Johnson GG9S MP, Installation Manual

Page 1: ... Condensate drain vertical installation 17 Typical Combustion Pipe Drain Tee 17 Upflow Configuration 18 Downflow Configuration 19 Horizontal Left Configuration 20 Horizontal Right Configuration 21 Dimensions 22 Home Layout 24 Termination Configuration 1 Pipe 25 Termination Configuration 2 Pipe 25 Termination Configuration 2 Pipe Basement 25 Double Horizontal Combustion Air Intake and Vent Terminat...

Page 2: ...ing outdoor air required for combustion Return air temperature maintained between 55ºF 13ºC and 80ºF 27ºC The air filter must be replaced upon substantial completion of the construction process Clean furnace duct work and components upon substantial completion of the construction process and verify furnace operating conditions including ignition input rate temperature rise and venting according to...

Page 3: ...urisdiction In the United States and Canada follow all codes and standards for the following using the latest edition available STEP 1 Safety US National Fuel Gas Code NFGC NFPA 54 ANSI Z223 1 and the Installation Standards Warm Air Heating and Air Conditioning Systems ANSI NFPA 90B CANADA CAN CGA B149 1 National Standard of Canada Natu ral Gas and Propane Installation Codes NSCNGPIC STEP 2 Genera...

Page 4: ...ion FOR FURNACES INSTALLED IN THE COMMON WEALTH OF MASSACHUSETTS ONLY For all side wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for resi dential purposes including those owned or operated by the Com monwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the ...

Page 5: ...access cover shall be attached in such a manner as to prevent leaks DUCT FLANGES Four flanges are provided to attach ductwork to the furnace These flanges are rotated down for shipment In order to use the flanges remove the screw holding an individual flange rotate the flange so it is in the upward position and reinstall the screw then repeat this for all 4 flanges If the flanges are not used they...

Page 6: ...ould always be installed on the side desig nated as top side See Figures 4 5 FURNACE ASSEMBLY 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 1 Position the coil casing over the furnace opening as shown in Fig ure 6 2 Place th...

Page 7: ...he unit BOTTOM RETURN AND ATTIC INSTALLATIONS Bottom return applications normally pull return air through a base plat form or return air plenum Be sure the return platform structure or return air plenum is suitable to support the weight of the furnace The internal bottom panel must be removed for this application Attic installations must meet all minimum clearances to combustibles and have floor s...

Page 8: ...n points must be level to ensure proper and quiet fur nace operation When suspending the furnace use a secure platform constructed of plywood or other building materials secured to the floor or ceiling joists Refer to Figure 11 for details and additional information When moving or handling this furnace prior to installation it is recom mended to leave the doors on the furnace to provide support an...

Page 9: ...abinet and Duct Dimensions BTUH kW Input Nominal CFM m3 min Cabinet Size Cabinet Dimensions Inches Approximate Operating Weights A in A cm B in B cm C in C cm Lbs kg 40 11 7 800 22 7 A 14 1 2 36 8 13 3 8 34 0 11 3 4 29 8 113 51 3 60 17 6 1000 28 3 A 14 1 2 36 8 13 3 8 34 0 11 3 4 29 8 118 53 5 60 17 6 1200 34 0 B 17 1 2 44 4 16 3 8 41 6 13 1 4 33 7 122 55 3 80 23 4 1200 34 0 B 17 1 2 44 4 16 3 8 4...

Page 10: ...the instructions in this section specify the type of gas approved for this furnace only use those approved gases The instal lation of a drip leg and ground union is required Refer to Figure 16 FIGURE 14 Side Return Cutout Markings Some accessories such as electronic air cleaners and pleated media may require a larger side opening Follow the instructions supplied with that accessory for side openin...

Page 11: ...e placed on the octa gon hub located on the gas inlet side of the valve Placing a wrench to the body of the gas valve will damage the valve causing improper operation and or the valve to leak Table 5 Nominal Manifold Pressure High Fire Manifold Pressures in w c Manifold Pressures kPa Altitude feet Altitude m 0 7999 8000 8999 9000 9999 0 2437 2438 2742 2743 3048 Gas Heating Value BTU cu ft 800 3 5 ...

Page 12: ...e as shown in Figure 17 Electronic thermo stats may require the common wire to be connected Apply strain relief to thermostat wires passing through cabinet If air conditioning equip ment is installed use thermostat wiring to connect the Y and C termi nals on the furnace control board to the proper wires on the condensing unit unit outside The 24 volt 40 VA transformer is sized for the furnace comp...

Page 13: ...pressor G Fan PP11C70224 THERMOSTAT RH 24 Volt Hot Heat XFMR RC 24 Volt Hot Cool XFMR W Full Stage Heat Clipping Jumper W914 for electric heat on thermostat is not necessary 24VAC Humidifier Optional C 24 Volt Common Y Compressor SINGLE STAGE AIR CONDITIONER Y Compressor Contactor SINGLE STAGE AIR CONDITIONER SINGLE STAGE AIR CONDITIONER G8C L Y M 8S G 9F G 8 9 S ID MODELS G T GLS G T G 8 9 S LF8 ...

Page 14: ...LS HGD HP RHS O Reversing Valve Energized in Cool C 24 Volt Common R 24 Volt Hot W1 66 out Heat Y Compressor DEMAND DEFROST CONTROL X L Malfunction Light W Auxiliary Heat SINGLE STAGE HEAT PUMP 1 1 Part Number S1 2HU16700124 3 24VAC Humidifier Optional External Humidistat Optional Open on Humidity Rise 3 Y2 Second Stage Compressor Step 9 of Thermostat Installer Configuration Menu must be set to Pu...

Page 15: ...he furnace that operates on W2 will be supplying cold air in the Heating mode to the occupied spaces unless W2 is energized GAS PIPING Furnace gas supplies must be provided as specified with these instruc tions Since the furnaces are side by side with no space between gas supplies must enter on the right and left respectively All gas piping must be in accordance with the national fuel gas code ANS...

Page 16: ...nect a wire from the TWIN terminal of Furnace 1 to the TWIN terminal of Furnace 2 3 Install a separate 24V relay as shown in the diagram below Use of this relay is required as it ensures that the transformers of the two furnaces are isolated thus preventing the possibility of any safety devices being bypassed 4 Connect the common between furnace 1 and furnace 2 Single Wire Staging Operation Heatin...

Page 17: ...h vacuum hose How ever ensure that all pressure switch hoses are routed such that they prevent any condensate from entering the pressure switch To Open Or Vented Drain Tee 5 Min Open Stand Pipe Anti siphon air vent NOTICE It is possible for condensation to form inside the combustion air intake pipe in the summer months if significant length of combus tion air pipe passes through conditioned space ...

Page 18: ...s will collect and hold condensate which will cause the furnace to not operate Shorten pressure switch hose Re route and shorten pressure switch hose Shorten rain gutter hose Move rain gutter hose to this position For 100 120 130K input furnaces the condensate drain is plumbed toward the left casing outlet from the factory For 040 060 080K input furnaces the condensate drain is plumbed toward the ...

Page 19: ...itch hose to this position NOTE May require the longer hose that is provided with wider cabinets Move condensate drain hose to this position May exit either side of the cabinet Move rain gutter hose to this position When drain hose routing changes are required be sure to cap all un used openings If rerouting hoses excess length should be cut off so that no sagging loops will collect and hold conde...

Page 20: ...re switch hose to this position NOTE May require the longer hose that is provided with wider cabinets Change condensate drain connection to the 90 fitting provided Move condensate drain hose to this position Move rain gutter hose to this position NOTE May require hose extension that is provided with wider cabinets Move condensate drain hose to this position Change condensate drain connection to th...

Page 21: ...o the 90 fitting provided Move condensate drain hose to this position Move rain gutter hose to this position Change condensate drain connection to the 90 fitting provided Move condensate drain hose to this position AIRFLOW Move pressure switch hose to this position When drain hose routing changes are required be sure to cap all un used openings If rerouting hoses excess length should be cut off so...

Page 22: ...h BOTH materials Metallic materials must not be used for venting or air intake 5 If a flexible connector is used in the vent system it must be made of a material that is resistant to acidic exposure and to at least 225 F 107 C temperature Flexible connectors are also allowed in the combustion air pipe 6 All models are supplied with 2 5 1 cm vent connections When the pipe must be increased to 3 7 6...

Page 23: ...event sagging 9 Seal around the openings where the combustion air and or vent piping pass through the roof or sidewalls COMBUSTION AIR VENTING TABLE 9 Equivalent Length of Fittings Fitting Equivalent Length 2 90º sweep elbow 5 feet of 2 pipe 2 45º sweep elbow 2 1 2 feet of 2 pipe 2 90º standard elbow 7 feet of 2 pipe 2 45º standard elbow 3 1 2 feet of 2 pipe 3 90º sweep elbow 5 feet of 3 pipe 3 45...

Page 24: ...equirements of the gas supplier 12 30 5 cm or in accordance with local installation codes and the requirements of the gas supplier F Clearance to outside corner 12 30 5 cm or in accordance with local installation codes and the requirements of the gas supplier 12 30 5 cm or in accordance with local installation codes and the requirements of the gas supplier G Clearance to inside corner 3 feet 91 4 ...

Page 25: ...on on air source from inside the building The vent for a single pipe system must be installed as specified in the venting section of these instructions with the vent terminating as shown in Figure 31 Each furnace must have a separate vent pipe Under NO circumstances can the two vent pipes be tied together The combustion air side of the two pipe configuration shown in Figure 32 can be installed so ...

Page 26: ...rom entering the terminal Also the terminal assembly should be located as far as possible from a swimming pool or a location where swimming pool chemicals might be stored Be sure the terminal assembly follows the outdoor clearances listed in Section 1 Outdoor Air Contaminants Ambient Combustion Air Supply This type installation will draw the air required for combustion from within the space surrou...

Page 27: ... free area of the air supply inlet opening to which it connects 4 The duct shall terminate within 12 30 5 cm above and within 24 61 cm horizontally from the burner level of the appliance having the largest input 5 A square or rectangular shaped duct shall only be used when the required free area of the supply opening is 9 in2 58 06 cm2 or larger When a square or rectangular duct is used its small ...

Page 28: ... ventilation VENT BLOWER ROTATION For ease of venting the vent blower may be rotated 90 in either direc tion For upflow installations the vent may exit through the top or either side of the cabinet For downflow installations the vent blower must be rotated so that the vent exits through either side of the cabinet See Fig ures 25 28 for details CARBON MONOXIDE POISONING HAZARD Failure to follow the...

Page 29: ...proper input rate using natural gas with a heating value of 1030 BTU Ft3 38 4 MJ m3 If the heating value of your gas is significantly different it may be necessary to replace the 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 revol...

Page 30: ...0 300 750 78 46 92 231 25 144 288 720 80 45 90 225 26 138 277 692 82 44 88 220 27 133 267 667 84 43 86 214 28 129 257 643 86 42 84 209 29 124 248 621 88 41 82 205 30 120 240 600 90 40 80 200 31 116 232 581 92 39 78 196 32 113 225 563 94 38 76 192 33 109 218 545 96 38 75 188 34 106 212 529 98 37 74 184 35 103 206 514 100 36 72 180 36 100 200 500 102 35 71 178 37 97 195 486 104 35 69 173 38 95 189 4...

Page 31: ...plies on and follow the operating instructions to place the unit back in operation 3 Adjust manifold pressure by adjusting gas valve regulator screw for the appropriate gas per the following 4 After the manifold pressure has been adjusted re calculate the furnace input to make sure you have not exceeded the specified input on the rating plate Refer to CALCULATING THE FURNACE INPUT NATURAL GAS 5 On...

Page 32: ...t 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 42 MANIFOLD PRESSURE U TUBE CONNECTION FIGURE 41 Reading Gas Pressure The temperature rise or temperature difference between the return air and the supply heated air from the furnace must...

Page 33: ...84 Medium Low 1232 1313 1291 1280 1250 1209 1207 1148 1055 937 Low 826 821 853 858 838 817 794 776 760 711 80 2200 C High 2529 2435 2338 2256 2162 2041 1920 1794 1654 1501 Medium High 2166 2111 2070 2001 1927 1849 1719 1614 1499 1344 Medium Low 1697 1685 1664 1631 1586 1531 1466 1393 1315 1185 Low 1383 1377 1358 1336 1285 1244 1199 1147 1048 925 100 1600 C High 1909 1880 1823 1776 1706 1637 1562 1...

Page 34: ...3 1483 1353 1209 Medium High 1543 1543 1516 1504 1477 1446 1382 1309 1202 1099 Medium Low 1238 1241 1243 1241 1252 1242 1201 1140 1074 967 Low 906 902 903 910 888 866 859 829 795 743 80 2200 C High 2585 2492 2405 2321 2232 2137 2015 1902 1745 1577 Medium High 2098 2067 2036 1982 1928 1860 1767 1670 1549 1331 Medium Low 1619 1628 1614 1584 1545 1488 1424 1339 1216 1121 Low 1338 1347 1327 1301 1262 ...

Page 35: ...mpleted between terminals R and W of the thermostat When the proper amount of combustion air is being provided the pressure switch will close the ignition control pro vides a 17 second ignitor warm up period the gas valve then opens the gas starts to flow ignition occurs and the flame sensor begins its sensing function The blower motor will energize 30 seconds after the gas valve opens if a flame ...

Page 36: ...ing out Low gas pressure faulty gas valve dirty or faulty flame sensor faulty hot surface ignitor or burner problem may cause this The furnace will lock out for one hour and then restart 8 RED FLASHES This fault is indicated if the flame is lost 5 times 4 recycles during the heating cycle This could be caused by low gas pressure dirty or faulty flame sensor or faulty gas valve The furnace will loc...

Page 37: ...Req d BRACKET BLOWER TRACK 2 Req d HEAT EXCHANGER ASS Y FABRICATED PARTS Continued MANIFOLD GAS PAN BOTTOM PANEL TOP PANEL DOOR 2 Req d PANEL BLOCKOFF MISCELLANEOUS ORIFICE BURNER Natural 45 SIGHT GLASS OVAL 2 Req d GASKET FOAM Door 1 5 ft req d PAN CONDENSATE BRACKET DOOR HARNESS WIRING FERRULE 3 Req d GROMMET 3 Req d MOTOR MOUNT TUBING SILICON HOSE RAIN GUTTER HOSE CONDENSATE PLUG SEAL 7 8 PLUG ...

Page 38: ...364861 UIM D 1209 38 Johnson Controls Unitary Products SECTION XIII WIRING DIAGRAM FIGURE 44 Wiring Diagram ...

Page 39: ...364861 UIM D 1209 Johnson Controls Unitary Products 39 NOTES ...

Page 40: ...nge without notice Published in U S A 364861 UIM D 1209 Copyright 2009 by Johnson Controls Inc All rights reserved Supersedes 364861 UIM C 0709 Johnson Controls Unitary Products 5005 York Drive Norman OK 73069 NOTES ...