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INSTALLATION MANUAL
RESIDENTIAL GAS FURNACE MODELS
TG9S*MP, GG9S*MP
(95.5% AFUE Single Stage Multi-position)
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TWINNING AND STAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
VENTING CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Duct Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Vertical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Coil Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Horizontal Right Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Horizontal Left Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PC Series Upflow Coil Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Horizontal Left or Right application (Right Shown) . . . . . . . . . . . . . . 6
Combustible Floor Base Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Horizontal Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Typical Attic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Typical Suspended Furnace / Crawl Space Installation . . . . . . . . . . . 7
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Side Return Cutout Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Upflow/Downflow Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Horizontal Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Single Stage PSC Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Single Stage PSC Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Typical Twinned Furnace Application . . . . . . . . . . . . . . . . . . . . . . . 14
Unit Clearances to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Coil Projection Dimensions - PC Series Coils . . . . . . . . . . . . . . . . . . 6
Cabinet and Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Recommended Filter Sizes (High Velocity 600 FPM) . . . . . . . . . . . . 8
Nominal Manifold Pressure - High Fire . . . . . . . . . . . . . . . . . . . . . . 10
Ratings & Physical / Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . 11
Maximum Equivalent Pipe Length . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Elbow Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Equivalent Length of Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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 IV listed and may not 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
COMBUSTION AIR and VENT SYSTEM . . . . . . . . . . . . . . . . . . . . 24
START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 31
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
REPLACEMENT PART CONTACT INFORMATION . . . . . . . . . . . . 39
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
LIST OF FIGURES
Single Stage Twinning Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . 15
Two-Stage Twinning Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . 15
Upflow Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Downflow Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Horizontal Left Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Horizontal Right Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Home Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Termination Configuration - 1 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Termination Configuration - 2 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Termination Configuration - 2 Pipe Basement . . . . . . . . . . . . . . . . . 24
Direct Vent Air Intake Connection and Vent Connection . . . . . . . . . 25
Combustion Airflow Path Through The Furnace Casing . . . . . . . . . 25
Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . 26
Attic and Crawl Space Combustion Air Termination . . . . . . . . . . . . . 27
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Furnace Control Event Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
LIST OF TABLES
els) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Unconfined Space Minimum Area in Square Inch . . . . . . . . . . . . . . 26
Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Gas Rate (CU FT/HR) at Full Input . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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.
EFFICIENCY
RATING
CERTIFIED
ISO 9001
Certified Quality
Management System
364861-UIM-B-0708
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Summary of Contents for Johnson Controls GG9S*MP
-
Page 1: Table Of Contents
Reading Gas Pressure ........30 Furnace Control Board ........31 Furnace Control Event Schedule . -
Page 2: Combustion Air Quality
• Furnaces installed near chemical storage areas • Chemical exposure The furnace requires OUTDOOR AIR for combustion when the furnace is located in an area where the furnace is being exposed to the follow- ing substances and / or chemicals. • Permanent wave solutions •... -
Page 3: Codes And Standards
The furnace area must not be used as a broom closet or for any other storage purposes, as a fire hazard may be created. Never store items such as the following on, near or in contact with the fur- nace. -
Page 4: Unit Clearances To Combustibles
A gas-fired furnace for installation in a residential garage must be installed so the burner(s) and the ignition source are located not less than 18 inches (46 cm) above the floor, and the furnace must be located or protected to avoid physical damage by vehicles. -
Page 5: Duct Attachment
The furnace should be installed with coil cabinet part number specifi- cally intended for downflow application. If a matching cooling coil is used, it may be placed directly on the furnace outlet and sealed to pre- vent leakage. For details of the coil cabinet dimensions and installation requirements, refer to the installation instructions supplied with the coil cabinet. -
Page 6: Coil Projection Dimensions - Pc Series Coils
These upflow coils are designed for installation on top of upflow fur- naces only. If the coil is used with a furnace of a different size, use a 45° transition to allow proper air distribution through the coil. Position the coil casing over the furnace opening as shown in Fig- ure 6, "PC Series Upflow Coil Installation". -
Page 7: Typical Suspended Furnace / Crawl Space Installation
FIBERGLASS TAPE sides of the furnace and the building joists, studs or framing. This line UNDER FLANGE may be in contact with combustible material. Refer to Figure 10, "Typi- cal Attic Installation". -
Page 8: Cabinet And Duct Dimensions
All applications require the use of a field installed filter. All filters and mounting provision must be field supplied. Filters must be installed external to the furnace cabinet. DO NOT attempt to install filters inside the furnace. NOTE: Single side return above 1800 CFM is approved as long as the filter velocity does not exceed filter manufacturer’s recommendation... -
Page 9: Side Return Cutout Markings
SIDE RETURN Locate the “L” shaped corner locators. These indicate the size of the cut- out to be made in the furnace side panel. Refer to Figure 13, "Side Return Cutout Markings". FIGURE 13: Side Return Cutout Markings Install the side filter rack following the instructions provided with that accessory. -
Page 10: Section V: Electrical Power
PROPANE AND HIGH ALTITUDE CONVERSION KITS It is very important to choose the correct kit and/or gas orifices for the altitude and the type of gas for which the furnace is being installed. Only use natural gas in furnaces designed for natural gas. Only use propane (LP) gas for furnaces that have been properly converted to use pro- pane (LP) gas. -
Page 11: Electrical Wiring
Annual Fuel Utilization Efficiency (AFUE) numbers are determined in accordance with DOE Test procedures. Wire size and over current protection must comply with the National Electrical Code (NFPA-70-latest edition) and all local codes. The furnace shall be installed so that the electrical components are protected from water. SUPPLY VOLTAGE CONNECTIONS... -
Page 12: Thermostat Chart - Single Stage Ac With Single Stage Psc Furnaces
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 THERMOSTAT *PP11C70224 Full Stage Compressor 24 –... -
Page 13: Thermostat Chart - Single Stage Hp With Single Stage Psc Furnaces
HP 2C Single Stage Heat Pump – Single Stage PSC Furnace THERMOSTAT THERMOSTAT *BP21H50124 *BN21H00124 *DN22U00124 *DP21H40124 *DN21H00124 FIGURE 19: Thermostat Chart - Single Stage HP with Single Stage PSC Furnaces Johnson Controls Unitary Products G*(8/9)S G*9F L(Y/M)8S THERMOSTAT SINGLE STAGE... -
Page 14: Typical Twinned Furnace Application
When two furnaces are installed using the same duct system, it is very important that the two furnace cir- culating air blowers operate in unison. If one blower starts before the... -
Page 15: Single Stage Twinning Wiring Diagram
On a call for second TWIN stage of heat, the burners of Furnace #2 will also light and both blowers will run. The twinning control ensures that both blowers come on and shut off at the same time. -
Page 16: Section Vii: Condensate Piping And Furnace Venting Configuration
This can cause improper operation or damage to the equipment. If the furnace is installed in an area that has the potential of freezing, the drain line must be protected. Use a 3 to 6 watt per foot at 115 vac, 40º... -
Page 17: Upflow Configuration
364861-UIM-B-0708 factory. from outlet casing left toward plumbed drain condensate furnaces, input 130K & 100, FIGURE 23: Upflow Configuration Johnson Controls Unitary Products... -
Page 18: Downflow Configuration
364861-UIM-B-0708 FIGURE 24: Downflow Configuration Johnson Controls Unitary Products... -
Page 19: Horizontal Left Configuration
364861-UIM-B-0708 FIGURE 25: Horizontal Left Configuration Johnson Controls Unitary Products... -
Page 20: Horizontal Right Configuration
364861-UIM-B-0708 FIGURE 26: Horizontal Right Configuration Johnson Controls Unitary Products... -
Page 21: Maximum Equivalent Pipe Length
This furnace may not be common vented with any other appliance, since it requires separate, properly sized air intake and vent lines. The furnace shall not be connected to any type of B, BW or L vent or vent connector, and not connected to any portion of a factory-... -
Page 22: Equivalent Length Of Fittings
Intake Pipe Size 2” (5.1 cm) Vent Pipe Size 2” (5.1 cm) *. Vent pipe size must be increased to 3” diameter after connection to furnace on this model. Equivalent Length Accessory concentric vent / intake termination kits 1CT0302 and 5 feet of 2"... -
Page 23: Vent Clearances
A vent shall not terminate less than 1 foot (30 cm) above a grade level. Any fresh air or make up inlet for dryer or furnace area is considered to be forced air inlet. Avoid areas where condensate drippage may cause problems such as above planters, patios, or adjacent to windows where steam may cause fogging. -
Page 24: Double Horizontal Combustion Air Intake And Vent Termination
364861-UIM-B-0708 VENT SYSTEM This furnace is certified to be installed with one of two possible vent configurations. Horizontal vent system. This vent system can be installed com- pletely horizontal or combinations of horizontal, vertical, or offset using elbows. Vertical vent system. This vent system can be installed completely vertical or a combination of horizontal, vertical, or offset using elbows. -
Page 25: Estimated Free Area
7.2, 7.3 or 7.4 of CAN/CGA B149.1 or .2 Installation Code - latest edi- tions. This furnace is certified to be installed with one of three possible com- bustion air intake configurations. OUTDOOR COMBUSTION AIR: This is a direct vent configuration... -
Page 26: Unconfined Space Minimum Area In Square Inch
364861-UIM-B-0708 When a Category I furnace is removed or replaced, the original venting system may no longer be correctly sized to properly vent the attached appliances. An improperly sized vent system can cause CARBON MONOXIDE to spill into the living space causing personal injury, and or death. -
Page 27: Tions
Z223.1 (latest edition). This type installation requires two properly sized pipes. One brings combustion air from a properly ventilated attic space or crawl space and a second pipe that extends from the furnace vent connection (top right of unit) to the exterior of the building. Refer to Table 7, "Maximum Equivalent Pipe Length"... -
Page 28: Tions
All electrical connections made in the field and in the factory should be checked for proper tightness. When the gas supply is initially connected to the furnace, the gas piping may be full of air. In order to purge this air, it is recommended that the ground union be loosened until the odor of gas is detected. -
Page 29: Gas Rate (Cu Ft/Hr) At Full Input
Table 14: Gas Rate (CU FT/HR) at Full Input Size of Test Dial Seconds For 1 Revolution 1 Cu Ft Johnson Controls Unitary Products Seconds For 1 Revolution 2 Cu Ft 5 Cu Ft 1800 1636 1500 1385 1286 1200... -
Page 30: Tions
10.5” W.C. (2.61 kPa) The inlet gas pressure operating range table specifies what the minimum and maximum gas line pressures must be for the furnace to operate safely. The gas line pressure MUST BE a minimum of: • 7” W.C. (1.74 kPA) for Natural Gas •... -
Page 31: Injury
The fan-off setting must be long enough to adequately cool the furnace, but not so long that cold air is blown into the heated space. The fan-off timing may be adjusted by positioning the jumper on two of the four pins as shown in Figure 40, "Furnace Control Board". -
Page 32: Furnace Control Diagnostics
(retry) counter. If three retries occur during a call for heat, the furnace will shut down for one hour. If at the end of the one hour shut down there is a call for heat, the furnace will initiate a normal start cycle. -
Page 33: Ation
“Delay on” mode, it will complete it, and any subsequent delay off period. The furnace will lock out for one hour and then restart. 7 RED FLASHES: This fault code indicates that the flame could not be established. -
Page 34: Tions
HOSE, RAIN GUTTER HOSE, CONDENSATE PLUG, SEAL, 7/8” PLUG, SEAL, 2-3/8” PLUG, VENT PIPE BAG, PARTS KNOB, QUARTER TURN DIAGRAM, WIRING Johnson Controls Unitary Products Consumer Relations 5005 York Drive Norman, OK 73069 DESCRIPTION 4 Req’d Johnson Controls Unitary Products... -
Page 35: Section Xii: Wiring Diagram
364861-UIM-B-0708 SECTION XII: WIRING DIAGRAM FIGURE 42: Wiring Diagram Johnson Controls Unitary Products... - Page 36 NOTES Subject to change without notice. Printed in U.S.A. 364861-UIM-B-0708 Copyright © 2008 by Johnson Controls, Inc. All rights reserved. Supersedes: 364861-UIM-A-0608 Johnson Controls Unitary Products 5005 York Drive Norman, OK 73069...
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Page 37: Els)
Vent termination elbows are not included in these calculations, minimum required vent length is 15 ft. 2. Must be changed if not in rise range. Subject to change without notice. Printed in U.S.A. *401260* Copyright © 2008 by Johnson Controls, Inc. All rights reserved. Johnson Controls Unitary Products 5005 York Drive Norman, OK 73069 This document does not replace the installation instructions, which must be referred to for detailed information. - Page 38 MOST COMMON INSTALLATION CONFIGURATIONS (MORE OPTIONS AVAILABLE MULTI-POSITION CONFIGURATION INFORMATION: Ensure that all PVC venting has at least 1/4” per foot slope towards the furnace. Furnace is multi-position and may be installed in any of the configurations shown. The furnace condensate pan is self priming and contains an internal trap.
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On my furnace only one burner out of 4 will light What could be the issue
what is the size of supply air and return air opening in furnace model GG9S040A08MP11A?