COLEMAN / EVCON IND. Furnaces/Heaters Manual L0601021
DGAM075BDD DGAM075BDD COLEMAN EVCON FURNACES/HEATERS - Manuals and Guides L0601021 View the owners manual for your COLEMAN EVCON FURNACES/HEATERS #DGAM075BDD.
User Manual: COLEMAN COLEMAN / EVCON IND. Furnaces/Heaters Manual COLEMAN / EVCON IND. Furnaces/Heaters Owner's Manual, COLEMAN / EVCON IND. Furnaces/Heaters installation guides
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035-20530-001 Rev. B (0804) DGAT PROGRAM KIT 37323712001 INS TALLA TION INSTRUCTIONS Heating _ Air Conditioning FOR MODELS: DGAM075BDD DGAT075BDD DGAM075BDE DGAT075BDE DGAM075BDF DGAT075BDF DGAT070BDD DLAS075BDD DGAT070BDE DLAS075BDE DGAT070BDF DLAS075BDF Use of this instruction factured is intended housing heating Fire or explosion hazard. Failure to properly loss of life. for qualified individuals experienced in the proper installation and service of manu- appliances. inspect and restore appliance to proper operation may cause property damage, personal injury or General Information A. Before You Start Once you have read this instruction 1. Thoroughly review Program Inspect a. Auxiliary limit switch d. Card Packet board assembly Natural 4. Unitary and assembly. with instructions "shoehorn" gas and labels for auxiliary bag assembly, assembly, and limit Digital b. 5/16" Hex head c. Flashlight or droplight d. Inspection mirror Phillipshead f. Two (2) crescent Tools needed bag C. Set the thermostat 3. Remove 4. Move gas control control Operating instructions 1 Part you To Turn Off Gas to Appli- to lowest instructions is are as follows: setting. to the appliance. access panel. switch will direct The Operating Instructions to "OFF" position. you to follow the Operating are as follows: 1. Set the thermostat 2. Turn off all electric 3. This appliance to lowest power to the appliance. lights Remove 5. Move force. 6. Wait five (5) minutes 7. with an the burner. ignition device Do NOT try to by hand. 4. control gas setting. is equipped automatically access control gas, determine Kit - Source Instructions light the burner Program Silicone Instructions to place the appliance in operation. A label with the Operating Instructions is located inside the lower door. wrenches DGAT will direct Turn off all power which screwdriver Group instructions 1. driver to install High temperature RTV Number MA-HTSS-R 2. Thermometer e. Products switch LP/Propane hardware test equipment. a. c. To Turn Off Gas to Appliance These orifice bag 11/32" Nut driver ance during the inspection. A label with these located inside the lower door. The instructions holes. Wire clamps Gather four (4) installation. gas orifice assembly. 3. B. liner assembly hooks 1/2" Wrench b. at dgatpro- These heat exchanger Part A has two (2) curved stainless steel bolts. Customer f. DGAT if you have any questions. (3) piece c. e. Contact or on line ii. Parts B and C have slotted b. tape. kit contents Three i. instruction. at: 1-888-665-4640 gram@york.com, 2. this view the video a. switch to "OFF" position. Do not to clear out any gas. If you smell source Move gas control panel. and repair to "ON" position. as necessary. Do not force. 035-20530-001Rev. B(0804) 8. Replace control access panel. 9. Turnonallelectrical power totheappliance. 10. Setthermostat to the desiredsetting.Burnerwill light,whichmaytake30-60seconds. 11. Afterthree(3)trials,iftheappliance willnotoperate, followthe instructions TO TURNOFFGASTO APPLIANCE andrefertotroubleshooting guideinthe Installation Instructions orOwner's Manual. D. Product Specifications Model No. DGAT070 DGAT075 Input 70,000 Btu/hr 75,000 Btu/hr Output 57,000 Btu/hr 61,000 Btu/hr Air Temperature Rise Range Maximum 45_75OF Outlet 165°F Tem peratu re Maximum External 0.30" wc Static Pressure Part 1: Basic Information Record the following Record information on the DGAT Program clearly Most of this information Claim 2. Form. and legibly. should g. be available before travelling to the job site. A. Rating 1. Plate Data Serial Number Customer Data 1. Customer code. name, 2. Customer telephone street address, city, state and zip number. Model Number Part 2: Inspection A. Inspect 1. Verify Roof Jack the proper is approved Roof Jack is being used. for use with only. See Figure 4000 the 4000 The DGAT Series SERIES The 7900 2. 3. 2 Roof inspect Roof or shows FIGURE Roof Jack can be converted Jack by replacing Jack. Remove bird crown. to a 1. Replace if damaged, or other obstructions 2: Turn Follow power instructions switch to off TO TURN position. OFF GAS TO APPLI- ANCE. Use pin Disconnect wires to gas valve, igniter, and flame sen- sor. tilted, deterioration. screens air inlet. Burner roof jack 2. crooked, bustion Assembly 7900 SERIES Series 4000 Series 4000-6941tC. Remove 1. FIGURE 1: Roof Jack NOTE: B. 3. Turn off gas supply to furnace by closing shut-off valve. Disconnect gas supply piping. 4. Remove to com- gas valve. See Figure manual 3. Unitary Products Group 035-20530-001 Rev.B(0804) C. Inspect Heat Exchanger 1. inspection Insert flashlight mirror or droplight entire interior dition per following a. Typical i. through perimeter of heat exchanger. heat pattern gray discoloration. 5. When Remove burner the burner is removed, the end of the burner Reference halves Figure to insure mounting should check to insure 5. Check See Figure the ribbon porting, it is concentric the seams entire 4. feel. located in closed may include light to dark any deforof the heat the of the heat exchanger by any or burn through, the heat exchanger through then you need to check surface If you feel no bumps 6. does not reveal or burn surface, inside crack and square. between that they are completely The flame spreader ment and to insure these assembly. crack, exchanger Note con- shape with See Figure inspection mation, Use Inspect Pattern Surface must be smooth or indentations. iii. If visual opening. surface. guidelines. Discoloration ii. Normal FIGURE 3: Gas valve removal burner to illuminate roughness, deformation, proceed with replacing with 37323713001. the burner and tight. needs to be checked for proper alignthat it is not distorted and the burner legs should items are found also be checked for distortion. to be out of alignment, If any of the burner be replaced.. FIGURE 6: Typical discoloration pattern b. Cracked. See Figure 7. FIGURE 4: Burner assembly removal FIGURE 7: Cracked c. heat exchanger Deformed. See Figure 8. FIGURE 5: Burner inspection Unitary Products Group 3 035-20530-001Rev. B(0804) replaced. FIGURE 8: Deformed d. heat exchanger Burn Through. See Figure 9. FIGURE 10: Overflame baffle located in top of heat exchanger assembly (cut-away view). D, Corrective 1. Heat Actions Exchanger or 1 or more missing. Replace Replacement provided 2. cracked, through Heat If heat exchanger burn through furnace you are feeling check the integrity the inside pushing against you should of the rivets that secure fle to the heat exchanger the rivets surface, drum. the overflame You can check each of the four (4) mounting are missing, the heat exchanger also baf- the rivets by Heat Exchanger with no defects. a. casing casing, burned rivets are with 37323713001 Follow instructions has resulted insulation you will to exhibits Install DGAT Program instructions in Part 3. in dama breach to contact the or on line at dgat- receive normal and/or need at: 1-888-665-4640 program@york.com replace furnace. 3. While pop with kit. DGAT program FIGURE 9: Burned through heat exchanger Exchanger. or baffle heat exchanger age to the furnace in the deformed overflame authorization to discoloration pattern Kit 37323712001. Follow legs. If any of will need to be Part 3: DGAT Program Kit Installation A. Install Heat Exchanger Liner FIGURE 11: Remove pressure switch tube. 4 FIGURE 12: Remove burner inlet pan 12 screws as marked and remove burner inlet pan. Unitary Products Group 035-20530-001 Rev.B(0804) FIGURE 13: Remove bottom screw from air vane, loosen top screw and rotate air vane counterclockwise. Use caution when rotating air vane so that foil faced insulation is not damaged. FIGURE 16: Rotate liner upward to hook on overflame baffle. FIGURE 17: Make sure the hooks on Part A straddle the rear right-hand leg of overflame baffle. FIGURE 14" Remove burner chute mounting screws (4) and remove burner chute. FIGURE 15: Insert stainless steel liner piece (Part A) with clips first. Unitary Products Group FIGURE 18: Push Part A of liner as far forward as leg will allow. 5 035-20530-001Rev. B(0804) insert Part C and rotate Place Part C over stud bolts install stainless steel upwards. in Part A. nuts. FIGURE 19: Insert Part B and rotate upwards. FIGURE 22: Again push assembled liner as far to front as )ossible and tighten all (4) stainless steel nuts. FIGURE 20: Place Part B over stud bolts in Part A. FIGURE 23: Inspect with light to make sure Part A, B, and C are pushed outward against drum. FIGURE 21: Install stainless steel nuts found in hardware bag. Do not tighten. 6 FIGURE 24: Reinstall burner chute to original position. Unitary Products Group 035-20530-001Rev. B(0804) FIGURE 25: Reposition air vane to original position. Reinstall bottom screw and tighten top screw. FIGURE 28: Reinstall burner. FIGURE 26: Install burner inlet pan with 12 screws. If needed, re-seal pan with high temperature RTV silicone. FIGURE 29: Reinstall gas valve and gas piping. FIGURE 27: Remove old gas orifice, install new per chart. FIGURE 30: Reconnect pressure tube to pressure switch and wiring connectors to gas valve, igniter and sensor. 7 Unitary Products Group 035-20530-001Rev. B(0804) FIGURE 31: Install warning label directly below rating plate on vestibule panel. B. Install Auxiliary FIGURE 34: Remove blower support shelf (7 screws). Limit Switch Assembly FIGURE 35: Remove blower support shelf. FIGURE 32: Remove Blower Assembly Mounting Screws (4). Unplug blower motor from control box. Remove wire clamp. Remove blower assembly. FIGURE 33: Remove wires from upper limit. 8 FIGURE 36: To protect side wall insulation insert cardboard sheet as a "shoe horn" to insert auxiliary limit switch assembly between insulation and heat exchanger. Unitary Products Group 035-20530-001 Rev.B(0804) FIGURE 37: Bow back plate of auxiliary limit switch assembly to insert on right-hand side of blower compartment. FIGURE 38: Compress stainless loop in middle to slide past heat exchanger. Do not skin or scrape foil from insulation while sliding switch down side of heat exchanger. FIGURE 39: Remove "shoe horn". Unitary Products Group FIGURE 40: Outer plate should compress against side casing foil (Cut-away view). FIGURE 41 : Push flange in until clearance holes line up with holes in blower shelf support bracket (Cut-away view). FIGURE 42: Reinstall blower shelf. Pass wires up through back slot of blower shelf before locating to final position. 9 035-20530-001Rev. B(0804) FIGURE 43: Install new wire clamp in blower shelf hole on rear left-hand side of shelf. Reinstall (7) screws to secure blower shelf. FIGURE 44: Install new auxiliary limit switch leads in series with upper limit per wiring diagram. FIGURE 45" Install and secure blower on shelf. Plug blower motor into control box. 10 FIGURE 46" Install new wiring diagram over existing diagram. FIGURE 47: Install danger label on vestibule panel just below upper limit switch. FIGURE 48: Turn gas supply back on and leak check gas valve piping connection. Unitary Products Group 035-20530-001 Rev.B(0804) FIGURE 50: Install Consumer Notice on top front furnace door and instruct the consumer on how to FIGURE 49: Turn electrical back on. DGAT Field Inspection Gas Orifice Selection properly maintain their furnace. Program Chart Natural Gas L P/Propane Elevation Diameter Drill Size Part No. Diameter Drill Size Part No. Sea Level .1520 24 9951-1521 .0935 42 9951-0931 2,000 .1495 25 9951-1491 .0935 42 9951-0931 3,000 .1495 25 9951-1491 .0890 43 9951-0891 4,000 .1470 26 9951-1471 .0890 43 9951-0891 5,000 .1440 27 9951-1441 .0890 43 9951-0891 6,000 .1440 27 9951-1441 .0860 44 9951-0861 7,000 .1405 28 9951-1401 .0860 44 9951-0861 8,000 .1360 29 9951-1361 .0820 45 9951-0821 9,000 .1360 29 9951-1361 .0810 46 9951-0810 .1285 30 .0785 47 9951-0781 10,000 Unitary Products Group 9951-1281 11 035-20530-001 Rev.B(0804) Part 4: Checkout A. Furnace 1. Data Checkout Verify Cardboard an overtired Pad "Shoehorn" was removed. furnace. make sure that found to meter be okay, to Once your again, you will gas pressure you determine should the need to is set properly. then units also firing If clock rate, the and if needed, check the supply duct system static pressure. Refer to Part 5 for information on how to measure Remove Cardboard Pad "Shoehorn" before operat- gas pressure, measure supply determine static the firing rate and pressure. ing furnace. If any Fire Hazard. Failure sonal to remove injury items parameters may cause property damage, tested listed of application/installation per- Since or loss of fife. Check a. b. c. Air Temperature Make sure minutes. furnace has operated for at least 5 charges 4. Measure return openings of top furnace air temperature Measure supply at top B. air temperature at the closet reg- 1. the return ply air temperature 3. If measured furnace air temperature to obtain ATR is outside rating plate, from the sup2. the ATR. parameters shown then you will need on the to determine why unit is operating beyond its design parameters. If the ATR is too low, it is an indication of an underfired 12 Verify mal Subtract furnace. Make properly. If the ATR sure that is too your gas pressure of be ATR 3. must for covering any design parameters, your on-site pro- visit. Visit appliances Follow manufacturer. Complete the DGAT are returned instructions Program Claim a. Record your name and company b. Obtain homeowner's signature. c. Sign Review under with the found. is within appliance claim design be addressed. this situation responsible all gas-fueled operation. the it is an indication are not covered to discuss On-Site properly is set high, it is an indication will If measured that problems any problems Complete ister/grille. d. they outside plate, ceed to step B and complete louver door. as to correct rating problems you will need homeowner Rise (ATR). in findings application/installation the warranty, 2. result on the units form to certify provided to norby the Form. information. the furnace has been upgraded. the Consumer Notice with the customer. Unitary Products Group 035-20530-001 Rev.B(0804) Part 5: Additional A. Measure a. Testing Procedures Gas Pressure Remove gas valve 3/16" Alien wrench. ting. See Figure OUT PRESS TAP plug using Install 1/8 NPT hose barb fit- 3. Allow 4. Measure time required (in seconds) for gas meter 2 cubic foot dial to rotate one complete turn (or 1/2 51. cubic 5. burner C. Calculate 2. FIGURE 51 : Pressure tap 4 complete turns). input: [Gas Heating Value] 2 x 7200 Time Assume 1030 BTU per cubic foot for natural gas if gas supplier cannot provide exact value. Measure 1. 5 minutes. foot dial to rotate Input 2. to operate Static Pressure Verify upper door is installed and furnace blower are operating in heating speed. Supply a. Static Remove burner and Pressure. top screws from coil cabinet cover plates (3 total). b. Connect fitting c. d. manometer to OUT Follow OPERATING furnace in operation. Allow burner Outlet positive PRESS hose b. barb fitting. INSTRUCTIONS to place c. to operate (Manifold) (+) pressure TAP hose Gas 30-60 seconds. Measure Adjust pressure Pressure. to 3.5" + 0.2 w.c. for natural gas, or 10.0" Connect manometer positive fitting to Static Pressure Insert Insert static pressure probe straight level (horizontal) Figure (+) pressure hose Probe. probe into each screw hole. into hole 6". Probe must be for proper measurement. See 52. _+0.2 w.c. for LPipropane. e. Follow instructions TO TURN OFF GAS TO APPLIANCE. f. 4. Remove Follow hose barb from gas valve. OPERATING Install plug. INSTRUCTIONS to place fur- nace in operation. 5. Operate heating B, Measure 1. Adjust prevent furnace cycle through to confirm Input at least proper one (1) complete operation. Rate controls on all other operation. Follow instructions facturer. Extinguish provided gas-fired appliances pilot(s), to if applicable. by the appliance manu- FIGURE 52: Measuring supply static pressure 2. Follow OPERATING INSTRUCTIONS to place fur- nace in operation. Part 6: Submit A. Claim Mail Documentation 1. Submit original DGAT Program Claim to: York International Attn: Warranty Dept. P.O. Box 385 Norman, OK 73070 Unitary Products Group 13 035-20530-001Rev. B(0804) NOTES 14 Unitary Products Group 035-20530-001 Rev.B(0804) NOTES Unitary Products Group 15 NOTES Subject to change without notice. Printed in U.S.A. Copyright t7 by York International Corp. 2004. All rights reserved. Unitary Products Group Supersedes: RO. Box 19014 035-20530-001 035-20530-001 Rev. B (0804) Rev. A (0804) Wichita KS 67204-901
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