INSTALLATION MANUAL - UPGNET

1 998491-UIM-C-0616 SINGLE STAGE PSCRESIDENTIAL GAS FURNACES MODELS: TG8S*MP, TGLS*MP(80% AFUE Multi-position / Standard Low NOx) INSTALLATION MANUALLIST OF SECTIONSSAFETY .. 1 DUCTWORK .. 5 FILTERS .. 9 GAS PIPING .. 10 ELECTRICAL POWER .. 12 TWINNING AND STAGING .. 15 VENT SYSTEM .. 16 START-UP AND ADJUSTMENTS .. 19 SAFETY CONTROLS .. 26 REPLACEMENT PARTS LIST .. 28 REPLACEMENT PART CONTACT INFORMATION .. 28 WIRING DIAGRAM .. 29 START UP SHEET .. 31 LIST OF FIGURESDuct Attachment .. 5 Vertical Applications .. 6 Coil Flange .. 6 Horizontal Right Application .. 6 Horizontal Left Application .. 6PC Series Upflow Coil INSTALLATION .. 6 Horizontal Left or Right application (Right Shown) .. 7 Combustible Floor Base Accessory .. 7 Horizontal Application .. 7 Typical Attic INSTALLATION .. 7 Typical Suspended Furnace / Crawl Space INSTALLATION .

2 8 Dimensions .. 9 Side Return Cutout Markings .. 10 Gas Valve .. 10 Gas Piping .. 10 Electrical Wiring .. 12 Thermostat Chart - Single Stage AC with Single Stage PSC Furnaces .. 13 Thermostat Chart - Single Stage HP with 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 Combustion Airflow Path Through The Furnace Casing to the Burner Compartment .. 17 Outside and Ambient Combustion Air .. 18 Gas Valve .. 22 Reading Gas Pressure .. 23 Furnace Control Board .. 23 Wiring Diagram .. 29 LIST OF TABLESDuct Attachment .. 5 Vertical Applications .. 6 Coil Flange .. 6 Horizontal Right Application .. 6 Horizontal Left Application .. 6PC Series Upflow Coil INSTALLATION .. 6 Horizontal Left or Right application (Right Shown).

3 7 Combustible Floor Base Accessory .. 7 Horizontal Application .. 7 Typical Attic INSTALLATION .. 7 Typical Suspended Furnace / Crawl Space INSTALLATION .. 8 Dimensions .. 9 Side Return Cutout Markings .. 10 Gas Valve .. 10 Gas Piping .. 10 Electrical Wiring .. 12 Thermostat Chart - Single Stage AC with Single Stage PSC Furnaces .. 13 Thermostat Chart - Single Stage HP with 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 Combustion Airflow Path Through The Furnace Casing to the Burner Compartment .. 17 Outside and Ambient Combustion Air .. 18 Gas Valve .. 22 Reading Gas Pressure .. 23 Furnace Control Board .. 23 Wiring Diagram .. 29 These high efficiency, compact units employ induced combustion, reli-able hot surface ignition and high heat transfer aluminized tubular heatexchangers.

4 The units are factory shipped for INSTALLATION in upflow orhorizontal applications and may be converted for downflow furnaces are designed for residential INSTALLATION in a basement,closet, alcove, attic, recreation room or garage and are also ideal forcommercial applications. All units are factory assembled, wired andtested to assure safe dependable and economical INSTALLATION and units are Category I listed and may be common vented withanother gas appliance as allowed by the National Fuel Gas I: SAFETYThis is a safety alert symbol. When you see this symbol onlabels or in manuals, be alert to the potential for and pay particular attention to the signal words DANGER,WARNING, or CAUTION. DANGER indicates an imminently hazardous situation, which, if not998491-UIM-C-06162 Johnson Controls Unitary Productsavoided, will result in death or serious indicates a potentially hazardous situation, which, if notavoided, could result in death or serious indicates a potentially hazardous situation, which, if notavoided may result in minor or moderate injury.

5 It is also used toalert against unsafe practices and hazards involving only property SAFETY RULES AND PRECAUTIONS1. Only Natural gas or Propane (LP) gas are approved for use with Install this furnace only in a location and position as specified inthese A gas-fired furnace for INSTALLATION in a residential garage must beinstalled as specified in these Provide adequate combustion and ventilation air to the furnacespace as specified in these Combustion products must be discharged outdoors. Connect thisfurnace to an approved vent system only, as specified in SECTIONVII of these Test for gas leaks as specified in these Always install the furnace to operate within the furnace s intendedtemperature rise range. Only connect the furnace to a duct systemwhich has an external static pressure within the allowable range, asspecified on the furnace rating When a furnace is installed so that supply ducts carry air circulatedby the furnace to areas outside the space containing the furnace,the return air shall also be handled by duct(s) sealed to the furnacecasing and terminating outside the space containing the It is permitted to use the furnace for heating of buildings or struc-tures under construction where the application and use must complywith all manufacturer s INSTALLATION instructions including: Proper vent INSTALLATION ; Furnace operating under thermostatic control; Return air duct sealed to the furnace; Air filters in place; Set furnace input rate and temperature rise per rating platemarking.

6 Means for providing outdoor air required for combustion; Return air temperature maintained between 55 F (13 C) and80 F (27 C); The air filter must be replaced upon substantial completion ofthe construction process; Clean furnace, duct work and components upon substantialcompletion of the construction process, and verify furnace-operating conditions including ignition, input rate, temperaturerise and venting, according to the manufacturer s When installed in a Non-HUD-Approved Modular Home or buildingconstructed on-site, combustion air shall not be supplied from occu-pied The size of the unit should be based on an acceptable heat loss cal-culation for the structure. ACCA, MANUAL J or other approved meth-ods may be When moving or handling this furnace prior to INSTALLATION it is rec-ommended to leave the doors on the furnace to provide support andto prevent damage or warping of the cabinet.

7 When lifting the fur-nace by the cabinet, support the ends of the furnace rather than lift-ing by the cabinet flanges at the return air openings (bottom orsides) or supply air When lifting the furnace, it is acceptable to use the primary heatexchanger tubes as a lifting point provided that the tubes are liftedat the front of the heat exchangers where attached to the vestibulepanel. Do not use the top return bend of the heat exchangers as lift-ing points as the tubes may shift out of position or their REQUIREMENTS Refer to the unit rating plate for the furnace model number, andthen see the dimensions page of this instruction for return air ple-num dimensions in Figure 12. The plenum must be installedaccording to the instructions. Provide clearances from combustible materials as listed underClearances to Combustibles.

8 Provide clearances for servicing ensuring that service access isallowed for both the burners and blower. These models ARE NOT CSA listed or approved for installationinto a HUD Approved Modular Home or a Manufactured(Mobile) Home. This furnace is not approved for INSTALLATION in trailers or recre-ational vehicles. Furnaces for INSTALLATION on combustible flooring shall not beinstalled directly on carpeting, tile or other combustible materialother than wood flooring. Check the rating plate and power supply to be sure that the elec-trical characteristics match. All models use nominal 115 VAC, 1 Phase, 60-Hertz power supply. DO NOT CONNECT THIS APPLI-ANCE TO A 50 HZ POWER SUPPLY OR A VOLTAGE ABOVE130 VOLTS. Furnace shall be installed so the electrical components are pro-tected from water.

9 Installing and servicing heating equipment can be hazardous dueto the electrical components and the gas fired components. Onlytrained and qualified personnel should install, repair, or servicegas heating equipment. Untrained service personnel can performbasic maintenance functions such as cleaning and replacing theair filters. When working on heating equipment, observe precau-tions in the manuals and on the labels attached to the unit andother safety precautions that may apply. WARNINGI mproper INSTALLATION may create a condition where the operation ofthe product could cause personal injury or property INSTALLATION , adjustment, alteration, service or maintenancecan cause injury or property damage. Failure to carefully read andfollow all instructions in this MANUAL can result in furnace mal-function, death, personal injury and/or property damage.

10 Only aqualified contractor, installer or service agency should install thisproduct. WARNINGFIRE OR EXPLOSION HAZARDF ailure to follow the safety warnings exactly could result in seriousinjury, death or property test for gas leaks with an open flame. Use a commerciallyavailable soap solution made specifically for detection of leaks tocheck all connections. A fire or explosion may result causing propertydamage, personal injury or loss of life.!!IMPORTANTD uring INSTALLATION , doors should remain on the furnace whenmoving or lifting. CAUTIONThis product must be installed in strict compliance with the installationinstructions and any applicable local, state, and national codesincluding, but not limited to building, electrical, and mechanical codes.!998491-UIM-C-0616 Johnson Controls Unitary Products3 COMBUSTION AIR QUALITY (LIST OF CONTAMINANTS)The furnace requires OUTDOOR AIR for combustion when the furnaceis located in any of the following environments.