Johnson Controls TM8M/TMLM*MP, YM8M/YMLM*MP, LM8M/LMLM*MP GAS Piping Leak Check, Setup Test Mode

368261-UIM-A-0508

6.Remove the burner assembly. It should be possible to swing the burner assembly out of the way without disconnecting the remain- ing wires.

7.With the burner assembly out of the way, simply slide the NOx screens out of the heat exchanger tubes and discard the screens.

8.Replace all components in reverse order. Reconnect all wiring.

GAS PIPING LEAK CHECK

FIRE OR EXPLOSION HAZARD

Failure to follow the safety warnings exactly could result in serious injury, death or property damage.

Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life.

Burner ignition may not be satisfactory on first startup due to resid- ual air in the gas line or until gas manifold pressure is adjusted. The ignition control will make three attempts to light before locking out.

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 leaks. Allow five minutes for any gas to dissipate before continuing with the startup procedure. Be sure that proper ventilation is available to dilute and carry away any vented gas.

With furnace in operation, check all of the pipe joints, gas valve connec- tions and manual valve connections for leakage using an approved gas detector, a non-corrosive leak detection fluid or other leak detection methods. Take appropriate action to stop any leak. If a leak persists, replace the faulty component.

The furnace and its equipment shutoff valve must be disconnected from the gas supply during any pressure testing of that system at test pres- sures in excess of 1/2 PSI (3.45 kPa).

The furnace must be isolated from the gas supply piping system by closing the equipment shutoff valve during any pressure testing of the gas supply system.

SETUP TEST MODE

During normal operation, the furnace input rate can vary between 50% and 100% of full nameplate input, making it difficult to check for proper operation. To help with the furnace startup process, the control has a TEST MODE available that allows the furnace input rate to stay at a constant input rate. To access this TEST MODE perform the following sequence:

1.With power to the board on and with no thermostat calls (no call for heating, cooling or continuous fan), push and hold the TEST but- ton on the board for one second. The LED on the board will glow red.

2.Release the TEST button. The LED on the board will flash a rapid green signal, indicating that TEST MODE is activated.

3.Turn the thermostat to call for heat (R & W signal).

4.The furnace will light and operate at high (100%) firing rate. The furnace firing rate should be checked at this level to confirm that the furnace is not overfired or underfired.

5.To run the furnace at minimum rate (50%), press the ERROR but- ton once. The LED will flash one green flash to confirm.

6.To run the furnace at a middle rate (70%), press the ERROR but- ton twice within a five-second period. The LED will flash green two times to confirm.

7.To again operate the furnace at maximum (100%) rate, press the ERROR button three times within a five-second period. The LED will flash green three times to confirm.

8.If the thermostat call for heat is removed, the LED will flash a rapid green signal, indicating that the furnace is still in TEST MODE.

9.When startup tests are completed, turning off power to the board will take the furnace out of TEST MODE and will restore normal operation. The furnace will automatically return to normal opera- tion after 150 minutes if power is not cycled.

CALCULATING THE FURNACE INPUT (NATURAL GAS)

NOTE: Burner orifices are sized to provide proper input rate using natu- ral gas with a heating value of 1030 BTU/Ft3 (38.4 MJ/m3). If the heat- ing value of your gas is significantly different, it may be necessary to replace the orifices.

NOTE: DO NOT set manifold pressure less than 3.2 in wc or more than

3.8in wc for natural gas at sea level. If manifold pressure is outside this range, change main burner orifices.

DO NOT bottom out gas valve regulator adjusting screw. This can result in unregulated manifold pressure and result in excess over- fire and heat exchanger failures.

NOTE: If orifice hole appears damaged or it is suspected to have been redrilled, check orifice hole with a numbered drill bit of correct size. Never redrill an orifice. A burr-free and sqaurely aligned orifice hole is essential for proper flame characteristics.

DO NOT bottom out gas valve regulator adjusting screw. This can result in unregulated manifold pressure and result in excess over- fire and heat exchanger failures.

Verify natural gas input rate by clocking meter.

1.Turn off all other gas appliances and pilots.

2.Run furnace for a minimum of 3 minutes in heating operation.

3.Measure time (in sec) for gas meter to complete 1 revolution and note reading. The 2 cubic feet dial provides a more accurate mea- surement of gas flow.

4.Refer to Table 10, "Gas Rate (CU FT/HR) at Full Input" for cubic feet of gas per hour.

5.Multiply cubic feet per hour by heating valve (BTU/cu ft) to obtain input.

If clocked rate does not match the input rate from the unit nameplate. follow steps in next section to adjust the manifold pressure. Repeat steps 2 - 5 until correct input is achieved.

Be sure to relight any gas appliances that were turned off at the start of this input check.

Johnson Controls Unitary Products 21