Johnson Controls GG9S*MP - User Manual

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.

Johnson Controls GG9S*MP Specifications

General

Brand	Johnson Controls
Model	GG9S*MP
Category	Furnace
Language	English

Summary

Safety

Specific Safety Rules and Precautions

Essential safety rules and precautions for furnace installation and operation.

Codes and Standards

Guidelines and compliance requirements for installation based on national and local codes.

Massachusetts Installation Requirements

Specific safety and installation requirements for Massachusetts.

Initial Inspection Procedures

Procedures for inspecting the unit upon receipt for transit damage.

Ductwork Installation

General Ductwork Information

Guidelines for designing and installing the duct system for optimal furnace operation.

Duct Flange Installation

Instructions for attaching ductwork flanges to the furnace.

Upflow;Horizontal Ductwork Installation

Connecting supply plenums and ductwork for upflow and horizontal installations.

Downflow Ductwork Installation

Installing furnaces and ductwork for downflow applications, including floor bases.

Coil Flange Installation

How to fit coils with different flange configurations for proper duct connection.

Critical Coil Projection

Ensuring proper distance between coil top and duct top for correct airflow.

Furnace Assembly with MC Series Coils

Instructions for installing MC series coils in horizontal furnace applications.

Furnace Assembly with PC Series Coils

Instructions for installing PC series coils on upflow furnaces.

Downflow Duct Connectors

Use of approved duct connectors for downflow installations.

Upflow Return Plenum Connection

Connecting return air plenums for upflow and modular home installations.

Horizontal Application Considerations

Specific considerations for horizontal furnace applications.

Attic Installation Requirements

Requirements and clearances for installing furnaces in attics.

Suspended Furnace; Crawl Space Installation

Methods for hanging or supporting furnaces in crawl spaces.

Filters

Filter Installation Guidelines

Guidelines for installing field-supplied filters external to the furnace cabinet.

Gas Piping

Side Return Air Filter Installation

Installing filters in side return configurations.

Horizontal & Downflow Filter Installation

Filter installation for horizontal and downflow applications.

Gas Safety Precautions

Critical safety warnings and precautions related to gas piping and leaks.

Gas Piping Installation Procedures

Procedures for installing gas piping, including materials and connections.

Gas Valve Body Precautions

Warnings about handling the gas valve body during installation.

Propane (LP) Gas Conversion

Information on converting the furnace for propane (LP) gas operation.

High Altitude Gas Conversion

Adjustments for high altitude operation, including orifices and pressure switches.

Electrical Power

Electrical Power Connections

Connecting the main power supply to the furnace unit.

Supply Voltage Connections

Instructions for making power supply connections to the junction box.

Low Voltage Control Wiring

Connecting thermostat and other low-voltage controls to the furnace.

Thermostat Wiring for AC Systems

Wiring diagram for connecting a thermostat with a single-stage AC system.

Thermostat Wiring for Heat Pump Systems

Wiring diagram for connecting a thermostat with a single-stage heat pump.

Twinning and Staging

Accessory Connections for Twinning

Connecting electronic air cleaners and humidifiers to the control board.

Twinning Duct System Requirements

Guidelines for duct systems when installing twinned furnaces.

Gas Piping for Twinning Installations

Gas piping considerations for twinned furnace installations.

Single-Wire Twinning Operation

How twinned furnaces operate together using a single-wire connection.

Single-Wire Staging Operation

How to stage twinned furnaces using a single-wire connection and thermostat.

Condensate Piping and Venting

Condensate Drain Location

Factory plumbing of the main drain for different furnace models.

Condensate Drain Termination

Proper methods for terminating condensate drain lines according to code.

Condensate Drain Freeze Protection

Precautions and methods to protect the drain line from freezing.

Upflow Condensate Routing

Routing condensate drains for upflow furnace configurations.

Downflow Condensate Routing

Routing condensate drains for downflow furnace configurations.

Horizontal Left Condensate Routing

Routing condensate drains for horizontal left furnace configurations.

Horizontal Right Condensate Routing

Routing condensate drains for horizontal right furnace configurations.

Multi-Position Configuration Details

Details on multi-position configurations, including inducer rotation and condensate hose routing.

Combustion Air and Vent System

Combustion Air and Vent Safety

Safety guidelines for installing combustion air and vent systems.

Combustion Air;Vent Pipe Sizing

Determining correct pipe sizes for combustion air and vent systems.

Pipe Sizing Examples

Examples illustrating pipe sizing calculations for vent and combustion air.

Combustion Air and Vent Piping Assembly

Step-by-step procedures for assembling combustion air and vent piping.

Vent Clearances

Required clearances for vent terminals based on location and configuration.

Vent System Configurations

Describes the two approved vent system configurations: horizontal and vertical.

Vent Applications and Termination

Factors to consider when selecting locations for vent and combustion air terminations.

Venting Multiple Units

Guidelines for venting multiple furnaces in single or two-pipe systems.

Combustion Air Supply

Combustion Air Intake Configurations

Three methods for supplying combustion air: outdoor, ambient, and ventilated.

Outdoor Combustion Air Requirements

Requirements for bringing combustion air from outdoors via piping.

Ambient Combustion Air Supply

Using surrounding air for combustion, often from unconfined spaces.

Ventilated Combustion Air Supply

Supplying combustion air from ventilated attic or crawl spaces.

Unconfined Space Requirements

Minimum area requirements for unconfined spaces providing combustion air.

Free Area Calculations

Calculating free area for louvers, grilles, and screens used for air supply.

Ventilated Combustion Air Details

Requirements for ventilated attic/crawl space air supply and termination.

Carbon Monoxide Poisoning Hazard

Procedures to prevent carbon monoxide poisoning during venting system checks.

Vent Blower Rotation

How to rotate the vent blower for different installation configurations.

Start-Up and Adjustments

Initial Start-Up Procedures

Initial steps for furnace start-up, including checking connections and purging air.

Gas Piping Leak Check

Methods for safely checking gas piping for leaks.

Ignition System Sequence

Step-by-step sequence of the furnace ignition and operation.

Calculating Furnace Input

Procedure for calculating natural gas input rate using meter readings.

Manifold Gas Pressure Adjustment

How to measure and adjust manifold gas pressure for proper input rate.

Inlet Gas Pressure Range

Specifies the required range for inlet gas pressure for safe operation.

Temperature Rise and Fan Control

Adjustment of Temperature Rise

How to adjust blower speed to achieve the correct temperature rise.

Adjustment of Fan Control Settings

Setting the fan off delay timer for optimal cooling efficiency.

Safety Controls

Control Circuit Fuse

Location and purpose of the 24-volt control circuit fuse.

Blower Door Safety Switch

Function of the interlock switch that prevents operation with the blower door removed.

Rollout Switch Controls

Operation and manual reset of rollout safety controls.

Pressure Switches

Function of pressure switches in monitoring venting and airflow.

Limit Controls

Function of the high-temperature limit control and lockout conditions.

Sequence of Operation

Detailed description of the furnace operation sequence for heating and cooling.

Troubleshooting Checks

Basic visual checks to perform before troubleshooting furnace issues.

Diagnostic Fault Codes

Interpreting fault codes indicated by the control board's LED.

Fault Code Retrieval and Clearing

How to retrieve and clear stored error codes from the control board.

Replacement Parts List

Component Categories

Lists of motor, electrical, fabricated parts, and miscellaneous components.

Replacement Part Contact Information

How to obtain a complete parts list and contact customer service.

Wiring Diagram

Furnace Wiring Diagram

Detailed diagram showing all electrical connections for the furnace.

Wiring Legend and Notes

Explanation of symbols used in the wiring diagram and important notes.