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5894307-UIM-B-0920

Johnson Controls Ducted Systems

23

Specially Engineered Installations

The above requirements are permitted to be waived where special engi-
neering, approved by the authority having jurisdiction, provides an ade-
quate supply of air for combustion and ventilation.

SECTION VIII: START-UP AND 

ADJUSTMENTS

The  following  start-up  checks 

MUST

  be  performed  by  the  furnace

installer on every new furnace installation:
1. Gas piping leak check
2. Ignition check
3. Furnace input rate check
4. Air temperature rise check
Instructions  on  how  to  perform  each  of  these  required  installation
checks are listed in the sections below.

When the gas supply is initially connected to the furnace, the gas piping
may  be full  of  air. To  purge this  air,  loosen the  ground union  until the
odor  of  gas  is  detected.  When  gas  is  detected,  immediately  retighten
the  union  and  check  for  leaks. Allow  5  min  for  any  gas  to  dissipate
before  continuing  with  the  start-up  procedure.  Make  sure  that  proper
ventilation is available to dilute and carry away any vented gas.

 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 carbon-
monxide 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. 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. Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so the appliance 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 min 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 CO

2

 and CO levels of each appliance. Use a draft gauge to check for a downdraft or inade-

quate draft condition.

6. After it has been determined that each appliance properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace

dampers, and any other gas burning appliance to their normal condition.

7. If improper venting is observed during any of the above tests, a problem exists with either the venting system or the appliance does not have

enough combustion air (Supply Air from outside) to complete combustion. This condition must be corrected before the appliance can function
safely.

8. Any corrections to the venting system and/or to the supply (outside) air system must be in accordance with the National Fuel Gas Code Z223.1

or CAN/CGA B149.1 Natural Gas and Propane Installation Code (latest editions). If the vent system must be resized, follow the appropriate
tables in Appendix G of the above codes or for this appliance.

!

 Figure 29: 

Attic and Crawl Space Combustion Air Termination

 WARNING

Be sure to instruct the owner not to block this intake pipe.

12” Min.

12” minimum
between bottom
of air intake and
any material below.

!

IMPORTANT:  

All electrical connections made in the field and in the

factory must be checked for proper tightness.

Summary of Contents for TL9E Series

Page 1: ...Wiring Diagram 32 LIST OF TABLES Unit Clearances to Combustibles 4 Cabinet and Duct Dimensions 6 Recommended Filter Sizes High Velocity 600 FPM 7 Ratings and Physical Electrical Data 8 Maximum Equival...

Page 2: ...alled directly on carpeting tile or other combustible material other than wood flooring Check the rating plate and power supply to be sure that the elec trical characteristics match All models use nom...

Page 3: ...t piping and elbows are required As centralized with the air distribution as possible Where adequate combustion air is available particularly when the appliance is not using outdoor combustion air Whe...

Page 4: ...be needed to ensure against drain pan distortion On all installations without a coil a removable access panel is recom mended in the outlet duct such that smoke or reflected light would be observable...

Page 5: ...ION This appliance is certified for line contact when the furnace is installed in the horizontal left or right position The line contact is only permissible between lines that are formed by the inters...

Page 6: ...t and quiet fur nace operation When suspending the furnace use a secure platform constructed of plywood or other building materials secured to the floor or ceiling joists See Figure 5 for details and...

Page 7: ...p leg and ground union is required See Figure 10 For left side supply gas pipe arrangement two 1 2 in elbows and two 1 2 in x 1 1 2 in pipe nipples must be used The arrangement shown in Figure 9 align...

Page 8: ...with DOE test procedures Wire size and overcurrent protection must comply with the National Electrical Code NFPA 70 latest edition and all local codes The furnace must be installed so the electrical...

Page 9: ...Figure 11 LOW VOLTAGE CONTROL WIRING CONNECTIONS Install the field supplied thermostat by following the instructions that come with the thermostat With the thermostat set in the OFF position and the m...

Page 10: ...1 67 LU RQGLWLRQHU 9ROW RPPRQ RPSUHVVRU RQWDFWRU XOO 6WDJH HDW 7 50267 7 Figure 13 Thermostat Chart Single Stage HP with Single Stage Furnaces 6LQJOH 6WDJH R1R XUQDFH 6LQJOH 6WDJH HDW 3XPS 6HFRQG 6WDJ...

Page 11: ...pplied to the hose con nected to the top of the condensate trap Screw the condensate trap to the condensate trap bracket supplied Then thread the hose adapters together below the furnace casing using...

Page 12: ...collec tor box as shown in Figures 16 and 17 The drain hose must not sag or droop after it is installed If glue is used when connecting the intake pipe to the intake coupling the drain opening in the...

Page 13: ...5894307 UIM B 0920 Johnson Controls Ducted Systems 13 Figure 16 Upflow Configuration UPFLOW LEFT SIDE DRAIN UPFLOW RIGHT SIDE DRAIN EXTERNAL CONDENSATE TRAP EXTERNAL CONDENSATE TRAP A1128 001...

Page 14: ...DRAIN AIRFLOW EXTERNAL CONDENSATE TRAP HORIZONTAL LEFT HORIZONTAL RIGHT MOVE RAIN GUTTER HOSE TO THIS POSITION MOVE CONDENSATE DRAIN HOSE TO THIS POSITION INTAKE PIPE DRAIN AIRFLOW EXTERNAL CONDENSAT...

Page 15: ...models are supplied with 2 in 5 1 cm vent connections When the pipe must be increased to 3 in 7 6 cm diameter the transition from 2 in to 3 in must be done as close to the furnace as possible The 2 i...

Page 16: ...igure 18 Elbow Dimensions A A A A STANDARD ELBOW LONG SWEEP ELBOW Table 6 Elbow Dimensions Elbow A Dimension Illustrated in Figure 18 2 in Standard 2 5 16 in 3 in Standard 3 1 16 in 2 in Sweep 3 1 4 i...

Page 17: ...nform to ASTM D2564 for PVC or ASTM D2235 for ABS piping 7 All joints must provide a permanent airtight and watertight seal 8 Install the combustion air and vent piping such that it has a 1 4 in ft 21...

Page 18: ...equirements of the gas supplier 12 in 30 5 cm or in accordance with local installation codes and the requirements of the gas supplier F Clearance to outside corner 12 in 30 5 cm or in accordance with...

Page 19: ...3 to 24 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 Figures 23 and 24 can...

Page 20: ...tion See Figure 28 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 att...

Page 21: ...operated damper or manually adjustable louvers are not permitted for use An automatically operated damper or automatically adjustable louvers must be interlocked so the main burner can not operate un...

Page 22: ...kW of the total input rating of all equipment located in the enclosure Not less than the sum of all vent connectors in the confined space The duct must be least the same cross sectional area as the fr...

Page 23: ...s 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 Follow the light...

Page 24: ...surface igniter glows for about 17 s b After this warm up the induced draft blower starts again and the ignition module opens the main gas valve c After flame is established the supply air blower sta...

Page 25: ...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 23...

Page 26: ...ws on main gas valve 2 Turn on gas and electrical supplies and follow the operating instruc tions to place the unit back in operation 3 Adjust manifold pressure by adjusting gas valve regulator screw...

Page 27: ...gas sample for analysis it is permissi ble to drill a small hole in the plastic flue pipe for a sample probe pro vided that the vent piping is PVC and the hole is correctly sealed afterwards If using...

Page 28: ...ated on the furnace vesti bule panel near the gas valve This is an automatic reset control that provides over temperature protection due to reduced airflow This may be caused by the following A dirty...

Page 29: ...sensed within 1 0 s The gas valve de energizes and the control begins a recycle operation A normal ignition sequence begins after a 15 s inter purge If during the five recycles the gas supply does not...

Page 30: ...d Red Flashes Indicates incorrect line voltage polarity The polar ity of the incoming power to the furnace is reversed Soft Lockout The control includes a soft lockout that resets automati cally after...

Page 31: ...Door 1 5 ft required GROMMET 3 required HARNESS WIRING HOSE CONDENSATE HOSE RAIN GUTTER KNOB QUARTER TURN 4 required MOTOR MOUNT ORIFICE BURNER PAN CONDENSATE PLUG SEAL 7 8 in PLUG SEAL 2 3 8 in PLUG...

Page 32: ...5894307 UIM B 0920 32 Johnson Controls Ducted Systems SECTION XII WIRING DIAGRAM Figure 33 Wiring Diagram...

Page 33: ...ree Ells 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 b...

Page 34: ...ure in w c Return Static in w c after Air Side Heating Air Side Cooling Air Side Continuous Fan Clean Up Give owner the owner s manual provided Explain thermostat use and programming if applicable to...

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