Johnson Controls Furnace Manual

The Johnson Controls Furnace is a high-efficiency heating system designed for residential and light commercial applications. This furnace features advanced combustion technology, variable-speed blower motor, electronic ignition system, multi-speed operation, built-in diagnostics, safety controls, energy-saving modes, and compatibility with various thermostat systems. Below are key sections for safety, features, installation, setup, operation, and troubleshooting.

1. Features at a Glance 2. Installation 3. First-Time Setup 4. Specifications 5. Controls and Settings 6. Connecting Thermostat 7. Operating Modes 8. Maintenance Schedule 9. Care & Cleaning 10. Regulatory Information 11. Troubleshooting

Features at a Glance

Key components: High-efficiency heat exchanger, Variable-speed blower motor, Electronic ignition system, Multi-position installation, Built-in diagnostic LED, Safety pressure switches, Filter access panel.

Feature	Description
Heat Exchanger	Stainless steel construction for maximum efficiency and durability
Blower Motor	Variable-speed ECM motor for quiet operation and energy savings
Ignition System	Hot surface igniter for reliable lighting
Multi-position	Can be installed in upflow, downflow, or horizontal configurations
Diagnostic LED	Flashing codes for troubleshooting and status indication
Pressure Switches	Safety devices to ensure proper venting operation
Filter Access	Easy-access panel for routine filter changes
Gas Valve	Precise gas flow control for optimal combustion
Limit Switches	Safety devices to prevent overheating
Control Board	Microprocessor-based for advanced operation and diagnostics

Installation

Unpack and inspect contents. Ensure proper clearances and venting requirements.

Position furnace: Install in approved location with proper clearances to combustibles.
Connect gas supply: Use black iron pipe with proper thread sealant; pressure test for leaks.
Connect electrical: 120V AC power supply with proper grounding; install disconnect switch.
Connect venting: Use approved PVC or metal vent pipe per local codes.
Connect thermostat: Use 18-gauge thermostat wire; follow wiring diagram.

WARNING! Installation must be performed by qualified HVAC technician. Gas leaks can cause explosion or fire.

First-Time Setup

Power on furnace; follow startup procedure.

Verify gas supply: Ensure gas valve is open; check for leaks with soap solution.
Set thermostat: Install compatible thermostat; set to heating mode.
Check airflow: Verify proper airflow through registers; adjust dampers if needed.
Test operation: Raise thermostat setting to initiate heating cycle.
Monitor operation: Listen for proper ignition sequence; check flame characteristics.

CAUTION! Never bypass safety controls. Ensure proper combustion air supply.

Specifications

Heating Capacity: 40,000 - 120,000 BTU/H (model dependent)
Efficiency: 80% - 96% AFUE (model dependent)
Electrical: 120V AC, 60Hz, 15 Amp circuit
Gas Type: Natural gas or LP (conversion kit required)
Gas Pressure: Natural gas: 3.5" WC, LP: 10" WC
Blower Speeds: Multi-tap for cooling and heating modes
Sound Level: Less than 75 dB in normal operation
Operating Temp: -30°F to 120°F ambient
Warranty: 20-year heat exchanger, 5-year parts

Controls and Settings

Access control board via front service panel. Diagnostic LED provides status codes.

Thermostat Controls: HEAT/COOL/OFF mode, FAN AUTO/ON, Temperature setting, Program schedules.

Blower Settings: Heating speed, Cooling speed, Continuous fan speed. Limit Controls: High limit switch, Rollout switches. Gas Valve: Pressure adjustment, On/Off control. Diagnostic Codes: LED flash patterns indicate specific faults (refer to troubleshooting chart).

Connecting Thermostat

Compatible with most 24VAC thermostats. Standard 5-wire connection.

Turn off power to furnace at disconnect switch.
Remove thermostat cover and label existing wires.
Connect wires: R (24V power), W (Heat), G (Fan), Y (Cool), C (Common).
Mount thermostat level on wall away from heat sources and drafts.
Restore power and test operation.

Tip: Use programmable thermostat for maximum energy savings.

Operating Modes

Supports heating, fan-only, and with AC unit, cooling operation.

Heating Mode: Thermostat calls for heat; ignition sequence begins.
Fan Mode: Continuous or intermittent blower operation.
Cooling Mode: Requires external AC unit; Y terminal activated.
Standby Mode: System ready but not actively heating.
Lockout Mode: Safety shutdown after multiple failed ignition attempts.

WARNING! Do not operate without proper venting. Carbon monoxide hazard.

Maintenance Schedule

Regular maintenance ensures optimal performance and safety.

Monthly: Check filter; clean or replace if dirty
Seasonal: Inspect burners and heat exchanger
Annual: Professional inspection and cleaning
As Needed: Clean blower assembly and motor

Care & Cleaning

Turn off power before servicing. Use soft brush and vacuum for cleaning.

CAUTION! Never use water or chemical cleaners on electrical components. Keep combustion area clear of debris.

Regulatory Information

UL certified; meets ANSI Z21.47 standards for gas-fired central furnaces. CSA certified for Canadian installations. Complies with Department of Energy efficiency standards. For technical support, visit www.johnsoncontrols.com or contact 1-800-972-8040.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Furnace won't start	Power, thermostat, door switch	Check power supply; verify thermostat setting; ensure door switch engaged.
No heat	Gas supply, ignition, limit switch	Verify gas valve open; check for spark at igniter; reset limit switches.
Short cycling	Filter, airflow, overheating	Replace dirty filter; check for blocked vents; verify proper airflow.
Blower not working	Motor, capacitor, control board	Check motor operation; test capacitor; verify control board output.
Unusual noises	Blower, bearings, ductwork	Inspect blower wheel; lubricate motor if applicable; check for loose panels.

Reset: Turn power off for 30 seconds then restore.

Service: 1-800-972-8040; www.johnsoncontrols.com