Johnson Controls TGLS*MP, TG8S*MP, GGLS*MP, GG8S*MP GAS Piping Leak Check, Ignition System Sequence

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356485-UIM-G-1211

GAS PIPING LEAK CHECK

FIRE OR EXPLOSION HAZARD

Failure to follow the safety warnings exactly could result in serious injury, death or property damage.

Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life.

Burner ignition may not be satisfactory on first startup due to resid- ual air in the gas line or until gas manifold pressure is adjusted. The ignition control will make three attempts to light before locking out.

It is recommended that when the gas supply is first connected to the furnace, the ground union be loosened until the odor of gas is detected. When gas is detected, immediately tighten the union and check for gas leaks. Allow five minutes for any gas to dissipate before continuing with the start-up procedure. Be sure that proper ventilation is available to dilute and carry away any vented gas.

With furnace in operation, check all of the pipe joints, gas valve connec- tions and manual valve connections for leakage using an approved gas detector, a non-corrosive leak detection fluid or other leak detection methods. Take appropriate action to stop any leak. If a leak persists, replace the faulty component.

The furnace and its equipment shut-off valve must be disconnected from the gas supply during any pressure testing of that system at test pressures in excess of 1/2 PSI (3.45 kPa).

The furnace must be isolated from the gas supply piping system by closing the equipment shut-off valve during any pressure testing of the gas supply system.

IGNITION SYSTEM SEQUENCE

1.Turn the gas supply ON at external valve and main gas valve.

2.Set the thermostat above room temperature to call for heat.

3.System start-up will occur as follows:

a.The induced draft blower motor will start and come up to speed. Shortly after inducer start-up, the hot surface igniter will glow for about 17 seconds.

b.After this warm up, the ignition module will energize (open) the main gas valve.

c.After flame is established, the supply air blower will start in about 30 seconds.

With furnace in operation, check all of the pipe joints, gas valve connec- tions and manual valve connections for leakage using an approved gas detector, a non-corrosive leak detection fluid, or other leak detection methods. Take appropriate steps to stop any leak. If a leak persists, replace the component.

CALCULATING THE FURNACE INPUT (NATURAL GAS)

NOTICE

Burner orifices are sized to provide proper input rate using natural

gas with a heating value of 1030 BTU/Ft3 (38.4 MJ/m3). If the heat- ing value of your gas is significantly different, it may be necessary to replace the orifices.

NOTICE

If orifice hole appears damaged or it is suspected to have been redrilled, check orifice hole with a numbered drill bit of correct size. Never redrill an orifice. A burr-free and sqaurely aligned orifice hole is essential for proper flame characteristics.

DO NOT bottom out gas valve regulator adjusting screw. This can result in unregulated manifold pressure and result in excess over- fire and heat exchanger failures.

NOTICE

DO NOT set manifold pressure less than 3.2 in wc or more than 3.8 in wc for natural gas at sea level. If manifold pressure is outside this range, change main burner orifices.

Verify natural gas input rate by clocking meter.

1.Turn off all other gas appliances and pilots.

2.Run furnace for a minimum of 3 minutes in heating operation.

3.Measure time (in sec) for gas meter to complete 1 revolution and note reading. The 2 cubic feet dial provides a more accurate mea- surement of gas flow.

4.Refer to Table 10 for cubic feet of gas per hour.

5.Multiply cubic feet per hour by heating valve (BTU/cu ft) to obtain input.

If clocked rate does not match the input rate from the unit nameplate. follow steps in next section to adjust the manifold pressure. Repeat steps 2 - 5 until correct input is achieved.

Burner ignition may not be satisfactory on first startup due to resi- 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.

Be sure to relight any gas appliances that were turned off at the start of this input check.

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Johnson Controls Unitary Products

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Contents Section I Safety List of SectionsList of Figures List of TablesAnce to a 50 HZ Power Supply or a Voltage Above 130 Volts Specific Safety Rules and PrecautionsSafety Requirements Combustion AIR Quality List of Contaminants Codes and StandardsDirectly BELOW. Keep Clear of ALL OBSTRUC- Tions InspectionFurnace Location and Clearances Floor Base and Ductwork Installation Downflow Coil InstallationSection II Ductwork Ductwork General InformationCOIL/FURNACE Assembly MC/FC/PC Series Coils Furnace Assembly MC & FC Series CoilsCoil Flange Installation Furnace Assembly PC Series CoilsCoil / Furnace Assembly HC Series Coils Downflow Duct ConnectorsBottom Return and Attic Installations Attic InstallationSuspended Furnace / Crawl Space Installation Typical Suspended Furnace / Crawl Space InstallationFilter Installation Attempt to install filters inside the furnaceSection III Filters Btuh kWGAS Safety GAS Piping InstallationSection IV GAS Piping Side ReturnHigh Altitude Pressure Switch Conversion GAS Orifice Conversion for Propane LPHigh Altitude GAS Orifice Conversion Manifold Pressures in wcSection V Electrical Power Electrical Power ConnectionsLOW Voltage Control Wiring Connections Supply Voltage ConnectionsSingle Stage PSC AIR Furnace Conditioner ID ModelsThermostat Single Stage Heat Pump Single Stage PSC FurnaceOD Models Section VI Twinning and Staging Vent Connections Section VII Vent SystemStaging Category 1 450 F. MAX. Vent Temp VentingVenting Into AN Existing Chimney FAN-ASSISTED Combustion SystemVent and Supply Outside Air Safety Check Procedure Air Supply Openings and DuctsVentilated Combustion Air Free AreaSection Viii START-UP Adjustments NOx Screen Removal Lo-NOx Models OnlyCalculating the Furnace Input Natural GAS GAS Piping Leak CheckIgnition System Sequence Revolution Revolution Cu FtSeconds For Adjustment of Manifold GAS Pressure & Input Rate Read the inlet gas pressureRead the manifold gas pressure Nominal Manifold PressureManifold Pressure U Tube Connection Adjustment of Temperature RiseAdjustment of FAN Control Settings Bottom Airflow Data Scfm 757 733 694 659 575 444 399 707 684 641 604 495 397 282 High 1371 1323 12511086 971 843 521 060A10 Medium High 1249 1207 1098 1018 921 669 503Section IX Safety Controls Furnace Control Diagnostics Section X Replacement Parts List Diagnostic Fault Code Storage and RetrievalSection XI Wiring Diagram Wiring DiagramJohnson Controls Unitary Products York Drive Norman, OK

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