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1034868-UIM-A-0513

Johnson Controls Unitary Products

33" 96% AFUE Two Stage Gas Furnace Start Up Sheet

Proper furnace start up is critical to customer comfort and equipment longevity

Name

Address

City

State or Province

Zip or Postal Code

Furnace Model

Furnace Serial

Evaporator Coil Model

Evaporator Coil Serial

Upflow

Downflow

Horizontal Left

Horizontal Right

Unit is level or tilted slightly forward

Filter Type

Thermostat Type

Other System Equipment and Accessories

Owner Information

Equipment Data

Furnace Configuration

Outdoor Unit Model

Outdoor Unit Serial

Filter, Thermostat, Accessories

Filter Location(s)

Connections -- All Per Installation Instructions and Local Code

Gas piping is connected (including drip leg)

Supply plenum and return air are connected

Filter Size

Vent system is connected

Technician Performing Start-Up

Installing Contractor Name

Start-Up Date

Continued on next Page

OFF

10 MIN

15 MIN

20 MIN

Thermostat Staging:

Staging:

Venting system is the proper size, within the limitations of the chart in the installation
instructions, properly connected to the furnace, and properly pitched

Condensate drain is connected

Intake Size

Exhaust Size

# of 90 Degree Ells

# of 45 Degree Ells

Length

# of 45 Degree Ells

# of 90 Degree Ells

Polarity is correct (black is L1 (hot), white is N (neutral)

Ground wire is connected from the furnace to electrical panel

Line voltage value to furnace (volts AC)

Low voltage value between "R" and "C" on furnace control board (volts AC)

Condensate Management

Venting

Electrical: Line Voltage

Thermostat wiring is complete

Electrical: Low Voltage

Condensate tubing is correctly installed for the furnace position

Sidewall

Roof

Sidewall

Roof

Attic

Exhaust

Termination

Intake

Termination

Thermostat heat anticipator set to .4 or (6 cycles per hour for electronic thermostats)

SECTION XIII: START UP SHEET

Summary of Contents for TM9V*C

Page 1: ...ons 27 Home Layout 28 Termination Configuration 1 Pipe 29 Termination Configuration 2 Pipe 29 Termination Configuration 2 Pipe Basement 29 Double Horizontal Combustion Air Intake and Vent Termination 30 Double Vertical Combustion Air Intake and Vent Termination 30 Downward Venting 30 Direct Vent Air Intake Connection and Vent Connection 30 Combustion Airflow Path Through The Furnace Casing 31 Outs...

Page 2: ...nition input rate temperature rise and venting according to the manufacturer s instructions 10 When installed in a non HUD Approved Modular Home or building constructed on site combustion air shall not be supplied from occu pied spaces 11 The size of the unit should be based on an acceptable heat loss calculation for the structure ACCA Manual J or other approved methods may be used 12 When moving ...

Page 3: ...jurisdiction In the United States and Canada follow all codes and standards for the following using the latest edition available STEP 1 Safety US National Fuel Gas Code NFGC NFPA 54 ANSI Z223 1 and the Installation Standards Warm Air Heating and Air Conditioning Systems ANSI NFPA 90B CANADA CAN CGA B149 1 National Standard of Canada Natu ral Gas and Propane Installation Codes NSCNGPIC STEP 2 Gener...

Page 4: ...ion FOR FURNACES INSTALLED IN THE COMMON WEALTH 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 resi dential purposes including those owned or operated by the Com monwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the ...

Page 5: ...his access cover shall be attached in such a manner as to prevent leaks DUCT FLANGES Four flanges are provided to attach ductwork to the furnace These flanges are rotated down for shipment In order to use the flanges remove the screw holding an individual flange rotate the flange so it is in the upward position and reinstall the screw then repeat this for all 4 flanges If the flanges are not used ...

Page 6: ...hould always be installed on the side desig nated as top side See Figures 4 5 FURNACE ASSEMBLY PC SERIES COILS These upflow coils are designed for installation on top of upflow fur naces only If the coil is used with a furnace of a different size use a 45 transition to allow proper air distribution through the coil 1 Position the coil casing over the furnace opening as shown in Figure 6 2 Place th...

Page 7: ...rnace is to be installed on a flat solid surface this bottom panel will provide an adequate seal to prevent air leakage through the unused bottom opening However if the furnace is to be installed on a surface that is uneven or if it is to be installed on blocks or otherwise raised off the floor it will be necessary to seal the edges of the bottom panel to the casing using tape or other appropriate...

Page 8: ...ts should be placed at the supply air end and near the blower deck Do not support at return air end of unit All four sus pension points must be level to ensure quite furnace operation When suspending the furnace use a secure platform constructed of plywood or other building material secured to the floor joists Refer to Figure 11 for typical crawl space installation DOWNFLOW APPLICATION To apply th...

Page 9: ...ional Return Air Cutout Either side 29 5 For Cladded door add appoximately an additional 75 C SUPPLY END 56 56 20 B 3 23 8 56 Combustion Air Inlet Vent Outlet RETURN END B 24 25 Table 3 Cabinet and Duct Dimensions BTUH kW Input Nominal CFM m3 min Cabinet Size Cabinet Dimensions Inches Approximate Operating Weights A in A cm B in B cm C in C cm Lbs kg 40 11 7 1000 28 3 A 14 1 2 36 8 13 3 8 34 0 11 ...

Page 10: ...ctions in this section specify the type of gas approved for this furnace only use those approved gases The instal lation of a drip leg and ground union is required Refer to Figure 16 FIGURE 14 Side Return Cutout Markings Some accessories such as electronic air cleaners and pleated media may require a larger side opening Follow the instructions supplied with that accessory for side opening requirem...

Page 11: ... cu m 29 8 0 87 0 87 0 87 850 3 5 3 5 3 5 31 7 0 87 0 87 0 87 900 3 5 3 5 3 5 33 5 0 87 0 87 0 87 950 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 TABLE 6 Nominal Manifold Pressure Low Fire First Stage Manifold Pressures in w c First Stage Manifold Pressures ...

Page 12: ...e furnace leads into the box using a protective bushing where the wires pass through the furnace panel After making the wiring connections replace the wiring box cover and screws Refer to Figure 17 3 The furnace s control system requires correct polarity of the power supply and a proper ground connection Refer to Figure 17 Use copper conductors only Table 7 Ratings Physical Electrical Data Input H...

Page 13: ...munications COMM mode it MUST be installed with the matching touch screen Communicating Control wall thermostat and an outdoor air conditioner or heat pump with a fully communicating control This furnace may also be used along with the Communicating Thermo stat Control and a non communicating outdoor air conditioner through the addition of a communicating Outdoor Aux Control board to the out door ...

Page 14: ...l the field supplied thermostat by following the instructions that come with the thermostat With the thermostat set in the OFF position and the main electrical source disconnected connect the thermostat wiring from the wiring connections on the thermostat to the terminal board on the ignition module as shown in Figures 21 24 Electronic thermostats may require the common wire to be connected Apply ...

Page 15: ...GLE STAGE AIR CONDITIONER Part Numbers SAP Legacy 265904 031 09169 449572 1 C 24 Volt Common R 24 Volt Hot Y1 Single Stage Compressor TWO STAGE VARIABLE SPEED FURNACE CONTROL G Fan TWO STAGE VARIABLE SPEED FURNACE W W1 First Stage Heat Y Y2 Second or Full Stage Compressor W2 Second Stage Heat O Reversing Valve X L Malfunction Light DHUM Dehumidification 1 Move DHUM jumper to YES if humidistat is t...

Page 16: ...d Stage Heat B O Switch on Thermostat must be in the O position 24VAC Humidifier Optional External Humidistat Optional Open on Humidity Rise Part Number S1 2HU16700124 O Reversing Valve Energized in Cool C 24 Volt Common R 24 Volt Hot W1 OUT First Stage Heat W2 OUT Second Stage Heat Y2 OUT Second Stage Compressor Y1 Single Stage Compressor X L Malfunction Light Y2 Second Stage Compressor W Auxilia...

Page 17: ...HM Dehumidification HM Humidistat Step 1 of Thermostat User Configuration Menu must be set to MLTISTG E W1 First Stage Heat 24VAC Humidifer Optional Optional Harness Part Numbers SAP Legacy 265904 031 09169 449572 1 C 24 Volt Common R 24 Volt Hot Y1 Single Stage Compressor TWO STAGE VARIABLE SPEED FURNACE CONTROL G Fan TWO STAGE VARIABLE SPEED FURNACE W W1 First Stage Heat Y Y2 Second or Full Stag...

Page 18: ...AP Legacy 126768 031 09137 18395 031 01996 340512 031 09178 1 1 Part Numbers SAP Legacy 265904 031 09169 449572 2 C 24 Volt Common R 24 Volt Hot Y1 Single Stage Compressor TWO STAGE VARIABLE SPEED FURNACE CONTROL G Fan TWO STAGE VARIABLE SPEED FURNACE W W1 First Stage Heat Y Y2 Second or Full Stage Compressor W2 Second Stage Heat O Reversing Valve X L Malfunction Light DHUM Dehumidification 2 Move...

Page 19: ...lope downwards at all points When drain hose routing changes are required shown in Figures 27 30 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 No hose clamps are needed for connecting to the condensate pan The condensate will flow to the drain better if an ...

Page 20: ... furnace FIGURE 26 Typical Combustion Pipe Drain Tee Connect to Drain Trap Combustion Air Pipe Tee with Drain Trap Exhaust Pipe DO NOT terminate the condensate drain in a chimney or where the drain line may freeze If the drain line will be exposed to temperatures below freezing adequate measures must be taken to prevent the drain line from freezing Failure to provide proper protection from freezin...

Page 21: ...f so that no sagging loops will collect and hold condensate which will cause the furnace to not operate Shorten pressure switch hose Re route and shorten pressure switch hose Shorten rain gutter hose Move rain gutter hose to this position For 100 120K input furnaces the condensate drain is plumbed toward the left casing outlet from the factory For 040 060 080K input furnaces the condensate drain i...

Page 22: ...itch hose to this position NOTE May require the longer hose that is provided with wider cabinets Move condensate drain hose to this position may exit either side of the cabinet Move rain gutter hose to this position 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 conde...

Page 23: ...hose to this position NOTE May require the longer hose that is provided with wider cabinets Change condensate drain connection to the 90 fitting provided Move condensate drain hose to this position Move rain gutter hose to this position NOTE May require hose extension that is provided with wider cabinets Move condensate drain hose to this position Change condensate drain connection to the 90 fitti...

Page 24: ...itting provided Move condensate drain hose to this position Move rain gutter hose to this position Change condensate drain connection to the 90 fitting provided Move condensate drain hose to this position AIRFLOW Move pressure switch hose to this position 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 s...

Page 25: ...with cement that is approved for use with BOTH materials Metallic materials must not be used for venting or air intake 5 If a flexible connector is used in the vent system it must be made of a material that is resistant to acidic exposure and to at least 225 F 107 2 C temperature Flexible connectors are also allowed in the combustion air pipe 6 All models are supplied with 2 5 1 cm vent connection...

Page 26: ...0 000 2 50 60 000 2 30 60 000 3 75 60 000 3 55 60 000 4 140 60 000 4 120 80 000 2 50 80 000 2 20 80 000 3 75 80 000 3 55 80 000 4 140 80 000 4 120 100 000 2 15 100 000 2 NA 100 000 3 75 100 000 3 55 100 000 4 140 100 000 4 120 120 000 3 75 120 000 3 55 120 000 4 140 120 000 4 120 Elevation 5001 6000 Elevation 9001 10000 Model Input BTUH Pipe Size in Max equivalent Length ft Model Input BTUH Pipe S...

Page 27: ...BUSTION AIR VENTING FIGURE 31 Dimensions TABLE 10 Elbow Dimensions Elbow A Dimension 2 Standard 2 5 16 3 Standard 3 1 16 2 Sweep 3 1 4 3 Sweep 4 1 16 TABLE 11 Equivalent Length of Fittings Fitting Equivalent Length 2 90 sweep elbow 5 feet of 2 pipe 2 45 sweep elbow 2 1 2 feet of 2 pipe 2 90 standard elbow 7 feet of 2 pipe 2 45 standard elbow 3 1 2 feet of 2 pipe 3 90 sweep elbow 5 feet of 3 pipe 3...

Page 28: ...requirements of the gas supplier 12 30 5 cm or in accordance with local installation codes and the requirements of the gas supplier F Clearance to outside corner 12 30 5 cm or in accordance with local installation codes and the requirements of the gas supplier 12 30 5 cm or in accordance with local installation codes and the requirements of the gas supplier G Clearance to inside corner 3 feet 91 4...

Page 29: ...e two vent pipes be tied together The combustion air side of the two pipe configuration shown in Figure 34 can be installed so the combustion air pipe terminates as described 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 t...

Page 30: ... Air Supply for proper installa tion Refer to Figures 40 and 41 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 42 for attic and crawl space ter...

Page 31: ...adjustable louvers are not permitted for use 4 A automatically operated damper or automatically adjustable lou vers shall be interlocked so that the main burner cannot operate unless either the damper or the louver is in the fully open position FIGURE 40 Combustion Airflow Path Through The Furnace Casing This type of installation requires that the supply air to the appliance s be of a sufficient a...

Page 32: ...6 45 cm3 per 0 879 kW of the total input rating of all equipment located in the enclosure b Not less than the sum of all vent connectors in the confined space 3 The duct shall be least the same cross sectional area as the free area of the air supply inlet opening to which it connects 4 The blocking effects of louvers grilles and screens must be given consideration in calculating free area If the f...

Page 33: ...iance shall operate continu ously 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 appli...

Page 34: ...ccur as follows a The induced draft blower motor will start and come up to speed Shortly after inducer start up the hot surface igniter will glow for about 17 seconds 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 about 30 seconds CALCULATING THE FURNACE INPUT NAT GAS Burner orifices are sized to provi...

Page 35: ... 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 2...

Page 36: ...ment screws on main gas valve 2 Turn gas and electrical supplies on and follow the operating instruc tions to place the unit back in operation 3 Adjust manifold pressure by adjusting gas valve regulator screw for the appropriate gas per the following 4 After the manifold pressure has been adjusted re calculate the fur nace input to make sure you have not exceeded the specified input on the rating ...

Page 37: ...e adjusted by positioning the jumper on two of the four pins as shown in Figure 45 MANIFOLD PRESSURE U TUBE CONNECTION FIGURE 44 Reading Gas Pressure The temperature rise or temperature difference between the return air and the supply heated air from the furnace must be within the range shown on the furnace rating plate and within the application limitations shown in Table 7 ELECTRICAL AND PERFORM...

Page 38: ...050 B A 1694 1157 A C 1502 1011 C B 1400 944 B C 1365 922 D B 1364 931 C A 1232 808 D A 1225 808 C C 1117 718 D C HIGH LOW HEAT CFM 040A10 060B12 80B12 Jumper Settings High Low High Low High Low HEAT Tap ADJ Tap 960 670 1364 843 1433 945 A Any 840 590 1253 745 1320 887 B Any 740 520 1102 660 1223 840 C Any 640 450 1014 607 1134 768 D Any 80C16 100C16 100C20 Jumper Settings High Low High Low High L...

Page 39: ...allations where the humidity is frequently very high during cooling season such as in the southern part of the country On a call for cooling the blower will ramp up to 50 of full capacity and will stay there for two minutes then will ramp up to 82 of full capacity and will stay there for five min utes and then will ramp up to full capacity where it will stay until the wall thermostat is satisfied ...

Page 40: ...tions The control continuously monitors its own operation and the operation of the system If a failure occurs the LED light will indicate the failure code The SLOW flash speed is two seconds on and two seconds off The other flash codes listed below have the following timing LED light will turn on for 1 3 second and off for 1 3 second This pattern will be repeated the number of times equal to the c...

Page 41: ...replacing pressure switch 4 AMBER FLASHES The control is receiving a Y signal from the thermostat without a G signal The furnace will operate normally in both heating and cooling but this fault code will be displayed in order to alert the user that there is a wiring problem Verify that the G wire from the thermostat is connected properly SOFT LOCKOUT This control includes a soft lockout that will ...

Page 42: ...ural 45 SIGHT GLASS OVAL 2 Req d GASKET FOAM Door 1 5 ft req d PAN CONDENSATE BRACKET DOOR HARNESS WIRING FERRULE 3 Req d GROMMET 3 Req d MOTOR MOUNT TUBING SILICON HOSE RAIN GUTTER HOSE CONDENSATE PLUG SEAL 7 8 PLUG SEAL 2 3 8 PLUG VENT PIPE BAG PARTS KNOB QUARTER TURN 4 Req d DIAGRAM WIRING 2 STAGE VS DESCRIPTION REPLACEMENT PART CONTACT INFORMATION This is a generic parts list To request a comp...

Page 43: ...versed OR poor ground neutral Gas valve shorted ON Check blower motor wiring Vent OR termination problem None Slow Green Slow Amber Rapid Amber 4 Amber Steady on Red 1 Red 2 Red 3 Red 4 Red 5 Red 6 Red 7 Red 8 Red 9 Red 10 Red 11 Red 13 Red DS ROS XFMR HSI PF PS1 PS2 PS3 IDM EAC LS HUM Legend Door switch Rollout switch Transformer Hot surface igniter Power factor choke Pressure switch 1 stage Pres...

Page 44: ...1034868 UIM A 0513 44 Johnson Controls Unitary Products NOTES ...

Page 45: ...orming Start Up Installing Contractor Name Start Up Date Continued on next Page OFF 10 MIN 15 MIN 20 MIN Thermostat Staging Staging Venting system is the proper size within the limitations of the chart in the installation instructions properly connected to the furnace and properly pitched Condensate drain is connected Intake Size Exhaust Size of 90 Degree Ells of 45 Degree Ells Length Length of 45...

Page 46: ...g PSC Air Side Continuous Fan PSC Clean Up Give owner the owner s manual provided Gas Type Explain thermostat use and programming if applicable to owner Cycle Test Operate the furnace through several heating cycles from the thermostat noting and correcting any problems Operate the furnace through continuous fan cycles from the thermostat noting and correcting any problems Operate the furnace throu...

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