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Johnson Controls TG9S*MP manual

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  • Page 1

    364861-UIM-B-0708 EFFICIENCY RATING CERTIFIED ISO 9001 Certified Quality Management System RESIDENTIAL GAS FURNACE MODELS TG9S*MP , GG9S*MP (95.5% AFUE Single S t age Multi-position) INSTALLATION MANUAL LIST OF SECTIONS SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 DUCTWORK . . . . . . . . . [...]

  • Page 2

    364861-UIM-B-0708 2 Johnson Controls Unitary Products SPECIFIC SAFETY RULES AND PRECAUTIONS 1. Only Natural gas or Propane (LP) ga s are 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 [...]

  • Page 3

    364861-UIM-B-0708 Johnson Controls Unitary Produ cts 3 CODES AND ST AND ARDS Follow all national, local codes and standar ds in addition to this installa- tion manual. The installation must co mply with regulations of the serv- ing gas supplier , local buildin g, heat ing, plumbing, and other codes. In absence of local codes, the installa tion must[...]

  • Page 4

    364861-UIM-B-0708 4 Johnson Controls Unitary Products FURNA C E L OCA TION AND CLEARANCES The furnace shall be locat ed using the following guideline s: 1. Where a minimum amount of air intake/vent piping and elbows will be required. 2. As centralized with the air distribution as possible. 3. Where adequate combustion air wi ll be available (partic[...]

  • Page 5

    364861-UIM-B-0708 Johnson Controls Unitary Produ cts 5 On all installations without a coil, a removable access panel is recom- mended in the outlet duct such that smoke or reflected light would be observable inside the casing to indi cate the presence of leaks in the heat exchanger . This access cover shall be attached in such a manner as to preven[...]

  • Page 6

    364861-UIM-B-0708 6 Johnson Controls Unitary Products COIL FLANGE INST ALL A TION The coils include removable flanges t o allow proper fit up with furna ces having various inlet and outlet flange configurations. The two flanges are attached to the top of the coil in the factory during production. For proper configuration of flanges re fer to Figur [...]

  • Page 7

    364861-UIM-B-0708 Johnson Controls Unitary Produ cts 7 DOWNFL OW DUCT CONNECTORS All downflow installations must us e a suitable duct connector approved by the furnace manufacturer for use with this furnace. The duct connec- tors are designed to be conn ected to the rectangular duct under the floor and sealed. Refer to the instructions supplied wit[...]

  • Page 8

    364861-UIM-B-0708 8 Johnson Controls Unitary Products SECTION III: FIL TERS FIL TER INST ALLA TION All applications require the use of a field installed filter . All filters and mounting provision must be field supplied. Filters must be installed external to the furnace cabinet. DO NOT attempt to install filters inside the furnace. NOTE: Single sid[...]

  • Page 9

    364861-UIM-B-0708 Johnson Controls Unitary Produ cts 9 SIDE RETURN Locate the “L” shaped corner loca tors. These indicate the size of the cut- out to be made in the furnace side panel. Refer to Figure 13, "Side Return Cutout Markings". Install the side filter rack followi ng the instructions provided with that accessory . If a filter([...]

  • Page 10

    364861-UIM-B-0708 10 Johnson Controls Unitary Products The furnace must be isolated from the gas supply piping system by closing its individual external manua l shutoff valve during any pressure testing of the gas supply piping system at pressures equal to or less than 1/2 psig (3.5 kPa). Gas piping may be connected from ei the r side of the furnac[...]

  • Page 11

    364861-UIM-B-0708 Johnson Controls Unitary Produ cts 11 Annual Fuel Utilizat ion Eff iciency (AFUE) numbers are determined in accordance wit h DOE T est procedures. Wire size and over current protection must comply with t he National Electrical Code (NFP A-70-latest editio n) and all local code s. The furnace shall b e installed so that the electri[...]

  • Page 12

    364861-UIM-B-0708 12 Johnson Controls Unitary Products For additional connection diagrams for all UPG equipment refer to “Low V oltage System Wi ring” do cument available on-line at www .upgnet.com in the Product Catalog Section. FIGURE 18: Thermostat Chart - Single S tage AC with Single St age PSC Furna ces AC 5D Single Stage Air Conditioner ?[...]

  • Page 13

    364861-UIM-B-0708 Johnson Controls Unitary Produ cts 13 FIGURE 19: Thermostat Chart - Single S tage HP with Single S tage PSC Furnaces HP 2C Single Stage Heat Pump – Single Stage PSC Furnace C 24 – Volt Comm on R 24 – Volt Hot Y1 First Stage Compressor O Reversing Valve Energi zed in Cool L Malfunction Light G Fan *DP32H70124 THERMOSTAT W1 Se[...]

  • Page 14

    364861-UIM-B-0708 14 Johnson Controls Unitary Products ACCESSOR Y CONNECTIONS The furnace control will allow power- switchin g control of various acces- sories. ELECTRONIC AIR CLEANER CONNECTION T wo 1/4” (0.64 cm) spade terminals (EAC and NEUTRAL) for electronic air cleaner connections are located on the control board. The te rminals provide 1 1[...]

  • Page 15

    364861-UIM-B-0708 Johnson Controls Unitary Produ cts 15 Single-Wire T winning Operatio n Heating - On a call for heat (W signal) from the wall ther mostat, both furnaces will start the igniti on sequence and the burners on both fur- naces will light. About thirty seconds after the burners light, the blowers on both furnaces will come on in heating [...]

  • Page 16

    364861-UIM-B-0708 16 Johnson Controls Unitary Products SECTION VII: CONDENSA TE PIP ING AND FURNA CE VENTING CONFIGURA TION CONDENSA TE DRAIN LOCA TION As shipped from the factory: • For all 040, 060, & 080K input furnaces the main dra in is plumbed through the casing right-side opening when viewed fro m the fr ont of the furnace. • For all[...]

  • Page 17

    364861-UIM-B-0708 Johnson Controls Unitary Produ cts 17 FIGURE 23: Upflow Configuration INDUCER ROT A TED FOR LEFT SIDE VENTING (As required for 130K model) UPFLOW AS RECEIVED (Except for 130K Model) INDUCER ROT A TED FOR RIGHT SIDE VENTING When drain hose routing changes are required, be sure to cap all un-used openings. If rerouting hoses - exces[...]

  • Page 18

    364861-UIM-B-0708 18 Johnson Controls Unitary Products FIGURE 24: Downflow Configuration AIRFLOW AIRFLOW Move rain gutter hose to this position DOWNFLOW - INDUCER ROT A TED FOR LEFT SIDE VENTING DOWNFLOW - INDUCER ROT A TED FOR RIGHT SIDE VENTING Move pressure switch hose to this position. NOTE: May require the longer hose that is provided with wid[...]

  • Page 19

    364861-UIM-B-0708 Johnson Controls Unitary Produ cts 19 FIGURE 25: Horizontal Left Configuration HORIZONT AL - LEFT INDUCER ROT A TED HORIZONT AL - LEFT INDUCER AS RECEIVED (Except for 130K Model) AIRFLOW AIRFLOW Move pressure switch hose to this position. NOTE: May require the longer hose that is provided with wider cabinets Move rain gutter hose [...]

  • Page 20

    364861-UIM-B-0708 20 Johnson Controls Unitary Products FIGURE 26: Horizontal Right Configuration AIRFLOW HORIZONT AL - RIGHT INDUCER ROT A TED HORIZONT AL - RIGHT INDUCER AS RECEIVED (Except for 130K Model) Move rain gutter hose to this position Move pressure switch hose to this position. Change condensate drain connection to the 90° fitting provi[...]

  • Page 21

    364861-UIM-B-0708 Johnson Controls Unitary Produ cts 21 SECTION VIII: COMBUSTION AIR AND VENT SY STEM COMBUSTION AIR AND VENT SAFETY This Category IV , dual certified direct vent furnace is designed for resi- dential application. It may be install ed without modification to the con- densate system in a basement, garage, equipment room, alcove , att[...]

  • Page 22

    364861-UIM-B-0708 22 Johnson Controls Unitary Products Example: An 80,000 BTUH furnace requires 32 feet of pipe and four 90º elbows. Using 2" pipe and standard elbows, t he total equivalent length will be: This exceeds the 65 foot maximum equi valent length of 2" pipe allowed for that model and is thus not acceptable. By using sweep elbo[...]

  • Page 23

    364861-UIM-B-0708 Johnson Controls Unitary Produ cts 23 VENT CLEARANCES † A vent shall not terminate directly above a sidewalk or pa v ed driveway that is locate d between two single family dwellings and serves both dwellings. †† 12 inches (30 cm) up from the bot tom edge of the structure fo r T wo-pipe (direct vent) applicati ons per ANSI Z [...]

  • Page 24

    364861-UIM-B-0708 24 Johnson Controls Unitary Products VENT SY STEM This furnace is certified to be installed with one of two possible vent configurations. 1. Horizontal vent system. This vent system can be inst alled co m- pletely horizontal or combinations of horizontal, vertical, or offset using elbows. 2. V ertical vent system. This vent system[...]

  • Page 25

    364861-UIM-B-0708 Johnson Controls Unitary Produ cts 25 COMBUSTION AIR SUPPL Y All installati ons must comply with Section 5.3, Air for Combustion and V entilation of the National Fuel Gas Code, ANSI Z223.1 or Sections 7.2, 7.3 or 7.4 of CAN/CGA B149.1 or .2 Installation Code - latest edi- tions. This furnace is certified to be installed with one o[...]

  • Page 26

    364861-UIM-B-0708 26 Johnson Controls Unitary Products Air Supply Openings and Duct s 1. An opening may be used in lieu of a duct to provide to provide the outside air supply to an appli ance unless otherwise permitted by the authority having jurisdiction. The opening shall be located within 12” (30.5 cm) horizontally from, the burner level of th[...]

  • Page 27

    364861-UIM-B-0708 Johnson Controls Unitary Produ cts 27 V entilated Combusti on Air The ventilated attic space or a cr awl space from which the combustion air is taken must comply with the requirements specified in “AIR SOURCE FROM O UTDOORS” in this instruction or in Section 5.3, Air for Combustion and V entilation of the N ational Fuel Gas Co[...]

  • Page 28

    364861-UIM-B-0708 28 Johnson Controls Unitary Products SECTION IX: ST ART -UP AND ADJUSTMENTS The initial start-up of the furnace requires the following addition al procedures: When the gas supply is initially connec ted to the furnace, the ga s piping may be full of air . In order to purge this air , it is recommended th at the ground union be loo[...]

  • Page 29

    364861-UIM-B-0708 Johnson Controls Unitary Produ cts 29 T ab le 14: Gas Rate (CU FT/HR) at Full Input Seconds For 1 Revolution Size of T est Dial Seconds For 1 Revolution Size of T est Dial 1 Cu Ft 2 Cu Ft 5 Cu Ft 1 Cu Ft 2 Cu Ft 5 Cu Ft 10 360 720 1800 55 65 131 327 1 1 327 655 1636 56 64 129 321 12 300 600 1500 57 63 126 316 13 277 555 1385 58 62[...]

  • Page 30

    364861-UIM-B-0708 30 Johnson Controls Unitary Products ADJUSTMENT OF MANIFO LD GAS PRESSURE & INPUT RA TE Inlet and manifold gas pressure may be measured by connecting the “U” tube manometer to the gas valve with a piece of tubing. Follow the appropriate section in the instructions below . Refer to Figure 38, "Gas V alve" for a dr[...]

  • Page 31

    364861-UIM-B-0708 Johnson Controls Unitary Produ cts 31 ADJUSTMENT OF TEMPERA TURE RISE After about 5 minutes of operation, determine the furnace temperature rise. T ake readings of both the return air and the heated air in the ducts, about six feet (1.83 m) from the furnace where they will not be affected by radiant heat. Increase the blower spee [...]

  • Page 32

    364861-UIM-B-0708 32 Johnson Controls Unitary Products LIMIT CONTROLS There is a high temperature limit control located on the furnace vesti- bule panel near the gas valve. This is an automatic reset control that provides over temperature protecti on due to reduced airflow . This may be caused by: 1. A dirty filter . 2. If the indoor fan motor shou[...]

  • Page 33

    364861-UIM-B-0708 Johnson Controls Unitary Produ cts 33 3 RED FLASHES: This indicates the normally open pressure switch contact did not close after the induc er was energized. This could be caused by a number of problems: faul ty inducer , blocked vent pipe, bro- ken pressure switch hose or faulty p ressure switch. 4 RED FLASHES: This indicates tha[...]

  • Page 34

    364861-UIM-B-0708 34 Johnson Controls Unitary Products SECTION XI: REPL A C EMENT P ARTS L IST DESCRIPTION MOTOR MOTOR, DIRECT DRIVE BLOWER BLOWER, COMBUSTION ELECTRICAL CAP ACITOR, RUN SWITCH, LIMIT CONTROL, FURNACE IGNITER SENSOR, FLAME SWITCHES, PRESSURE SWITCH, DOOR TRANSFORMER VA LV E , G A S CONTROL, TEMPERA TURE AIR MOVING HOUSING , BLOWER W[...]

  • Page 35

    364861-UIM-B-0708 Johnson Controls Unitary Produ cts 35 SECTION XII: W IRING DIAGRAM FIGURE 42: Wiring Diagram[...]

  • Page 36

    Subject to change without notice. Printed in U.S.A. 364861-UIM-B-0708 Copyright © 2008 by Johnson Controls, Inc. All rights reserved. Supersedes: 364861-UIM-A-0608 Johnson Contro ls Unit ary Product s 5005 Y o rk Drive Norman, OK 73069 NOTES[...]

  • Page 37

    NOTES: 1. Refer to the condensate manag ement and drain hose plumbing for different configurations in this document. No hose clamps are needed for the condensate pan hook up. 2. Drip leg in the gas line must be installed. 3. The furnace controls requi re correct polarity on the power supply and a proper ground. 4. Y & G must be connected to the[...]

  • Page 38

    Furnace is multi-position and may be installed in any of the configurations shown. Ensure that all PVC venting has at least 1/4” per foot slope towards the furnace. The furnace condensate pan is self priming and cont ains an internal trap. . Do not inst all an external condensate trap When drain hose routing changes are required (shown in red), b[...]