Installation Guide

ManualsBrandsWinchester ManualsForced Air Furnaces120,000 BTU 96% 2-Stage Variable Speed Multi-Positional Gas Furnace

Johnson Controls Ducted Systems 5750149-UIM-D-1219

TWO STAGE VARIABLE SPEED ECM

RESIDENTIAL GAS FURNACES

MODELS: TM9V*C Series

(96% AFUE Multi-Position)

INSTALLATION MANUAL

LIST OF SECTIONS

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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

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

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

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

CONDENSATE PIPING AND FURNACE

VENTING CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . 16

COMBUSTION AIR AND VENT SYSTEM . . . . . . . . . . . . . . . . 22

START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . 30

SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

NORMAL OPERATION AND DIAGNOSTICS . . . . . . . . . . . . . 36

REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . 39

REPLACEMENT PART CONTACT INFORMATION . . . . . . . . 39

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

START UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

LIST OF FIGURES

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

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

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

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

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

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

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

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

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

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

Left Side Supply Gas Pipe Arrangement . . . . . . . . . . . . . . . . . . . . . . 9

Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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

Two-stage Furnace with Communicating AC or HP . . . . . . . . . . . . . 12

Furnace Control Board – Communications Connections . . . . . . . . . 13

Terminal Screw Wire Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Furnace with Variable Capacity AC or HP . . . . . . . . . . . . . . . . . . . . 13

Thermostat Chart - Single Stage Air Conditioner with

Two Stage Variable Speed Furnace . . . . . . . . . . . . . . . . . . . . . . . . 14

Thermostat Chart - Single Stage Heat Pump with

Two Stage Variable Speed Furnace . . . . . . . . . . . . . . . . . . . . . . . . 15

Thermostat Chart - Two Stage Air Conditioner with

Two Stage Variable Speed Furnace . . . . . . . . . . . . . . . . . . . . . . . . 15

Thermostat Chart - Two Stage Heat Pump with Two Stage

Variable Speed Furnace (Hot Heat Pump or Conventional) . . . . . . .16

Typical. Condensate Drain, Vertical Installation . . . . . . . . . . . . . . . .17

Upflow Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Downflow Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Horizontal Left Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Horizontal Right Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Home Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Termination Configuration - 1 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . .26

Termination Configuration - 2 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . .26

Termination Configuration - 2 Pipe Basement . . . . . . . . . . . . . . . . .26

Double Horizontal Combustion Air Intake and Vent Term. . . . . . . . .27

Double Vertical Combustion Air Intake and Vent Term. . . . . . . . . . .27

Downward Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Direct Vent Air Intake Connection and Vent Connection . . . . . . . . .27

Combustion Airflow Path Through The Furnace Casing . . . . . . . . .28

Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Attic and Crawl Space Combustion Air Termination . . . . . . . . . . . . .30

Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

LIST OF TABLES

Unit Clearances to Combustibles. All furnaces

approved for alcove and attic installation . . . . . . . . . . . . . . . . . . 4

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

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

Nominal Manifold Pressure - High Fire . . . . . . . . . . . . . . . . . . . 10

Nominal Manifold Pressure - Low Fire . . . . . . . . . . . . . . . . . . . 10

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

Maximum Equivalent Pipe Length . . . . . . . . . . . . . . . . . . . . . . . 23

High Altitude Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . 24

Elbow Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Equivalent Length of Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Combustion Air Intake and Vent Connection

Size at Furnace (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Unconfined Space Minimum Area . . . . . . . . . . . . . . . . . . . . . . . 28

Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Gas Rate (CU FT/HR) at Full Input . . . . . . . . . . . . . . . . . . . . . . 32

Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Default Blower Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Air Flow Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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

able hot surface ignition and high heat transfer aluminized tubular heat

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

horizontal applications and may be converted for downflow applica-

tions.

These furnaces are designed for residential installation in a basement,

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

commercial applications. All units are factory assembled, wired and

tested to assure safe dependable and economical installation and oper-

ation.

These units are Category IV listed and may not be common vented with

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

Summary of content (42 pages)

PAGE 1
INSTALLATION MANUAL TWO STAGE VARIABLE SPEED ECM RESIDENTIAL GAS FURNACES MODELS: TM9V*C Series (96% AFUE Multi-Position) LIST OF SECTIONS SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 2
5750149-UIM-D-1219 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.
PAGE 3
5750149-UIM-D-1219 COMBUSTION AIR QUALITY (LIST OF CONTAMINANTS) ! WARNING The furnace area must not be used as a broom closet or for any other storage purposes, as a fire hazard may be created. Never store items such as the following on, near or in contact with the furnace. 1. Spray or aerosol cans, rags, brooms, dust mops, vacuum cleaners or other cleaning tools. 2.
PAGE 4
5750149-UIM-D-1219 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 shall be sat
PAGE 5
750149-UIM-D-1219 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
5750149-UIM-D-1219 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. )851$&( :$50 $,5 3/(180 :,7+ ´ )/$1*(6 The indoor coil must be mounted on the supply side of the furnace as shown in Figure 3.
PAGE 7
5750149-UIM-D-1219 HORIZONTAL APPLICATION SUSPENDED FURNACE / CRAWL SPACE INSTALLATION FIGURE 4: Horizontal Application IMPORTANT: This furnace may be installed in a horizontal position on either side as shown above. It must not be installed on its back. The furnace can be hung from floor joists or installed on suitable blocks or pad. Blocks or pad installations shall provide adequate height to ensure the unit will not be subject to water damage.
PAGE 8
5750149-UIM-D-1219 /()7 6,'( &RPEXVWLRQ $LU ,QOHW 5,*+7 6,'( &RPEXVWLRQ $LU ,QOHW )5217 &RQGHQVDWH 'UDLQ 'RZQIORZ ´ 9HQW &RQQHFWLRQ 2XWOHW *DV 3LSH (QWU\ *DV 3LSH (QWU\ (OHFWULFDO (QWU\ (OHFWULFDO (QWU\ &RQGHQVDWH 'UDLQ 7KHUPRVWDW :LULQJ &RQGHQVDWH 'UDLQ 'RZQIORZ ´ 9HQW &RQQHFWLRQ 2XWOHW ´ &RQGHQVDWH 'UDLQ 7KHUPRVWDW :LULQJ 2SWLRQDO 5HWXUQ $LU &XWRXW (LWKHU VLGH ´ ´ ´ ´ ´ ´ $ ´ &RPEXVWLRQ $LU ,QOHW % ´ ´ 9HQW &RQQHFWLRQ 2XWOHW % & ´ ´
PAGE 9
5750149-UIM-D-1219 SIDE RETURN GAS PIPING INSTALLATION Locate the “L” shaped corner locator's. These indicate the size of the cutout to be made in the furnace side panel. Refer to Figures 8 and 9. )5217 2) )851$&( 6,'( 2) )851$&( &251(5 0$5.,1*6 $ FIGURE 9: Side Return Cutout Markings Install the side filter rack following the instructions provided with that accessory.
PAGE 10
5750149-UIM-D-1219 $ FIGURE 12: Gas Piping HIGH ALTITUDE GAS ORIFICE CONVERSION HIGH ALTITUDE PRESSURE SWITCH CONVERSION This furnace is constructed at the factory for natural gas-fired operation 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.
PAGE 11
5750149-UIM-D-1219 DANGER ! PROPANE AND HIGH ALTITUDE CONVERSION KITS It is very important to choose the correct kit and/or gas orifices for the altitude and the type of gas for which the furnace is being installed. Only use natural gas in furnaces designed for natural gas. Only use propane (LP) gas for furnaces that have been properly converted to use propane (LP) gas. Do not use this furnace with butane gas.
PAGE 12
5750149-UIM-D-1219 SUPPLY VOLTAGE CONNECTIONS -XQFWLRQ %R[ &RQQHFW JURXQG OHDG WR VFUHZ (OHFWULFDO (QWU\ / +RW %/. 1HXWUDO :+7 This furnace may be used with the Communicating Thermostat Control and a non-communicating outdoor air conditioner by installing the AC Communicating Control Board Kit to the outdoor unit. This system allows full communication between the furnace and thermostat and limited communication to the outdoor unit. See Figure 14.
PAGE 13
5750149-UIM-D-1219 &20081,&$7,216 $ 5 & % $ 5 & % &219(17,21$/ /2: 92/7$*( 767$7 &211(&7,216 /$67 (5525 %87721 ',$*1267,& /,*+7 &20081,&$7,216 $ 5 & % $ 5 & % 67$786 /$67 (5525 )/2$7 6:,7&+ &211(&7,21 &)0 ,1',&$725 $8; 6:7 7(03 )/7 6:7 1(875$/6 &)0 & * 7(03 6(1625 &211(&7,216 &20081,&$7,1* 767$7 &211(&7,216 5 : : $8;,/,$5< 6:,7&+ &211(&7,216 < < +80,',67$7 6(/(&7,21 < $,5)/2: 6(/(&7,2
PAGE 14
5750149-UIM-D-1219 Float Switch Input CONVENTIONAL LOW VOLTAGE CONTROL WIRING An optional switch may be connected to the FLT SWT terminals on the control board. This feature is only functional when used with the Communicating Control. It is intended for use with a water overflow switch that has contacts in either the normally open (NO) or (NC) position. Do NOT install a float switch in series with any thermostat wiring when using communicating controls.
PAGE 15
5750149-UIM-D-1219 6LQJOH 6WDJH +HDW 3XPS ± 7ZR 6WDJH 9DULDEOH 6SHHG )XUQDFH 7:2 67$*( 9$5,$%/( 63((' )851$&( 6,1*/( 67$*( +($7 3803 & ± 9ROW &RPPRQ & ± 9ROW &RPPRQ & ± 9ROW &RPPRQ 5 ± 9ROW +RW 5 ± 9ROW +RW 5 ± 9ROW +RW * )DQ * )DQ < )LUVW 6WDJH &RPSUHVVRU < < )XOO 6WDJH &RPSUHVVRU 7+(50267$7 127( 5RRP WKHUPRVWDW 0867 FRQWURO IRVVLO IXHO RSHUDWLRQ < )LUVW 6WDJH &RPSUHVVRU : )LUVW 6WDJH +HDW : : 6HFRQG 6WDJH +HDW : : )LUVW 6WDJH +HDW < 6HFRQG 6WDJH &RPSU
PAGE 16
5750149-UIM-D-1219 7ZR 6WDJH +HDW 3XPS ± 7ZR 6WDJH 9DULDEOH 6SHHG )XUQDFH 7+(50267$7 7:2 67$*( 9$5,$%/( 63((' )851$&( 7:2 67$*( +($7 3803 & ± 9ROW &RPPRQ & ± 9ROW &RPPRQ & ± 9ROW &RPPRQ 5 ± 9ROW +RW 5 ± 9ROW +RW 5 ± 9ROW +RW * )DQ * )DQ < )LUVW 6WDJH &RPSUHVVRU < )LUVW 6WDJH &RPSUHVVRU < )LUVW 6WDJH &RPSUHVVRU : )LUVW 6WDJH +HDW : 6HFRQG 6WDJH +HDW : : : )LUVW 6WDJH +HDW : 287 $X[ +HDW : 6HFRQG 6WDJH +HDW : 2XW 6HFRQG 6WDJH +HDW RU 2 2 5HYHUVLQJ 9DOYH
PAGE 17
5750149-UIM-D-1219 IMPORTANT: The furnace, indoor coil, and humidifier drains may be combined and drained together. The indoor coil drain may have an external, field-supplied trap prior to the furnace drain connection to prevent conditioned air leakage. All drain connections (furnace, indoor coil, or humidifier) must be terminated into an open or vented drain as close to the respective equipment as possible. Regular maintenance is required on condensate drainage system.
PAGE 18
5750149-UIM-D-1219 A0945-001 FIGURE 23: Upflow Configuration 18 Johnson Controls Ducted Systems
PAGE 19
Johnson Controls Ducted Systems DOWNFLOW - INDUCER ROTATED FOR LEFT SIDE VENTING AIRFLOW drain hose to this position (may exit either side of the cabinet). 4 Move condensate hose to this position. 3 Move rain gutter hose to this position. NOTE: May require the longer hose that is provided with wider cabinets. 2 Move pressure switch gutter hose to this position.
PAGE 20
5750149-UIM-D-1219 A0946-001 FIGURE 25: Horizontal Left Configuration 20 Johnson Controls Ducted Systems
PAGE 21
5750149-UIM-D-1219 A0946-001 FIGURE 26: Horizontal Right Configuration Johnson Controls Ducted Systems 21
PAGE 22
5750149-UIM-D-1219 SECTION VII: COMBUSTION AIR AND VENT SYSTEM COMBUSTION AIR AND VENT SAFETY This Category IV, dual certified direct vent furnace is designed for residential application. It may be installed without modification to the condensate system in a basement, garage, equipment room, alcove, attic or any other indoor location where all required clearance to combustibles and other restrictions are met. The combustion air and the venting system must be installed in accordance with Section 5.
PAGE 23
5750149-UIM-D-1219 Table 7: Maximum Equivalent Pipe Length Model Input (BTUH) 40,000 40,000 40,000 60,000 60,000 60,000 80,000 80,000 80,000 100,000 100,000 100,000 120,000 120,000 Model Input (BTUH) 40,000 40,000 40,000 60,000 60,000 60,000 80,000 80,000 80,000 100,000 100,000 100,000 120,000 120,000 Model Input (BTUH) 40,000 40,000 40,000 60,000 60,000 60,000 80,000 80,000 80,000 100,000 100,000 100,000 120,000 120,000 Model Input (BTUH) 40,000 40,000 40,000 60,000 60,000 60,000 80,000 80,000 80,000 100,
PAGE 24
5750149-UIM-D-1219 Table 8: High Altitude Pressure Switches High Altitude Pressure Switches required for all installations above 5000 Feet Part Number Models S1-1PS3308 All TABLE 11: Combustion Air Intake and Vent Connection Size at Furnace (All Models) $ FURNACE VENT CONNECTION SIZES Furnace Input All Intake Pipe Size 2” (5.1 cm) Vent Pipe Size 2” (5.1 cm) $ $ $ 67$1'$5' (/%2: /21* 6:((3 (/%2: $ FIGURE 27: Dimensions IMPORTANT: Furnace vent pipe connections are sized for 2” (5.1 cm).
PAGE 25
5750149-UIM-D-1219 VENT CLEARANCES ,16,'( &251(5 '(7$,/ * 9 $ ' 9 ( ),;(' &/26(' % / 9 % % ) % 9(17 7(50,1$/ ; $,5 6833/< % , 9 & 9 9 9 + 9 9 % ; - 0 ; 9 $5($ :+(5( 7(50,1$/ ,6 127 3(50,77(' . ),;(' &/26(' 23(5$%/( $ FIGURE 28: Home Layout Direct Vent Terminal Clearances Canadian Installations1,3 A. Clearance above grade, veranda, porch, deck, or 12” (30.5 cm) balcony B. Clearance to window or door that may be opened 12” (30.
PAGE 26
5750149-UIM-D-1219 VENT SYSTEM This furnace is certified to be installed with one of two possible vent configurations. 1. Horizontal vent system. This vent system can be installed completely horizontal or combinations of horizontal, vertical, or offset using elbows.
PAGE 27
5750149-UIM-D-1219 COMBUSTION AIR SUPPLY 9(17 &20%867,21 $,5 ´ 0,1 $ FIGURE 32: Double Horizontal Combustion Air Intake and Vent Term. 0,1 ´ All installations must comply with Section 5.3, Air for Combustion and Ventilation of the National Fuel Gas Code, ANSI Z223.1 or Sections 7.2, 7.3 or 7.4 of CAN/CGA B149.1 or B149.2 Installation Code - latest editions. This furnace is certified to be installed with one of three possible combustion air intake configurations. 1.
PAGE 28
5750149-UIM-D-1219 Ambient Combustion Air Supply Table 12: Estimated Free Area This type installation will draw the air required for combustion from within the space surrounding the appliance and from areas or rooms adjacent to the space surrounding the appliance. This may be from within the space in a non-confined location or it may be brought into the furnace area from outdoors through permanent openings or ducts. It is not piped directly into the furnace.
PAGE 29
5750149-UIM-D-1219 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 37: Ambient Combustion Air Air Supply Openings and Ducts 1.
PAGE 30
5750149-UIM-D-1219 ! 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 31
5750149-UIM-D-1219 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 32
5750149-UIM-D-1219 Table 15: Gas Rate (CU FT/HR) at Full Input 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 50 51 52 53 54 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 72 71 69 68 67 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
PAGE 33
5750149-UIM-D-1219 IMPORTANT: The inlet gas pressure operating range table specifies what the minimum and maximum gas line pressures must be for the furnace to operate safely. The gas line pressure MUST BE a minimum of: • 7” w.c. (1.74 kPA) for Natural Gas • 11” w.c. (2.74 kPA) for Propane (LP) Gas in order to obtain the BTU input s1pecified on the rating plate and/or the nominal manifold pressure specified in these instructions and on the rating plate. 2.
PAGE 34
5750149-UIM-D-1219 Continuous Fan Airflow Settings The default blower speed for continuous fan operation is L (Low) speed. This furnace may be operated in continuous fan mode by setting the wall thermostat FAN switch to ON. To select the desired continuous fan airflow, set the FAN SPEED jumper on the control board to the desired position. There are three options: 1.
PAGE 35
5750149-UIM-D-1219 &20081,&$7,216 ',$*1267,& /,*+7 $ 5 & % $ 5 & % &219(17,21$/ /2: 92/7$*( 767$7 &211(&7,216 /$67 &)0 (5525 ,1',&$725 %87721 )/2$7 6:,7&+ &211(&7,21 $ 5 & % $ 5 & % &20081,&$7,1* 767$7 &211(&7,216 7(03 6(1625 &211(&7,216 +80,',67$7 6(/(&7,21 &217,18286 )$1 63((' $8;,/,$5< 6:,7&+ &211(&7,216 $,5)/2: 6(/(&7,21 +($7 3803 6(/(&7,21 +, +($7 '(/$< %/2:(5 2)) '(/$< $ FIGURE
PAGE 36
5750149-UIM-D-1219 Table 19: Air Flow Data (Continued) 040A10 HIGH HEAT LOW HEAT 890 770 790 660 711 578 646 514 HIGH/LOW HEAT CFM 060B12 080B12 080C16 Jumper Settings HIGH HEAT LOW HEAT HIGH HEAT LOW HEAT HIGH HEAT LOW HEAT HEAT Jumper ADJ Jumper 1200 870 1366 1156 1580 1156 A Any 1070 770 1293 1022 1422 1027 B Any 970 693 1185 924 1293 924 C Any 890 630 1094 840 1185 840 D Any 100C16 100C20 120D20 Jumper Settings HIGH HEAT LOW HEAT HIGH HEAT LOW HEAT HIGH HEAT LOW HEAT HEAT Jumper ADJ Jumper 1975 1444 19
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5750149-UIM-D-1219 Tap D is the normal profile, best suited for most of the country, where neither excessive humidity nor extremely dry conditions are the norm. On a call for cooling, the motor will ramp up to 63% of full capacity and will stay there for 90 seconds, then will ramp up to full capacity. At the end of the cooling cycle, the motor will ramp down to 63% of full capacity and will stay there for 30 seconds, then will ramp down to zero.
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5750149-UIM-D-1219 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 turn on the supply air blower and inducer.
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5750149-UIM-D-1219 SECTION XI: REPLACEMENT PARTS LIST DESCRIPTION DESCRIPTION MOTOR FABRICATED PARTS Continued MOTOR, DIRECT DRIVE BLOWER MANIFOLD, GAS BLOWER, COMBUSTION 2-STAGE PAN, BOTTOM ELECTRICAL PANEL, TOP CAPACITOR, RUN PANEL, DOOR (2 Req’d) SWITCH, LIMIT PANEL, BLOCKOFF CONTROL, FURNACE 2-STAGE VS MISCELLANEOUS IGNITER ORIFICE, BURNER (Natural #45) SENSOR, FLAME SIGHT GLASS, OVAL (2 Req’d) SWITCHES, PRESSURE GASKET, FOAM (Door) (1.
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5750149-UIM-D-1219 SECTION XII: WIRING DIAGRAM Wiring Diagram 96% Two-Stage COMM Furnace CAUTION PRECAUTION OPEN ALL DISCONNECTS BEFORE SERVICING THIS UNIT WHT 115VAC NEUT. DOOR N.O.
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5750149-UIM-D-1219 SECTION XIII: 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 Upflow Downflow Horizontal Left Horizontal Right Filter, Thermostat, Accessorie
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Gas Side Gas Type Natural Gas LP Gas (Requires LP conversion kit) LP Gas Conversion Kit Part # Used Inlet Gas Pressure (in. w.c.") LP Conversion Kit Installed By Low Fire Manifold Gas Pressure (in. w.c.") High Fire Manifold Gas Pressure (in. w.c.