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York International TG9S series Installation Manual

Single stage psc residential gas furnaces
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INSTALLATION MANUAL
SINGLE STAGE PSC
RESIDENTIAL GAS FURNACES
MODELS: TG9S and GG9S Series
(95.5% AFUE Multi-position)
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TWINNING AND STAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
VENTING CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Duct Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Vertical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Coil Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Horizontal Right Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Horizontal Left Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PC Series Upflow Coil Installation . . . . . . . . . . . . . . . . . . . . . . . . 7
Combustible Floor Base Accessory . . . . . . . . . . . . . . . . . . . . . . . 7
Horizontal Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Typical Attic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Downflow Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Side Return Cutout Markings . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Single Stage PSC Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Single Stage PSC Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Typical Twinned Furnace Application . . . . . . . . . . . . . . . . . . . . 15
Twinning Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Unit Clearances to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . 4
Coil Projection Dimensions - PC Series Coils . . . . . . . . . . . . . . . 7
Cabinet and Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Nominal Manifold Pressure - High Fire . . . . . . . . . . . . . . . . . . . 11
Ratings & Physical / Electrical Data . . . . . . . . . . . . . . . . . . . . . 12
Maximum Equivalent Pipe Length . . . . . . . . . . . . . . . . . . . . . . . 22
High Altitude Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . 23
Elbow Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Equivalent Length of Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
LIST OF SECTIONS
COMBUSTION AIR and VENT SYSTEM . . . . . . . . . . . . . . . . . 22
START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . 30
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
NORMAL OPERATION AND DIAGNOSTICS . . . . . . . . . . . . . 37
REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . 39
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
START UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
LIST OF FIGURES
Staging Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Upflow Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Downflow Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Horizontal Left Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Horizontal Right Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 21
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Home Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Termination Configuration - 1 Pipe . . . . . . . . . . . . . . . . . . . . . . 26
Termination Configuration - 2 Pipe . . . . . . . . . . . . . . . . . . . . . . 26
Termination Configuration - 2 Pipe Basement . . . . . . . . . . . . . 26
and Vent Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Downward Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
LIST OF TABLES
Size at Furnace (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Unconfined Space Minimum Area . . . . . . . . . . . . . . . . . . . . . . . 28
Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Gas Rate (CU FT/HR) at Full Input . . . . . . . . . . . . . . . . . . . . . . 32
Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
(without filter) - Bottom Return . . . . . . . . . . . . . . . . . . . . . . . . . 35
(without filter) - Left Side Return . . . . . . . . . . . . . . . . . . . . . . . . 36
1083287-UIM-A-0114

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Summary of Contents for York International TG9S series

  • Page 1: Table Of Contents

    INSTALLATION MANUAL SINGLE STAGE PSC RESIDENTIAL GAS FURNACES MODELS: TG9S and GG9S Series (95.5% AFUE Multi-position) LIST OF SECTIONS SAFETY ......... . . 2 COMBUSTION AIR and VENT SYSTEM .

  • Page 2: Safety

    1083287-UIM-A-0114 These high efficiency, compact units employ induced combustion, reli- 8. When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, able hot surface ignition and high heat transfer aluminized tubular heat the return air shall also be handled by duct(s) sealed to the furnace exchangers.

  • Page 3: Combustion Air Quality

    1083287-UIM-A-0114 • Check the rating plate and power supply to be sure that the elec- When outdoor air is used for combustion, the combustion air intake duct trical characteristics match. All models use nominal 115 VAC, 1 system termination must be located external to the building and in an Phase, 60-Hz power supply.

  • Page 4: Unit Clearances To Combustibles

    1083287-UIM-A-0114 4. Where it will not interfere with proper air circulation in the confined FOR FURNACES INSTALLED IN THE COMMON- space. WEALTH OF MASSACHUSETTS ONLY 5. Where the outdoor vent terminal will not be blocked or restricted. Refer to “VENT CLEARANCES” located in SECTION VII of these For all side wall horizontally vented gas fueled equipment installed in instructions.

  • Page 5: Ductwork

    1083287-UIM-A-0114 SECTION II: DUCTWORK DUCTWORK GENERAL INFORMATION The duct system’s design and installation must: The duct system must be properly sized to obtain the correct airflow for the furnace size that is being installed. 1. Handle an air volume appropriate for the served space and within Refer to the furnace rating plate for the correct rise range and static the operating parameters of the furnace specifications.

  • Page 6: Vertical Applications

    1083287-UIM-A-0114 COIL INSTALLATION FURNACE ASSEMBLY - MC SERIES COILS ONLY MC coils are supplied ready to be installed in a horizontal position. A horizontal pan is factory installed. MC coils should be installed in all hor- izontal applications with the horizontal drain pan side down. 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 Mounting Plate...

  • Page 7: Pc Series Upflow Coil Installation

    1083287-UIM-A-0114 DOWNFLOW DUCT CONNECTORS All downflow installations must use a suitable duct connector approved by the furnace manufacturer for use with this furnace. The duct connec- (Min) tors are designed to be connected to the rectangular duct under the floor and sealed. Refer to the instructions supplied with the duct con- nector for proper installation.

  • Page 8: Typical Attic Installation

    1083287-UIM-A-0114 ATTIC INSTALLATION Units may also be suspended from rafters or floor joists using rods, pipe angle supports or straps. In all cases, the furnace should be supported Line contact only permissible Supply with rods, straps, or angle supports at three locations to properly sup- between lines formed by the port the furnace.

  • Page 9: Filters

    1083287-UIM-A-0114 RIGHT SIDE LEFT SIDE FRONT Combustion Air Inlet Combustion Air Inlet Condensate Drain Gas Pipe Gas Pipe Condensate Drain (Downflow) Entry Entry (Downflow) Vent Outlet Electrical Electrical Entry Entry Vent Outlet Condensate Drain Condensate 23” Drain Thermostat Wiring Thermostat Optional Return Air Wiring 14”...

  • Page 10: Gas Piping

    1083287-UIM-A-0114 SIDE RETURN of the duct in a return filter grille(s). The use of straps and/or supports is required to support the weight of the external filter box. Locate the “L” shaped corner locators. These indicate the size of the cut- SECTION IV: GAS PIPING out to be made in the furnace side panel.

  • Page 11: Electrical Power

    1083287-UIM-A-0114 Gas piping may be connected from either side of the furnace using any of the gas pipe entry knockouts on both sides of the furnace. Refer to Figures 13 and 16. An accessible manual shutoff valve must be installed upstream of the GAS ORIFICE CONVERSION FOR PROPANE (LP) furnace gas controls and within 6 feet (1.8 m) of the furnace.

  • Page 12: Electrical Wiring

    1083287-UIM-A-0114 Table 6: Ratings & Physical / Electrical Data Nominal Air Temp. Max. Outlet Min. wire Size Input Output Blower AFUE Blower Total Unit Airflow Rise Air Temp Over-Current (awg) @ 75 ft Size Amps Protect one way CFM m °F °C °F...

  • Page 13: Thermostat Chart - Single Stage Ac With Single Stage Psc Furnaces

    1083287-UIM-A-0114 For additional connection diagrams for all UPG equipment refer to “Low Voltage System Wiring” document available on-line at www.upgnet.com in the Product Catalog Section. Single Stage Air Conditioner – Single Stage Furnace ID MODELS G*(8/9)S GF(8/9) G*9F L(Y/M)8S (G, T)G(8/9)S THERMOSTAT (G/T)GLS SINGLE STAGE...

  • Page 14: Thermostat Chart - Single Stage Hp With Single Stage Psc Furnaces

    1083287-UIM-A-0114 Single Stage Heat Pump – Single Stage Furnace ID MODELS OD MODELS G*(8/9)S GF(8/9) E*R* *RHS G*9F E*ZD L(Y/M)8S (G,T)G(8/9)S E*B* *HGD THERMOSTAT THERMOSTAT THERMOSTAT (G/T)GLS *BP21H50124 SINGLE STAGE SINGLE STAGE *BN21H00124 *DN22U00124 *DP32H70124 FURNACE HEAT P UMP *DP21H40124 *DN21H00124 SINGLE STAGE DEMAND DEFROST...

  • Page 15: Twinning And Staging

    1083287-UIM-A-0114 HUMIDIFIER CONNECTION Vent Pipe Two 1/4” (6.4 mm) spade terminals (HUM and NEUTRAL) for humidifier connections are located on the control board. The terminals provide 115 VAC (1.0 amp maximum) during heating system operation. A mounting hole is provided on the control panel next to the furnace control board for mounting a humidifier transformer if required.

  • Page 16: Condensate Piping And Furnace Venting Configuration

    1083287-UIM-A-0114 Twinning Operation Staging Operation Heating - On a call for heat (W signal) from the wall thermostat, both Heating - On a call for first-stage heat (W1 signal) from the wall thermo- furnaces will start the ignition sequence and the burners on both fur- stat, Furnace #1 will start the ignition sequence and the burners will naces will light.

  • Page 17: Typical. Condensate Drain, Vertical Installation

    1083287-UIM-A-0114 If evaporator coil or humidifier drains are combined with the furnace drain, then the open stand pipe could be raised higher, above the 5” minimum. The furnace, evaporator coil, and humidifier drains may be combined Do not drain other devices (humidifier, evaporator coil, etc.) into the top and drained together.

  • Page 18: Upflow Configuration

    1083287-UIM-A-0114 FIGURE 24: Upflow Configuration Johnson Controls Unitary Products...

  • Page 19: Downflow Configuration

    1083287-UIM-A-0114 FIGURE 25: Downflow Configuration Johnson Controls Unitary Products...

  • Page 20: Horizontal Left Configuration

    1083287-UIM-A-0114 FIGURE 26: Horizontal Left Configuration Johnson Controls Unitary Products...

  • Page 21: Horizontal Right Configuration

    1083287-UIM-A-0114 FIGURE 27: Horizontal Right Configuration Johnson Controls Unitary Products...

  • Page 22: Maximum Equivalent Pipe Length

    1083287-UIM-A-0114 SECTION VIII: COMBUSTION AIR AND Table 7 lists the maximum equivalent length of pipe allowed for each VENT SYSTEM model of furnace. The equivalent length of pipe for each elbow installed is listed in Table 10. The equivalent length of the vent system is the total COMBUSTION AIR AND VENT SAFETY length of straight pipe PLUS the equivalent length of all of the elbows.

  • Page 23: High Altitude Pressure Switches

    1083287-UIM-A-0114 Table 7: Maximum Equivalent Pipe Length (Continued) Elevation 2001 - 4000 Elevation 7001-8000 Model Input (BTUH) Pipe Size (in) Max. equivalent Length (ft) Model Input (BTUH) Pipe Size (in) Max. equivalent Length (ft) 40,000 40,000 40,000 40,000 40,000 40,000 60,000 60,000 60,000...

  • Page 24: Elbow Dimensions

    1083287-UIM-A-0114 TABLE 11: Combustion Air Intake and Vent Connection Size at Furnace (All Models) FURNACE VENT CONNECTION SIZES Furnace Input Intake Pipe Size 2” (5.1 cm) Vent Pipe Size 2” (5.1 cm) STANDARD ELBOW LONG (SWEEP) ELBOW Furnace vent pipe connections are sized for 2” (5.1 cm). pipe. Any FIGURE 28: Dimensions pipe size change must be made outside the furnace casing in a verti- cal pipe section to allow proper drainage of condensate.

  • Page 25: Home Layout

    1083287-UIM-A-0114 VENT CLEARANCES VENT TERMINAL FIXED AIR SUPPLY CLOSED AREA WHERE TERMINAL IS NOT PERMITTED FIXED CLOSED OPERABLE FIGURE 29: Home Layout Direct Vent Terminal Clearances Canadian Installations US Installation A. Clearance above grade, veranda, porch, deck, or 12” (30.5 cm) 12”...

  • Page 26: Termination Configuration - 1 Pipe

    1083287-UIM-A-0114 VENT SYSTEM 12” vertical separation between combustion air This furnace is certified to be installed with one of two possible vent Maintain 12” minimum 12” minimum intake and vent. clearance above configurations. below overhang highest anticipated 12” minimum 1. Horizontal vent system. This vent system can be installed com- snow level.

  • Page 27: Double Horizontal Combustion Air Intake And Vent Termination

    1083287-UIM-A-0114 COMBUSTION AIR SUPPLY All installations must comply with Section 5.3, Air for Combustion and VENT Ventilation of the National Fuel Gas Code, ANSI Z223.1 or Sections 7.2, 7.3 or 7.4 of CAN/CGA B149.1 or B149.2 Installation Code - latest editions.

  • Page 28: Combustion Airflow Path Through The Furnace Casing

    1083287-UIM-A-0114 Ambient Combustion Air Supply Table 12: Estimated Free Area This type installation will draw the air required for combustion from Wood or Metal Wood 20-25%* within the space surrounding the appliance and from areas or rooms Louvers or Grilles Metal 60-70% * adjacent to the space surrounding the appliance.

  • Page 29: Ambient Combustion Air

    1083287-UIM-A-0114 Vent Vent Vent Gable Gable Vent Vent Ventilated Ventilated Attic Attic Optional Top Above Inlet (a) Top Above Insulation Insulation Outlet Soffit Air (a) Soffit Vent Outlet Outlet Vent Air (b) Air (a) Water Heater Water Water Inlet Heater Inlet Heater Inlet...

  • Page 30: Start-Up And Adjustments

    1083287-UIM-A-0114 CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon- monxide poisoning or death. The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation: 1.
  • Page 31 1083287-UIM-A-0114 IGNITION SYSTEM SEQUENCE NOTICE 1. Turn the gas supply ON at external valve and main gas valve. 2. Set the thermostat above room temperature to call for heat. If orifice hole appears damaged or it is suspected to have been 3.

  • Page 32: Gas Rate (Cu Ft/Hr) At Full Input

    1083287-UIM-A-0114 Table 15: Gas Rate (CU FT/HR) at Full Input Size of Test Dial Size of Test Dial Seconds For Seconds For 1 Revolution 1 Revolution 1 Cu Ft 2 Cu Ft 5 Cu Ft 1 Cu Ft 2 Cu Ft 5 Cu Ft 1800 1636...

  • Page 33: Gas Valve

    1083287-UIM-A-0114 ADJUSTMENT OF MANIFOLD GAS PRESSURE & INPUT RATE Inlet and manifold gas pressure may be measured by connecting the The cap for the pressure regulator must be removed entirely to gain “U” tube manometer to the gas valve with a piece of tubing. Follow the access to the adjustment screw.

  • Page 34: Reading Gas Pressure

    1083287-UIM-A-0114 After about 5 minutes of operation, determine the furnace temperature MANIFOLD PRESSURE “U” TUBE CONNECTION rise. Take readings of both the return air and the heated air in the ducts, OUTLET about six feet (1.8 m) from the furnace where they will not be affected PRESSURE TAP by radiant heat.

  • Page 35: Blower Performance Cfm - Any Position (Without Filter) - Bottom Return

    1083287-UIM-A-0114 Table 18: Blower Performance CFM - Any Position (without filter) - Bottom Return Bottom Airflow Data (SCFM) Models Ext. Static Pressure (in. H Speed Input/Airflow/Cabinet High 1128 1077 1035 Medium High 40/800/A Medium Low High 1360 1290 1230 1165 1103 1043 Medium High...

  • Page 36: Blower Performance Cfm - Any Position (Without Filter) - Left Side Return

    1083287-UIM-A-0114 Table 19: Blower Performance CFM - Any Position (without filter) - Left Side Return Left Side Airflow Data (SCFM) Models Ext. Static Pressure (in. H Speed Input/Airflow/Cabinet High 1131 1091 1053 1003 Medium High 40/800/A Medium Low High 1431 1375 1304 1244...

  • Page 37: Safety Controls

    1083287-UIM-A-0114 SECTION X: SAFETY CONTROLS Intermittent Blower - Cooling CONTROL CIRCUIT FUSE Cooling/heating thermostats have a fan switch that has an ON and AUTO position. In the AUTO position the thermostat circuit is completed A 3-amp fuse is provided on the control circuit board to protect the 24- between terminals R and G when there is a call for cooling.

  • Page 38: Furnace Control Diagnostics

    1083287-UIM-A-0114 FURNACE CONTROL DIAGNOSTICS 5 RED FLASHES: This fault is indicated if the normally closed rollout switch opens. The rollout control is manually reset. Check for proper The furnace has built-in, self-diagnostic capability. A blinking LED light combustion air, proper inducer operation, and primary heat exchanger on the control board can flash red, green or amber to indicate various failure or burner problem.

  • Page 39: Replacement Parts List

    1083287-UIM-A-0114 DIAGNOSTIC FAULT CODE STORAGE AND To retrieve the error codes, push the LAST ERROR button. The LED on RETRIEVAL the control will then flash the error codes that are in memory, starting with the most recent. There will be a two-second pause between each The control in this furnace is equipped with memory that will store up to flash code.

  • Page 40: Wiring Diagram

    1083287-UIM-A-0114 SECTION XIII: WIRING DIAGRAM Wiring Diagram - 95% Single-Stage Furnace CAUTION PRECAUTION OPEN ALL DISCONNECTS BEFORE OUVREZ LES DISJONCTEURS AVANT SERVICING THIS UNIT DE PROCEDER AVEC LE SERVICE RED - LOW YEL - MED LOW Legend BLK - HI SEE NOTE 2 BLU - MED HI DS -...

  • Page 41: Start Up Sheet

    1083287-UIM-A-0114 SECTION XIV: START UP SHEET 33" 95% AFUE Single Stage Gas Furnace Start Up Sheet Proper furnace start up is critical to customer comfort and equipment longevity Start-Up Date Technician Performing Start-Up Installing Contractor Name Owner Information Name Address City State or Province Zip or Postal Code...
  • Page 42 Explain thermostat use and programming (if applicable) to owner Additional Job Detail Subject to change without notice. Published in U.S.A. 1083287-UIM-A-0114 Copyright © 2014 by Johnson Controls, Inc. All rights reserved. Supersedes: 997982-UIM-C-1013 York International Corp. 5005 York Drive Norman, OK 73069...

This manual is also suitable for:

Gg9s series

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