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INSTALLATION MANUAL
RESIDENTIAL GAS FURNACE MODELS
TG8S*MP, TGLS*MP, GG8S*MP, GGLS*MP
(Single Stage Multi-position / Low NOx)
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TWINNING AND STAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Side Return Cutout Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Ratings & Physical / Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . 12
Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Unconfined Space Minimum Area . . . . . . . . . . . . . . . . . . . . . . . . . . 18
These high efficiency, compact units employ induced combustion, reli-
able hot surface ignition and high heat transfer aluminized tubular heat
exchangers. The units are factory shipped for installation in upflow or
horizontal applications and may be converted for downflow applica-
tions.
These furnaces are designed for residential installation in a basement,
closet, alcove, attic, recreation room or garage and are also ideal for
commercial applications. All units are factory assembled, wired and
tested to assure safe dependable and economical installation and oper-
ation.
These units are Category I listed and may be common vented with
another gas appliance as allowed by the National Fuel Gas Code.
SECTION I: SAFETY
This is a safety alert symbol. When you see this symbol on
labels or in manuals, be alert to the potential for personal
injury.
Understand and pay particular attention to the signal words DANGER,
WARNING, or CAUTION.
LIST OF SECTIONS
VENT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REPLACEMENT PART CONTACT INFORMATION . . . . . . . . . . . . 28
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
LIST OF FIGURES
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Single Stage PSC Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Single Stage PSC Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Typical Twinned Furnace Application . . . . . . . . . . . . . . . . . . . . . . . . 15
Single Wire Twinning Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . 16
Single Wire Staging Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . 16
Combustion Air Inducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Casing to the Burner Compartment . . . . . . . . . . . . . . . . . . . . . . . . . 17
Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . 18
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
LIST OF TABLES
Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Gas Rate (CU FT/HR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
(without filter) - Bottom Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
(without filter) - Left Side Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DANGER indicates an imminently hazardous situation, which, if not
avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation, which, if not
avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation, which, if not
avoided may result in minor or moderate injury. It is also used to
alert against unsafe practices and hazards involving only property dam-
age.
Improper installation may create a condition where the operation of
the product could cause personal injury or property damage.
Improper installation, adjustment, alteration, service or mainte-
nance can cause injury or property damage. Failure to carefully
read and follow all instructions in this manual can result in fur-
nace malfunction, death, personal injury and/or property dam-
age. Only a qualified contractor, installer or service agency should
install this product.
356485-UIM-G-1211
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Summary of Contents for Johnson Controls TG8S*MP
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Page 1: Table Of Contents
INSTALLATION MANUAL RESIDENTIAL GAS FURNACE MODELS TG8S*MP, TGLS*MP, GG8S*MP, GGLS*MP (Single Stage Multi-position / Low NOx) LIST OF SECTIONS SAFETY ..........1 VENT SYSTEM . - Page 2 11. The size of the unit should be based on an acceptable heat loss calculation for the structure. ACCA, Manual J or other approved tions in the manuals and on the labels attached to the unit and methods may be used. other safety precautions that may apply. Johnson Controls Unitary Products...
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Page 3: Safety
In some instances these instructions exceed certain local codes and ordinances, especially those who have not kept up with changing residential and non-HUD modular home construction practices. These instructions are required as a minimum for a safe installation. Johnson Controls Unitary Products... -
Page 4: Unit Clearances To Combustibles
1. Special floor base or air conditioning coil required for use on combustible floor. 2. Line contact only permitted between lines formed by the intersection of the rear panel and side panel (top in horizontal position) of the furnace jacket and building joists, studs or framing. Johnson Controls Unitary Products... -
Page 5: Ductwork
This access cover shall be attached in such a manner as to prevent leaks. Johnson Controls Unitary Products... -
Page 6: Vertical Applications
3-1/2 Mounting Plate PC24 4-1/2 PC30, PC32, PC35 4-1/2 PC42, PC43, PC36, PC37 5-1/2 PC48 6-1/2 Furnace PC60 Dimension “C” should be at least 2/3 of dimension “D”. See Figure 6 FIGURE 4: Horizontal Right Application Johnson Controls Unitary Products... -
Page 7: Pc Series Upflow Coil Installation
18” (45.7 cm) 12” Openings is from the Recommended furnace COMBUSTIBLE FLOOR 12” BASE ACCESSORY 30” MIN. Work Area FIGURE 8: Combustible Floor Base Accessory Return Sediment Trap FIGURE 10: Typical Attic Installation Johnson Controls Unitary Products... -
Page 8: Typical Attic Installation
Maintain a 6” (15.2 cm) minimum clearance between the front of the furnace and the support rods or straps. 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 return with a transition to allow use of a 20x25 filter. Johnson Controls Unitary Products... -
Page 10: Gas Piping
Drip Leg Union Union External Ground Manual Union Shut-off Valve Pipe Valve Valve Drip Drip Drip Drip To Gas Gas Pipe Supply Ground Upflow Downflow Horizontal Union Drip Leg Configuration Configuration Configuration FIGURE 15: Gas Piping Johnson Controls Unitary Products... -
Page 11: Nominal Manifold Pressure
Do not attempt to drill out any orifices to obtain the proper orifice size. Drilling out a gas orifice will cause misalignment of the burner flames, causing premature heat exchanger burnout, high levels of carbon monoxide, excessive sooting, a fire hazard, personal injury, property damage and/or death. Johnson Controls Unitary Products... -
Page 12: Electrical Power
The transformer may provide power for an panel. After making the wiring connections replace the wiring box air conditioning unit contactor. cover and screws. Refer to Figure 16. 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 17: 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 18: Thermostat Chart - Single Stage HP with Single Stage PSC Furnaces Johnson Controls Unitary Products... -
Page 15: Twinning And Staging
W2 is energized. furnaces are isolated, thus preventing the possibility of any safety devices being bypassed. Connect the common wires of furnace #1 to the common terminal of furnace #2. Johnson Controls Unitary Products... -
Page 16: Vent System
Pressure furnaces are isolated, thus preventing the possibility of any safety Switch devices being bypassed. Mounting Screw Connect the common between furnace #1 and furnace #2. (Remove) FIGURE 22: Combustion Air Inducer Johnson Controls Unitary Products... -
Page 17: Estimated Free Area
Combustion air is brought into the furnace through the unit top panel opening. Johnson Controls Unitary Products... -
Page 18: Unconfined Space Minimum Area
Section 7 and Appendix B of the CSA B149.1, Natural Gas and of ducts with the outdoors, crawl spaces or attic spaces. Propane Installation Codes, the local building codes, furnace and vent manufacture's instructions. Johnson Controls Unitary Products... -
Page 19: Start-Up And Adjustments
With the burner assembly out of the way, simply slide the NOx screens out of the heat exchanger tubes and discard the screens. Replace all components in reverse order. Reconnect all wiring. Johnson Controls Unitary Products... - Page 20 Burner ignition may not be satisfactory on first startup due to resi- start of this input check. dential air in the gas line or until gas manifold pressure is adjusted. The ignition control will make 3 attempts to light before locking out. Johnson Controls Unitary Products...
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Page 21: Gas Rate (Cu Ft/Hr)
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 22: Gas Valve
Refer to Figure 26 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 23: Furnace Control Board
Carbon Monoxide, a fire hazard, personal injury, property damage, and/or death. TWIN Blower Off PARK PARK Delay Timer (In seconds) HI COOL HEAT EAC-H XFMR FIGURE 27: Furnace Control Board Johnson Controls Unitary Products... -
Page 24: Blower Performance Cfm - Any Position (Without Filter) - Bottom Return
1805 1791 1738 1725 1675 1623 1567 1487 1394 1256 1425 1427 1403 1335 1324 1280 1236 1176 1103 NOTES: 1. Airflow expressed in standard cubic feet per minute (CFM). 2. Motor voltage at 115 V. Johnson Controls Unitary Products... -
Page 25: 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 across motor side (right side) may be slightly less than the data shown above. Johnson Controls Unitary Products... -
Page 26: Safety Controls
Do not try to repair controls. Replace defective controls with UPG cooling terminal on the control board. The fan off setting is fixed at 60 Source 1 Parts. seconds to improve cooling efficiency. Never adjust pressure switch to allow furnace operation. Johnson Controls Unitary Products... -
Page 27: 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 0.1 microamps DC (µa) control will also indicate 4 Red Flashes and will enter a one-hour soft lockout. Johnson Controls Unitary Products... -
Page 28: Replacement Parts List
3. Customer Service contact information. a. Click on the “Brand Links” button b. Click on the “Customer Service” button • 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 29: Wiring Diagram
356485-UIM-G-1211 SECTION XI: WIRING DIAGRAM FIGURE 28: Wiring Diagram Johnson Controls Unitary Products... - Page 30 NOTES Subject to change without notice. Published in U.S.A. 356485-UIM-G-1211 Copyright © 2011 by Johnson Controls, Inc. All rights reserved. Supersedes: 356485-UIM-F-0910 Johnson Controls Unitary Products 5005 York Drive Norman, OK 73069...
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