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York International TM9T Series Installation Manual

Two stage psc residential gas furnaces
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INSTALLATION MANUAL
TWO STAGE PSC
RESIDENTIAL GAS FURNACES
MODELS: TM9T Series
(96% AFUE Multi-position)
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TWINNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
VENTING CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Duct Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Vertical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Coil Cabinet Attachment Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Horizontal Right Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Horizontal Left Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PC Series Upflow Coil Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Combustible Floor Base Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Horizontal Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Typical Attic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Downflow Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Side Return Cutout Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Single Stage PSC Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Typical Twinned Furnace Application . . . . . . . . . . . . . . . . . . . . . . . 15
Twinning Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Unit Clearances to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Coil Projection Dimensions - PC Series Coils . . . . . . . . . . . . . . . . . . 7
Cabinet and Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Nominal Manifold Pressure - High Fire . . . . . . . . . . . . . . . . . . . . . . 11
Nominal Manifold Pressure - Low Fire . . . . . . . . . . . . . . . . . . . . . . . 11
Ratings & Physical / Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maximum Equivalent Pipe Length . . . . . . . . . . . . . . . . . . . . . . . . . . 23
High Altitude Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Elbow Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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.
LIST OF SECTIONS
COMBUSTION AIR and VENT SYSTEM . . . . . . . . . . . . . . . . . . . . 22
START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
NORMAL OPERATION AND DIAGNOSTICS . . . . . . . . . . . . . . . . . 36
REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
REPLACEMENT PART CONTACT INFORMATION . . . . . . . . . . . . 38
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
START UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
LIST OF FIGURES
Typical Condensate Drain, Vertical Installation . . . . . . . . . . . . . . . . 16
Upflow Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Downflow Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Horizontal Left Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Horizontal Right Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Home Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Termination Configuration - 1 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Termination Configuration - 2 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Termination Configuration - 2 Pipe Basement . . . . . . . . . . . . . . . . . 26
Downward Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
LIST OF TABLES
Equivalent Length of Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Size at Furnace (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Unconfined Space Minimum Area . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Gas Rate (CU FT/HR) at Full Input . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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.
1083286-UIM-F-1116

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  • Page 1: Table Of Contents

    INSTALLATION MANUAL TWO STAGE PSC RESIDENTIAL GAS FURNACES MODELS: TM9T Series (96% AFUE Multi-position) LIST OF SECTIONS SAFETY ..........2 COMBUSTION AIR and VENT SYSTEM .

  • Page 2: Safety

    1083286-UIM-F-1116 SECTION I: SAFETY • The air filter must be replaced upon substantial completion of the construction process; This is a safety alert symbol. When you see this symbol on • Clean furnace, duct work and components upon substantial com- labels or in manuals, be alert to the potential for personal pletion of the construction process, and verify furnace-operating injury.
  • Page 3 1083286-UIM-F-1116 COMBUSTION AIR QUALITY In the United States and Canada, follow all codes and standards for the (LIST OF CONTAMINANTS) following, using the latest edition available: STEP 1 - Safety WARNING • US: National Fuel Gas Code (NFGC) NFPA 54/ANSI Z223.1 and the Installation Standards, Warm Air Heating and Air Conditioning The furnace area must not be used as a broom closet or for any other Systems ANSI/NFPA 90B...

  • Page 4: Unit Clearances To Combustibles

    1083286-UIM-F-1116 4. Where it will not interfere with proper air circulation in the confined FOR FURNACES INSTALLED IN THE COMMON- space. WEALTH OF MASSACHUSETTS ONLY 5. Where the outdoor vent terminal will not be blocked or restricted. Refer to “VENT CLEARANCES” located in SECTION VII of these For all side wall horizontally vented gas fueled equipment installed in instructions.

  • Page 5: Ductwork

    1083286-UIM-F-1116 SECTION II: DUCTWORK WARNING DUCTWORK GENERAL INFORMATION The duct system must be properly sized to obtain the correct airflow The duct system’s design and installation must: for the furnace size that is being installed. 1. Handle an air volume appropriate for the served space and within Refer to the furnace rating plate for the correct rise range and static the operating parameters of the furnace specifications.

  • Page 6: Vertical Applications

    1083286-UIM-F-1116 COIL INSTALLATION FURNACE ASSEMBLY - MC SERIES COILS ONLY IMPORTANT MC coils are supplied ready to be installed in a horizontal position. A horizontal pan is factory installed. MC coils should be installed in all hor- izontal applications with the horizontal drain pan side down. 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 Mounting Plate...

  • Page 7: Pc Series Upflow Coil Installation

    1083286-UIM-F-1116 DOWNFLOW DUCT CONNECTORS All downflow installations must use a suitable duct connector approved by the furnace manufacturer for use with this furnace. The duct connec- (Min) tors are designed to be connected to the rectangular duct under the floor and sealed. Refer to the instructions supplied with the duct con- nector for proper installation.

  • Page 8: Horizontal Application

    1083286-UIM-F-1116 HORIZONTAL APPLICATION SUSPENDED FURNACE / CRAWL SPACE INSTALLATION The furnace can be hung from floor joists or installed on suitable blocks or pads. Blocks or pad installations shall provide adequate height to ensure that the unit will not be subject to water damage. Units may also be suspended from rafters or floor joists using rods, pipe angle supports or straps.

  • Page 9: Filters

    1083286-UIM-F-1116 FIGURE 13: Dimensions Table 3: Cabinet and Duct Dimensions Approximate Cabinet Dimensions (Illustrated in Figure 13) Nominal BTUH (kW) Cabinet Operating Weights Input Size CFM (m /min) A (in) A (cm) B (in) B (cm) C (in) C (cm) Lbs (kg) 60 (17.6) 1200 (34.0)

  • Page 10: Gas Piping

    1083286-UIM-F-1116 HORIZONTAL FILTERS HIGH STAGE REGULATOR ADJUSTMENT Any branch duct (rectangular or round duct) attached to the plenum OUTLET must attach to the vertical plenum before the filter. The use of straps PRESSURE PORT and/or supports is required to support the weight of the external filter VENT PORT box.

  • Page 11: Nominal Manifold Pressure - High Fire

    1083286-UIM-F-1116 GAS ORIFICE CONVERSION FOR PROPANE (LP) HIGH ALTITUDE MANIFOLD PRESSURE SETTINGS This furnace is constructed at the factory for natural gas-fired operation, This furnace is constructed at the factory for natural gas-fired operation but may be converted to operate on propane (LP) gas by using a fac- at 0 –...

  • Page 12: Electrical Power

    1083286-UIM-F-1116 SECTION V: ELECTRICAL POWER Field wiring to the unit must be grounded. Electric wires that are field installed shall conform to the temperature limitation for 63°F (35°C) rise ELECTRICAL POWER CONNECTIONS wire when installed in accordance with instructions. Refer to Table 7 in these instructions for specific furnace electrical data.

  • Page 13: Thermostat Chart - Single Stage Ac With Single Stage Psc Furnaces

    1083286-UIM-F-1116 For additional connection diagrams for all Johnson Controls Unitary Products’ equipment refer to “Low Voltage System Wiring” document available on-line at www.upgnet.com in the Product Catalog Section. Two Stage Air Conditioner - Two Stage Furnace ID MODELS PT(8/9) (F/L)*(8/9)T (G/L)*(8/9)T THERMOSTAT THERMOSTAT...

  • Page 14: Thermostat Chart - Two Stage Hp With Two Stage Psc Furnace

    1083286-UIM-F-1116 Two Stage Heat Pump - Two Stage Furnace (Hot Heat Pump or Conventional) OD MODEL L S ID MODELS PT(8/9) (F/L)*(8/9)T (G/L)*(8/9)T THERMOSTAT THERMOSTAT TM9* *DN22H00124 TWO STAGE TWO STAGE *PP32U70124 FURNACE HEAT PUMP *DP22U70124 TWO STAGE YORKGUARD VI FURNACE CONTROL 24 –...

  • Page 15: Twinning

    1083286-UIM-F-1116 ACCESSORY CONNECTIONS Both furnaces must be identical models in both heating capacity and CFM capacity. Both furnaces must be operated on the same motor The furnace control will allow power-switching control of various speed tap. See typical application, Figure 20. accessories.

  • Page 16: Condensate Piping And Furnace Venting Configuration

    1083286-UIM-F-1116 Twinning Instructions The condensate hoses must slope downwards at all points. NOTICE CAUTION Furnace control boards must be set up the same. Confirm that the The furnace condensate pan is self priming and contains an internal staging jumper is on the same setting. Confirm that the blower motors trap to prevent flue gas leaking.
  • Page 17 1083286-UIM-F-1116 CONDENSATE DRAIN TERMINATION The condensate will flow to the drain better if an open stand pipe is installed in the drain line. See Figure 22. A condensate sump pump MUST be used if required by local codes, or If evaporator coil or humidifier drains are combined with the furnace if no indoor floor drain is available.

  • Page 18: Upflow Configuration

    1083286-UIM-F-1116 FIGURE 23: Upflow Configuration Johnson Controls Unitary Products...

  • Page 19: Downflow Configuration

    1083286-UIM-F-1116 FIGURE 24: Downflow Configuration Johnson Controls Unitary Products...

  • Page 20: Horizontal Left Configuration

    1083286-UIM-F-1116 FIGURE 25: Horizontal Left Configuration Johnson Controls Unitary Products...

  • Page 21: Horizontal Right Configuration

    1083286-UIM-F-1116 FIGURE 26: Horizontal Right Configuration Johnson Controls Unitary Products...

  • Page 22: Combustion Air And Vent System

    1083286-UIM-F-1116 SECTION VIII: COMBUSTION AIR AND 4. All PVC or ABS combustion air and vent pipe must conform to VENT SYSTEM American National Standards Institute (ANSI) and American Soci- ety for Testing and Materials (ASTM) standards D1785 (Schedule COMBUSTION AIR AND VENT SAFETY 40 PVC), D2665 (PVC-DWV), F891 (PVC-DWV Cellular Core), D2261 (ABS-DWV) or F628 (Schedule 40 ABS).

  • Page 23: Maximum Equivalent Pipe Length

    1083286-UIM-F-1116 Table 8: Maximum Equivalent Pipe Length Elevation Sea level - 2000 Elevation 6001 - 7000 Model Input (BTUH) Pipe Size (in) Max. equivalent Length (ft) Model Input (BTUH) Pipe Size (in) Max. equivalent Length (ft) 60,000 60,000 60,000 60,000 60,000 60,000 80,000...

  • Page 24: Elbow Dimensions

    1083286-UIM-F-1116 This is less than the 90 foot maximum equivalent length of 3" pipe allowed for that model and is thus acceptable. TABLE 12: Combustion Air Intake and Vent Connection Size at Furnace (All Models) FURNACE VENT CONNECTION SIZES Furnace Input Intake Pipe Size 2”...

  • Page 25: Home Layout

    1083286-UIM-F-1116 VENT CLEARANCES VENT TERMINAL FIXED AIR SUPPLY CLOSED AREA WHERE TERMINAL IS NOT PERMITTED FIXED CLOSED OPERABLE FIGURE 28: Home Layout Direct Vent Terminal Clearances Canadian Installations US Installation A. Clearance above grade, veranda, porch, deck, or 12” (30.5 cm) 12”...

  • Page 26: Termination Configuration - 1 Pipe

    1083286-UIM-F-1116 VENT SYSTEM 12” vertical separation between combustion air This furnace is certified to be installed with one of two possible vent Maintain 12” minimum 12” minimum intake and vent. clearance above configurations. below overhang highest anticipated 12” minimum 1. Horizontal vent system. This vent system can be installed com- snow level.

  • Page 27: Double Horizontal Combustion Air Intake And Vent Termination

    1083286-UIM-F-1116 COMBUSTION AIR SUPPLY All installations must comply with Section 5.3, Air for Combustion and VENT Ventilation of the National Fuel Gas Code, ANSI Z223.1 or Sections 7.2, 7.3 or 7.4 of CAN/CGA B149.1 or B149.2 Installation Code - latest editions.

  • Page 28: Combustion Airflow Path Through The Furnace Casing

    1083286-UIM-F-1116 Ambient Combustion Air Supply Table 13: Estimated Free Area This type installation will draw the air required for combustion from Wood or Metal Wood 20-25%* within the space surrounding the appliance and from areas or rooms Louvers or Grilles Metal 60-70% * adjacent to the space surrounding the appliance.

  • Page 29: Ambient Combustion Air

    1083286-UIM-F-1116 Vent Vent Vent Gable Gable Vent Vent Ventilated Ventilated Attic Attic Optional Top Above Inlet (a) Top Above Insulation Insulation Soffit Outlet Soffit Outlet Outlet Vent Air (a) Vent Air (b) Air (a) Water Heater Water Water Inlet Inlet Inlet Inlet Heater...

  • Page 30: Start-Up And Adjustments

    1083286-UIM-F-1116 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.
  • Page 31 1083286-UIM-F-1116 NOTICE It is recommended that when the gas supply is first connected to the furnace, the ground union be loosened until the odor of gas is detected. When gas is detected, immediately tighten the union and check for gas DO NOT set manifold pressure less than 3.2”...

  • Page 32: Gas Rate (Cu Ft/Hr) At Full Input

    1083286-UIM-F-1116 Table 16: Gas Rate (CU FT/HR) at Full Input Size of Test Dial Size of Test Dial Seconds For Seconds For 1 Revolution 1 Revolution 1 Cu Ft 2 Cu Ft 5 Cu Ft 1 Cu Ft 2 Cu Ft 5 Cu Ft 1800 1636...

  • Page 33: Gas Valve

    1083286-UIM-F-1116 ADJUSTMENT OF MANIFOLD GAS PRESSURE & NOTICE INPUT RATE Inlet and manifold gas pressure may be measured by connecting the The regulated outlet pressure has been calibrated at the factory. “U” tube manometer to the gas valve with a piece of tubing. Follow the Additional pressure adjustment should not be necessary.

  • Page 34: Reading Gas Pressure

    1083286-UIM-F-1116 All direct-drive blowers have multi-speed motors. The blower motor MANIFOLD PRESSURE “U” TUBE CONNECTION speed taps are located on the furnace control board in the blower com- OUTLET partment. Refer to Figure 41, and the unit-wiring label to change the PRESSURE TAP blower speed.

  • Page 35: Blower Performance Cfm - Any Position (Without Filter)

    1083286-UIM-F-1116 Table 19: Blower Performance CFM - Any Position (without filter) Bottom Airflow Data (SCFM) Ext. Static Pressure (in. H Models Speed High 1492 1442 1378 1325 1243 1176 1075 Medium High 1236 1201 1161 1139 1082 1011 060B12MP11 Medium Low High 1597 1537...

  • Page 36: Safety Controls

    1083286-UIM-F-1116 SECTION X: SAFETY CONTROLS Intermittent Blower - Cooling CONTROL CIRCUIT FUSE Cooling/heating thermostats have a fan switch that has an ON and AUTO position. In the AUTO position the thermostat circuit is completed A 3-amp fuse is provided on the control circuit board to protect the 24- between terminals R and G when there is a call for cooling.
  • Page 37 1083286-UIM-F-1116 FURNACE CONTROL DIAGNOSTICS 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 The furnace has built-in, self-diagnostic capability. A blinking LED light switch has opened. Check for proper combustion air, proper inducer on the control board can flash red, green or amber to indicate various operation, and primary heat exchanger failure or burner problem.

  • Page 38: Replacement Parts List

    1083286-UIM-F-1116 DIAGNOSTIC FAULT CODE STORAGE AND To retrieve the error codes, push the LAST ERROR button. The LED on RETRIEVAL the control will then flash the error codes that are in memory, starting with the most recent. There will be a two-second pause between each The control in this furnace is equipped with memory that will store up to flash code.

  • Page 39: Wiring Diagram

    1083286-UIM-F-1116 SECTION XIII: WIRING DIAGRAM Wiring Diagram - 96% Two-Stage PSC Furnace CAUTION PRECAUTION OUVREZ LES DISJONCTEURS AVANT OPEN ALL DISCONNECTS BEFORE DE PROCEDER AVEC LE SERVICE SERVICING THIS UNIT RED - LOW SEE NOTE 2 YEL - MED LOW BLU - MED HI BLK - HI Legend...
  • Page 40 1083286-UIM-F-1116 NOTES Johnson Controls Unitary Products...

  • Page 41: Start Up Sheet

    1083286-UIM-F-1116 SECTION XIV: START UP SHEET 33" 96% AFUE Two Stage Gas Furnace Start Up Sheet Proper furnace start up is critical to customer comfort and equipment longevity Start-Up Date Technician Performing Start-Up Installing Contractor Name Owner Information Name Address City State or Province Zip or Postal Code...
  • Page 42 Explain the importance of regular filter replacement and equipment maintenance Explain thermostat use and programming (if applicable) to owner Subject to change without notice. Published in U.S.A. 1083286-UIM-F-1116 Copyright © 2016 by Johnson Controls, Inc. All rights reserved. Supersedes: 1083286-UIM-E-1016 York International Corp. 5005 York Drive Norman, OK 73069...

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