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York TL8E User Manual

York TL8E
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Johnson Controls Ducted Systems 5532522-UIM-B-0619
SINGLE STAGE ECM
RESIDENTIAL GAS FURNACES
MODELS: TL8E
(80% Upflow/Horizontal - Ultra Low NOx
Natural Gas Only)
INSTALLATION MANUAL
LIST OF SECTIONS
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
VENT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . 13
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION & DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . 19
REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . 21
REPLACEMENT PART CONTACT INFORMATION . . . . . . . . 21
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
START UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
LIST OF FIGURES
Duct Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Furnace and Coil Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Horizontal Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Typical Attic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Typical Suspended Furnace / Crawl Space Installation . . . . . . . . . . . 6
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Side Return Cutout Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Thermostat Chart - Single Stage AC with Single Stage Furnaces . . . 9
Thermostat Chart - Single Stage HP with Single Stage Furnaces . .10
Thermostat Chart - 1H/2C - Single Stage
Furnace (STD-ECM) - Two Stage Air Conditioner . . . . . . . . . . . . . .10
Combustion Air Inducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Combustion Airflow Path Through The Furnace
Casing to the Burner Compartment . . . . . . . . . . . . . . . . . . . . . . . . .11
Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . .12
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
LIST OF TABLES
Unit Clearances to Combustibles (All Dimensions in Inches, and All
Surfaces Identified with the Unit in an Upflow Configuration) . . . 3
Cabinet and Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Recommended Filter Sizes (High Velocity 600 FPM) . . . . . . . . . 7
Ratings & Physical / Electrical Data . . . . . . . . . . . . . . . . . . . . . . 8
Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Unconfined Space Minimum Area . . . . . . . . . . . . . . . . . . . . . . . 12
Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Gas Rate (CU FT/HR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
New: Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . 16
Blower Performance CFM - Any Position (without filter) . . . . . . 18
These high efficiency, compact units employ induced combustion, reli-
able hot surface ignition and high heat transfer tubular heat exchang-
ers. The units are factory shipped for installation in upflow or horizontal
applications.
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 I listed and may be common vented with
another gas appliance as allowed by the National Fuel Gas Code.
SECTION I: SAFETY
This is a safety alert symbol. When you see this symbol on
labels or in manuals, be alert to the potential for personal
injury.
Understand and pay particular attention to the signal words DANGER,
WARNING, or CAUTION.
DANGER indicates an imminently hazardous situation, which, if not
avoided,
will result in death or serious injury.
WARNING indicates a potentially hazardous situation, which, if not
avoided,
could result in death or serious injury.
CAUTION indicates a potentially hazardous situation, which, if not
avoided
may result in minor or moderate injury. It is also used to
alert against unsafe practices and hazards involving only property dam-
age.
SPECIFIC SAFETY RULES AND PRECAUTIONS
1. Only Natural gas is approved for use with this furnace.
2. Install this furnace only in a location and position as specified in
these instructions.
3. A gas-fired furnace for installation in a residential garage must be
installed as specified in these instructions.
4. Provide adequate combustion and ventilation air to the furnace
space as specified in these instructions.
5. Combustion products must be discharged outdoors. Connect this
furnace to an approved vent system only, as specified in SECTION
VI of these instructions.
6. Test for gas leaks as specified in these instructions.
WARNING
Improper installation may create a condition where the operation of
the product could cause personal injury or property damage.
Improper installation, adjustment, alteration, service or maintenance
can cause injury or property damage. Failure to carefully read and
follow all instructions in this manual can result in furnace mal-
function, death, personal injury and/or property damage. Only a
qualified contractor, installer or service agency should install this
product.
!
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York TL8E Specifications

General IconGeneral
AFUE80%
Heat Exchanger MaterialAluminized Steel
Blower MotorPSC
Fuel TypeNatural Gas
Heating Capacity80000 BTU/h

Summary

SECTION I: SAFETY

Signal Word Definitions

Explains the meaning of DANGER, WARNING, and CAUTION signal words for potential hazards.

SECTION II: DUCTWORK

Ductwork General Information

Provides general guidelines and requirements for designing and installing duct systems for proper furnace operation.

Ductwork Installation and Supply Plenum Connection

Details the connection of the supply plenum to the furnace outlet and recommended practices.

Coil Installation

Instructions for mounting indoor coils relative to the furnace, with specific spacing requirements.

SECTION III: FILTERS

Filter Installation

Instructions for installing field-supplied filters external to the furnace cabinet, with size recommendations.

Side Return Filter Installation

Instructions for side return filter rack installation and cutout markings.

Horizontal Filter Installation

Guidelines for attaching branch ducts to the plenum and supporting external filter boxes for horizontal applications.

SECTION IV: GAS PIPING

Gas Safety

Critical safety warning regarding gas pressure regulators and potential hazards from overpressure.

Gas Piping Installation

Requirements for gas pipe material, sizing, and connections, including drip legs and ground unions.

SECTION V: ELECTRICAL POWER

Electrical Power Connections

Guidelines for field wiring, grounding, and circuit protection, emphasizing copper conductors and correct voltage.

Low Voltage Control Wiring Connections

Instructions for connecting thermostat wiring to the furnace control board, including AC and heat pump applications.

Accessory Connections

Details for connecting electronic air cleaners and humidifiers to the furnace control board.

SECTION VI: VENT SYSTEM

Vent Connections

Information on vent transition sizing and connections for combustion air inducer.

Category 1 - 450 F. Max. Vent Temp.

Requirements for venting systems, including NFGC compliance, avoiding solid fuel appliance vents, and temperature considerations.

Venting

Guidelines for Category I venting, including B-vent and masonry chimney installations, and common venting.

Venting Into an Existing Chimney

Rules for connecting to existing chimneys, emphasizing the need for approved liners and prohibiting unlined chimneys.

SECTION VII: START-UP AND ADJUSTMENTS

Vent and Supply (Outside) Air Safety Check Procedure

Procedure to detect inadequate ventilation or combustion air issues that could cause CO poisoning.

Gas Piping Leak Check

Detailed procedure for checking gas piping for leaks, emphasizing safety and leak detection methods.

Ignition Check

Instructions for performing a combustion check, measuring CO2/CO levels, and adjusting gas flow if necessary.

Furnace Input Rate Check

Procedure for calculating and verifying furnace input rate using the gas meter, including necessary calculations.

Air Temperature Rise Check

Steps to determine furnace temperature rise, adjust blower speed, and ensure safe operating temperatures.

SECTION VIII: SAFETY CONTROLS

Control Circuit Fuse

Information about the 3-amp fuse protecting the 24-volt transformer from overload.

Blower Door Safety Switch

Explanation of the electrical interlock switch that interrupts power when the blower panel is removed.

Auxiliary Limit Switch

Describes the auxiliary limit switch that de-energizes the gas valve if the burner temperature exceeds a set point.

Pressure Sensor

Explains the function of the pressure sensor monitoring the combustion air/vent piping system.

Limit Controls

Details the high temperature limit control located near the gas valve for over-temperature protection.

SECTION IX: OPERATION & DIAGNOSTICS

Sequence of Operation

Describes the step-by-step process of furnace operation for continuous blower, cooling, and heating cycles.

Hot Surface Ignition System

Crucial safety warning about not lighting the furnace manually due to shock hazards.

Troubleshooting

Provides basic visual checks and steps to begin troubleshooting furnace operation issues.

Furnace Control Diagnostics

Explains the furnace's self-diagnostic capability using blinking LED lights to indicate failure codes.

SECTION X: REPLACEMENT PARTS LIST

Replacement Part Contact Information

Provides contact details and website for ordering replacement parts and obtaining a complete parts list.

SECTION XI: WIRING DIAGRAM

Wiring Diagram

Presents the detailed wiring diagram for the furnace, including component connections and legends.

Diagnostic Codes

Lists diagnostic fault codes indicated by LED flashes and their corresponding conditions.

Fault Code Retrieval

Instructions for service technicians on how to retrieve stored fault codes from the furnace control board.

SECTION XII: START UP SHEET

Owner Information

Fields for collecting owner's name, address, and contact details for the installation record.

Equipment Data

Fields for recording furnace model, serial number, and associated coil/unit models.

Furnace Configuration

Options to specify the furnace's installation orientation (Upflow, Horizontal Left, Horizontal Right).

Filter, Thermostat, Accessories

Fields to document the type, size, and location of filters and the type of thermostat installed.

Connections -- All Per Installation Instructions and Local Code

Checkpoints to confirm unit level, gas piping, vent system, and plenum connections.

Venting: B Vent

Fields for documenting B Vent termination details like pipe size, number of elbows, and total height.

Venting: Lined Masonry Chimney

Fields for documenting connections to lined masonry chimneys, including connector type and number of elbows.

Electrical: Line Voltage

Checks for correct line voltage polarity and records the measured voltage.

Electrical: Low Voltage

Verifies thermostat wiring and records low voltage readings between 'R' and 'C' terminals.

Gas Side

Inlet Gas Pressure

Field to record the measured inlet gas pressure to the furnace.

Manifold Gas Pressure

Field to record the measured manifold gas pressure at the gas valve.

CO2 in Vent

Field to record the measured carbon dioxide level in the vent exhaust.

CO in Vent

Field to record the measured carbon monoxide level in the vent exhaust.

Calculated Input in Btuh

Field to record the calculated furnace input based on gas meter readings.

Air Side: System External Static Pressure

Supply Static Before Indoor Coil

Field to record static pressure reading before the indoor coil.

Return Static After Filter

Field to record static pressure reading after the filter, on the furnace return side.

Total External Static Pressure

Field to record the calculated total external static pressure of the duct system.

Air Side: Heating

Heat Blower Speed Selected

Checkbox to indicate the selected blower speed for heating operation.

Temperature Rise in Degrees F

Field to record the measured temperature rise across the furnace during heating.

Air Side: Cooling

Cool Blower Speed Selected

Checkbox to indicate the selected blower speed for cooling operation.

Air Side: Continuous Fan

Blower Speed Selected

Checkbox to indicate the selected blower speed for continuous fan operation.

Cycle Test

Heating Cycle Test

Task to test heating cycles, document issues, and perform corrections.

Continuous Fan Cycle Test

Task to test continuous fan operation, document issues, and perform corrections.

Clean Up

Installation Site Cleanliness

A checklist item to ensure the installation site is cleaned after work is completed.

Owner Education

Provide Owner's Manual

Task to ensure the owner receives the installation and operation manual.

Explain System Operation

Task to educate the owner on how the installed system operates.

Explain Maintenance Importance

Task to inform the owner about essential maintenance for optimal performance and longevity.

Explain Thermostat Usage

Task to instruct the owner on using and programming the installed thermostat.

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