Johnson Controls TM9V C Series, Installation Manual

Page 1: ... 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...

Page 2: ...port and 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 ex...

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: ...r 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 including but not limited to decks and porches the following req...

Page 5: ... 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: ...ottom 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 base plat form or return air plenum Be sure the return platform structure or return air plenum is suitable to support the weight of the furnace The internal bottom panel must be removed for this applicat...

Page 7: ...ists using rods pipe angle supports or straps Angle supports 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 6 for typical ...

Page 8: ...9HQW RQQHFWLRQ 2XWOHW 9HQW RQQHFWLRQ 2XWOHW Table 2 Cabinet and Duct Dimensions BTUH kW Input Nominal CFM m3 min Cabinet Size Cabinet Dimensions Illustrated in Figure 8 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 51 2 60 17 6 1200 34 0 B 17 1 2 44 4 16 3 8 41 6 13 1 4 33 7 122 55 3 80 23 4 1200 34 0 B 17 1 2 44 4 16...

Page 9: ...ng its individual external manual shutoff valve during any pressure testing of the gas supply piping system at pressures equal to or less than 0 5 psig 3 5 kPa Gas piping may be connected from either side of the furnace using any of the gas pipe entry knockouts on both sides of the furnace Refer to Figures 8 and 12 GAS ORIFICE CONVERSION FOR PROPANE LP This furnace is constructed at the factory fo...

Page 10: ...ng Value BTU cu ft Altitude feet Gas Heating Value MJ cu m Altitude m 0 7999 8000 8999 9000 9999 0 2437 2438 2742 2743 3048 in w c in w c in w c kPa kPa kPa 800 3 5 3 5 3 5 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 8...

Page 11: ... installer must take every precaution to insure that the furnace has been converted to the proper gas orifice size when the furnace is installed Do not attempt to drill out any orifices to obtain the proper orifice size Drilling out a gas orifice will cause misalignment of the burner flames caus ing premature heat exchanger burnout high levels of carbon monoxide excessive sooting a fire hazard per...

Page 12: ... 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 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 betw...

Page 13: ... wire connectors to connect this wire to the room thermostat wire and the outdoor unit ther mostat wire The outdoor unit contains its own control transformer DO NOT run a thermostat R wire to the outdoor unit See Figure 17 for details FIGURE 15 Furnace Control Board Communications Connections 219 17 21 2 92 7 767 7 211 7 216 20081 7 1 767 7 211 7 216 1267 7 67 5525 87721 0 1 725 2 7 6 7 211 7 21 7...

Page 14: ...y 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 furnace components only and should not be connected to power auxiliary devices such as humidifiers air clean...

Page 15: ...QJ 9DOYH 80 HKXPLGL FDWLRQ 6HFRQG 6WDJH HDW 6HFRQG 6WDJH HDW LUVW 6WDJH HDW 287 X HDW 9 XPLGLVWDW 2SWLRQDO 127 5RRP WKHUPRVWDW 0867 FRQWURO IRVVLO IXHO RSHUDWLRQ FIGURE 20 Thermostat Chart Two Stage Air Conditioner with Two Stage Variable Speed Furnace 7ZR 6WDJH LU RQGLWLRQHU 7Z R 6WDJH 9DULDEOH 6SHHG XUQDFH LUVW 6WDJH RPSUHVVRU RU 2 5HYHUVLQJ 9DOYH DQ 6HFRQG 6WDJH RPSUHVVRU 5 9ROW RW LUVW 6WDJH H...

Page 16: ...NDENSATE PIPING AND FURNACE VENTING CONFIGURATION CONDENSATE DRAIN LOCATION As shipped from the factory For all 040 060 080K input furnaces the main drain is plumbed through the casing right side opening when viewed from the front of the furnace For all 100 120 130K input furnaces the main drain is plumbed through the casing left side opening when viewed from the front of the furnace The condensat...

Page 17: ...h FIGURE 22 Typical Condensate Drain Vertical Installation 23 1 67 1 3 3 QWL VLSKRQ DLU YHQW 72 23 1 25 9 17 5 1 7 0D CAUTION It is possible for condensation to form inside the combustion air intake pipe in the summer months if significant length of combustion air pipe passes through conditioned space This problem can be averted by installing the supplied vent drain and drain hose located in the l...

Page 18: ...5750149 UIM D 1219 18 Johnson Controls Ducted Systems FIGURE 23 Upflow Configuration A0945 001 ...

Page 19: ...ose 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 condensate ...

Page 20: ...5750149 UIM D 1219 20 Johnson Controls Ducted Systems FIGURE 25 Horizontal Left Configuration A0946 001 ...

Page 21: ...5750149 UIM D 1219 Johnson Controls Ducted Systems 21 FIGURE 26 Horizontal Right Configuration A0946 001 ...

Page 22: ...n the 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 Ven...

Page 23: ...5 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 24: ...all installations above 5000 Feet Part Number Models S1 1PS3308 All FIGURE 27 Dimensions TABLE 9 Elbow Dimensions Elbow A Dimension Illustrated in Figure 27 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...

Page 25: ...m 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 feet 91 4 cm H Clearance to each sid...

Page 26: ...hown in Figure 29 Each 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 Figure 35 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 a...

Page 27: ... tions Refer to Ambient Combustion Air Supply for proper installa tion Refer to Figures 36 and 37 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 Figur...

Page 28: ...r 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 36 Combustion Airflow Path Through The Furnace Casing WARNING This type of installation requires that the supply air to the appliance s b...

Page 29: ...n 2 3 000 BTU hr 700mm2 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 ...

Page 30: ...horizontal pitch Determine that there is no blockage restriction leakage corrosion or other defi ciencies 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 Fol...

Page 31: ...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 value BTU cu ft to obtain input If clocked rate does not match ...

Page 32: ...t 2 Cu Ft 5 Cu Ft 1 Cu Ft 2 Cu Ft 5 Cu Ft 10 360 720 1800 55 65 131 327 11 327 655 1636 56 64 129 321 12 300 600 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 2...

Page 33: ...ECM blower motor The motor and blower are capable of delivering airflow over a wide range of operating conditions The desired cooling airflow may be selected by placing the COOL jumper on the control board in the desired position A B C or D The A position will give the highest airflow and the D position gives the low est Additional fine tuning of the cooling airflow can be done by using the ADJUST...

Page 34: ...ntrols to shut down the furnace Measurement of Temperature Rise After about ten minutes of operation determine the furnace tempera ture rise Measure the temperature of both the return air and the heated air in the ducts about six feet 1 83 m from the furnace where they will not be affected by radiant heat Increase the blower speed to decrease the temperature rise decrease the blower speed to incre...

Page 35: ...11 996 658 952 686 1343 843 B A 886 620 1075 703 1037 728 1402 858 A C 785 538 861 579 845 611 1255 799 C B 804 547 895 590 866 622 1167 769 B C 685 483 669 454 686 505 1005 666 D B 740 492 782 533 792 568 1108 710 C A 630 428 613 421 632 473 916 593 D A 666 437 714 477 739 526 990 637 C C 565 428 556 421 579 473 828 534 D C 100C16 100C20 120D20 Jumper Settings HIGH COOL LOW COOL HIGH COOL LOW COO...

Page 36: ...und levels for various regions of the coun try Tap A is the default profile It provides a 30 second ramp up from zero airflow to full capacity and a 30 second ramp down from full capacity back to zero airflow Whenever there is a change in airflow mode such as from low heat to high heat the motor will take 30 seconds to ramp from one speed to the other Tap B is the humid profile This profile is bes...

Page 37: ...hed for more than 10 seconds after ignition during a retry the control will clear the ignition attempt retry counter If three retries occur during a call for heat the furnace will shut down for one hour If at the end of the one hour shut down there is a call for heat the furnace will initiate a normal start cycle If the problem has not been corrected the furnace will again lockout after three retr...

Page 38: ...valve and gas valve wiring 11 RED FLASHES This indicates that the limit circuit has remained open for more than five minutes and less than fifteen minutes This con dition is usually caused by a failed blower motor or blower wheel The control will enter a hard lockout and power will have to be cycled off and on to reset the control after the problem has been corrected 12 RED FLASHES This indicates ...

Page 39: ...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 40: ...ed 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 Pressure switch 2 stage Pressure switch condensat...

Page 41: ...ming Start Up Installing Contractor Name Start Up Date Continued on next Page OFF 10 MIN 15 AUTO 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 42: ... and programming if applicable to owner 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 through cooling cycles as applicable noting and correcting any problems Air Side Heating PSC Low Heat Blower Speed Selected High ...