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INSTALLATION MANUAL
RESIDENTIAL GAS FURNACE MODELS
EFFICIENCY
RATING
CERTIFIED
TG9S*MP, GG9S*MP
ISO 9001
Certified Quality
(95.5% AFUE Single Stage Multi-position)
Management System
LIST OF SECTIONS
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 COMBUSTION AIR and VENT SYSTEM . . . . . . . . . . . . . . . . . . . . 24
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 START-UP AND ADJUSTMENTS
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364861-UIM-B-0708 SPECIFIC SAFETY RULES AND PRECAUTIONS • Refer to the unit rating plate for the furnace model number, and then see the dimensions page of this instruction for return air ple- 1. Only Natural gas or Propane (LP) gas are approved for use with num dimensions in Figure 12, "Dimensions". The plenum must be this furnace. installed according to the instructions. 2. Install this furnace only in a location and position as specified in • Provide clearances from combustible materials as li
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364861-UIM-B-0708 These instructions cover minimum requirements and conform to exist- ing national standards and safety codes. In some instances these instructions exceed certain local codes and ordinances, especially The furnace area must not be used as a broom closet or for any those who have not kept up with changing residential and non-HUD other storage purposes, as a fire hazard may be created. Never modular home construction practices. These instructions are required store items such as th
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364861-UIM-B-0708 FURNACE LOCATION AND CLEARANCES Table 1: Unit Clearances to Combustibles The furnace shall be located using the following guidelines: Application Upflow Downflow Horizontal 1. Where a minimum amount of air intake/vent piping and elbows will Top 1" 0" 0" be required. Vent 0" 0" 0" 2. As centralized with the air distribution as possible. Rear 0" 0" 0" 3. Where adequate combustion air will be available (particularly Side 0" 0" 1" when the appliance is not using outdoor combust
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364861-UIM-B-0708 On all installations without a coil, a removable access panel is recom- FLOOR BASE AND DUCTWORK INSTALLATION - mended in the outlet duct such that smoke or reflected light would be DOWNFLOW observable inside the casing to indicate the presence of leaks in the Installations on combustible material or directly on any heat exchanger. This access cover shall be attached in such a manner floors must use a combustible floor base shown in Figure 8, as to prevent leaks. "Combustible F
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Air flow 364861-UIM-B-0708 COIL FLANGE INSTALLATION The coils include removable flanges to allow proper fit up with furnaces having various inlet and outlet flange configurations. The two flanges Do not drill any holes or drive any screws into the front duct are attached to the top of the coil in the factory during production. For flange on the coil in order to prevent damaging coil tubing. See proper configuration of flanges refer to Figure 3, "Coil Flange". Figure 6, "PC Series Upflow Coil Ins
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364861-UIM-B-0708 DOWNFLOW DUCT CONNECTORS ATTIC INSTALLATION All downflow installations must use a suitable duct connector approved Line contact only permissible Supply by the furnace manufacturer for use with this furnace. The duct connec- between lines formed by the Air Vent (Maintain tors are designed to be connected to the rectangular duct under the intersection of furnace top required floor and sealed. Refer to the instructions supplied with the duct con- and two sides and building clearan
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364861-UIM-B-0708 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 33 Condensate 23” Drain Thermostat Wiring Thermostat Optional Return Air Wiring 14” Cutout (Either side) 1” 28.5” A 1.5” 29.5” (For Cladded door add appoximately an additional .75”) .56” 23.8” 3” Vent Outlet Combustion B B Air Inlet C .56” 24.25” .56”
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364861-UIM-B-0708 SIDE RETURN Outlet Locate the “L” shaped corner locators. These indicate the size of the cut- Vent Port Pressure out to be made in the furnace side panel. Refer to Figure 13, "Side Port Return Cutout Markings". Inlet Outlet Wrench Boss Front of Inlet Main Regulator Furnace Pressure Adjustment On/Off Switch Port Side of (Shown in ON position) Furnace FIGURE 14: Gas Valve Corner Markings FIGURE 13: Side Return Cutout Markings Plan your gas supply before determining the correc
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364861-UIM-B-0708 The furnace must be isolated from the gas supply piping system by GAS ORIFICE CONVERSION FOR PROPANE (LP) closing its individual external manual shutoff valve during any pressure This furnace is constructed at the factory for natural gas-fired operation, testing of the gas supply piping system at pressures equal to or less but may be converted to operate on propane (LP) gas by using a fac- than 1/2 psig (3.5 kPa). tory-supplied LP conversion kit. Follow the instructions supplie
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364861-UIM-B-0708 Table 6: Ratings & Physical / Electrical Data Nominal Max. Outlet Max Min. wire Size Input Output Air Temp. Rise Total Unit AFUE Airflow Air Temp Over-Current (awg) @ 75 ft Amps % 3 Protect one way MBH kW MBH kW CFM °F °C °F °C /min m 40 11.7 38 11.1 800 22.7 8.0 95.5 30-60 17-33 15 14 155 68.3 60 17.6 57 16.7 1000 28.3 10.0 95.5 30-60 19-36 15 14 155 68.3 60 17.6 57 16.7 1200 34.0 10.0 95.5 30-60 19-36 15 14 160 71.1 80 23.4 76 22.3 1200 34.0 10.0 95.5 35-65 19-36 15 14 165
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364861-UIM-B-0708 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. AC 5D Single Stage Air Conditioner – Single Stage PSC Furnace ID MODELS G*(8/9)S GF(8/9) G*9F LF8 L(Y/M)8S (G,T)G(8/9)S THERMOSTAT G8C (G/T)GLS SINGLE STAGE SINGLE STAGE *PP11C70224 PSC AIR FURNACE CONDITIONER SINGLE STAGE PSC 1 SINGL SINGLE E STA STAGE GE FURNACE AIR CONDITIONER AIR CONDITIONER C C 24 – Volt
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364861-UIM-B-0708 HP 2C Single Stage Heat Pump – Single Stage PSC Furnace ID MODELS OD MODELS G*(8/9)S GF(8/9) E*R* *RHS G*9F LF8 E*ZD HP* L(Y/M)8S (G,T)G(8/9)S E*B* *HGD THERMOSTAT THERMOSTAT THERMOSTAT G8C (G/T)GLS *BP21H50124 SINGLE STAGE SINGLE STAGE *BN21H00124 *DN22U00124 *DP32H70124 PSC HEAT PUMP *DP21H40124 FURNACE *DN21H00124 SINGLE STAGE PSC 2 DEMAND DEFROST 1 FURNACE CONTROL C C C 24 – Volt Common 24 – Volt Common 24 – Volt Common Y1 Y/Y2 Y First Stage Compressor Full Stage Compress
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COMMON SUPPLY PLENUM 364861-UIM-B-0708 ACCESSORY CONNECTIONS Vent Pipe The furnace control will allow power-switching control of various acces- sories. ELECTRONIC AIR CLEANER CONNECTION Two 1/4” (0.64 cm) spade terminals (EAC and NEUTRAL) for electronic air cleaner connections are located on the control board. The terminals Gas Supply provide 115 VAC (1.0 amp maximum) during circulating blower opera- Electrical (Both sides) tion. Supply HUMIDIFIER CONNECTION 1 Coil for Two 1/4” (0.64 cm) spade
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364861-UIM-B-0708 Single-Wire Twinning Operation Single-Wire Staging Instructions Heating - On a call for heat (W signal) from the wall thermostat, both Connect the control wiring as shown in Figure 22, "Two-Stage Twinning furnaces will start the ignition sequence and the burners on both fur- Wiring Diagram". naces will light. About thirty seconds after the burners light, the blowers 1. Connect the low voltage wiring from the wall thermostat to the ter- on both furnaces will come on in heating
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364861-UIM-B-0708 SECTION VII: CONDENSATE PIPING AND FURNACE VENTING CONFIGURATION CONDENSATE DRAIN LOCATION Condensate must be disposed of properly. Follow local plumbing or wastewater codes. The drain line must maintain a 1/4" per foot As shipped from the factory: (0.635 cm per meter) downward slope to the drain. • For all 040, 060, & 080K input furnaces the main drain is plumbed through the casing right-side opening when viewed from the front CONDENSATE DRAIN TERMINATION of the furnace. A co
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364861-UIM-B-0708 For 040, 060 & 080K input furnaces, the condensate drain is plumbed toward the right casing outlet from the factory. FIGURE 23: Upflow Configuration Johnson Controls Unitary Products 17 When drain hose routing changes are required, be sure to cap all un-used openings. If rerouting hoses - excess length should be cut off so that no sagging loops will collect and hold condensate, which will cause the furnace to not operate. 130 K Model does not have provisions for top venting,
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364861-UIM-B-0708 FIGURE 24: Downflow Configuration 18 Johnson Controls Unitary Products When drain hose routing changes are required, be sure to cap all un-used openings. If rerouting hoses - excess length should be cut off so that no sagging loops will collect and hold condensate, which will cause the furnace to not operate. AIRFLOW AIRFLOW Move rain gutter hose to this position Move pressure switch 1 hose to this position. NOTE: May require the longer hose that is provided with wider cabine
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364861-UIM-B-0708 FIGURE 25: Horizontal Left Configuration Johnson Controls Unitary Products 19 When drain hose routing changes are required, be sure to cap all un-used openings. If rerouting hoses - excess length should be cut off so that no sagging loops will collect and hold condensate, which will cause the furnace to not operate. HORIZONTAL - LEFT INDUCER ROTATED AIRFLOW 1 Move rain gutter hose to this position NOTE: May require hose 2 Move pressure switch hose extension that is to this po
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364861-UIM-B-0708 FIGURE 26: Horizontal Right Configuration 20 Johnson Controls Unitary Products When drain hose routing changes are required, be sure to cap all un-used openings. If rerouting hoses - excess length should be cut off so that no sagging loops will collect and hold condensate, which will cause the furnace to not operate. HORIZONTAL - RIGHT INDUCER ROTATED 1 AIRFLOW Move pressure switch hose to this position. 4 Move rain gutter hose to this position 2 Change condensate drain conne
