Johnson Controls TM9T, Installation Manual

Page 1: ...r Intake and Vent Termination 26 Downward Venting 26 Direct Vent Air Intake Connection and Vent Connection 26 Combustion Airflow Path Through The Furnace Casing 27 Ambient Combustion Air 28 Attic and Crawl Space Combustion Air Termination 29 Gas Valve 32 Reading Gas Pressure 33 Furnace Control Board 33 Wiring Diagram 38 LIST OF TABLES Unit Clearances to Combustibles 4 Cabinet and Duct Dimensions 8...

Page 2: ...nd 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 cabinet flanges at the return air openings bottom or sides or sup ply air opening 13 When lifting the furnace 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 exchange...

Page 3: ...e National Fire Protection Association Inc Batterymarch Park Quincy MA 02269 or for only the NFGC contact the American Gas Association 400 N Capital N W Washington DC 20001 or www NFPA org CANADA NSCNGPIC For a copy contact Standard Sales CSA International 178 Rexdale Boulevard Etobicoke Toronto Ontario Canada M9W 1RS STEP 3 Combustion and Ventilation Air US Section 5 3 of the NFGC air for Combust...

Page 4: ...ide 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 including but not limited to decks and porches the following require me...

Page 5: ...ividual 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 remain in the rotated down posi tion as shipped DUCTWORK INSTALLATION AND SUPPLY PLENUM CONNECTION UPFLOW HORIZONTAL Attach the supply plenum to the furnace outlet The use of an approved flexible duct connector is recommended on all insta...

Page 6: ...ation Refer to the separate accessory parts list at the end of these instructions for the approved accessory duct con nectors FIGURE 2 Furnace and Coil Attachment 127 9HULI WKDW DOO GUDLQV DUH WUDSSHG RU SOXJJHG 83 2 33 7 21 2 1 2 33 7 21 35 0 5 5 1 75 3 211 7 21 6 21 5 5 1 75 3 211 7 21 5 1 3 8 25 25 217 6 21 5 5 1 35 0 5 5 1 75 3 211 7 21 2 2 5 7 2 33 7 21 7 2 33 7 21 2 2 5 1 3 8 25 9 57 6 21 5 ...

Page 7: ...ng 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 hun...

Page 8: ...HW DV 3LSH QWU OHFWULFDO QWU RQGHQVDWH UDLQ 2SWLRQDO 5HWXUQ LU XWRXW LWKHU VLGH RU ODGGHG GRRU DGG DSSR LPDWHO DQ DGGLWLRQDO 6833 1 RPEXVWLRQ LU QOHW 5 7851 1 9HQW RQQHFWLRQ 2XWOHW 9HQW RQQHFWLRQ 2XWOHW 9HQW RQQHFWLRQ 2XWOHW Table 2 Cabinet and Duct Dimensions BTUH kW Input Nominal CFM m3 min Cabinet Size Cabinet Dimensions Approximate Operating Weights A in A cm B in B cm C in C cm Lbs kg 60 17 6...

Page 9: ...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 SECTION IV GAS PIPING GAS SAFETY CAUTION All filters and mounting provision must be field supplied All installa tions must have a filter installed NOTICE Single side return above 1800 CFM is approved as long as the filter velocity does not exceed filter manufacture...

Page 10: ...ow the instructions supplied with the LP kit HIGH ALTITUDE MANIFOLD PRESSURE SETTINGS 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 leve...

Page 11: ... 0 41 0 37 0 34 1050 1 5 1 4 1 3 39 1 0 37 0 34 0 31 1100 1 3 1 2 1 1 41 0 0 34 0 31 0 28 2500 LP 4 1 3 8 3 5 93 2 LP 1 03 0 95 0 87 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 propan...

Page 12: ...module as shown in Figures 14 or 15 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 terminals on the furnace control board to the proper wires on the con densing unit unit outside The 24 volt 40 VA transformer is sized for the f...

Page 13: ... HDW 7 50267 7 WHUQDO XPLGLVWDW 2SWLRQDO 2SHQ RQ XPLGLW 5LVH 9 XPLGL HU 2SWLRQDO FIGURE 15 Thermostat Chart Two Stage HP with Two Stage PSC Furnace 7ZR 6WDJH HDW 3XPS 7ZR 6WDJH XUQDFH LUVW 6WDJH RPSUHVVRU DQ 6HFRQG 6WDJH HDW 5 9ROW RW LUVW 6WDJH HDW 9ROW RPPRQ 9ROW RPPRQ 5 9ROW RW 6HFRQG RU XOO 6WDJH RPSUHVVRU LUVW 6WDJH RPSUHVVRU DQ 7 2 67 36 XUQDFH 7 2 67 7 3803 9ROW RPPRQ 5 9ROW RW LUVW 6WDJH R...

Page 14: ... on the first furnace operates on W1 and the gas burner on the second furnace operates on W2 then the use of an air mixing device in the plenum to mix the air from both furnaces is strongly recommended The mixing device must be installed before any ducts that supply air to occupied spaces Twinning causes both indoor fans to operate simultaneously If a mixing device is not used any ducts that are c...

Page 15: ...n drain hose routing changes are required shown in Figures 19 22 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 open stand pipe is installed in ...

Page 16: ...intake coupling the drain opening in the vent drain must not be plugged If the intake drain is used 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 term...

Page 17: ... 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 is...

Page 18: ...tch 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 conden...

Page 19: ...ose 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 fittin...

Page 20: ...QJ SURYLGHG 0RYH FRQGHQVDWH GUDLQ KRVH WR WKLV SRVLWLRQ 0RYH UDLQ JXWWHU KRVH WR WKLV SRVLWLRQ KDQJH FRQGHQVDWH GUDLQ FRQQHFWLRQ WR WKH ILWWLQJ SURYLGHG 0RYH FRQGHQVDWH GUDLQ KRVH WR WKLV SRVLWLRQ 5 2 0RYH SUHVVXUH VZLWFK KRVH WR WKLV SRVLWLRQ KHQ GUDLQ KRVH URXWLQJ FKDQJHV DUH UHTXLUHG EH VXUH WR FDS DOO XQ XVHG RSHQLQJV I UHURXWLQJ KRVHV H FHVV OHQJWK VKRXOG EH FXW RII VR WKDW QR VDJJLQJ ORRSV Z...

Page 21: ...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 22: ... 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 60 000 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...

Page 23: ...23 Dimensions TABLE 9 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 10 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 45 sweep elbow 2 1 2 feet o...

Page 24: ...ements 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 25: ...ace 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 26 and 27 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 ventilated ...

Page 26: ...s Refer to Ambient Combustion Air Supply for proper installa tion Refer to Figures 32 and 33 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 34 ...

Page 27: ...rated damper or manually 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 32 Combustion Airflow Path Through The Furnace Casing WARNING This type of installation requires that the supply air to the...

Page 28: ...m2 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 free area of a sp...

Page 29: ...ll 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 open ing after 5 minutes of m...

Page 30: ...r 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 orifices Verify natural gas input rate by clocking meter 1 Turn off all other gas appliances and pilots 2 Run furnace for a minimum of 3 minutes in high fire heating opera tion 3 Measure ti...

Page 31: ... 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 47...

Page 32: ...lectrical supplies on and follow the operating instruc tions to place the unit back in operation 3 Place jumper wire from W1 to W2 to R on the furnace control board for the furnace to operate HIGH fire Once correct manifold pres sure is set HI remove jumper from W2 for the furnace to operate on low fire Set the manifold pressure LO to correct manifold pres sure 4 After the manifold pressure has be...

Page 33: ...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 horizontal section of the vent pipe ensure that it is located away from the bottom where condensation may be flowing back toward the furnace 2 Operate the furnace a minimum of 10 min...

Page 34: ... 1267 1232 1183 1143 1080 1003 871 798 120D20MP11 High 2341 2245 2153 2072 1977 1876 1769 1642 1506 1306 Medium High 2002 1952 1878 1823 1739 1657 1563 1458 1322 1185 Medium Low 1615 1579 1533 1473 1430 1368 1282 1186 1091 953 Low 1352 1295 1259 1245 1190 1141 1076 998 938 820 Left Side Airflow Data SCFM Models Speed Ext Static Pressure in H2O 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 0 060B12MP11 Hig...

Page 35: ...oper amount of combustion air is being provided the pressure switch will close the ignition control pro vides a 17 second ignitor warm up period the gas valve then opens the gas starts to flow ignition occurs and the flame sensor begins its sensing function The blower motor will energize 30 seconds after the gas valve opens if a flame is detected Normal furnace operation will continue until the th...

Page 36: ...ter a one hour soft lock out 5 RED FLASHES This fault is indicated if the limit circuit is open for more than fifteen minutes usually indicating that a manual reset rollout switch has opened Check for proper combustion air proper inducer operation and primary heat exchanger failure or burner problem The control will enter a hard lockout and power will have to be cycled off and on to reset the cont...

Page 37: ...D will flash three green flashes when the memory has been cleared then will resume the normal slow green flash after a five second pause SECTION XII REPLACEMENT PARTS LIST DESCRIPTION MOTOR BLOWER COMBUSTION MOTOR DIRECT DRIVE BLOWER ELECTRICAL CONTROL FURNACE CONTROL TEMPERATURE IGNITER SENSOR FLAME SWITCH DOOR SWITCH LIMIT SWITCHES PRESSURE TRANSFORMER VALVE GAS AIR MOVING HOUSING BLOWER WHEEL B...

Page 38: ...RE CAUTION PRECAUTION OUVREZ LES DISJONCTEURS AVANT DE PROCEDER AVEC LE SERVICE 1042426 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 butt...

Page 39: ...HU IXUQDFH VWDUW XS LV FULWLFDO WR FXVWRPHU FRPIRUW DQG HTXLSPHQW ORQJHYLW 2ZQHU QIRUPDWLRQ TXLSPHQW DWD XUQDFH RQILJXUDWLRQ LOWHU 7KHUPRVWDW FFHVVRULHV RQQHFWLRQV OO 3HU QVWDOODWLRQ QVWUXFWLRQV DQG RFDO RGH 6WDJLQJ RQGHQVDWH 0DQDJHPHQW 9HQWLQJ OHFWULFDO LQH 9ROWDJH OHFWULFDO RZ 9ROWDJH KDXVW 7HUPLQDWLRQ QWDNH 7HUPLQDWLRQ ...

Page 40: ...sedes 1083286 UIM K 1019 York International Corp 5005 York Drive Norman OK 73069 DV 6LGH LU 6LGH 6 VWHP WHUQDO 6WDWLF 3UHVVXUH 2ZQHU GXFDWLRQ LU 6LGH HDWLQJ 36 LU 6LGH RROLQJ 36 LU 6LGH RQWLQXRXV DQ 36 OHDQ 8S FOH 7HVW LU 6LGH HDWLQJ 9DULDEOH 6SHHG 0 2WKHU XPSHUV LU 6LGH RROLQJ 9DULDEOH 6SHHG 0 LU 6LGH RQWLQXRXV DQ 9DULDEOH 6SHHG 0 ...