York TL9E Series User Manual

Johnson Controls Ducted Systems 5894307-UIM-B-0920
SINGLE-STAGE ECM
RESIDENTIAL GAS FURNACES
MODELS: TL9E Series
95% Upflow/Horizontal
- Ultra-Low NOx
Natural Gas Only
INSTALLATION MANUAL
LIST OF SECTIONS
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CONDENSATE PIPING AND FURNACE VENTING
CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
COMBUSTION AIR AND VENT SYSTEM . . . . . . . . . . . . . . . . 15
START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . 23
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
NORMAL OPERATION AND DIAGNOSTICS . . . . . . . . . . . . . 29
REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . 31
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
START-UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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
Left Side Supply Gas Pipe Arrangement . . . . . . . . . . . . . . . . . . . . . . 7
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Thermostat Chart - Single-Stage AC with Single-Stage Furnaces .10
Thermostat Chart - Single-Stage HP with Single-Stage Furnaces .10
Thermostat Chart - 1H/2C - Single-Stage Furnace (STD-ECM)
- Two-Stage Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Typical - Condensate Drain, Vertical Installation . . . . . . . . . . . . . . . 12
Upflow Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Horizontal Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Elbow Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Home Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Termination Configuration - 1 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . .19
Termination Configuration - 2 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . .19
Termination Configuration - 2 Pipe Basement . . . . . . . . . . . . . . . . .19
Double Horizontal Combustion Air Intake and Vent Termination . . .20
Double Vertical Combustion Air Intake and Vent Termination . . . . .20
Downward Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Direct Vent Air Intake Connection and Vent Connection . . . . . . . . .20
Combustion Airflow Path Through the Furnace Casing . . . . . . . . . .21
Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Attic and Crawl Space Combustion Air Termination . . . . . . . . . . . . .23
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
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 Equivalent Pipe Length . . . . . . . . . . . . . . . . . . . . . . . 16
Elbow Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Equivalent Length of Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Combustion Air Intake and Vent Connection Size at Furnace
(All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Unconfined Space Minimum Area . . . . . . . . . . . . . . . . . . . . . . . 21
Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Gas Rate (CU FT/HR) at Full Input . . . . . . . . . . . . . . . . . . . . . . 25
Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Blower Performance CFM - Any Position (Without Filter) . . . . . 28
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 ensure safe, dependable, and economical installation and
operation.
These units are Category IV listed and can not 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.

York TL9E Series Specifications

General

Brand	York
Model	TL9E Series
Category	Furnace
Language	English

Summary

Section I: Safety

Safety Requirements

Safety requirements for installation and operation.

Combustion Air Quality

Lists contaminants affecting combustion air quality.

Codes and Standards

Lists applicable national and local codes and standards.

Inspection

Procedure for inspecting the unit upon receiving it.

Furnace Location and Clearances

Guidelines for furnace placement and required clearances.

Clearances for Access and Service

Recommended minimum clearances for unit servicing.

Installation in a Residential Garage

Specific requirements for garage installation.

Section II: Ductwork

Ductwork General Information

General guidelines for designing and installing duct systems.

Duct Flanges

Procedure for preparing and using duct flanges.

Ductwork Installation and Supply Plenum Connection

Connecting ductwork and supply plenum to the furnace.

Indoor Coil Installation

Instructions for installing an indoor coil with the furnace.

Residential Home Upflow Return Plenum Connection

Connecting return air plenum for upflow configurations.

Side Return Application

Instructions for side return air connections.

Bottom Return and Attic Installations

Requirements for bottom return and attic installations.

Horizontal Application

Guidelines for horizontal furnace installation.

Attic Installation

Specific considerations for attic installations.

Suspended Furnace/Crawl Space Installation

Guidelines for suspending furnaces in crawl spaces.

Section III: Filters

Filter Installation

Instructions and precautions for installing air filters.

Side Return Filters

Filter placement and sizing for side return applications.

Horizontal Filters

Filter considerations for horizontal duct connections.

Section IV: Gas Piping

Gas Safety

Important safety precautions for gas piping installation.

Gas Piping Installation

Procedures for connecting the gas supply to the furnace.

High Altitude Considerations

Adjustments needed for furnaces installed at high altitudes.

Section V: Electrical Power

Electrical Power Connections

Guidelines for making electrical power connections to the unit.

Supply Voltage Connections

Wiring instructions for the main power supply.

Low Voltage Control Wiring Connections

Wiring instructions for low voltage thermostat and controls.

Section VI: Condensate Piping and Furnace Venting Configuration

Condensate Drain Installation

Instructions for installing condensate drain and trap.

Accessory Connections

Connecting optional accessories like air cleaners and humidifiers.

Condensate Drain Termination

Proper methods for terminating condensate drain lines.

Section VII: Combustion Air and Vent System

Combustion Air and Vent Safety

Safety precautions for combustion air and vent system installation.

Combustion Air/Vent Pipe Sizing

Determining correct pipe size for combustion air and vent.

Polypropylene Vent/Intake Piping

Approved polypropylene piping materials and installation.

Furnace Vent Connection Sizes

Specifies connection sizes for furnace vent and intake pipes.

Combustion Air and Vent Piping Assembly

Step-by-step assembly for combustion air and vent piping.

Vent Clearances

Required clearances for vent terminal installations.

Vent System Configurations

Overview of vent system configurations: horizontal and vertical.

Vent Applications and Termination

Selecting locations and methods for vent termination.

Downward Venting

Procedures for installing vent and intake pipes downwards.

Combustion Air Supply

Requirements for supplying combustion air to the furnace.

Ambient Combustion Air Supply

Drawing combustion air from the surrounding space.

Air Supply Openings and Ducts

Requirements for air supply openings and duct connections.

Section VIII: Start-Up and Adjustments

Gas Piping Leak Check

Procedure for checking gas piping for leaks.

Ignition Check

Verifying proper ignition sequence and burner operation.

Ignition System Sequence

Step-by-step process of the furnace ignition sequence.

Calculating the Furnace Input

Methods for determining the furnace's input rate.

Adjustment of Manifold Gas Pressure and Input Rate

Adjusting gas pressure and input rate for optimal furnace performance.

Adjustment of Temperature Rise

Adjusting blower speed to achieve correct temperature rise.

Adjustment of Fan Control Settings

Configuring fan on/off delays for heating and cooling.

Taking a Flue Gas Sample

Procedure for safely taking flue gas samples for analysis.

Section IX: Safety Controls

Control Circuit Fuse

Location and purpose of the control circuit fuse.

Blower Door Safety Switch

Function and importance of the blower door interlock switch.

Auxiliary Limit Switch

Operation and reset procedure for the auxiliary limit switch.

Pressure Sensor

Role of the pressure sensor in monitoring system operation.

Limit Controls

Function of high temperature limit controls and lockout logic.

Section X: Normal Operation and Diagnostics

Normal Operation Sequence

Describes the furnace's sequence of operation for heating and cooling.

Troubleshooting

Basic visual checks and steps for troubleshooting furnace issues.

Furnace Control Diagnostics

Interpreting fault codes indicated by the control board LED.

Diagnostic Fault Code Storage and Retrieval

How to retrieve and clear stored error codes from the control board.

Section XI: Replacement Parts List

Replacement Part Contact Information

How to obtain complete parts lists and contact customer service.

Section XII: Wiring Diagram

Wiring Diagram

Schematic showing electrical connections for the furnace.

Section XIII: Start-Up Sheet