Johnson Controls GG9S*MP User Manual

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364861-UIM-B-0708
EFFICIENCY
RATING
CERTIFIED
ISO 9001
Certified Quality
Management System
RESIDENTIAL GAS FURNACE MODELS
TG9S*MP, GG9S*MP
(95.5% AFUE Single Stage Multi-position)
INSTALLATION MANUAL
LIST OF SECTIONS
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TWINNING AND STAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CONDENSATE PIPING AND FURNACE
VENTING CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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
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
Thermostat Chart - Single Stage AC with
Single Stage PSC Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Thermostat Chart - Single Stage HP with
Single Stage PSC Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Typical Twinned Furnace Application . . . . . . . . . . . . . . . . . . . . . . . 14
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
Double Horizontal Combustion Air Intake and Vent Termination . . .24
Double Vertical Combustion Air Intake and Vent Termination . . . . . 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
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
Combustion Air Intake and Vent Connection Size at Furnace (All Mod-
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
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.
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.
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Summary of Contents

Page 1 - INSTALLATION MANUAL

364861-UIM-B-0708EFFICIENCYRATINGCERTIFIEDISO 9001Certified QualityManagement SystemRESIDENTIAL GAS FURNACE MODELSTG9S*MP, GG9S*MP(95.5% AFUE Single S

Page 2

364861-UIM-B-070810 Johnson Controls Unitary ProductsThe furnace must be isolated from the gas supply piping system byclosing its individual external

Page 3

364861-UIM-B-0708Johnson Controls Unitary Products 11Annual Fuel Utilization Efficiency (AFUE) numbers are determined in accordance with DOE Test proc

Page 4 - SECTION II: DUCTWORK

364861-UIM-B-070812 Johnson Controls Unitary ProductsFor additional connection diagrams for all UPG equipment refer to “Low Voltage System Wiring” doc

Page 5 - For duct attachment

364861-UIM-B-0708Johnson Controls Unitary Products 13 FIGURE 19: Thermostat Chart - Single Stage HP with Single Stage PSC FurnacesHP 2C Single Stage

Page 6 - Mounting Plate

364861-UIM-B-070814 Johnson Controls Unitary ProductsACCESSORY CONNECTIONSThe furnace control will allow power-switching control of various acces-sori

Page 7 - Sediment

364861-UIM-B-0708Johnson Controls Unitary Products 15Single-Wire Twinning OperationHeating - On a call for heat (W signal) from the wall thermostat, b

Page 8 - SECTION III: FILTERS

364861-UIM-B-070816 Johnson Controls Unitary ProductsSECTION VII: CONDENSATE PIPING AND FURNACE VENTING CONFIGURATIONCONDENSATE DRAIN LOCATIONAs shipp

Page 9 - SECTION IV: GAS PIPING

364861-UIM-B-0708Johnson Controls Unitary Products 17 FIGURE 23: Upflow ConfigurationINDUCER ROTATED FORLEFT SIDE VENTING(As required for 130K model)

Page 10 - SECTION V: ELECTRICAL POWER

364861-UIM-B-070818 Johnson Controls Unitary Products FIGURE 24: Downflow ConfigurationAIRFLOWAIRFLOWMove raingutter hoseto this positionDOWNFLOW - I

Page 11 - SUPPLY VOLTAGE CONNECTIONS

364861-UIM-B-0708Johnson Controls Unitary Products 19 FIGURE 25: Horizontal Left ConfigurationHORIZONTAL - LEFTINDUCER ROTATEDHORIZONTAL - LEFTINDUCE

Page 12

364861-UIM-B-07082 Johnson Controls Unitary ProductsSPECIFIC SAFETY RULES AND PRECAUTIONS1. Only Natural gas or Propane (LP) gas are approved for use

Page 13

364861-UIM-B-070820 Johnson Controls Unitary Products FIGURE 26: Horizontal Right ConfigurationAIRFLOWHORIZONTAL - RIGHTINDUCER ROTATEDHORIZONTAL - R

Page 14

364861-UIM-B-0708Johnson Controls Unitary Products 21SECTION VIII: COMBUSTION AIR AND VENT SYSTEMCOMBUSTION AIR AND VENT SAFETYThis Category IV, dual

Page 15

364861-UIM-B-070822 Johnson Controls Unitary ProductsExample:An 80,000 BTUH furnace requires 32 feet of pipe and four 90º elbows.Using 2" pipe an

Page 16 - FURNACE VENTING CONFIGURATION

364861-UIM-B-0708Johnson Controls Unitary Products 23VENT CLEARANCES† A vent shall not terminate directly above a sidewalk or paved driveway that is l

Page 17

364861-UIM-B-070824 Johnson Controls Unitary ProductsVENT SYSTEMThis furnace is certified to be installed with one of two possible ventconfigurations.

Page 18 - FOR RIGHT SIDE VENTING

364861-UIM-B-0708Johnson Controls Unitary Products 25COMBUSTION AIR SUPPLYAll installations must comply with Section 5.3, Air for Combustion andVentil

Page 19 - HORIZONTAL - LEFT

364861-UIM-B-070826 Johnson Controls Unitary ProductsAir Supply Openings and Ducts1. An opening may be used in lieu of a duct to provide to provide th

Page 20 - HORIZONTAL - RIGHT

364861-UIM-B-0708Johnson Controls Unitary Products 27Ventilated Combustion AirThe ventilated attic space or a crawl space from which the combustionair

Page 21 - VENT SYSTEM

364861-UIM-B-070828 Johnson Controls Unitary ProductsSECTION IX: START-UP AND ADJUSTMENTSThe initial start-up of the furnace requires the following ad

Page 22 - COMBUSTION AIR / VENTING

364861-UIM-B-0708Johnson Controls Unitary Products 29Table 14: Gas Rate (CU FT/HR) at Full InputSeconds For 1 RevolutionSize of Test DialSeconds For 1

Page 23 - VENT CLEARANCES

364861-UIM-B-0708Johnson Controls Unitary Products 3CODES AND STANDARDSFollow all national, local codes and standards in addition to this installa-tio

Page 24 - VENTING MULTIPLE UNITS

364861-UIM-B-070830 Johnson Controls Unitary ProductsADJUSTMENT OF MANIFOLD GAS PRESSURE & INPUT RATEInlet and manifold gas pressure may be measur

Page 25

364861-UIM-B-0708Johnson Controls Unitary Products 31ADJUSTMENT OF TEMPERATURE RISEAfter about 5 minutes of operation, determine the furnace temperatu

Page 26 - Air Supply Openings and Ducts

364861-UIM-B-070832 Johnson Controls Unitary ProductsLIMIT CONTROLSThere is a high temperature limit control located on the furnace vesti-bule panel n

Page 27 - VENT BLOWER ROTATION

364861-UIM-B-0708Johnson Controls Unitary Products 333 RED FLASHES: This indicates the normally open pressure switchcontact did not close after the in

Page 28 - ADJUSTMENTS

364861-UIM-B-070834 Johnson Controls Unitary ProductsSECTION XI: REPLACEMENT PARTS LISTDESCRIPTIONMOTORMOTOR, DIRECT DRIVE BLOWERBLOWER, COMBUSTIONELE

Page 29

364861-UIM-B-0708Johnson Controls Unitary Products 35SECTION XII: WIRING DIAGRAM FIGURE 42: Wiring Diagram

Page 30

Subject to change without notice. Printed in U.S.A. 364861-UIM-B-0708Copyright © 2008 by Johnson Controls, Inc. All rights reserved. Supersedes: 36486

Page 31 - SECTION X: SAFETY CONTROLS

NOTES:1. Refer to the condensate management and drain hoseplumbing for different configurations in this document. Nohose clamps are needed for the con

Page 32

Furnace is multi-position and may be installed in any of the configurations shown.Ensure that all PVC venting has at least 1/4” per foot slope towards

Page 33 - RETRIEVAL

364861-UIM-B-07084 Johnson Controls Unitary ProductsFURNACE LOCATION AND CLEARANCESThe furnace shall be located using the following guidelines:1. Wher

Page 34

364861-UIM-B-0708Johnson Controls Unitary Products 5On all installations without a coil, a removable access panel is recom-mended in the outlet duct s

Page 35 - SECTION XII: WIRING DIAGRAM

364861-UIM-B-07086 Johnson Controls Unitary ProductsCOIL FLANGE INSTALLATIONThe coils include removable flanges to allow proper fit up with furnacesha

Page 36 - Norman, OK 73069

364861-UIM-B-0708Johnson Controls Unitary Products 7DOWNFLOW DUCT CONNECTORSAll downflow installations must use a suitable duct connector approvedby t

Page 37 - QUICK REFERENCE GUIDE

364861-UIM-B-07088 Johnson Controls Unitary ProductsSECTION III: FILTERSFILTER INSTALLATIONAll applications require the use of a field installed filte

Page 38 - DOWNFLOW

364861-UIM-B-0708Johnson Controls Unitary Products 9SIDE RETURNLocate the “L” shaped corner locators. These indicate the size of the cut-out to be mad

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