York TL9E080 - 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.

Summary

SECTION I: SAFETY

SAFETY REQUIREMENTS AND PRECAUTIONS

Covers general safety rules, fire/explosion hazards, and specific precautions for safe installation.

COMBUSTION AIR QUALITY

Lists contaminants that require outdoor air for combustion and explains the furnace's needs.

CODES AND STANDARDS

APPLICABLE CODES AND STANDARDS

Details national and local codes for installation, including safety, general, combustion, duct, gas piping, and electrical.

INSTALLATION GUIDELINES AND CLEARANCES

Provides guidelines for furnace inspection, location, and required clearances to combustibles and for service.

SECTION II: DUCTWORK

DUCTWORK GENERAL INFORMATION

Explains requirements for duct system design, installation, and creating a closed system for proper airflow.

FURNACE AND COIL INSTALLATION

Details flange usage, supply plenum connection, and indoor coil installation for optimal performance.

FURNACE CONFIGURATION AND RETURN AIR

Explains various furnace configurations and return air connections for different installation types.

SECTION III: FILTERS

FILTER INSTALLATION

Provides instructions and cautions for installing filters externally to the furnace for proper operation.

SECTION IV: GAS PIPING

GAS SAFETY AND PIPING INSTALLATION

Highlights critical safety warnings for gas piping and details the installation process, including leak checks.

HIGH ALTITUDE CONSIDERATIONS

Explains altitude limitations and required adjustments or accessory kits for specific models.

SECTION V: ELECTRICAL POWER

ELECTRICAL POWER CONNECTIONS

Details field wiring requirements, grounding, and power supply connections for safe operation.

LOW VOLTAGE CONTROL WIRING

Explains thermostat wiring, connection to the control board, and auxiliary device connections.

SECTION VI: CONDENSATE PIPING AND FURNACE VENTING CONFIGURATION

CONDENSATE DRAIN INSTALLATION

Provides procedures for installing condensate traps and drain lines for various furnace configurations.

CONDENSATE DRAIN TERMINATION

Specifies requirements for terminating condensate drains, including sump pumps and avoiding freezing.

SECTION VII: COMBUSTION AIR AND VENT SYSTEM

COMBUSTION AIR AND VENT SAFETY

Outlines safety requirements and warnings for combustion air intake and venting systems.

COMBUSTION AIR;VENT PIPE SIZING AND ASSEMBLY

Details pipe sizing, elbow equivalents, materials, and assembly procedures for vent and intake piping.

COMBUSTION AIR SUPPLY CONFIGURATIONS

Explains different methods for supplying combustion air, including outdoor, ambient, and ventilated air.

SECTION VIII: START-UP AND ADJUSTMENTS

START-UP CHECKS AND PROCEDURES

Lists mandatory start-up checks, including gas leaks, ignition, input rate, and temperature rise.

GAS PRESSURE AND INPUT RATE ADJUSTMENT

Details how to measure and adjust manifold gas pressure and calculate furnace input rate.

TEMPERATURE RISE AND FAN CONTROL ADJUSTMENTS

Guides on adjusting temperature rise by changing blower speed and setting fan control delays.

SECTION IX: SAFETY CONTROLS

FURNACE SAFETY CONTROLS OVERVIEW

Describes the function of safety controls such as fuses, switches, sensors, and limit controls.

SECTION X: NORMAL OPERATION AND DIAGNOSTICS

NORMAL OPERATION SEQUENCE

Details the step-by-step operation sequence for continuous blower, cooling, and heating cycles.

TROUBLESHOOTING AND DIAGNOSTICS

Offers troubleshooting steps and explains how to use diagnostic codes to identify furnace issues.

SECTION XI: REPLACEMENT PARTS LIST

REPLACEMENT PARTS AND CONTACT INFORMATION

Lists available parts and contact information for ordering or obtaining a complete parts catalog.

SECTION XII: WIRING DIAGRAM

SECTION XIII: START-UP SHEET

York TL9E080 Specifications

General

Model	TL9E080
Heating Capacity	80, 000 BTU
AFUE	Up to 96%
AFUE Rating	96%
Ignition Type	Hot Surface Ignition
Fuel Type	Natural Gas
Warranty	10-Year Limited Warranty
BTU Input	80, 000 BTU
BTU Output	76, 800 BTU
Vent Type	Direct Vent