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Johnson Controls Unitary Products

1083163-UIM-I-0618

SINGLE STAGE ECM
RESIDENTIAL GAS FURNACES

MODELS: TM9E Series

(95% AFUE Multi-position)

INSTALLATION MANUAL

LIST OF SECTIONS

SAFETY 2
DUCTWORK 5
FILTERS 8
GAS PIPING 9
ELECTRICAL POWER 10
CONDENSATE PIPING AND FURNACE VENTING CONFIGURATION
13

COMBUSTION AIR and VENT SYSTEM 19
START-UP AND ADJUSTMENTS 27
SAFETY CONTROLS 32
NORMAL OPERATION AND DIAGNOSTICS 33
REPLACEMENT PARTS LIST 35
WIRING DIAGRAM 36
START UP SHEET 38

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
Downflow Venting   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Dimensions   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Side Return Cutout Markings  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Gas Piping  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Wiring  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Typical Low Voltage Wiring   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Typical Low Voltage Wiring   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Typical. Condensate drain, vertical installation   . . . . . . . . . . . . . . . . 13
Upflow Configuration  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Downflow Configuration  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Horizontal Left Configuration  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Horizontal Right Configuration  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Elbow Dimensions   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Home Layout   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Termination Configuration - 1 Pipe  . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Termination Configuration - 2 Pipe  . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Termination Configuration - 2 Pipe Basement   . . . . . . . . . . . . . . . . . 23
Double Horizontal Combustion Air Intake and Vent Termination  . . . 24
Double Vertical Combustion Air Intake and Vent Termination  . . . . . 24
Downward Venting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Direct Vent Air Intake Connection and Vent Connection   . . . . . . . . . 24
Combustion Airflow Path Through The Furnace Casing   . . . . . . . . . 25
Ambient Combustion Air  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Attic and Crawl Space Combustion Air Termination  . . . . . . . . . . . . . 27
Gas Valve  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Reading Gas Pressure  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Furnace Control Board  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Wiring Diagram  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

LIST OF TABLES

Unit Clearances to Combustibles  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cabinet and Duct Dimensions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Recommended Filter Sizes (High Velocity 600 FPM)   . . . . . . . . . . . . 8
Nominal Manifold Pressure - High Fire   . . . . . . . . . . . . . . . . . . . . . . 10
Ratings & Physical / Electrical Data  . . . . . . . . . . . . . . . . . . . . . . . . . 11
Maximum Equivalent Pipe Length  . . . . . . . . . . . . . . . . . . . . . . . . . . 20
High Altitude Pressure Switches   . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Elbow Dimensions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Equivalent Length of Fittings  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Combustion Air Intake and Vent Connection
Size at Furnace (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Unconfined Space Minimum Area   . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Free Area  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Gas Rate (CU FT/HR) at Full Input . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Inlet Gas Pressure Range   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Blower Performance CFM - Any Position (without filter) . . . . . . . . . . 32

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.

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Summary of Contents for TM9E Series

Page 1: ... and Vent Connection 24 Combustion Airflow Path Through The Furnace Casing 25 Ambient Combustion Air 26 Attic and Crawl Space Combustion Air Termination 27 Gas Valve 30 Reading Gas Pressure 30 Furnace Control Board 31 Wiring Diagram 36 LIST OF TABLES Unit Clearances to Combustibles 4 Cabinet and Duct Dimensions 8 Recommended Filter Sizes High Velocity 600 FPM 8 Nominal Manifold Pressure High Fire ...

Page 2: ...s Gas furnaces manufactured on or after May 1 2017 are NOT per mitted to be used in Canada for heating of buildings or structures under construction 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 Manua...

Page 3: ...sdiction 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 General I...

Page 4: ...URNACES 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 venting i...

Page 5: ...s 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 they must...

Page 6: ...tom 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 gasket material to prevent air leakage BOTTOM RETURN AND ATTIC INSTALLATIONS Bottom return applications normally pull return air through a ba...

Page 7: ...rt located approximately in the center of the furnace near the blower shelf and the third support should be at the return end of the fur nace Maintain a 6 15 2 cm minimum clearance between the front of the furnace and the support rods or straps All six suspension points must be level to ensure proper and quiet fur nace operation When suspending the furnace use a secure platform constructed of plyw...

Page 8: ...dded 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 2 Cabinet and Duct Dimensions BTUH kW Input Nominal CFM m3 min Cabinet Size Cabinet Dimensions Illustrated in Figure 13 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 3 4 29 8 113 60 17 6 1200 34 0...

Page 9: ...instructions 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 9 Side Return Cutout Markings IMPORTANT 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 o...

Page 10: ...ced on the octagon hub located on the gas inlet side of the valve Placing a wrench to the body of the gas valve will damage the valve causing improper opera tion and or the valve to leak Table 4 Nominal Manifold Pressure High Fire Gas Heating Value BTU cu ft Manifold Pressures Gas Heating Value MJ cu m Manifold Pressures Altitude feet Altitude m 0 7999 8000 8999 9000 9999 0 2437 2438 2742 2743 304...

Page 11: ...trical 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 18 or 19 Electronic thermostats may require the common wire to be connected Apply strain relief to thermostat wires passing through cabinet If air condition ing equipment is installed use thermostat wiring to connect the Y and C ter...

Page 12: ... Single Stage Furnace STD ECM Single Stage Air Conditoner STD ECM Y Compressor 24 Volt Common C 24 Volt Common Compressor Contactor R 24 Volt Hot Y Y2 Second or Full Stage Compressor FIGURE 14 Typical Low Voltage Wiring Full Stage Compressor G Fan THERMOSTAT 1H 2C W Heat C 24 Volt Common Y1 TWO STAGE AIR CONDITIONER C 24 Volt Common R 24 Volt Hot W Full Stage Heat G Fan SINGLE STAGE FURNACE Y1 Fir...

Page 13: ...drain better if an open stand pipe is installed in the drain line See Figure 20 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 Do not drain other devices humidifier evaporator coil etc into the top opening of the vent stand pipe Instead install a second tee in the vented drain tube below the furnace dr...

Page 14: ...sed the bird screen cannot be installed This is only approved for upflow and horizontal applications when the intake pipe is located on the top of the furnace This is true for all long horizontal venting in any furnace configuration This will keep condensate from entering the furnace WARNING DO NOT terminate the condensate drain in a chimney or where the drain line may freeze If the drain line wil...

Page 15: ...ff 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 100 120 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 16: ...witch 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 cond...

Page 17: ...ch 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 condensa drain connection to the 90 fitt...

Page 18: ...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 19: ...he combustion air pipe 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 The 2 to 3 increase should be installed in the vertical position as to not create an area that will pool water 7 In Canada vents shall be certified to ULC S636 Standard for Type BH Gas Ventin...

Page 20: ...45 80 000 4 125 100 000 2 20 100 000 2 NA 100 000 3 80 100 000 3 60 100 000 4 145 100 000 4 125 120 000 3 80 120 000 3 60 120 000 4 145 120 000 4 125 Elevation 4001 5000 Elevation 8001 9000 Model Input BTUH Pipe Size in Max equivalent Length ft Model Input BTUH Pipe Size in Max equivalent Length ft 40 000 2 50 40 000 2 30 40 000 3 75 40 000 3 55 40 000 4 140 40 000 4 120 60 000 2 50 60 000 2 30 60...

Page 21: ...T Part Number Models S1 1PS3302 100k 120k S1 1PS3306 60k S1 1PS3307 40k 80k FIGURE 20 Elbow Dimensions TABLE 8 Elbow Dimensions Elbow A Dimension Illustrated in Figure 25 2 Standard 2 5 16 3 Standard 3 1 16 2 Sweep 3 1 4 3 Sweep 4 1 16 TABLE 9 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 o...

Page 22: ...rements 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 cm 3...

Page 23: ...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 Figures 28 and 29 can be installed so the combustion air pipe terminates as described in outdoor combustion air or ventilated combustion air sec tions in these instructions Follow the instructions for outdoor combus tion air or ventila...

Page 24: ...ons Refer to Ambient Combustion Air Supply for proper installa tion Refer to Figures 34 and 35 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 3...

Page 25: ...able 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 29 Combustion Airflow Path Through The Furnace Casing WARNING This type of installation requires that the supply air to the appliance s be of a sufficient...

Page 26: ...r 322 cm2 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 ...

Page 27: ...nd 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 F...

Page 28: ...other gas appliances and pilots 2 Run furnace for a minimum of 3 minutes in heating operation 3 Measure time in sec for gas meter to complete 1 revolution and note reading The 2 cubic feet dial provides a more accurate mea surement of gas flow 4 Refer to Table 15 for cubic feet of gas per hour 5 Multiply cubic feet per hour by heating valve BTU cu ft to obtain input If clocked rate does not match ...

Page 29: ...0 300 750 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 4...

Page 30: ... 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 plate Refer to CALCULATING THE FURNACE INPUT NATURAL GAS 5 Once the correct BT...

Page 31: ...rill a small hole in the plastic flue pipe for a sample probe provided that the vent piping is PVC and the hole is properly sealed afterwards If using a polypropylene vent system the vent sys tems manufacturer test port fitting must be used DONOT drill a test port hole in polypropylene piping Use the following procedure 1 Drill a 11 32 hole in the side wall of the PVC vent pipe If the hole is in a...

Page 32: ...03 1182 1150 1125 1095 1064 1031 980 Medium 1076 1059 1029 1007 973 946 908 883 843 800 Medium Low 988 967 936 903 875 838 806 765 737 685 Low 798 769 727 695 650 619 574 517 485 443 TM9E080B12MP11 High 1445 1423 1397 1365 1339 1311 1283 1250 1204 1140 Medium High 1282 1266 1232 1211 1182 1157 1128 1097 1069 1013 Medium 1098 1084 1059 1027 998 967 939 910 879 822 Medium Low 1012 993 953 930 894 85...

Page 33: ...f and a retry operation begins Also if the flame is lost for 2 seconds during the 10 second stabilization period the gas valve is shut off and a retry operation begins During a retry operation the vent motor starts a 15 second inter purge and the ignitor warm up time is extended to 27 seconds If the flame is established for more than 10 seconds after ignition during a retry the control will clear ...

Page 34: ...former wires Both heating and cooling operations will be affected Check polarity at furnace and branch Check furnace grounding Check that flame probe is not shorted to chassis The furnace will not start the ignition sequence until this problem is corrected 10 RED FLASHES Gas valve energized with no call for heat The main blower and inducer blower will run and no ignition sequence will be started a...

Page 35: ...RING FERRULE 3 req d GASKET FOAM Door 1 5 ft req d GROMMET 3 req d HARNESS WIRING HOSE CONDENSATE HOSE RAIN GUTTER KNOB QUARTER TURN 4 req d MOTOR MOUNT ORIFICE BURNER Natural 45 PAN CONDENSATE PLUG SEAL 7 8 PLUG SEAL 2 3 8 PLUG VENT PIPE SIGHT GLASS OVAL 2 req d TUBING SILICON DESCRIPTION REPLACEMENT PART CONTACT INFORMATION This is a generic parts list To request a complete parts list refer to t...

Page 36: ...C LE SERVICE 1042427 UWD A 0413 Fault Code Retrieval To retrieve fault codes push and release ERROR button on control board The LED will flash the last five error codes beginning with the most recent If there are no fault codes in memory the LED will give two green flashes To clear the fault code memory push and hold the ERROR button for at least five seconds The LED will give three green flashes ...

Page 37: ...1083163 UIM I 0618 Johnson Controls Unitary Products 37 NOTES ...

Page 38: ...of 90 Degree Ells Polarity is correct black is L1 hot white is N neutral Ground wire is connected Line voltage value to furnace volts AC Low voltage value between R and C on furnace control board volts AC Thermostat Type Other System Equipment and Accessories Owner Information Equipment Data Furnace Configuration Condensate Management Venting Electrical Line Voltage Outdoor Unit Model Outdoor Unit...

Page 39: ...t maintenance Gas Side Air Side System External Static Pressure Owner Education Additional Job Detail Supply static before evaporator coil in w c Calculated input in btuh clock the gas meter Nat Gas Only Manifold Gas Pressure in w c Inlet Gas Pressure in w c LP Gas Conversion Kit Part Used Burner flame inspected flames are blue and extending directly into the primary heat exchanger cells Return St...

Page 40: ... to change without notice Published in U S A 1083163 UIM I 0618 Copyright 2018 by Johnson Controls Inc All rights reserved Supersedes 1083163 UIM H 0817 York International Corp 5005 York Drive Norman OK 73069 ...

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