Table of Contents
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INSTALLATION MANUAL
RESIDENTIAL GAS FURNACE
MODELS: TG9S*MP, GG9S*MP
(95.5% AFUE Single Stage 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
Horizontal Left or Right application (Right Shown) . . . . . . . . . . . 7
Combustible Floor Base Accessory . . . . . . . . . . . . . . . . . . . . . . . 7
Horizontal Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Typical Attic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Typical Suspended Furnace / Crawl Space Installation . . . . . . . 8
Downflow Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Side Return Cutout Markings . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
with Single Stage PSC Furnaces . . . . . . . . . . . . . . . . . . . . . . . 13
with Single Stage PSC Furnaces . . . . . . . . . . . . . . . . . . . . . . . 14
Typical Twinned Furnace Application . . . . . . . . . . . . . . . . . . . . 15
Twinning Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Staging Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Unit Clearances to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . 4
Coil Projection Dimensions - PC Series Coils . . . . . . . . . . . . . . . 7
Cabinet and Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Recommended Filter Sizes (High Velocity 600 FPM) . . . . . . . . . 9
Nominal Manifold Pressure - High Fire . . . . . . . . . . . . . . . . . . . 11
Ratings & Physical / Electrical Data . . . . . . . . . . . . . . . . . . . . . 12
Maximum Equivalent Pipe Length . . . . . . . . . . . . . . . . . . . . . . . 22
Elbow Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Equivalent Length of Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Size at Furnace (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
LIST OF SECTIONS
COMBUSTION AIR and VENT SYSTEM . . . . . . . . . . . . . . . . . 22
START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . 29
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
NORMAL OPERATION AND DIAGNOSTICS . . . . . . . . . . . . . 36
REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . 38
REPLACEMENT PART CONTACT INFORMATION . . . . . . . . 38
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
LIST OF FIGURES
Typical. Condensate drain, vertical installation . . . . . . . . . . . . . 17
Typical. Combustion Pipe Drain Tee . . . . . . . . . . . . . . . . . . . . . 17
Upflow Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Downflow Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Horizontal Left Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Horizontal Right Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 21
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Home Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Termination Configuration - 1 Pipe . . . . . . . . . . . . . . . . . . . . . . 25
Termination Configuration - 2 Pipe . . . . . . . . . . . . . . . . . . . . . . 25
Termination Configuration - 2 Pipe Basement . . . . . . . . . . . . . 25
Air Intake and Vent Termination . . . . . . . . . . . . . . . . . . . . . . . . 26
Air Intake and Vent Termination . . . . . . . . . . . . . . . . . . . . . . . . 26
Downward Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Direct Vent Air Intake Connection and Vent Connection . . . . . . 26
Combustion Airflow Path Through The Furnace Casing . . . . . . 27
Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . 28
Attic and Crawl Space Combustion Air Termination . . . . . . . . . 28
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
LIST OF TABLES
Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Unconfined Space Minimum Area . . . . . . . . . . . . . . . . . . . . . . . 27
Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Gas Rate (CU FT/HR) at Full Input . . . . . . . . . . . . . . . . . . . . . . 31
Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
(without filter) - Bottom Return . . . . . . . . . . . . . . . . . . . . . . . . . 34
(without filter) - Left Side Return . . . . . . . . . . . . . . . . . . . . . . . . 35
364861-UIM-H-0712
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Summary of Contents for Johnson Controls TG9S*MP
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Page 1: Table Of Contents
INSTALLATION MANUAL RESIDENTIAL GAS FURNACE MODELS: TG9S*MP, GG9S*MP (95.5% AFUE Single Stage Multi-position) LIST OF SECTIONS SAFETY ......... . . 2 COMBUSTION AIR and VENT SYSTEM . -
Page 2: Safety
• Furnaces for installation on combustible flooring shall not be which has an external static pressure within the allowable range, as installed directly on carpeting, tile or other combustible material specified on the furnace rating plate. other than wood flooring. Johnson Controls Unitary Products... -
Page 3: Combustion Air Quality
• Printing inks, paint removers, varnishes, etc. modular home construction practices. These instructions are required • Water softening chemicals as a minimum for a safe installation. Johnson Controls Unitary Products... -
Page 4: Unit Clearances To Combustibles
3. Where adequate combustion air will be available (particularly when * 24" clearance in front and 18" on side recommended for service access. the appliance is not using outdoor combustion air). All furnaces approved for alcove and attic installation. Johnson Controls Unitary Products... -
Page 5: Ductwork
Attach the air conditioning coil cabinet to the duct connector, and then position the furnace on top of the coil cabinet. The connection to the fur- nace, air conditioning coil cabinet, duct connector, and supply air duct must be sealed to prevent air leakage. Johnson Controls Unitary Products... -
Page 6: Vertical Applications
See Figure 6. FACTORY FLANGE LOCATION (Used for upflow or horizontal right installations) ALTERNATE FLANGE LOCATION (Used for downflow or horizontal left installations) FIGURE 3: Coil Flange Johnson Controls Unitary Products... -
Page 7: Pc Series Upflow Coil Installation
FIGURE 9: Horizontal Application FIGURE 7: Horizontal Left or Right application (Right Shown) This furnace may be installed in a horizontal position on either side as shown above. It must not be installed on its back. Johnson Controls Unitary Products... -
Page 8: Typical Attic Installation
FIGURE 12: Downflow Venting The furnace can be hung from floor joists or installed on suitable blocks or pads. Blocks or pad installations shall provide adequate height to ensure that the unit will not be subject to water damage. Johnson Controls Unitary Products... -
Page 9: Filters
2. Do not exceed 1800 CFM using a single side return and a 16x25 filter. For CFM greater than 1800, you may use two side returns or one side and the bottom or one side return with a transition to allow use of a 20x25 filter. Johnson Controls Unitary Products... -
Page 10: Gas Piping
Supply Ground Union Drip Leg Valve External Manual Shut-off Valve Ground Pipe Union Drip Drip Valve Ground Union To Gas Valve Supply Pipe Drip Ground Drip Pipe Union Upflow Downflow Horizontal Drip FIGURE 16: Gas Piping Johnson Controls Unitary Products... -
Page 11: Electrical Power
Field wiring to the unit must be grounded. Electric wires that are field installed shall conform to the temperature limitation for 63°F (35°C) rise wire when installed in accordance with instructions. Refer to Table 6 in these instructions for specific furnace electrical data. Johnson Controls Unitary Products... -
Page 12: Electrical Wiring
Refer to Figure air conditioning unit contactor. 3. The furnace's control system requires correct polarity of the power supply and a proper ground connection. Refer to Figure 17. Johnson Controls Unitary Products... -
Page 13: Thermostat Chart - Single Stage Ac With Single Stage Psc Furnaces
24VAC Humidifier (Optional) Humidistat Clipping Jumper W914 for electric heat on thermostat is not necessary Other Part Numbers: SAP = Legacy 265901 = 031-09166 FIGURE 18: Thermostat Chart - Single Stage AC with Single Stage PSC Furnaces Johnson Controls Unitary Products... -
Page 14: Thermostat Chart - Single Stage Hp With Single Stage Psc Furnaces
Menu must be set to Pump OFF Other Part Numbers: Part Numbers: Part Number: SAP = Legacy SAP = Legacy S1-2HU16700124 265901 = 031-09166 67297 = 031-01975 FIGURE 19: Thermostat Chart - Single Stage HP with Single Stage PSC Furnaces Johnson Controls Unitary Products... -
Page 15: Twinning And Staging
W2 is energized. devices being bypassed. 4. Connect the 24V common wires of furnace #1 to the 24V common terminal of furnace #2. Johnson Controls Unitary Products... -
Page 16: Condensate Piping And Furnace Venting Configuration
No hose clamps are needed for connecting to the condensate pan. 4. Connect the 24V common between furnace #1 and furnace #2. Johnson Controls Unitary Products... -
Page 17: Typical. Condensate Drain, Vertical Installation
DO NOT attempt to winterize the furnace using liquid anti-freeze. A loop has been added to the pressure switch vacuum hose. How- ever, ensure that all pressure switch hoses are routed such that they prevent any condensate from entering the pressure switch. Johnson Controls Unitary Products... -
Page 18: Upflow Configuration
364861-UIM-H-0712 FIGURE 25: Upflow Configuration Johnson Controls Unitary Products... -
Page 19: Downflow Configuration
364861-UIM-H-0712 FIGURE 26: Downflow Configuration Johnson Controls Unitary Products... -
Page 20: Horizontal Left Configuration
364861-UIM-H-0712 FIGURE 27: Horizontal Left Configuration Johnson Controls Unitary Products... -
Page 21: Horizontal Right Configuration
364861-UIM-H-0712 FIGURE 28: Horizontal Right Configuration Johnson Controls Unitary Products... -
Page 22: Maximum Equivalent Pipe Length
For example, if the table allows 65 equivalent feet for a particular model, then the vent can have 65 equivalent feet of pipe, AND the combustion air intake can have another 65 equivalent feet of pipe. Johnson Controls Unitary Products... -
Page 23: Elbow Dimensions
Total = 67 equivalent feet of 3" pipe and must comply with local codes and requirements. This is less than the 90 foot maximum equivalent length of 3" pipe allowed for that model and is thus acceptable. Johnson Controls Unitary Products... -
Page 24: Home Layout
If a metal shield is used it must be a stainless steel material at a minimum dimension of 20 inches (51 cm). It is recommended that a retaining type collar be used that is attached to the building sur- face to prevent movement of the vent pipe. Johnson Controls Unitary Products... -
Page 25: Termination Configuration - 1 Pipe
Under NO circumstances can the two combus- tion air or vent pipes be tied together. The combustion air and vent pipes must terminate in the same atmospheric zone. Johnson Controls Unitary Products... -
Page 26: Double Horizontal Combustion Air Intake And Vent Termination
16’ MAX Or vent pipe may be clamped into outlet of drain coupling 6” MIN. 6” MIN. FIGURE 37: Direct Vent Air Intake Connection and Vent Connection FIGURE 36: Downward Venting Johnson Controls Unitary Products... -
Page 27: Combustion Airflow Path Through The Furnace Casing
Appliance 1 Appliance 2 Total Input + 30,000 = (130,000 4,000) = 32.5 Sq. In. Vertical 100,000 Appliance 1 Appliance 2 Total Input + 30,000 = (130,000 2,000) = 65 Sq. In. Horizontal 100,000 Johnson Controls Unitary Products... -
Page 28: Outside And Ambient Combustion Air
4. The blocking effects of louvers, grilles and screens must be given consideration in calculating free area. If the free area of a specific louver or grille is not known. Refer to Table 11. Johnson Controls Unitary Products... -
Page 29: Start-Up And Adjustments
Be sure proper ventilation is available to dilute and carry away any vented gas. 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. Johnson Controls Unitary Products... - Page 30 Be sure to relight any gas appliances that were turned off at the start w.c. for natural gas at sea level. If manifold pressure is outside this of this input check. range, change main burner orifices. Johnson Controls Unitary Products...
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Page 31: Gas Rate (Cu Ft/Hr) At Full Input
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 1500 1385 1286 1200 1125 1059 1000 Johnson Controls Unitary Products... -
Page 32: Gas Valve
Refer to Figure 41 for connection details. in operation, check for gas leakage around the gas valve pressure port for leakage using an approved non-corrosive gas leak detec- tion fluid, or other non-flammable leak detection methods. Johnson Controls Unitary Products... -
Page 33: Reading Gas Pressure
Carbon Monoxide, a fire hazard, personal injury, property damage, and/or death. TWIN PARK PARK Blower Off Delay Timer Adjustment Jumper HI COOL (in seconds) HEAT EAC-H XFMR FIGURE 43: Furnace Control Board Johnson Controls Unitary Products... -
Page 34: Blower Performance Cfm - Any Position (Without Filter) - Bottom Return
130/2000/D Medium Low 1614 1591 1549 1531 1459 1400 1335 1267 1180 1061 1327 1294 1257 1224 1198 1171 1124 1036 NOTES: 1.Airflow expressed in standard cubic feet per minute (CFM). 2.Motor voltage at 115 V. Johnson Controls Unitary Products... -
Page 35: Blower Performance Cfm - Any Position (Without Filter) - Left Side Return
1.Airflow expressed in standard cubic feet per minute (CFM). 2.Return air is through side opposite motor (left side). 3.Motor voltage at 115 V. 4.Airflow through motor side (right side) may be slightly less than the data shown above. Johnson Controls Unitary Products... -
Page 36: Safety Controls
Never adjust pressure switch to allow furnace operation. speed tap wire that is connected to the “HI COOL” cooling terminal on the control board. To obtain a constant air circulation at lower flow rate, change the high-speed wire to another lower speed wire. Johnson Controls Unitary Products... -
Page 37: Furnace Control Diagnostics
If the main limit switch opens five times within a single call for heat, the Low flame signal control lockout point is control will also indicate 4 Red Flashes and will enter a one-hour soft 0.1 microamps DC (µa) lockout. Johnson Controls Unitary Products... -
Page 38: Replacement Parts List
3. Customer Service contact information. a. Click on the “Brand Links” button b. Click on the “Customer Service” buttont • You can contact us by mail. Just send a written request to: Johnson Controls Unitary Products Consumer Relations 5005 York Drive Norman, OK 73069... -
Page 39: Wiring Diagram
364861-UIM-H-0712 SECTION XIII: WIRING DIAGRAM FIGURE 44: Wiring Diagram Johnson Controls Unitary Products... - Page 40 NOTES Subject to change without notice. Published in U.S.A. 364861-UIM-H-0712 Copyright © 2012 by Johnson Controls, Inc. All rights reserved. Supersedes: 364861-UIM-G-1211 York International Corp. 5005 York Drive Norman, OK 73069...