEALTH OF MASSACHUSETTS ONLY For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements
PAGE 5
594752-UIM-B-0419 SECTION II: DUCTWORK DUCTWORK GENERAL INFORMATION The duct system’s design and installation must: 1. Handle an air volume appropriate for the served space and within the operating parameters of the furnace specifications. 2. Be installed in accordance of National Fire Protection Association as outlined in NFPA standard 90B (latest editions) or applicable national, provincial, state, and local fire and safety codes. 3. Create a closed duct system.
PAGE 6
5594752-UIM-B-0419 COIL INSTALLATION IMPORTANT: On all installations without a coil, a removable access panel is recommended in the outlet duct such that smoke or reflected light would be observable inside the casing to indicate the presence of leaks in the heat exchanger. This access cover shall be attached in such a manner as to prevent leaks. 83)/2: $33/,&$7,21 '2:1)/2: $33/,&$7,21 The indoor coil must be mounted on the supply side of the furnace as shown in Figure 2.
PAGE 7
5594752-UIM-B-0419 DOWNFLOW APPLICATION For downflow applications, the furnace must be turned upside-down so that the circulating air enters at the top and exits the furnace at the bottom. The combustion air inducer must be rotated 90° as shown in Figure 14. DO NOT BLOCK COMBUSTION AIR INLET OPENINGS. 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.
PAGE 8
5594752-UIM-B-0419 /()7 6,'( )5217 9HQW &RQQHFWLRQ 2XWOHW (OHFWULFDO (QWU\ *DV 3LSH (QWU\ *DV 3LSH (QWU\ ´ ´ 7KHUPRVWDW :LULQJ 7KHUPRVWDW :LULQJ ´ $ ´ ´ ´ ´ ´ 'LDPHWHU 9HQW &RQQHFWLRQ 2XWOHW ´ ´ 5,*+7 6,'( (OHFWULFDO (QWU\ 9HQW &RQQHFWLRQ 2XWOHW ´ ´ % % & ´ ´ ´ 5(7851 (1' 6833/< (1' $ FIGURE 7: Dimensions Table 2: Cabinet and Duct Dimensions Nominal CFM (m /min) Cabinet Size A A (cm) B B (cm) C C (cm) Lbs 40 (11.
PAGE 9
5594752-UIM-B-0419 SECTION IV: GAS PIPING SIDE RETURN Locate the “L” shaped corner locators. These indicate the size of the cutout to be made in the furnace side panel. Refer to Figure 8. GAS SAFETY ! DANGER An overpressure protection device, such as a pressure regulator, must be installed in the gas piping system upstream of the furnace and must act to limit the downstream pressure to the gas valve so it does not exceed 0.5 PSI (14" w.c., 3.48 kPa). Pressures exceeding 0.5 PSI (14” w.c., 3.
PAGE 10
5594752-UIM-B-0419 IMPORTANT: An accessible manual shutoff valve must be installed upstream of the furnace gas controls and within 6 feet (1.8 m) of the furnace. The furnace must be isolated from the gas supply piping system by closing its individual external manual shutoff valve during any pressure testing of the gas supply piping system at pressures equal to or less than 1/2 psig (3.5 kPa).
PAGE 11
5594752-UIM-B-0419 Table 5: Ratings & Physical / Electrical Data Input Nominal Airflow Output MBH kW MBH kW CFM 40 60 80 80 80 100 100 100 120 120 130 11.7 17.6 23.5 23.5 23.5 29.3 29.3 29.3 33.7 33.7 38.1 32 48 64 64 64 80 80 80 96 96 104 9.4 14.1 18.8 18.8 18.8 23.4 23.4 23.4 26.9 26.9 30.5 1200 1200 1200 1600 2000 1200 1600 2000 1600 2000 2000 m3/min 34.0 34.0 34.0 45.3 56.6 34.0 45.3 56.6 45.3 56.6 56.6 AFUE 80.0 80.0 80.0 80.0 80.0 80.0 80.0 80.0 80.0 80.0 80.0 Air Temp. Rise Max.
PAGE 12
5594752-UIM-B-0419 6LQJOH 6WDJH $LU &RQGLWLRQHU ± 6LQJOH 6WDJH )XUQDFH 7+(50267$7 6,1*/( 67$*( (&0 )XUQDFH 6,1*/( 67$*( $,5 &21',7,21(5 & ± 9ROW &RPPRQ & ± 9ROW &RPPRQ & ± 9ROW &RPPRQ 5 ± 9ROW +RW 5 ± 9ROW +RW 5 ± 9ROW +RW * )DQ * )DQ < )LUVW 6WDJH &RPSUHVVRU < < )XOO 6WDJH &RPSUHVVRU : )LUVW 6WDJH +HDW : )XOO 6WDJH +HDW RU 2 < )LUVW 6WDJH &RPSUHVVRU 5HYHUVLQJ 9DOYH < &RPSUHVVRU &RQWDFWRU < 6HFRQG 6WDJH &RPSUHVVRU : 6HFRQG 6WDJH +HDW $ FIGURE 12: The
PAGE 13
5594752-UIM-B-0419 ACCESSORY CONNECTIONS The furnace control will allow power-switching control of various accessories. ELECTRONIC AIR CLEANER CONNECTION Two 1/4” (6.4 mm) spade terminals (EAC and NEUTRAL) for electronic air cleaner connections are located on the control board. The terminals provide 115VAC (1.0 Amp maximum) during circulating blower operation. HUMIDIFIER CONNECTION Two 1/4” (6.4 mm) spade terminals (HUM and NEUTRAL) for humidifier connections are located on the control board.
PAGE 14
5594752-UIM-B-0419 Dampers, Louvers and Grilles (Canada Only) 1. The free area of a supply air opening shall be calculated by subtracting the blockage area of all fixed louvers grilles or screens from the gross area of the opening. 2. Apertures in a fixed louver, a grille, or screen shall have no dimension smaller than 1/4” (6.4 mm). 3. A manually operated damper or manually adjustable louvers are not permitted for use. 4.
PAGE 15
5594752-UIM-B-0419 9HQWLODWHG $WWLF 7RS $ERYH ,QVXODWLRQ 2XWOHW $LU D *DV :DWHU +HDWHU $ *DV 9HQW *DV 9HQW 9HQWLODWHG $WWLF 7RS $ERYH ,QVXODWLRQ 6RIILW 9HQW 9HQWLODWHG &UDZO 6SDFH ,QOHW $LU E 2XWOHW $LU D 2XWOHW $LU E *DV :DWHU +HDWHU ,QOHW $LU D ,QOHW $LU E *DV :DWHU +HDWHU )XUQDFH 6RIILW 9HQW *DEOH 9HQW )XUQDFH 2SWLRQDO ,QOHW D *DV 9HQW )XUQDFH *DEOH 9HQW ,QOHW $LU D FIGURE 16: Outside and Ambient Combustion Air Air Supply Openings and Ducts 1.
PAGE 16
5594752-UIM-B-0419 ! WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbonmonxide 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.
PAGE 17
5594752-UIM-B-0419 GAS PIPING LEAK CHECK ! WARNING FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in serious injury, death or property damage. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life.
PAGE 18
5594752-UIM-B-0419 Table 9: Gas Rate (CU FT/HR) Seconds For 1 Revolution 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 18 1 Cu Ft 360 327 300 277 257 240 225 212 200 189 180 171 164 157 150 144 138 133 129 124 120 116 113 109 106 103 100 97 95 92 90 88 86 84 82 80 78 76 75 73 Size of Test Dial 2 Cu Ft 720 655 600 555 514 480 450 424 400 379 360 343 327 313 300 288 277 267 257 248 240 232 225 218 212 206 200 195 189 185 180 176 172
PAGE 19
5594752-UIM-B-0419 ADJUSTMENT OF MANIFOLD GAS PRESSURE & INPUT RATE Inlet and manifold gas pressure may be measured by connecting the “U” tube manometer to the gas valve with a piece of tubing. Follow the appropriate section in the instructions below. Refer to Figure 17 for a drawing of the locations of the pressure ports on the gas valve. Turn gas off at the ball valve or gas cock on gas supply line before the gas valve. Find the pressure ports on the gas valve marked Out P and In P. 1.
PAGE 20
5594752-UIM-B-0419 AIRFLOW SETTINGS Gas Heating Airflow Default Setting Cooling Airflow Settings This unit is equipped with a five-speed blower motor. The heating blower speed is set at the factory to the default blower speed, which is the blower speed that will deliver the correct airflow for proper heating operation in most applications. The default heating blower speed for each model is shown in Table 12.
PAGE 21
5594752-UIM-B-0419 DIAGNOSTIC ERROR CODE RETRIEVAL BUTTON BLOWER OFF DELAY JUMPER ELECTRONIC AIR CLEANER TERMINAL CONTINUOUS FAN SPEED JUMPER HUMIDIFIER TERMINAL FIGURE 19: Furnace Control Board Table 13: Blower Performance CFM - Any Position (without filter) Airflow Data (SCFM)1, 2 Models 040A12 060A12 080B12 080C16 080C20 100B12 Speed High Medium High Medium Medium Low Low High Medium High Medium Medium Low Low High Medium High Medium Medium Low Low High Medium High Medium Medium Low Low High
PAGE 22
5594752-UIM-B-0419 Table 13: Blower Performance CFM - Any Position (without filter) (Continued) Airflow Data (SCFM)1, 2 Models Speed High Medium High Medium Medium Low Low High Medium High Medium Medium Low Low High Medium High Medium Medium Low Low High Medium High Medium Medium Low Low High Medium High Medium Medium Low Low 100C16 100C20 120C16 120C20 130D20 Ext. Static Pressure (in. H2O) 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.
PAGE 23
5594752-UIM-B-0419 SEQUENCE OF OPERATION The following describes the sequence of operation of the furnace. Refer to Owners Manual for component location. Continuous Blower Cooling/heating thermostats have a fan switch that has an ON and AUTO position. In the ON position the thermostat circuit is completed between terminals R and G. The motor will operate continuously on the speed selected on the “FAN SPEED” jumper on the main control board.
PAGE 24
5594752-UIM-B-0419 3 RED FLASHES: This indicates the pressure switch contacts are open when they should be closed. Check for faulty inducer, blocked vent pipe, broken pressure switch hose, disconnected pressure switch or inducer wires or faulty pressure switch. 4 RED FLASHES: This indicates that the main limit switch has opened its normally closed contacts. The control will operate the supply air blower and inducer while the open limit condition exists.
PAGE 25
5594752-UIM-B-0419 SECTION IX: REPLACEMENT PARTS LIST DESCRIPTION MOTOR MOTOR, DIRECT DRIVE BLOWER BLOWER, COMBUSTION ELECTRICAL CAPACITOR, RUN SWITCH, LIMIT CONTROL, FURNACE IGNITER SENSOR, FLAME SWITCH, PRESSURE SWITCH, DOOR TRANSFORMER VALVE, GAS CONTROL, TEMPERATURE AIR MOVING HOUSING, BLOWER HOUSING, BLOWER w/WHEEL WHEEL, BLOWER FABRICATED PARTS BAFFLE, FLUE BURNER, MAIN GAS BRACKET, IGNITER SHELF, BLOWER RAIL, BLOWER (2 Req’d) DESCRIPTION (Continued) FABRICATED PARTS BRACKET, BLOWER TRACK (2 Req’d)
PAGE 26
5594752-UIM-B-0419 SECTION X: WIRING DIAGRAM Wiring Diagram - 80% Standard ECM Furnace CAUTION PRECAUTION OUVREZ LES DISJONCTEURS AVANT DE PROCEDER AVEC LE SERVICE OPEN ALL DISCONNECTS BEFORE SERVICING THIS UNIT GND LS 7 4 8 5 9 6 1 2 3 3 4 2 1 DS Door switch ROS - Rollout switch PS Pressure switch TST - Wall thermostat HSI - Hot surface igniter MOT - Circulating motor IDM - Inducer motor FS Flame sensor GV Gas valve EAC - Electronic air cleaner LS Limit switch HUM - Humidifier XFMR - Trans
PAGE 27
5594752-UIM-B-0419 SECTION XI: START UP SHEET 33" 80% AFUE Single Stage Gas Furnace Start Up Sheet Proper furnace start up is critical to customer comfort and equipment longevity Start-Up Date Technician Performing Start-Up Installing Contractor Name Owner Information Name Address City State or Province Zip or Postal Code Equipment Data Furnace Model Furnace Serial Indoor Coil Model Indoor Coil Serial Outdoor Unit Model Outdoor Unit Serial Furnace Configuration Horizontal Left Horizontal Righ
PAGE 28
Gas Side Gas Type Natural Gas LP Gas (Requires LP conversion kit) LP Gas Conversion Kit Part # Used LP Conversion Kit Installed By Inlet Gas Pressure (in. w.c.") Manifold Gas Pressure (in. w.c.") Calculated input in btuh - clock the gas meter (Nat Gas Only) Air Side: System External Static Pressure Supply static before indoor coil (in w.c.") Supply static after indoor coil (in w.c.") Return Static (in w.c.") before Return Static (in w.c.