Coleman DGAA070BDTB User Manual FURNACE Manuals And Guides 1302277L

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.........................................

HIGH EFFICIENCY
SEALED COMBUSTION

', H',

,'1.-¢" 'l.I

GAS FURNACE

MODELS: DGAA and DGAH
(Single Stage Downflow Only)

ISO

9OOl

Certified
Management

For Installation

56-90 MBH INPUT
(16.41 -26.38 KW)INPUT

Quality
System

In:

1.
2.

Manufactured (Mobile) Homes
Recreational Vehicles & Park Models

Modular Homes & Buildings

I
LIST OF SECTIONS

SAFETY ................................................
DUCTWORK
............................................

1
4

RETURN AIR REQUIREMENTS
.............................
FI LTE RS ...............................................
GAS LINE INSTALLATION
.................................

8
9
9

ELECTRICAL POWER
..................................
ROOF JACK VENT/COMBUSTION
AIR SYSTEM
SAFETY CONTROLS
...................................
START-UP AND ADJUSTMENTS
..........................
WIRING DIAGRAM
.....................................

.............

12
13
20
20
26

LIST OF FIGURES
Furnace Dimensions

......................................

Air Distribution Systems ....................................
Closet To Door Clearance - 5" or Greater ......................
Furnace To Closet Door Clearance - 1" To 5" . ..................
Furnace To Closet Door Clearance - Less Than 1" . ..............
Duct Connector Dimensions
................................
Recommended Floor Cut-out ................................

5
5
6
6
6
7

Duct Connector Depth .....................................
Duct Connector Screw Attachment
...........................
Duct Connector Tab Attachment
.............................

7
7
7

Anti-Backflow Damper .....................................
Floor Installation ..........................................
Furnace Air Filters ........................................

8
8
9

Gas Piping .............................................
Burner Assembly ........................................
Line Wiring Connections
..................................
Wiring for Heat Only Thermostat
............................

10
10
12
13

Wiring for Electronic Heat-Cool Thermostat ...................
Wiring for Standard Heat-Cool Thermostat
...................
Wiring for Blend Air Accessory .............................
Standard Roof Jack .....................................
Roof Jack With Removable Crowns .........................
Roof Jack .............................................

13
13
13
15
16
17

Connecting Roof Jack to Furnace ..........................
Roof Jack Assembly .....................................
Ceiling Rings ...........................................
Home Layout ..........................................
Pressure Switch Tubing Routing ...........................
Gas Valve .............................................

17
18
18
19
20
23

Reading Gas Pressure ...................................
Furnace Control Board ...................................

24
24

Wiring Diagram - DGAA ..................................
Wiring Diagram - DGAH ..................................

26
27

LIST OF TABLES
Unit Clearances to Combustibles .............................
External Static Pressure Range ..............................
Filter Sizes - All Models ....................................

4
8
9

High Altitude Duration Chart ...............................
Ratings & Physical / Electrical Data ..........................

12
13

SECTION

Roof Jack Options ......................................
Inlet Gas Pressure Range ................................
Nominal Manifold Pressure ................................

18
23
23

Blower Performance CFM - Downflow Without Filters ...........
AC Accessories
........................................

25
25

I: SAFETY

kWARNING
[_

This
alert symbol.
see thisforsymbol
on
labelsis ora safety
in manuals,
be alert When
to theyoupotential
personal
injury.

Understand and pay particular
WARNING, or CAUTION.

attention to the signal words DANGER,

DANGER indicates an imminently
hazardous
avoided, will result in death or serious iniurv.

situation, which,

if not

WARNING indicates a potentially
hazardous situation, which,
avoided, could result in death or serious iniurv.

if not

CAUTION indicates a potentially hazardous situation, which, if not
avoided mav result in minor or moderate injury, It is also used to
alert against unsafe practices and hazards involving only property dam-

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 maintenance can cause injury or property damage. Refer to this manual
for assistance or for additional information, consult a qualified contractor, installer or service agency.

CAUTION
This product must be installed in strict compliance with the installation instructions and any applicable local, state, and national codes
including, but not limited to building, electrical, and mechanical
codes.

age.

Johnson Controls Unitary Products

129098-UIM-H-1011

129098-UIM-H-1011
SPECIFIC
SAFETY RULES
AND PRECAUTIONS
1. Only Natural gas or Propane (LP) gas are approved for use with
this furnace. Refer to the furnace
these instructions.

rating plate or Section

Install this furnace only in a location and position as specified
SECTION I of these instructions.

A gas-fired furnace for installation in a residential garage must be
installed as specified in SECTION I of these instructions.

The furnace and ductwork should be thoroughly and completely cleaned prior to occupancy of the dwelling to insure
the proper operation of the furnace and to avoid potential
health concerns.

&WARNING

In Canada refer to the Natural Gas and Propane Installation code,
section on Central Furnaces. When installed in a Manufactured

HAZARD

Failure to follow the safety warnings exactly could result in serious
injury, death or property damage.
Never test for gas leaks with an open flame. Use a commercially
available soap solution made specifically for detection of leaks to
check all connections. A fire or explosion may result causing property damage, personal injury or loss of life.
in SECTION

The external static pressure of the air distribution system
ductwork must be set for heating operation to be at least 0.10
to 0.20 inches water column, based on the input rate of the
furnace, with the lower value for input rates less than 55,000
btu/hr and the upper value for units with input rates above
100,000 btu/hr.

IV of

FIRE OR EXPLOSION

(Mobile) Home, combustion
pied spaces.

air shall not be supplied from occu-

The size of the unit should be based on an acceptable heat loss
calculation for the structure. ACCA, Manual J or other approved
methods may be used.

Manufactured (Mobile) Home and
This appliance must be installed in a
ration using a roof jack vent system.
vent system that can be used to vent

IX of these instruc-

Modular Home Installation:
(sealed combustion) configuA roof jack is only approved
this appliance.

Test for gas leaks as specified
tions.

Always install the furnace to operate within the furnace's intended
temperature rise range. Only connect the furnace to a duct system
which has an external static pressure within the allowable range,
as specified on the furnace rating plate.

10.

Modular Home Definition:
Factory-built home constructed to the
state, local, or regional code where the house will be located. The
home is transported in one or more modules and joined at the
home site.

When a furnace is installed so that supply ducts carry air circulated
by the furnace to areas outside the space containing the furnace,
the return air may also be handled by duct(s) sealed to the furnace
casing and terminating outside the space containing the furnace.
The return air duct system is not required by the furnace manufacturer provided the combustion air and vent system have been
installed and maintained as a Sealed Combustion Direct Vent System and provided a return air duct system and return air plenum
are not required by state, local, or regional codes.

11.

Manufactured
(Mobile)
Home Definition:
Factory-built home
constructed, transported and installed under the federal building
code administered by the U.S. Department of Housing and Urban
Development (HUD Code), rather than to building codes at their
destination. The house is built, transported and installed on a nonremovable chassis.

SAFETY

kWARNING

requirements

•

Failure to carefully read and follow all instructions
in this
manual can result in furnace malfunction,
death, personal
injury and/or property damage.

•

to be met:

The temperature of the return air to the furnace must not be
less than 55° F (13 ° C), with no evening setback or furnace
shutdown, to prevent condensation
in the primary heat
exchangers.

The air temperature rise must be within the stated rise range
as indicated on the furnace rating plate, and the firing input
rate must be set to the unit nameplate value.

that service access is

These models are CSA listed and approved for installation into a
Modular Home, Manufactured (Mobile) Home, or Recreational
Vehicles.

Clean, outside combustion air is provided to the furnace to
minimize the impact of corrosive adhesives, sealants, and
other construction materials. Drywall dust is a major concern
during construction, which can be pulled into the combustion
air path, leading to plugged heat exchangers, burners, and
inducer assemblies.
Filter must be installed in the furnace as specified in the
installation instructions, and must be replaced or thoroughly
cleaned prior to occupancy of the home. Again, drywall dust
is the key issue, as that dust can be pulled into the circulating
blower motor, plugging the motor vents, coating the rotors
and stators, etc. which can lead to a potential fire hazard.

as listed under

•

Do not test the fuel system at more than 14 inches water column
after furnace has been connected to the fuel line. Such testing may
void the warranty. Any test run above 14 inches water column may
damage the furnace control valve which could cause an explosion,
fire, or asphyxiation.
The following

materials

Provide clearances for servicing ensuring
allowed for both the burners and blower.

Improper installation may damage equipment, can create a shock
hazard, and will void the warranty.
The furnace shall be installed so the electrical components are protected from water.
The furnace is not to be used for temporary heating of buildings
structures under construction.

REQUIREMENTS

Provide clearances from combustible
Furnace Locations and Clearances.

Furnaces for installation on combustible flooring shall not be
installed directly on carpeting, tile or other combustible material
other than wood flooring.
Check the rating plate and power supply to be sure that the electrical characteristics match. All models use nominal 115 VAC, 1
Phase, 60-Hertz power supply. DO NOT CONNECT THIS APPLIANCE TO A 50 HZ POWER SUPPLY OR A VOLTAGE ABOVE
130 VOLTS.
Furnace shall be installed so the electrical
tected from water.

components

are pro-

Installing and servicing heating equipment can be hazardous due
to the electrical components and the gas fired components. Only
trained and qualified personnel should install, repair, or service
gas heating equipment. Untrained service personnel can perform
basic maintenance functions such as cleaning and replacing the
air filters. When working on heating equipment, observe precautions in the manuals and on the labels attached to the unit and
other safety precautions that may apply.
•

These instructions cover minimum requirements and conform to
existing national standards and safety codes. In some instances
these instructions exceed certain local codes and ordinances,
especially those who have not kept up with changing Modular
Home and Manufactured (Mobile) Home home construction practices. These instructions are required as a minimum for a safe
installation.

Johnson Controls Unitary Products

129098-UIM-H-1011
Manufactured

homes

in the U.S.A.:

INSPECTION

Federal Manufactured Home Construction
& Safety
(H.U.D. Title 24, Part 3280).
National Fuel Gas Code (ANSI-Z223.1, NFPA-54).

Standard

National Electrical Code (NFPA 70).
Manufactured

homes

in Canada:

Natural Gas and Propane Installation Code (CAN/CSA

B149.1 ).

Canadian Electrical Code, Part 1 (CSA C22.1)
Recreational

Vehicles

FURNACE

in U.S.A.:

Standard on Recreational Vehicles (NFPA 1192, formerly NFPA
501C).
National Electrical Code (NFPA 70).
Recreational

Vehicles

in Canada:

Unit installation shall comply with current CSA standard CAN/
CGA-Z240.4.2
- Installation Requirements for Propane Appliances and Equipment in Recreational Vehicles.
Unit electrical wiring and grounding shall comply with current
CSA standard
C22.2 No.148/CAN/CSA-Z240.6.2
- Electrical
Requirements
COMBUSTION
(LIST

for recreational
AIR

As soon as the furnace and/or accessories are received, it should be
inspected for damage during transit. If damage is evident, the extent of
the damage should be noted on the carrier's freight bill. A separate
request for inspection by the carrier's agent should be made in writing.
Also, before installation the furnace and!or accessories should be
checked for screws or bolts which have loosened in transit or shipping
and spacer brackets the need to be removed.

The furnace
1.
2.
3.
4.
5.

vehicles.

QUALITY
6.

OF CONTAMINANTS)

The furnace will require OUTDOOR AIR for combustion
INCLUDING any of the following environments.
Restricted Environments

AT ALL TIMES,

Commercial buildings
Buildings with indoor pools
Laundry rooms
Hobby or craft rooms
Near chemical storage areas
Chemical exposure
This furnace requires OUTDOOR AIR for combustion AT ALL TIMES,
AS WELL AS where the furnace is being exposed to the following substances and / or chemicals.

Permanent wave solutions
Chlorinated waxes and cleaners

quidelines:

in freezina

temoeratures:

Furnace shall be installed in an area where ventilation facilities
provide for safe limits of ambient temperature under normal operating conditions. Ambient temperatures may fall below 32 ° F (0 ° C)
providing the flue temperature does not fall below 260 ° F (127 ° C)
at any point in the flue pipe. If the flue temperature falls below 260 °
F (127 ° C) the flue products will condense in the vent pipe causing
the vent pipe to deteriorate rapidly.
Do not allow return air temperature to be below 550 F (13 ° C) for
extended periods. To do so may cause condensation to occur in
the main heat exchanger, leading to premature heat exchanger
failure.

If this furnace is installed in an unconditioned space and an
extended power failure occurs, there will be potential damage to
the internal components. Following a power failure situation, do
not operate the unit until inspection and repairs are performed.

Clearances

for access:

Ample clearances should be provided to permit easy access to the unit.
The following minimum clearances are recommended:
air intake duct

system termination must be located external to the building and in an
area where there will be no exposure to the substances listed above.

_WARNING
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 furnace.
1. Spray or aerosol cans, rags, brooms, dust mops, vacuum
cleaners or other cleaning tools.
2. Soap powders, bleaches, waxes or other cleaning compounds; plastic items or
3. Containers; gasoline, kerosene, cigarette lighter fluid, dry
cleaning fluids or other volatile fluid.
4. Paint thinners and other painting compounds.
5. Paper bags, boxes or other paper products
Never operate the furnace with the blower door removed.
To
do so could result in serious personal injury and/or equipment
damage.

Johnson Controls Unitary Products

shall be located usinq the followinq

Installation in an ambient below 32°F (0,0 ° C) could create a hazard, resulting in damage, injury or death,

Halogen type refrigerants
Cleaning solvents (such as perchloroethylene)
Printing inks, paint removers, varnishes, etc.
Hydrochloric acid
Cements and glues
Antistatic fabric softeners for clothes dryers
Masonry acid washing materials
the combustion

CLEARANCES

AWARNING

Chlorine based swimming pool chemicals
Water softening chemicals
De-icing salts or chemicals
Carbon tetrachloride

When outdoor air is used for combustion,

AND

The furnace should be located where the roof jack can be installed
with out major modifications to the roof of the structure.
As centralized with the air distribution as possible.
Where there is access to fresh air particularly when the blend air
accessory will be installed.
Where it will not interfere with proper air circulation in the confined
space.
Where the outdoor roof jack terminal will not be blocked or
restricted. Refer to "VENT CLEARANCES"
located in SECTION
VII of these instructions. These minimum clearances must be
maintained through out the installation.
Where the unit will be installed in a level position with no more
than 1/4" (0.64 cm) slope side-to-side and front-to-back to provide
a proper roof jack connection and seal.

Installation
1.

LOCATION

Twenty-four 24 inches (61 cm) between the front of the furnace
and an adjacent wall or another appliance, when access is
required for servicing and cleaning.

Eighteen 18 inches (46 cm) at the side where access is required
for passage to the front when servicing or for inspection or
replacement of flue/vent connections.

In all cases, accessibility clearances shall take precedence over clearances for combustible
materials where accessibility clearances are
greater. See Table 1.

AWARNING
Check the rating plate and power supply to be sure that the electrical characteristics
match. All models use nominal 115 VAC, 1
Phase 60Hz power supply.
Furnace shall be installed so the electrical components are protected from water.
Installation

in a residential aaraae:

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.

129098-UIM-H-1011
TABLE 1: Unit Clearances to Combustibles
Top
Application

Downflow

Closet

Front

Alcove

Rear

Sides

Closet

Alcove

Closet

In. (cm)

In. (cm) In. (cm) In. (cm) In. (cm) In. (cm) In. (cm) In. (cm) In. (cm) In. (cm) In. (cm)

2(50.8)

6(15.24)

24(60.96)

inches

c.m.

59=1/2"

151.0

76"

193.0

24.3/4"

62.9

23"

58.4

19=1/2"

49.5

9=3/4"

24.8

12"

30.5

Alcove

Closet

Alcove

Closet

Duct 1

In. (cm)

Closet

Floor I

In. (cm) In. (cm)
2(50.8)

Alcove

Roof Jack Flue

Alcove

Closet

Alcove

1. Approved duct connector required for use on combustible floor.

]
B

]
DGAH Series

DGAA Series

FIGURE 1: Furnace Dimensions

SECTION
DUCTWORK

I1: DUCTWORK
GENERAL

The duct system's

INFORMATION

design and installation

must:

Handle an air volume appropriate for the served space and within
the operating parameters of the furnace specifications.

Be installed in accordance with standards of NFPA (National Fire
Protection Association) as outlined in NFPA pamphlets 90A and
90B (latest editions), in Canada CAN/CGA-B149.1-00
Natural Gas
and Propane Installation Code. or applicable national, provincial,
or state, and local fire and safety codes.

For Manufacture (Mobile) Home and Modular Home Return
Duct System Installations:
The return air duct and the return air plenum are not required by
the furnace manufacturer, provided a return air duct and plenum
are not required by state, local, or regional codes. The only vent
system that is approved for use on this furnace is a Roof Jack
which is a Sealed Combustion Direct Vent System.

Complete a path for heated or cooled air to circulate through the
air conditioning and heating equipment and to and from the conditioned space.

CAUTION

The duct system must be properly sized to obtain the correct airflow
for the furnace size that is being installed.
Refer to the furnace rating plate for the correct rise range and Table
4 for static pressures.
If the ducts are undersized, the result will be high duct static pressures and/or high temperature rises which can result in a heat
exchanger OVERHEATING CONDITION. This condition can result
in premature heat exchanger failure, which can result in personal
injury, property damage, or death.

HAZARD OF ASPHYXIATION,
FLOOR OPENING.

with a cooling coil, the coil

must be installed parallel with, or in the supply air side of the furnace to
avoid condensation in the primary heat exchanger. When a parallel flow
arrangement is used, dampers or other means used to control airflow
must be adequate to prevent chilled air from entering the furnace. If
manually operated, the damper must be equipped with means to prevent the furnace or the air conditioner from operating unless the damper

OR RESTRICT

IIMPORTANT

The cooling coil must be installed in the supply air duct, downstream of the furnace. Cooled air may not be passed over the heat
exchanger, and must comply with (H.U.D.) TITLE 24, PART
3280.709
When the furnace is used in conjunction

DO NOT COVER

Fabricate and install an inspection door in the plenum base below
the unff to allow an annual inspection of the heat exchangers. The
inspection door can be fabricated by the following method.
1.

Cut a rectangular opening in the plenum base.

A sheet metal plate can be made that completely covers the opening in the base.

The plate must be secured with screws.

This plate must be sealed to prevent leaks.

is in full heat or cool position.

Johnson Controls Unitary Products

129098-UIM-H-1011
DUCT

AWARNING

Air Distribution

NOTE: Refer to HRA Digest Residential Air System Design Manual,
Sections 5 and 6, the requirements of which are summarized as follows:
1.

The kilowatt output of each duct register shall not exceed 2.35 kW.

The furnace output should not be more than 20% greater than the
calculated heat loss of the home. If a larger furnace is used, the
duct system shall be capable of the increased air volumes necessary to maintain a maximum air temperature
air passes over the furnace heat exchanger.

INSTALLATION
Systems

For proper air distribution, the supply duct system shall be designed so
that the static pressure does not exceed the listed static pressure rating
on the furnace rating plate.
Three typical distribution

- CANADA

Supply duct design shall be in accordance with the latest HRA Digest,
the ASHRAE Handbook Fundamentals, or other good engineering principles.

The supply air temperature MUST NEVER exceed the Maximum
Supply Air Temperature, specified on the nameplate.
Operating the furnace above the maximum supply air temperature
will cause the heat exchanger to overheat, causing premature heat
exchanger failure. Improper duct sizing, dirty air filters, incorrect
manifold pressure, incorrect gas orifice and/or a faulty limit switch
can cause the furnace to operate above the maximum supply air
temperature. Refer to sections II, III and XI for additional information on correcting the problem.
DUCTWGRK

DESIGN

systems are illustrated

rise of 50° C as the

At least one warm air supply outlet shall be provided in each room.

When rooms are located adjacent to the exterior walls, warm air
outlets shall be located so as to bathe at least one exterior wall
and, where practical, a window area with warm air, except for bathrooms or kitchens where this might not be practical.

in Figure 2.

Location, size and number of registers should be selected on the basis
of best air distribution and floor plan of the home.

The Air Temperature Rise is to be adjusted to obtain a temperature
within the range(s) specified on the furnace rating plate.

CLEARANCE

rise

Where practical, outlets shall be provided
of the home.
REQUIREMENTS

near the exterior doors

- CANADA

Supply air ducts from warm air furnaces having a specified minimum
plenum clearance shall maintain this clearance from combustible material for at least the distance specified in CSA Standards C22.2 No. 23 or
B140.10 or CGA Standard CAN/CGA-2.3.

A
Single trunk duct

C
Transition Duct with Branches

B*
Dual trunk duct with crossover
I
_r
Dual trunk duct
_,
Crossover
I

Transition

duct

connector
I

Branches U

J
'_'-3

1.
2.
3.
4.

Crossover Duct must be centered directly under furnace.
Use 12" (30.5 cm) Diameter Round or insulated Flex-duct only.
Terminate Flex-duct (opposite furnace) in the center of the trunk duct.
Flex-duct material must be pulled tight
No Loops or unnecessary dips

Air Flow may be impeded.

FIGURE 2: Air Distribution Systems

Furnace to Closet Door Clearance
5 ranches (12.7 cm) or more

Return Air Grille Part No.
7900-287P/A * White

The closet door MUST have a minimum of 250 ranches2(1613 cm 2)
of free area in the upper half of the door.
If opening for return air is located in the floor or sidewalls and
below the top of the furnace casing:
1. 6 inches (15.2 cm) minimum clearance must be provided on side
where return is located, and
2. 6 inches (15.2 cm) minimum clearance must be maintained from
the front of furnace.

250 IN. 2 (161 cm 2)
MINIMUM
FREE AREA
250 IN. 2 (161 cm 2)
/50 IN. _(322 cm _)
_ MINIMUM
J FREE AREA

FREE AREA

_- 5 in (12.7 cm) or greater

DOOR
FIGURE 3: Closet To Door Clearance

Johnson Controls Unitary Products

Door C, .......

* Closet

Return Air Closet Door Part No.
7900-7771/C* White

- 5" or Greater

129098-UIM-H-1011

Furnace to Closet Door Cmearance
Greater than 1 ranch (2.54 cm) and Up to 5 (12.7 cm) ranches
1. The closet door MUST have a minimum of 250 Inches 2 (1613 cm 2) of free
area in the upper half of the door and a minimum of 56 Inches _ (322 cm 2) of
free area in the lower area of the door. The lower closet door grille may be
omitted if an undercut of 2-1/2 inches (16.1 cm)is provided in the door.
2. A fully Iouvered closet door MUST have a minimum of
250 Inches 2 (1613 cm _) of free area in the upper half of the door.

250 IN.2(161 cm 2)
MINIMUM
FREE AREA

250 IN. _(161cm _)
MINIMUM
FREE AREA

50 IN. _ (322 cm _)
MINIMUM
J FREE AREA

As an option to the lower grill,
an undercut of 2-1/2" will provide
50 inches 2 (322 cm 2) of free area.

FIGURE 4:

Furnace To Closet Door Clearance - 1" To 5"

Furnace to Closet Door Clearance
Less than 1 ranch (2.54 cm)

250 IN.2(161 cm _)
MINIMUM
FREE AREA

DUCT

Furnace

To Closet

Door

Clearance

The closet door MUST have three return air grilles. The total free area of the
two upper grilles must be minimum of 250 ranches 2 (1613 cm 2) . The total
free area of the lower grille MUST be a minimum of 56 Inches 2 (322 cm2).
The grilles MUST BE ALIGNED directmy opposite the return air grHme of
the furnace door.

MINIMUM
0IN. _(322cm _)
FREE AREA

FIGURE

- Less Than

CONNECTORS
,ql-i

2-3/8
(6.0cm)

18-3/4 (47.6 cm)ii..i_

ISEE

2-3/8 -(6.0 cm)
•

--'1°"ART
F-

14 (35.6 cm)_

2-3/8
(6.o cm)

SEE l

CHART

2-3/8 -(6.0 cm)

(33.0 cm)

t ?"

13 (27.9 cm ,

4-3/8

4-3/8
DUCT

CONNECTOR

(11.1 cm)

DIMENSIONS

DUCTCONNECTOR
PART NUMBER
7990-6011
7990-6021

DUCT

CONNECTOR
DEPTH

1(11,1

DUCT CONNECTOR
DUCT

CONNECTOR

PART

NUMBER

1" (2.5 cm)

7990-6211

2" (5.7 cm)

7990-6221

ore)

DIMENSIONS
DUCT

CONNECTOR
DEPTH
1" (2.5 cm)
2" (5.7 cm)

7990-6041

4-1/2"

(11.4 cm

7990-6241

7990-6061

6-1-2"

(16.5

cm)

7990-6261

6-1-2"

(16.5 cm)

7990-6071

7-1/2"

(19.0

cm)

7990-6271

7-1/2"

(19.0

cm)

7990-6081

8-1/2"

(21.6

cm)

7990-6281

8-1/2"

(21.6

cm)

7990-6101

10-1/4"

(26.0 cm)

7990-6301

10-1/4"

(26.0

cm)

7990-6121

12-1/4"

(21.1 cm)

7990-6321

12-1/4"

(21.1

cm)

4-1/2"

(11.4 cm

FIGURE 6: Duct Connector Dimensions

Johnson Controls Unitary Products

129098-UIM-H-1011
REAR WALL
OF ENCLOSURE
2-3/4

(7,0

cm)

NOTE: Duct sealant and tape must be classified as meeting HUD Standard 3280.715, U.L. Standard 181A.

CEILING CUT-OUT
FOR ROOF JACK

If tape is used to provide a better air seal, it should be a type approved
by the applicable national or local codes.

MIN

J. _

I "i

/E
_•

FLOOR

v, _/"1

-_l_/'t

CONNECTOR

i/\

............ _//"_,'_--

I I I f-'_

__/__..__

CUT-OUT

FOR

/--

LOCATOR BRACKET
NAILS, FLAT HEAD SCREWS
/ ...........
OR STAPLES

DUCT

FURNACE
/

r I_-1 L_oUTL,NE

/
/¢
IP" i'

BEND
DUCT

TABS UNDER
OPENING
TO

SECURE TO THE
SUPPLYDUCT,
FLOOR

I
2-1/8

._1

(5,4,cm)I,I

(31 '\

[_"

_----1"-

----

I_'_'_ 9_-3/4,--I"
I
z4mcm)z4._
cm)
14
'

_(8.30m:

OR ELECTRIC
OP
NAL GAS
ENTRANCE
jFRONTPANEL

OF FURNACE
SUPPLY DUCT

FUTURE

REFRIGERANT
LINE ENTRANCE

FIGURE 7: Recommended

FIGURE 10: Duct Connector Tab Attachment
INSTALLATION

Floor Cut-out

_'
DUCT

;

FLOOR

[,_

DUCT

...............
NAILS, FLATHEAD SCREWS
OR STAPLES

/
//

SCREWS

Determine the depth of the floor cavity from the surface of the floor
to the top of the supply air duct and select the appropriate duct
connector from the chart. See Figures 6 and 8.

Place locating bracket (supplied with the duct connector)
rear of the floor area for the furnace. See Figure 10.

Determine which of the four positions the duct connector best centers over the supply duct and insert it through the floor cut-out.

Mark cut-out location on the supply duct and remove the duct connector.

Cut out the opening to the supply duct.

Bend tabs down through and back up under the supply duct.

Secure the duct connector to the floor with nails, flat head screws
or staples.

to the

The duct connector is designed for use on ducts down to 12" in width.
When using the connector on smaller width ducts, there will not be sufficient clearance to bend the tabs on two sides of the duct connector.

.............
FLOOR

In such cases the tabs may be attached to the sides of the duct by
using sheet metal screws or other suitable fasteners. Holes for sheet
metal screws are provided in three (3) tabs on each side of the duct
connector. If more than 3 tabs need to be used to provide a more
secure and air tight connection, the remaining tabs can also be fastened to the duct with screws after drilling the required screw hole.

SUPPLY DUCT

FIGURE 9:

Make floor cut out as shown in Figure 7.

..................JOIST

LOCATORBRACKET

DUCT

2.
FLOOR

/
]/

ATTACHMENT

Duct Connector Depth
/

OF TAB

CONNECTORS

COpNTNHECTOR

SUPPLY

FIGURE 8:

FLOOR

20.--I,
(5O.8 cm)

Furnace

Duct Connector Screw Attachment

and Air Conditioner

Installations

If an air conditioner is installed which does not use the blower for air disINSTALLATION

OF SCREW

ATTACHMENT

DUCT

CONNECTOR
1.

Make floor cut out as shown in Figure 7.

Determine the depth of the floor cavity from the surface of the floor
to the top of the supply air duct and select the appropriate duct
connector from the chart. See Figures 6 and 8.

Place locating bracket (supplied with the duct connector)
back edge of the floor opening. See Figure 9.

Apply a water based duct sealant to the 1!2" supply duct attachment flange of the duct connector.

Determine which of the four positions the duct connector best centers over the supply duct and insert it through the floor cut-out.

When properly aligned with the supply duct, secure the duct connector to the floor with nails, flat head screws or staples.

Use screws as required to secure the duct connector to the supply
duct.

Cut out the opening to the supply duct. If sealant was not used, the
installer should tape the mating flanges to provide a good air seal.

Johnson Controls Unitary Products

to the

tribution and operates completely independent of the furnace, the thermostat system must have an interlock to prevent the furnace and air
conditioner from operating at the same time. This interlock system usually contains a heat-cool switch which must be turned to either HEAT or
COOL to activate either heating or cooling operation, or a positive OFF
switch on the cooling thermostat.
When used in connection with a cooling unit the furnace shall be
installed parallel with or on the upstream side of the cooling unit to avoid
condensation in the heat exchanger.
For installations with a parallel flow arrangement, the furnace must be
equipped with a damper to prevent cold air from being discharged up
around the heat exchanger. Cold air causes condensation inside the
exchanger and can cause it to rust out which can allow products of
combustion to be circulated into the living area by the furnace blower
resulting in possible asphyxiation.
An air flow activated automatic
damper, PIN 7900-6771, is available from furnace manufacturer. See
Figure 11.

129098-UIM-H-1011
NOTE: See label on coil panel for conversion and lighting instructions.
Obtain a temperature rise within the ranges specified on the name
plate.

SECTION
II1: RETURN
REQUIREMENTS
CLOSET

AIR

INSTALLATIONS

Additional

Requirements

Additional requirements for floor and ceiling return system for closet
installed sealed combustion heating appliance are given in the next
paragraph.
AUTOMATIC
DAMPER

kWARNING
HAZARD OF ASPHYXIATION,
FLOOR OPENING

DO NOT COVER

OR RESTRICT

TABLE 2: External Static Pressure Range
Ext. Static Pressure

Nominal
Input
FURNACE
CONNECTOR
FOR BEST AIR DELIVERY
WITH BLADES
PARALLEL

FIGURE 11: Anti-Backflow
INSTALLATION

Air Flow I

Minimum
kPa

Maximum

MBH

CFM cmm

In.W.C

kPa

16.4

12.9

1305 36.9

0.10

0.0249

0.30

0.0747

20.5

16.4

1305 36.9

0.10

0.0249

0.30

0.0747

22.5

18.0

1305 36.9

0.10

0.0249

0.30

0.0747

26.3

21.1

1305 36.9

0.10

0.0249

0.30

0.0747

DUCT

BASE

NOTE:

Output

INSTALL
DAMPER
TO SUPPLY
DUCT.

Damper

RECOMMENDATIONS

Remove the front panels and set the furnace onto the duct connector. Slide it back until the rear of the unit engages the Iocator
bracket.

Secure the front of the furnace with two screws at the mounting
holes provided.

Secure
through
to any
Installer
through

the top of the furnace to a structural member using screw
the strap at the back of the furnace. Strap may be moved
of the holes located along the top back of the furnace.
may provide an equivalent method, such as screws
the casing side.

The duct system is a very important part of the installation. If the duct
system is improperly sized the furnace will not operate properly. The
ducts attached to the furnace plenum, should be of sufficient size so
that the furnace operates at the specified external static pressure and
within the air temperature rise specified on the nameplate.
Consideration should be given to the heating capacity required and also
to the air quantity (CFM) required. These factors can be determined by
calculating the heat loss and heat gain of the home or structure. If these
calculations are not performed and the furnace is over-sized, the following may result:
1.

Short cycling of the furnace.

Wide temperature

Reduced overall operating efficiency of the furnace.

fluctuations

1. Std. Blower-High

Speed-No Coil.

IMPORTANT
The air temperature rise should be taken only after the furnace has
been operating for at least 15 minutes. Temperatures should be
taken 6" (15.2 cm) past the first bend from the furnace in the supply
duct. The return air temperature must be taken at the return air Iouvered door. Return static pressures can be taken by pushing probe
through the air filter on the Iouvered door.

BLEND

AIR INSTALLATIONS

If a blend air ventilation system is installed, the 5" (12.7 cm) diameter
knockout in the top cover must be removed. The blend air damper is to
be placed on the top cover and secured with screws as shown in Figure
12. The power wires for the Blend Air Damper are inserted through the
7/8" (2.22 cm) hole in the top cover. The wires to the Blend Air Damper
will be connected as shown in Figure 20. Refer to the Blend Air Installation Manual to complete the installation.

from the thermostat setting.

The supply and return duct system must be of adequate size and
designed such that the furnace will operate within the designed air temperature rise range and not exceed the maximum designed static pressure. These values are listed in Table 2.

BLEND AIR
FLEX DUCT
BLEND AIR
DAMPER

FLOOR

FIGURE 12: Floor Installation

Johnson Controls Unitary Products

129098-UIM-H-1011
SECTION
FILTER

IV: FILTERS

If the standard throwaway filter are used the external filter
grille must have a minimum area of 540 in2 (3483 cm2) which
would equal a 15" X 36" filter grille.

If the Pleated Media or Washable Filters are used the exter-

INSTALLATION

All applications require the use of a filter. A standard air filter is located
in the return filter rack on the Iouvered door. The air filter(s) must be
replaced with air filter(s) that are the same size and same type.
Replacement filter size is shown in Table 3.

[
All installations

nal filter grille must have a minimum area of 684 in2 (4413
cm2) which would equal a 18" X 38" filter grille. The increased
area is to reduce the pressure drop across the air filter.

CAUTION

Consideration should be given when locating the return filter
grille for maintenance.

Any filter that has a large pressure drop should be checked to
be sure the pressure drop caused by the air filter will not prevent the furnace from operating within the rise range, specified on the rating plate and in Table 7. If the furnace does not
operate within the specified rise range then a larger air filter
or an air filter that has a lower pressure drop must be
installed.

must have a filter instafled.

Downflow Filters:
There are two types of downflow filter racks.
1.

FURNACE

FILTER RACK: A return filter rack with two standard

throwaway type filters are supplied on all models. The return filter
rack is located on the inside of the Iouvered door. This type of filter
rack is designed for two standard air filters only. Pleated Media or
Washable Filters cannot be used in this filter rack because they
cause too much pressure drop causing a reduction in airflow.
Refer to Figure 13.
2.

Air Filters Can Be
Found On The Inside
Of This Panel

EXTERNAL RETURN FILTER GRILLE: The second type is an
external return air filter grille that can only be used in applications where the furnace is installed in a closet. This type of filter grille is typically installed in a closet door or wall with the filters
located within 12" (30.5 cm) of the return air opening of the furnace. There must be a minimum clearance of 6" (15.2 cm)
between the front of the furnace and the closet door and!or the furnace and the filter grille to prevent the return air flow from being
obstructed. Refer to Table 1 Unit Clearances to Combustibles.

NOTE: Remove air filters inside Iouvered door when using an external
filter grille.
FIGURE 13: Furnace Air Filters

TABLE 3: Filter Sizes - All Models
Input

Output

Air Flow

Cabinet Width

Door Filter 1

MBH

CFM

cmm

16.4

44.8

13.1

1305

34.0

193/4

2-16x20x1

2x41

cm
x51

20.5

16.4

1305

34.0

193!4

2-16x20x1

2x41

x51

22.5

18.1

1305

34.0

193!4

2-16x20x1

2x41

x51

26.3

21.1

1305

34.0

193!4

2-16x20x1

2x41

x51

1. All Models shipped with disposable filters mounted inside upper furnace door.
2. Pleated filters have high pressure drop and require cleaning every 60 days.
3. Dirty filters can cause excess heating bills, lower air flow, and reduce heat exchanger life.

SECTION
GAS

V: GAS

LINE

INSTALLATION

SAFETY

GAS PIPING
Installation

ADANGER
This furnace is designed to operate on NATURAL GAS or PROPANE GAS ONLY. Do Not Bum any other Fuel in this furnace.
Burning any fuel except NATURAL GAS or PROPANE GAS can
cause premature heat exchanger burnout, high levels of carbon
monoxide, excessive sooting, a fire hazard, personal injury, property damage and/or death.

ADANGER
An overpressure protection device, such as a pressure regulator,
must be installed in the gas piping system upstream of the furnace
and must act to limff the downstream pressure to the gas valve so it
does not exceed 0.5 PSI (14" w.c. (3.48 kPa). Pressures exceeding
0.5 PSI (14" w.c. (3.48 kPa) at the gas valve will cause damage to
the gas valve, resulting in a fire or explosion or cause damage to
the furnace or some of its components that will result in property
damage and loss of life.

Johnson Controls Unitary Products

and Checking

of Gas Line

Gas Supply piping must be sized in accordance with the recommendations contained in National Fuel Gas Code (ANSI-Z223.1, NFPA-54)
unless local codes or regulations state otherwise.
Materials used and pipe sizing for U.S. manufactured homes must comply with requirements contained in Manufactured Homes Al19.1, Recreational Vehicles Al19.2 and H.U.D. Title 24, Section 3280.705 and
any local or state codes.
NOTE: The gas line inlet on the gas valve is 1!2-14 N.RT. The gas line
may be installed through the furnace floor or furnace side to the gas
valve.

CAUTION]
If the gas input to the furnace is too great because of excessive gas
pressure, wrong size orifice, high altitude, etc., the burner flame will
be sooty and may produce carbon monoxide, which could result in
unsafe operation, explosion, and/or fire or asphyxiation.

129098-UIM-H-1011

CAUTION

CAUTION]
To install gas line and to connect it to the gas valve, care must be
taken to hold gas valve firmly to prevent misalignment of the burner
orifice, or to damage gas valve which could result in improper heating, explosion, fire or asphyxiation.
DO NOT USE EXCESSIVE PIPE SEALANT ON PIPE JOINTS.
Pipe sealant, metal chips or other foreign material that could be
deposited in the inlet of the gas valve, when gas pipe is installed or
carried through the gas piping into the gas valve inlet after installation, may cause the gas valve to malfunction and could result in
possible improper heating, explosion, fire or asphyxiation. Also,
pipe sealant must be resistant to Propane gas.
Where regulations require, a main shut-off valve shaft be installed
extemafty of furnace casing. After piping has been installed, turn
gas on and check aft connections with a leak detector or soap solution.

The gas valve body is a very thin casting that cannot take any
external pressure. Never apply a pipe wrench to the body of the gas
valve when installing piping. A wrench must be placed on the
square 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.
Gas piping may be connected from either side of the furnace using any
of the gas pipe entry knockouts on both sides of the furnace. Refer to
Figure 14 Gas Piping.

GAS ORIFICE

Do not test the fuel system at more than 14" W.C. after furnace has
been connected to fuel line. Such testing could void the warranty.
Any test run above 14" W.C. may damage furnace control valve
which could cause an explosion, fire or asphyxiation.
in the gas supply line to trap moisture and

Refer to Figure 14.

For natural gas operation,

the furnace is designed for 7" W.C. inlet gas

pressure. Pressure to main burner is then reduced to 3 1!2" W.C.
GAS

PIPING

(LP)

This conversion shaft be installed by a qualified service agency in
accordance with the manufacturer's instructions and all applicable
codes and requirements of the authority having jurisdiction. If the
information in these instructions is not followed exactly, a fire, an
explosion or production of carbon monoxide may result causing
property damage, personal injury or loss of life. The qualified service agency is responsible for the proper installation. The installation is not proper and complete until the operation of the converted
appliance is checked as specified in the manufacturer's
instructions.

occur.

contaminations.

FOR PROPANE

AWARNING

Never use open flame to test for gas leaks as fire or explosion could

A drip leg is recommended

CONVERSION

_WARNING

INSTALLATION

Properly sized wrought iron, approved flexible or steel pipe must be
used when making gas connections to the unit. If local codes allow the

Improper installation may damage equipment,
hazard, and will void the warranty.

use of a flexible gas appliance connection, always use a new listed connector. Do not use a connector that has previously serviced another gas
appliance.

can create a shock

IMPORTANT

Some utility companies or local codes require pipe sizes larger than the
minimum sizes listed in these instructions and in the codes. The furnace

These instructions are for the use of qualified individuals specially
trained, experienced and certified in the installation of this type of
equipment and related systems components. Installation and service personnel are required by some states to be licensed. Persons
not qualified shaft not install this equipment nor interpret these
instructions.

rating plate and the instructions in this section specify the type of gas
approved for this furnace - only use those approved gases.

NOTE: The words

"Shall" or "Must" indicate a requirement,

essential to satisfactory

which is

and safe product performance.

NOTE: The words "Should" or "May" indicate a recommendation
or
advice which is not essential and not required but which may be useful
or helpful.
CONTENTS

I'_-MANUAL
SHUT-OFF
VALVE

MANUAL_[_:::_'/_]'_

GAS

DRIP

SHUT'OFF I]

BURNER

VALVE

LEG

IDR_lP

Burner orifices for LP (propane) gas are located in bag attached to
the gas valve. Size is marked on orifice.

Conversion

plate.

FIGURE 14: Gas Piping

[IMPORTANT
An accessible manual shut-off valve must be installed upstream of
the furnace gas controls and within 6 feet (1.8 m) of the furnace.
The furnace

must be isolated from the gas supply piping system

closing its individual external manual shut-off valve during any pressure
testing of the gas supply piping system at pressures equal to or less
than 1/2 psig (3.5 kPa).

SCREWS

_----_

..............

GAS VALVE

FIGURE 15: Burner Assembly

Johnson Controls Unitary Products

129098-UIM-H-1011
CONVERSION

PROCEDURE

[IMPORTANT

CAUTION
The gas supply must be shut off prior to disconnecting
power, before proceeding with the conversion.

the electrical

HIGH

AWARNING
SHOCK HAZARD

Shut off gas supply at valve upstream from furnace or at meter as
required. Refer to Figure 14.

Disconnect

Disconnect electrical wires from gas valve, noting which wires are
connected to which terminals.

Remove 4 bolts that attach the gas valve to the 90 ° flange.

gas supply piping from gas valve on furnace.

Remove the four screws that attach the gas manifold to the burner
support box. See Figure 15.

Remove and discard natural gas orifices.

Remove LP (propane)
valve.

Install the LP (propane) gas orifices supplied with the furnace.
Tighten to 15 - 25 inch - pounds of torque.

Reinstall
process.

10.

Reconnect the wires to the proper terminals on the gas valve.

11.

Remove the regulator with the blue cap and turn it upside down so
the letters "LF" are upright. Place the blue cap on the opposite end
of the regulator.

12.

Convert the gas valve for LP (propane) gas operation by following
the instructions. Remove the natural tag and replace with the propane tag supplied in the orifice bag.
Remove the blue conversion label on the furnace door after the
furnace has been converted.

13.

at the factory for natural gas-fired operation

The gas orifices on this furnace must be changed in order to maintain
proper and safe operation, when the furnace is installed in a location
where the altitude is greater than 2,000 ft. (610 m) above sea level on
natural gas or the altitude is greater than 4,000 ft. (1219 m) above sea
level on propane (LP) gas. Refer to Table 6 or the instructions in the
high altitude conversion kit for the proper gas orifice size.

The unit may also be converted

The rubber "0" ring provided seals the gas valve to the 90 ° flange.
Make sure ff is installed when the gas valve is attached to that
flange.

by reversing

CONVERSION

For Propane gas operation, the furnace is designed for 11" W.C. inlet
gas pressure. Pressure to main burner is then reduced to 10" W.C.

CAUTION

in the assembly

GAS ORIFICE

at 0 - 2,000 ft. (0 m - 610 m) above sea level.

the manifold

ALTITUDE

This furnace is constructed

- Turn off electrical supply to furnace.

orifices from the bag attached

When converting gas valve from or to Propane gas, it will be necessary to change main burner orifice to prevent an underfired or overfired condition. See label inside lower furnace door for complete
instructions.

to the gas

the removal

14.

Reconnect the gas supply piping to the gas valve and insure that
all gas connections are tight.

15.

Remove pressure tap plugs from gas valve and connect water
gauge to the pressure tap ports. See Figure 30 for location of the
gas valve pressure taps and pressure regulator adjustment.

16.

Turn on gas supply to furnace and check all gas connections
suitable leak detector.

with

AWARNING

for altitudes up to 10,000 ft. (3048 m)

on natural and propane (LP) gas with additional derate as shown in
Table 6 or refer to ANSI Z223.1 NFPA 54 National Fuel Gas Code or in
Canada
Code.

CAN/CGA-B149.1-00

Natural

Gas and Propane

Installation

&DANGER
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 propane (LP) gas. Do not use this furnace with butane gas.
Incorrect gas orifices or a furnace that has been improperly converted will create an extremely dangerous condition resulting in premature heat exchanger failure, excessive sooting, high levels of
carbon monoxide, personal injury, property damage, a fire hazard
and/or death.
High altitude and propane (LP) conversions are required in order
for the appliance to satisfactory meet the application.
An authorized

distributor or dealer must make all gas conversions.

In Canada, a certified conversion station or other qualified agency,
using factory specified and/or approved parts, must perform the
con version.
The installer must take every precaution to insure that the furnace
has been converted to the proper gas orifice size when the furnace
is installed. Do not attempt to drill out any orifices to obtain the
proper orifice size. Drilling out a gas orifice will cause misalignment
of the burner flames, causing premature heat exchanger burnout,
high levels of carbon monoxide, excessive sooting, a fire hazard,
personal injury, property damage and/or death.

Never use an open flame to check for leaks. Fire or explosion could
occur. Since some leak solutions including soap and water may
cause corrosion or stress cracking, the piping must be rinsed with
water after testing unless ff has been determined that the leak test
solution is non-corrosive.

Johnson Controls Unitary Products

129098-UIM-H-1011
TABLE 4: High Altitude Duration Chart
NATURAL
Elevation
Feet

Meters

Sea Level

56,000 -- Input
Orifice
Drill
Dia.

Size

Part #

GAS

70,000 -- Input
Drill
Part #
Dia.
Size

Orifice

77,000 -Drill

Dia.

Size

Input

90,000 -- Input
Orifice
Drill
Part #
Dia.
Size

Part #

0.136

9951-1361

0.154

9951-1541

0.161

9951-1611

0.180

9951-1801

2,000

618

0.136

9951-1361

0.149

9951-1491

0.157

9951-1571

0.177

9951-1771

3,000

914

0.128

9951-1281

0.149

9951-1491

0.157

9951-1571

0.173

9951-1731

4,000

1219

0.128

9951-1281

0.147

9951-1471

0.154

9951-1541

0.173

9951-1731

5,000

1524

0.128

9951-1281

0.144

9951-1441

0.152

9951-1521

0.169

9951-1691

6,000

1829

0.128

9951-1281

0.144

9951-1441

0.149

9951-1491

0.166

9951-1661

7,000

2134

0.120

9951-1201

0.140

9951-1401

0.147

9951-1471

0.161

9951-1611

8,000

2438

0.120

9951-1201

0.136

9951-1361

0.144

9951-1441

0.161

9951-1611

9,000

2743

0.120

9951-1201

0.136

9951-1361

0.140

9951-1401

0.157

9951-1571

10,000

3048

0.116

9951-1161

0.128

9951-1281

0.136

9951-1361

0.152

9951-1521

Input

90,000 -- Input
Orifice
Drill
Part #
Dia.
Size

PROPANE
Elevation
Feet

Meters

Sea Level

56,000 -- Input
Orifice
Drill
Dia.
Size

Part #

GAS

70,000 -- Input
Orifice
Drill
Part #
Dia.
Size

Orifice
Dia.

77,000 -Drill
Size

Part #

0.082

9951-0821

0.093

9951-0931

0.098

9951-0981

0.106

9951-1061

2,000

618

0.081

9951-0811

0.093

9951-0931

0.096

9951-0961

0.104

9951-1041

3,000

914

0.078

9951-0781

0.089

9951-0891

0.093

9951-0931

0.101

9951-1011

4,000

1219

0.078

9951-0781

0.089

9951-0891

0.093

9951-0931

0.101

9951-1011

5,000

1524

0.078

9951-0781

0.089

9951-0891

0.093

9951-0931

0.099

9951-0991

6,000

1829

0.076

9951-0761

0.086

9951-0861

0.089

9951-0891

0.098

9951-0981

7,000

2134

0.076

9951-0761

0.086

9951-0861

0.089

9951-0891

0.096

9951-0961

8,000

2438

0.073

9951-0731

0.082

9951-0821

0.086

9951-0861

0.096

9951-0961

9,000

2743

0.073

9951-0731

0.081

9951-0811

0.086

9951-0861

0.093

9951-0931

10,000

3048

0.070

9951-0700

0.078

9951-0781

0.082

9951-0821

0.089

9951-0891

Table shows 4% Input Reduction per 1,000 feet Elevation. Reference Source: NFPA No. 54, ANSI Z 223.1, National Fuel Gas Code.
For Canadian installation, no orifice or manifold pressure reduction is required for 0-4, 500ft.

SECTION
Electrical

VI:
Power

ELECTRICAL

POWER

The furnace's control system requires correct polarity of the power
supply and a proper ground connection. Refer to Figure 16.

Connections

Field wiring to the unit must be grounded. Electric wires that are field
installed shall conform to the temperature limitation for 63°F (35°C) rise
wire when installed in accordance with instructions. Refer to Table 5 in

W.T
l_

these instructions for specific furnace electrical data.

CAUTION]
Use copper conductorsonly.

NOMINAL 1

FIGURE 16: Line Wiring Connections
LOW

VOLTAGE

CONTROL

WIRING

CONNECTIONS

Insert 24 volt wires through the small plastic bushing just above
the control panel.

Connect the thermostat wires to the furnace low voltage pigtails.
See Figure 17 (heating only) and Figure 18 or 19 (heating and
cooling).

nience in servicing. With the disconnect or fused switch in the OFF
position, check all wiring against the unit wiring label. Refer to the
wiring diagram in this instruction.

Connect thermostat wires to the furnace when installing blend air
accessory as shown in Figure 20.

Connect low-voltage circuit to the wall thermostat pigtails.

Remove the screws retaining the wiring box cover. Route the
power wiring through the opening in the unit into the junction box
with a conduit connector or other proper connection. In the junction
box there will be three wires, a Black Wire, a White Wire and a
Green Wire. Connect the power supply as shown on the unit-wiring label on the inside of the blower compartment door or the wiring schematic in this section. The black furnace lead must be
connected to the L1 (hot) wire from the power supply. The white
furnace lead must be connected to neutral. Connect the green furnace lead (equipment ground) to the power supply ground.

NOTE:

VOLTAGE

CONNECTIONS

Provide a power supply separate from all other circuits. Install
overcurrent protection and disconnect switch per local/national
electrical codes. The switch should be close to the unit for conve-

f 120VOLT

SUPPLY

GRN

FIGURE 22:

AIR
x

DUCT
x

FLOOR
\

CONNECTOR
x

................

DUCT
x

CONNECTOR
x

WARM

AIR

DUCT
x

Roof Jack With Removable Crowns

Johnson Controls Unitary Products

129098-UIM-H-1011
EXTERIOR

ROOF JACK

Available to comply with instances in which the roof jack crown needs to
be raised to meet a roof clearance requirement. One extension will
raise the roof jack crown by 18 inches.

STEP 1 :
Remove upper and lower cap.
Remove the two (2) screws
that secure the upper cap to
the crown assembly base and
remove the upper cap. Next,
remove the three (3) screws
that secure the lower cap to
the crown assembly base.
Set bothcaps aside for later use.

CONNECTING

ROOF JACK

TO FURNACE

CAUTION]
The inner flue pipe must be present.
It is mandatory that the combustion air pipe and flue pipe assembly be fully engaged. The combustion air pipe MUST be securely
fastened to the furnace with a sheet metal screw in the hole provided.
Use a 1/2" blunt
jack combustion
hole is provided
may extend to
exceed I i/2" in

STEP 2:

or sharp end sheet metal screw to fasten roof
air pipe to furnace combustion air collar. Screw
in the pipe and collar. Excessively long screws
flue pipe and puncture it. Screws are not to
length.

NOTE: Combustion air tube and flue pipe are part of the same assembly. Only the combustion air tube need be fastened to the furnace.

Place the roof jack extension on top of the
crown assembly base, pushing down firmly
to assure a snug fit.
IMPORTANT:
connected.

EXTENSION

Check to be certain that the flue pipe and combustion
present.

Pull the telescoping flue tube and combustion air tube assembly
down from the roof jack. Slide the flue tube/combustion
air tube
assembly down firmly over the furnace flue outlet and combustion
air collar. Insure that the back, side and front of combustion air
tube collar is fully engaged and is in contact with gasket. Fasten
the combustion air tube to the furnace combustion air collar using
a 1/2 inch sheet metal screw. (Screw hole provided in combustion
air tube and furnace combustion air collar. See Figure 24).

Make sure that the pipes are

Extension
Using the four (4) holes at the base of the
extension as a guide, drill four (4) holes
1/8" diameter into the crown assembly base.
Secure the extension to the crown assembly
base with the four (4) screws provided.
Install the lower cap on top of the extension
so that the center pipe sticks through
the hole in the lower cap.

Crown
Y
Base

COMBUSTION

UPPER
CAP

#8 OR #10 SCREW
RECOMMENDED

AIR TUBE _
TSoE
CwURL_STRAP

STEP 3:
Reinstall upper and lower cap to extension.
Using the three (3) screws removed
in Step 1, attach the lower cap to the
extension bracket. Install the upper
cap over the center pipe of the extension.
Using the two (2) holes located at the
base of the upper cap as guides, drill
two (2) 1/8" diameter holes into the center pipe.
Finally, attach the upper cap to the center
pipe using the two (2) screws removed in
Step 1 to the center pipe.
/

air tube are

COMBUSTION
AIR TUBE COLLAR
/

LOWER
CAP

EXTENSION
BRACKET

CROWN
ASSEMBLY
BASE

FRONT OF
FURNACE

It is mandatory that the combustion air and flue tube assembly
be fully engaged at back sides and front, and combustion air
tube securely fastened to the furnace with a sheet metal screw
in the screw hole provided.
STEP 4:
Complete assembly.
Place these instructions in the customer
packet provided with the furnace.

FIGURE 24:

Connecting

COMBUSTION

Roof Jack to Furnace

AND VENTILATION

AIR

This furnace is a sealed combustion (direct vent) unit and is design certified to use only a 4000 Series roof jack. These roof jacks are designed
to provide combustion air to the furnace and to exhaust flue products to
the outside. No other combustion air openings or ducts are needed.

FIGURE 23: Roof Jack

Johnson Controls Unitary Products

129098-UIM-H-1011

CAUTION
COM_INT
AIR PIPE AND
FLUE ASSEMBLY

"_t_---_
_

MUST BE
BELOW CEILING

INTERIOR
EXTENSION
(OPTIONAL)

Use 1/2" (1.27 cm) blunt or sharp end sheet metal screws to fasten
roof jack combustion air pipe to furnace combustion air collar Screw
holes are provided in pipe and collar. Excessively long screws may
extend to flue pipe and puncture ft. If substitute screws are used,
they must not exceed 1 1/2" (3.81 cm) in length. It is mandatory that
the combustion air and flue tube assembly be properly engaged,
and the combustion air pipe fastened to the furnace with sheet
metal screws in the holes provided.

If using an optional interior extension, place extension down on furnace
top and mate with furnace flue and combustion air collar until it lines up
with screw holes in combustion air collar. Secure the extension to the
furnace using the pre-punched holes. Use 1/2" (1.27 cm) blunt or sharp
end sheet metal screws to fasten roof jack combustion air pipe to furnace combustion air collar. Screw holes are provided in pipe and collar.

FURNACE COMBUSTION
AIR COLLAR

FIGURE 25:

Roof Jack Assembly

INTERIOR

EXTENSIONS

Excessively long screws may extend to flue pipe and puncture, it. If
substitute screws are used. they must not exceed 1 1/2" (3.8a cm) in
length. Pull the roof jack flue and combustion air pipe assembly down

To choose the proper length roof jack with or without the optional extension see Figure 25 and Table 8. More than one interior extension may
be used to accommodate

A "dimensions

up to 110" (284.5 cm).

and mate with extension flue and combustion air pipes until the screw
holes line up. See Figure 25. Fasten interior extension to combustion
air pipe assembly with sheet metal screws not exceeding 1 1/2" (3.8
cm) in length.

IMPORTANT

WARNING

Under no circumstances

The joint where the optional interior extension connects to the roof
jack must be below the ceiling. Failure to observe this requirement
may result in asphyxiation, fire, or explosion
NOTE: Use of an interior extension will increase the roof jack adjustable heights by the amount of the interior extension height. If the furnace is installed on an elevated plenum, the plenum height must be
added to the roof jack height.

CAUTION]
Do not exceed the maximum adjustable height as listed in Table 6.
These maximum heights allow an additional 1 1/2" (3.81 cm) travel
before the flue pipe assembly is fully extended against the built-in
stop. This provides an additional safeguard against the flue assembly being pulled from the roof jack if upward movement should
occur when the home is being transported or subjected to other
stress conditions. Failure to follow these instructions may result in
fire, explosion, or asphyxiation.

shaft the connection

between the flue and

combustion air pipe assembly of the roof jack and the interior extension be above the ceiling line.
Secure the roof jack to the roof with screws. Non-hardening
mastic
sealer or caulking compound must be used to seal the roof flange to
prevent water leakage. The roof jack swivel joint must also be sealed to
prevent water leakage.

INSTALLING

CEILING

RING

The ceiling ring is to meet fire stop requirements. Accessory Ceiling
Ring may be used (See Figure 26) or the mobile home or modular
home manufacturer or the installer may use other approved methods to
fire stop. If required, three sections of the Accessory ring may be used
as in Figure 26 to provide closer clearance around the roof jack.
NOTE: A portion of the outer edge of the ceiling ring may be trimmed so
the ring will fit between the warm air plenum and roof jack.

TABLE 6: Roof Jack Options
Roof Jack
Model Number

Adjustable Height with
no Interior Extension

Adjustable Height with
on 17" Interior Extension

4000B7141

14" to 78"

64" to 95"

FIGURE 26: Ceiling Rings

4000B7151

66" to 90"

83" to 107"

VENT

4000B8161

59" to 79"

76" to 96"

4000B8181

73" to 103"

90" to 110"

Models 4000B8161 and 4000B8181 have removable crowns.

CLEARANCES

IMPORTANT
The vent must be installed with the minimum clearances as shown
in Figure 27, and must comply with local, state, regional codes and
requirements.

Johnson Controls Unitary Products

129098-UIM-H-1011

FIXED
CLOSED
"'

[]

VENT TERMINAL

AIR SUPPLY

[]

AREA WHERE

TERMINAL

IS NOT PERMITTED

"\ .................
FIXED
CLOSED

OPERABLE

FIGURE

27:

Home

Layout
Canadian

A.Clearance

above grade, veranda,

B.Clearance
C.Clearance

porch, deck, or balcony

Installations

US Installation

12 inches (30 cm)

to window or door that may be opened

12 inches (30 cm) for models <100,000 BTUH
(30 kW), 36 inches (91 cm) for models > 100,000
BTUH (30 kW)

4 Feet

to permanently

4 Feet

closed window

D.Vertical clearance to ventilated soffit located
above the terminal within a horizontal distance
of 2 feet (61 cm) from the center line of the terminal
E.Clearance

to unventilated

12 Inches

F. Clearance

to outside corner

12 Inches

G.Clearance

to inside corner

6 Feet

H.Clearance

to each side of center line extended

3 feet (91 cm) within a height 15 feet (4.5 m)
above the
meter/regulator assembly

3 feet (91 cm) within a height 15 feet (4.5 m)
above the meter/regulator
assembly

3 feet (91 cm)

J. Clearance to nonmechanical air supply inlet to building
or the combustion air inlet to any other appliance

12 inches (30 cm) for models <100,000 BTUH
(30 kW), 35 inches (91 cm) for models >100,000
BTUH (30 kW)

4 Feet

K.Clearance

6 feet (1.83 m)

3 feet (91 cm) above if within 10 feet (3 cm) her!zontally

7 feet (2.13 m) 1-

7 _et(2.13

12 inches (30.4 cm)

12inches(30.4

12" (30.4 cm)

12"(30.4

cm)

12" (30.4 cm)

12"(30.4

cm)

above meter/regulator
I. Clearance

assembly

to service regulator vent outlet

to a mechanical

_.Clearance
above paved
public property
M.Clearance

soffit

supply inlet
sidewalk

or paved

driveway

located

under veranda, porch, deck, or balcony

Vent Termination

from any Building Surface

Above anticipated snow depth

m) t
cm)

1. In accordance with the current CSA B149.1-00,

Natural Gas and Propane Installation Code.
2. In accordance with the current ANSI Z223.1 / NFPA 54, National Gas Code. In accordance with the current UL 311 Standard for Safety for Roof Jacks for Manufactured Homes and Recreational Vehicles.
1" A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.
_: Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor. For clearance not specified in ANSI Z223.1 / NFPA
54 or CSA B149.1-00.
** Clearance

in accordance

with local installation codes and the requirements

Any fresh air or make up inlet for dryer or furnace area is considered

of the gas supplier and the manufacturer's

Avoid areas where condensate drippage may cause problems such as above planters, patios, or adjacent
A terminus of a vent shall be either:
Fitted with a cap in accordance

with the vent manufacturer's

Installation

Manual.

to be forced air inlet.

installation instructions,

to windows where steam may cause fogging.

or In accordance with the installation

instructions

for a special venting system.

Responsibility for the provision of proper adequate venting and air supply for application shall rest with the installer.
Vent shall extend high enough above building, or a neighboring obstruction, so that wind from any direction will not create a positive pressure in the vicinity of the vent.

IMPORTANT
Consideration must be given for degradation of building materials by flue gases. Sidewall termination may require sealing or shielding of building
surfaces with a corrosion resistant material to protect against combustion product corrosion. Consideration must be given to wind direction in
order to prevent flue products and/or condensate from being blown against the building surfaces. If a metal shield is used ff must be a stainless
steel material at a minimum dimension of 20 inches. It is recommended that a retaining type collar be used that is attached to the building surface
to prevent movement of the vent pipe.

Johnson Controls Unitary Products

129098-UIM-H-1011

AWARNING
CARBON MONOXIDE

POISONING

HAZARD

Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon
monoxide poisoning or death,
The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances
connected to the venting system are not in operation:
1. Inspect the venting system for proper size and horizontal pitch. Determine that there is no blockage,
deficiencies, which could cause an unsafe condition

restriction, leakage, corrosion or other

2. Close all building doors and windows and all doors.
3. Turn on clothes dryers and TURN ON any exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum
speed. Open the fireplace dampers. Do not operate a summer exhaust fan.
4. Follow the lighting instructions.
uously.

Place the appliance

being inspected in operation. Adjust thermostat so the appliance

shall operate contin-

5. Test each appliance (such as a water heater) equipped with a draft hood for spillage (down-draft or no draft) at the draft hood relief opening
after 5 minutes of main burner operation. Appliances that do not have draft hoods need to be checked at the vent pipe as close to the
appliance as possible. Use a combustion analyzer to check the CO2 and CO levels of each appliance. Use a draft gauge to check for a
downdraft or inadequate draft condition.
6. After it has been determined that each appliance properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their normal condition.
7. If improper venting is observed during any of the above tests, a problem exists with either the venting system or the appliance does not
have enough combustion air (Supply Air from outside) to complete combustion. This condition must be corrected before the appliance can
function safely.
NOTE: An unsafe condition exists when the CO reading at the furnace vent exceeds 40 ppm and the draft reading is not in excess of - 0.1 in.
W.C. (-25 kPa) with all of the appliance(s) operating at the same time.
8. Any corrections

to the venting system and / or to the supply (outside) air system must be in accordance

with the National Fuel Gas Code

Z223.1 or CAN/CGA B149.1-00 Natural Gas and Propane Installation Code (latest editions). If the vent system must be resized, follow the
appropriate tables in Appendix G of the above codes or for this appliance.

FAN-ASSISTED

COMBUSTION

SYSTEM

An appliance equipped with an integral mechanical means to either
draw or force products of combustion through the combustion chamber
and/or heat exchanger.

SECTION
CONTROL

VIII:

SAFETY

CIRCUIT

FUSE

CONTROLS

A 3-amp fuse is provided on the control circuit board to protect the 24volt transformer from overload caused by control circuit wiring errors.
This is an ATO 3, automotive type fuse and is located on the control
board.
PRESSURE

SWITCHES

This furnace is supplied with a pressure switch, which monitors the flow
through the combustion air/vent piping system. This switch de-energizes the ignition control module and the gas valve if any of the following conditions are present. Refer to Figure 28 for tubing connections.
1.

Blockage of combustion

2.
3.

Blockage of vent piping or terminal.
Failure of combustion air blower motor.

FIGURE 28:

LIMIT

CONTROLS

There is high temperature limit control located on the furnace vestibule
panel near the gas valve. This is an automatic reset control that provides over temperature protection due to reduced airflow, that may be
caused by a dirty filter, or if the indoor fan motor should fail. The control
module will lockout if the limit trips 3 consecutive times. Control will
reset and try ignition again after 1 hour.

SECTION
IX: START-UP
ADJUSTMENTS

AND

The initial start-up of the furnace requires the following
procedures:

additional

IMPORTANT
All electrical connections made in the field and in the factory should
be checked for proper tightness.

air piping or terminal.
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. When gas is
detected, immediately retighten the union and check for leaks. Allow
five minutes for any gas to dissipate before continuing with the start-up
procedure. Be sure proper ventilation is available to dilute and carry
away any vented gas.

Pressure Switch Tubing Routing

Johnson Controls Unitary Products

129098-UIM-H-1011
TOOLS

AND

REQUIRED
FURNACE
1.

INFORMATION

IN ORDER
START-UP

THAT

WILL

TO PROPERLY
PROCECURE.

PERFORM

AWARNING

THE

Call the local gas supplier to obtain heating value of the natural
gas. If you cannot obtain the heating valve of the gas from the gas
supplier, you may use a default value of 1030 BTU/SCF (38.8 MJ !

FIRE OR EXPLOSION

m3).

Never test for gas leaks with an open flame. Use a commercially
available soap solution made specifically for the detection of leaks
to check all connections. A fire or explosion may result causing
property damage, personal injury or loss of life.

You will need a thermometer or portable digital thermometer
read the supply and return air temperatures.

You will need a U-tube manometer or digital equipment that has
the ability to read pressures between 0 - 15" in.w.c (0 - 3.73 kPa)
in order to measure the gas line and the manifold pressures.

You will need a 3!32" Allen wrench for the pressure port plugs in
the gas valve.

You will need 2 pieces of 1!8" (0.3 cm) ID flexible tubing that is 12"
(30 cm) in length, 2 - pieces of 1!8" (0.3 cm) tubing that are 4"
(10.0 cm)in length, and a 1!8" (0.3 cm) adapter to connect the Utube manometer or the digital pressure measuring equipment to
the gas valve pressure ports.

There is an accessory kit (1PK0601)
has the following items:

available

from Source 1, which

[IMPORTANT
Burner ignition may not be satisfactory on first start-up due to residual air in the gas line or until gas manifold pressure is adjusted. The
ignition control will make 3 attempts to light before locking out.
With furnace in operation, check all of the pipe joints, gas valve connections and manual valve connections for leakage using an approved gas
detector, a non-corrosive leak detection fluid, or other leak detection
methods. Take appropriate steps to stop any leak. If a leak persists,
replace the component.

1 - 12" (30 cm) length x 1!8" (0.3 cm) diameter tubing
2 - pieces of 4" (10 cm) length x 1!8" (0.3 cm) diameter tubing
1 - 5!16" (0.8 cm) tee

The furnace and its equipment shut-off valve must be disconnected
from the gas supply piping system during any pressure testing of that
system at test pressures in excess of 1!2 PSI (3.45 kPa).
The furnace must be isolated from the gas supply piping system by
closing the equipment shut-off valve during any pressure testing of the

1 - 5!16" (0.8 cm) x 1!8" (0.3 cm) reducing coupling
1 - 1!8" (0.3 cm) adapter
There is a accessory
the following items:

HAZARD

Failure to follow the safety warnings exactly could result in serious
injury, death or property damage.

kit (1PK0602) available from Source 1, which has

gas supply piping system.
CALCULATING

12" (30 cm) length x 1!8" (0.3 cm) diameter tubing

(NATURAL

2 - pieces of 4" (10 cm) length x 1!8" (0.3 cm) diameter tubing
1 - 5!16" (0.8 cm) tee
1 - 5!16" (0.8 cm) x 1!8" (0.3 cm) reducing coupling

THE

INPUT

NOTE: Burner orifices are sized to provide proper input rate using natural gas with a heating value of 1030 BTU/Ft 3. If the heating value of

1 - 1!8" (0.3 cm) adapter

your gas is significantly
fices.

1 - Dwyer-

Manometer

FURNACE

GAS)

different, it may be necessary

to replace the ori-

Turn off all other gas appliances connected to the gas meter.

These items are required in order to properly perform the required startup procedure.

At the gas meter, measure the time (with a stop watch) it takes to

IGNITION

SYSTEM

SEQUENCE

Turn the gas supply ON at external valve and main gas valve.

Set the thermostat above room temperature

System start-up will occur as follows:

Calculate the furnace
tions.

input by using one of the following

equa-

to call for heat.

The induced draft blower motor will start and come up to
speed. Shortly after inducer start-up, the hot surface igniter
will glow for about 30 seconds.

After this warm up, the ignition module will energize
the main gas valve.

After flame is established, the supply air blower will start in
the time set on the control board.

Johnson Controls Unitary Products

use 2 cubic ft. (0.0566 m3) of gas.

(open)

129098-UIM-H-1011
In the USA use the following

formula

to calculate

the furnace

input.

For natural gas multiply the heat content of the gas BTU!SCF or Default 1030 BTU!SCF (38.4 Mj/m3), times 2 cubic ft. (0.056 m) of gas measured at
the gas meter, times a barometric pressure and temperature correction factor of 0.960; times 3600, then divided by the time (In seconds) it took to
measure 2 cubic ft. (0.056 m) of gas from the gas meter.
For propane (LP) gas multiply the heat content of the gas BTU/SCF or Default 2500 BTU/SCF (93.15 Mj/m3), times 1 cubic ft. (0.028 m) of gas measured at the gas meter, times a barometric pressure and temperature
took to measure 1 cubic ft. (0.028 m) of gas from the gas meter.
The formula

for US input calculation

using a cubic foot gas meter:

BTU/ft 3 x 2 cu.ft, x 0.960 x 3600
Seconds it took to measure the 2 cu.ft, of gas
NATURAL GAS INPUT CALCULATION
EXAMPLE:
1030 x 2 x 0.960 x 3600
90.5
Natural Gas
1030 BTU/SCF

In Canada you will use the following

correction factor of 0.960; times 3600, then divided by the time (In seconds) it

formula

BTU/H

78,666.90

to calculate

BTU/ft3 x 1 cu,ft, x 0.960 x 3600
Seconds it took to measure the 1 cu.ft, of gas
PROPANE (LP) GAS INPUT CALCULATION
EXAMPLE:
2500 x 1 x 0.960 x 3600
108
Propane Gas
2500 BTU/SCF

the furnace

BTU/H

80.000.00

input if you are using a cubic foot gas meter.

For Natural Gas multiply the Heat content of the gas MJ/m 3 (or Default 38.4), times 2 cubic ft. of gas x 0.028 to convert from cubic feet to cubic
meters measured at the gas meter, times a barometric pressure and temperature correction factor of 0.960; times 3600, then divided by the time it
took to measure 2 cubic ft. (0.056 m) of gas from the gas meter.
For Propane (LP) Gas multiply the Heat content of the gas M Jim 3 (or Default 93.15), times 1 cu. ft. of gas x 0.028 to convert from cubic feet to cubic
meters measured at the gas meter, times a barometric pressure and temperature
took to measure 1 cubic ft. (0.028 m) of gas from the gas meter.
The formula

for metric input calculation

correction factor of 0.960; times 3600, then divided by the time it

using a cubic foot gas meter:

MJ/m 3 x 2 cu.ft, x 0.028 x 0.960 x 3600
Seconds it took to measure the 2 cu.ft, of gas
NATURAL GAS INPUT CALCULATION
EXAMPLE:
38.4 x 2 x 0.028 x 0.960 x 3600
90.5
Natural Gas

MJ/H

0.2777

3412.14

BTU/H

82.12

0.2777

22.80

3412.14

77,796.80

83.46

0.2777

23.18

3412.14

79,093.4

1030 BTU/SCF = 38.4 MJ/m 3
PROPANE (LP) GAS INPUT CALCULATION
EXAMPLE:
93.15 x 1 x 0.028 x 0.960 x 3600
108
Propane Gas
2500 BTU/SCF

In Canada use the following

= 93.15 MJ/m 3

formula

to calculate

the furnace

input if you are using a gas meter that measures cubic meters.

For Natural Gas multiply the Heat content of the gas MJ/m 3 (or Default 38.4), times 0.10 m3 of gas measured at the gas meter, times a barometric
pressure and temperature

correction factor of 0.960; times 3600, then divided by the time it took to measure 0.10 m3 of gas from the gas meter.

For Propane (LP) Gas multiply the Heat content of the gas M Jim 3 (or Default 93.15), times 0.10 m 3 of gas measured at the gas meter, times a barometric pressure and temperature

correction

factor of 0.960; times 3600, then divided by the time it took to measure 0.10 m3 of gas from the gas

meter.
The formula

for metric input calculation

using a cubic meter gas meter:

MJ/m 3 x m 3 x 0.960 x 3600
Seconds it took to measure the 0.10 m 3 of gas
NATURAL GAS INPUT CALCULATION
EXAMPLE:
38.4 x 0.1 x 0.960 x 3600
160
Natural Gas
1030 BTU/SCF = 38.4 M Jim 3
PROPANE (LP) GAS INPUT CALCULATION
EXAMPLE:
93.15 x 0.1 x 0.960 x 3600
387
Propane Gas
2500 BTU/SCF = 93.15 M Jim 3

MJ/H

0.2777

3412.14

BTU/H

82.94

0.2777

23.03

3412.14

78,581.60

83.19

0.2777

23.10

3412.14

78,826.3

DO NOT ADJUST the manifold pressure regulator if the actual input is equal to or within 8% less than the furnace input specified on the rating plate
or if the furnace rise is above the specified rise range on the rating plate.
If the actual input is significantly
higher than the furnace
of the proper size for the type of gas you are using.

input specified

on the rating

plate then replace the gas orifices with the gas orifices

For altitudes above 2,000 ft. (610 m) the furnace input MUST BE DERATED. Refer to the GAS CONVERSION
ALTITUDES IN SECTION IV for information on high altitude conversions.

FOR PROPANE (LP) AND HIGH

Johnson Controls Unitary Products

129098-UIM-H-1011

,& CAUTION
Be sure to relight any gas appliances
start of this input check.
CHECKING
1.

THE

GAS

Refer to Figure 29 for location of pressure regulator
cap and adjustment screw on main gas valve.

Turn gas and electrical supplies on and follow
instructions to place the unit back in operation.

Adjust manifold pressure by adjusting gas valve regulator
for the appropriate gas per the following:

that were turned off at the

PRESSURES

adjustment

the operating
screw

TABLE 8: Nominal Manifold Pressure

The pressure ports on the gas valve are marked OUT PRESSURE
TAP and INLET PRESSURE TAR

The manifold pressure must be taken at the port marked OUT R

The inlet gas supply pressure must be taken at the port marked IN
R

Using a 3/32" (0.2 cm) Allen wrench, loosen the set screw by turning it 1 turn counter clockwise. DO NOT REMOVE THE SET
SCREW FROM THE PRESSURE PORT.

Push one end of the 3/8" (0.9 cm) ID flexible tubing over the pressure port so that the body of the port is inside the tubing.

Use a reducer connector to connect the 3/8" (0.9 cm) ID flexible
tube that is connected to a "U" tube manometer or digital pressure
measuring equipment.

NOMINAL

MANIFOLD

PRESSURE

Natural Gas

3.5" w.c. (0.87 kPa)

Propane (LP) Gas

10.0" w.c. (2.488 kPa)

TABLE 7: Inlet Gas Pressure Range
INLET

GAS

PRESSURE

RANGE

Natural Gas

CONNECTIONS

Minimum

4,5" W,C, (1,12 kPa)

8,0" W,C, (1,99 kPa)

Maximum

10,5" W,C. (2.61 kPa)

13,0" (3,24 kPa) W.C.

FIGURE 29:

The inlet gas pressure operating range table specifies the minimum
and maximum gas line pressures required for safe furnace operation.

fied on the rating plate and in these instructions

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)".

Once the correct BTU (kW) input has been established, turn the
gas valve to OFF and turn the electrical supply switch to OFF; then
remove the flexible tubing and fittings from the gas valve pressure
tap and tighten the pressure tap plug using the 3!32" Allen wrench.

Turn the electrical and
in operation, check for
port for leakage using
leak detection fluid, or

is shown below:

4.5" W.C. (1.12 kPA) for Natural Gas
Propane (LP) Gas

OF MANIFOLD

GAS PRESSURE

Manifold gas pressure may be measured at the gas valve.
Turn

gas off at the ball valve

or gas ¢o¢k on gas supply

before the gas valve. Find the pressure
valve marked
OUT P and IN R

ports

line

on the gas

The manifold pressure must be taken at the port marked OUT R

The gas line pressure must be taken at the port marked IN R

Using a 3/32" Allen wrench, loosen the set screw by turning it 1
turn counter clockwise. DO NOT REMOVE THE SET SCREW
FROM THE PRESSURE PORT.

Use the 4" (10.2 cm) piece of 1/8" (0.3 cm) tubing to connect the positive side of the manometer to the gas valve pressure reference port.
Refer to Figure 30 for connection

Gas Valve

If gas valve regulator is turned in (clockwise), manifold pressure is
increased. If screw is turned out (counter clockwise), manifold pressure will decrease.

The minimum inlet gas pressure required to obtain the BTU input speci-

ADJUSTMENT

OUTLET

[IMPORTANT

IMPORTANT

11.0" W.C. (2.74 kPA)for

(shown in OFF position)

Propane (LP)

details.

IMPORTANT

gas supplies back on, and with the burners
gas leakage around the gas valve pressure
an approved gas detector, a non-corrosive
other leak detection methods.

_WARNING
The manifold pressure must be checked with the screw-off cap for
the gas valve pressure regulator in place. If not, the manifold pressure setting could result in an over-fire condition. A high manifold
pressure will cause an over-fire condition, which could cause premature heat exchanger failure. If the manifold pressure is too low,
sooting and eventual clogging of the heat exchanger could occur.
Be sure that gas valve regulator cap is in place and burner box to
gas valve pressure reference hose is connected.

The cap for the pressure regulator must be removed entirely to gain
access to the adjustment screw. Loosening or tightening the cap
does not adjust the flow of gas.

Johnson Controls Unitary Products

129098-UIM-H-1011
MANIFOLD

PRESSURE

"U" TUBE

CONNECTION
TRANSFORMER

[]

LINEVOLTAGE
BLACK-HIGH
RED-LOW

SPEED
SPEED

÷
TUBING

I II I
GAS VALVE

FAN OFF
JUMPER

3.5 IN (0.87 kPa)
WATER
COLUMN
T

AS
PRESSURE
SHOWN

ADJUSTMENT
FAN ON
JUMPER

I_
]

FIGURE 30: Reading Gas Pressure
ADJUSTMENT

OF TEMPERATURE

RISE

FUSE

_DANGER

FIGURE 31:

The temperature rise, or temperature difference between the return
air and the supply (heated) air from the furnace, must be within the
range shown on the furnace rating plate and within the application
limitations shown in Table 7 "ELECTRICAL AND PERFORMANCE
DATA ".
The supply air temperature cannot exceed the "Maximum Supply
Air Temperature"
specified in these instructions and on the furnace rating plate. Under NO circumstances can the furnace be
allowed to operate above the Maximum Supply Air Temperature.
Operating the furnace above the Maximum Supply Air Temperature
will cause premature heat exchanger failure, high levels of Carbon
Monoxide, a fire hazard, personal injury, property damage, and/or
death.

FILTER

Furnace Control Board

PERFORMANCE

The airflow capacity data published
mance WITHOUT filters.
APPLYING

FILTER

DETERMINE

SYSTEM

in Table 9 represents blower perfor-

PRESSURE

DROP

AIRFLOW

Example: For a 90,000 BTUH (26.4 kW) furnace operating on highspeed blower, it is found that total system static is 0.18" (0.045 kPa) w.c.
To determine the system airflow, complete the following steps:
Obtain the airflow values at 0.10 w.c. (0.02 Pa) & 0.20 w.c. (0.05 Pa)
ESR
Airflow @ 0.10": 1425 CFM (40.4 m3/min)

The temperature rise, or temperature difference between the return air
and the heated supply air from the furnace, must be within the range

Airflow @ 0.20": 1380 CFM (38.2 m3/min)

shown on the furnace rating plate and within the application
as shown in Table 7.

Subtract the airflow @ 0.10 w.c. (0.02 Pa) from the airflow @ 0.20 w.c.
(0.05 Pa) to obtain airflow difference.

limitations

After about 20 minutes of operation, determine the furnace temperature
rise. Take readings of both the return air and the heated air in the ducts.

CAUTION]
Do not energize more than one motor speed at a time or damage to
the motor will result.

1425 - 1250 = -175 CFM (5.0 m3/min)
Subtract the total system static from 0.10 w.c. (125 Pa) and divide this
difference by the difference in ESP values in the table
0.18 w.c. (0.045 kPa) - 0.10 w.c. (125 Pa), to obtain a percentage.
(0.18- 0.10) ! (0.20 - 0.10) = 0.2
Multiply percentage

by airflow difference to obtain airflow reduction.

(0.2) X (175) = -35 CFM (0.99 m3/min)

ADJUSTMENT

OF FAN CONTROL

SETTINGS

This furnace is equipped with a time-on/time-off heating fan control. The
fan off delay has 4 settings (60, 90, 120 and 180 seconds). The fan off
delay is factory set to 120 seconds. 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 31.

Subtract airflow reduction value to airflow @ 0.10 w.c. (125 Pa) to
obtain actual airflow @ 0.18 in. w.c. (0.045 kPa) ESR
1425 (40.4) - 35 = 1390 (39.4 m3/min)
FINAL
Install

PROCEDURE
Furnace

Doors

Install the lower door first by sliding the bottom of the door down until
the tabs on the casing base engage the slots in the bottom door end
cap. Then push the top of the lower door in until the door clips snap into
place. Install the upper door in a similar manner, first engaging the slots
in the top of the upper door on the tabs on the casing top. Then snap
the bottom of the upper door into place against the casing.
Finish

and Trim

Alcove and Closet Installations

may now be finished and trimmed as

necessary.

Johnson Controls Unitary Products

129098-UIM-H-1011
TABLE 9: Blower Performance CFM - Downflow Without Filters
STANDARD
BTU/H (kW)
Input / Output

56/45 (16.4!13.1)

70!56 (20.5!16.4)

77!62 (22.5!18.5)

90!72 (26.3!21.1)

HEATING BLOWERS

Nominal
Cabinet
CFM(m3/min)
Size

1305 (37)

7900 - 7751 AC/ACCESSORY
BTU/H (kW)
Input / Output

56/45 (16.4!13.1)

70!56 (20.5!16.4)

77!62 (22.5!18.5)

90!72 (26.3!21.1)

EXTERNAL STATIC PRESSURE,
Speed
Tap

0.1 (0.025)

cm/m

cfm

cm/m

cfm

cm/m

cfm

cm/m

High No Coil

1425

40.4

1380

39.1

1305

37.0

1245

35.3

1180

33.4

High w/Coil

1385

39.2

1315

37.3

1260

35.7

1200

34.0

1135

32.2

Low No Coil

1250

35.4

1205

34.1

1145

32.4

1085

30.7

1030

29.2

Low w/Coil

1235

35.0

1190

33.7

1135

32.2

1080

30.6

1015

28.8

High No Coil

1425

40.4

1380

39.1

1305

37.0

1245

35.3

1180

33.4

High w/Coil

1385

39.2

1315

37.3

1260

35.7

1200

34.0

1135

32.2

Low No Coil

1250

35.4

1205

34.1

1145

32.4

1085

30.7

1030

29.2

Low w/Coil

1235

35.0

1190

33.7

1135

32.2

1080

30.6

1015

28.8

High No Coil

1425

40.4

1380

39.1

1305

37.0

1245

35.3

1180

33.4

High w/Coil

1385

39.2

1315

37.3

1260

35.7

1200

34.0

1135

32.2

Low No Coil

1250

35.4

1205

34.1

1145

32.4

1085

30.7

1030

29.2

Low w/Coil

1235

35.0

1190

33.7

1135

32.2

1080

30.6

1015

28.8

High No Coil

1425

40.4

1380

39.1

1305

37.0

1245

35.3

1180

33.4

High w/Coil

1385

39.2

1315

37.3

1260

35.7

1200

34.0

1135

32.2

Low No Coil

1250

35.4

1205

34.1

1145

32.4

1085

30.7

1030

29.2

Low w/Coil

1235

35.0

1190

33.7

1135

32.2

1080

30.6

1015

28.8

EXTERNAL

1725 (48.9)

0.5 (0.124)

cfm

Nominal
Cabinet
CFM(m3/min)
Size

1725 (48.9)

0.4 (0.099)

cm/m

Speed
Tap

0.3 (0.075)

cfm

BLOWER

1725 (48.9)

0.2 (0.050)

INCHES WC (kPa)

0.1 (0.025)

STATIC PRESSURE,

0.2 (0.050)

0.3 (0.075)

INCHES WC (kPa)
0.4 (0.099)

cfm

cm/m

cfm

cm/m

cfm

cm/m

cfm

0.5 (0.124)

cm/m

cfm

cm/m

High w/Coil

1800

51.0

1760

49.9

1725

48.9

1680

47.6

1650

46.7

Med High w/Coil

1535

43.5

1505

42.6

1480

41.9

1445

40.9

1410

39.9

Med Loww/Coil

1270

36.0

1240

35.1

1215

34.4

1185

33.6

1100

31.2

Low w/Coil

1085

30.7

1055

29.9

1025

29.0

1005

28.5

980

27.8

High No Coil

1800

51.0

1760

49.9

1725

48.9

1680

47.6

1650

46.7

High w/Coil

1535

43.5

1505

42.6

1480

41.9

1445

40.9

1410

39.9

Low No Coil

1270

36.0

1240

35.1

1215

34.4

1185

33.6

1100

31.2

Low w/Coil

1085

30.7

1055

29.9

1025

29.0

1005

28.5

980

27.8

High No Coil

1800

51.0

1760

49.9

1725

48.9

1680

47.6

1650

46.7

High w/Coil

1535

43.5

1505

42.6

1480

41.9

1445

40.9

1410

39.9

Low No Coil

1270

36.0

1240

35.1

1215

34.4

1185

33.6

1100

31.2

Low w/Coil

1085

30.7

1055

29.9

1025

29.0

1005

28.5

980

27.8

High No Coil

1800

51.0

1760

49.9

1725

48.9

1680

47.6

1650

46.7

High w/Coil

1535

43.5

1505

42.6

1480

41.9

1445

40.9

1410

39.9

Low No Coil

1270

36.0

1240

35.1

1215

34.4

1185

33.6

1100

31.2

Low w/Coil

1085

30.7

1055

29.9

1025

29.0

1005

28.5

980

27.8

TABLE 10: AC Accessories
MODEL

DESCRIPTION

USED WITH

7900-7761

NO.

AC CONTROL KIT

A/C RELAY FOR DGPH MODELS

7900-7741/A

4 TON BLOWER

4 TON, 2 SPEED BLOWER FOR DGPH, DGPA

7900-7751

5 TON BLOWER

5 TON, 4 SPEED BLOWER FOR ALL MODELS

1PS0166
1PS0167

HIGH ALTITUDE
HIGH ALTITUDE

Johnson Controls Unitary Products

KIT FOR NATURAL GAS

ALL MODELS

KIT FOR PROPANE (LP) GAS

ALL MODELS

'11

¢o

(.o
O
(.o

T
i

5"
_3

o
BLOWER

SPEED

(CHARTE

B
i

INPUT
(ENTREE)

LADDER

CHART

DIAGRAM

DIAGRAMME

DE VITESSE

ELEMENTAIRE

CONNECTION

SOUFFLERIE)

(DIAGRAMME

CFM
(PCM)

CeOL
HIGH
(CL[MA)

HEAT
(CHAU)

O56

1200

BLK
(NOIRJ

REO
(ROUG)

070

1200

&K
(NOIR)

REO
(RO(JG}

077

1200

O9O

1200

BLK
{NOIR)
BLK
(NOLO)

RED
(ROUG)
RED
(ROUG)

WIRE

COLOR

DIAGRAM

RACCORDEMENT)

KEY

(CODE
DE COULEUR
DU FILAGE}
BLK

8LACK

(OIR)
!_LU
(BLEU)
RED
(ROUG)
YEL
{,AUN

{NOIR)
BLUE
(BLEUJ
REO
(qOUGE)
YELLOW
(AUNE)

WHT
(BLANC)
_RN

WHITE
(BLANC]
eqo_x

?f'4N
(VERT

GREE
(VERT)

PRP
:POURPRE}
O'RN
(ORA)

PURPLE
[POURPRE
OftANGE
(O'_ANOE)

CAUTION
OPEN

ALL

DISCONNECTS

SERVICING

THIS

DE SURCHARGE
DE TIR}

NOTES:

BEFORE
NIT

ALL

FIELD

WIRING

PER_

(A)
NATIONA
(B) CANADIA
(C) LOCAL 0

PRE_CAUTION
?
OUVREZ

LES

DISJQNCTE

DE PR!?CEOER

AVEC

IF A

RS AVANT

THE

REPLACED,
TEMRERAT

BERV[CE

IT MUST
RE RATIG

CONNECTORS

ALL

AqE

COMPONE

ALL

LSI

L ELEC
N ELEC
R CITY

CODE (NEC)
CODE (DEC)
CODES.

AND/OR/
AND/OR/

NDUCTORS
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VALVE

HOT

SURFACE

PI/SI

GROUNDED.

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AND

ION

ONLY

PROPERLY

LS2

(FOURNAISE
VENTILEE

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TOUT

FILAGE

EN CHANTIER

SELON:

80X
LE

BAS)

)
)
)

SI bE FILAGE
DOIT
ET_E REMPLACE
L'ETRE
AVEC UN MATERIAUX
POUVANT
O'AU MOINS
221_F (105_8).

NPATRIE
RESISTER

SEULEME

E CUIVRE.

TQUTE

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COMPOSANTE

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SOCKET

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PLUG

2 ¢_I

_/54

9 PIN

Pk,

CODE ELEC
NATIONAL
(CEN') ET/OU/
CODE ELEC CANAD[EN
(CEC) ET/OU/
CODES LOCAUX
ET MUNICIPAUX.

PLG

6 PI

LSI,2

(A
(B
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FURNACE

SWITCH

°5/S:_

PAR

CONTROL
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CAPAC[TEUR

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CONNECTION
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COMM_TATEUR
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FACTORY

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TRANSFORMER,

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PRESSURE

IRC

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& SOCKET

AUXILIAqY

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IT
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DOWNFLOW

9 PIN

ECT

P2/$2

NOTES:
80X

L£GENDE

LEGEND

PPLIED WITH THE FURNACE
MUST BE
H WIRING MATERIAL
HAVING A
I_F (I05_C).

SUPPLIES

POWER

PROTE!

WITH

TS MUST

FOR

INHERENTLY

SERIES

FOR COPPER

ISCONNECTS

MOTORS
SSI

WIRE

BE REPLACED
WIT
OF AT LEAST 22

SUITABLE

REPLACEME

5, PROVIDE

ORIGINAL

TIER

ET
ET

APPAREILS
APPARE[L

IGNITION

?? ................

CO TACTE9

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SUR LA

PLAQUETT

E t;E

CONTROLE

9'1

NITION

L'ALIMENTA[TON
LEUR

CONCEPTION

L_}

155887

UWD A 0705

"11

5"
_3

B
B

WIRE

COLOR

LADDER DIAGRAM
DIAGRAMME E[EMENTAIRE

KEY

(CODE
DE COULEUR
DU FILAGE)
BLK
(NOIR}
BLU
(BLEU)

BLACK
(NOIR)
BLUE
(BLEU}

RED
{ROUG)
YEL
_JAUN)
WHT

RED
(ROUGE_
YELLOW
(JAUNE)
WHITE

(BLANC)
BRN
(SPUN)
GRN
(VERT)
PRP

(BLANC)
BROW\
(SPUN)
GREEN
(VERT}
PURPLE

(POURPRE}
ORN
(ORA)

(POURPRE}
ORANGE
_RANGE)

CONNECTION
(DIAGRAMME

POWER
_

SUPPLY

(AL[MENTATION

115160

SEE

115 160

VOiR

NOTE

DIAGRAM

RACCORDEMENT)

(EN

TEqRE)

TERRE)

HEAT/COOL
I

RELAY

BLU

RE©

24V

BLK

BLU

SEC

.......

115V

_LU

WHT

PR[

COM

8RY
RELAY

CAUTION
OPEN ALL

DISCO

SERVICI

(........
D'l DUCT)

(RELA[

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THIS

BEFORE

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YEL
RELAY

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[TIO

LES

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IT

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SENSOR

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(EN TERRE}

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{CAPTEUR
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WHT

{__

I .....

SERVICE

_HT

_©_

I COOL
_;>

......

RELAy
GAS
VALVE
•

HOT

RED

R_
_LLKKWHT

•

(IGNITION
SURFACE

BLKBLK

OE
CHAUDE)
COMMUTATEUR

©E
HEAT/COOL

GAZI

BLK

THERMOSTAT

',THERMOSTAT

(IISVCA

BLK

NEUT.',

CLIMA/CHAUFJ
DE SURCHARGE
DE TIR)

NOTES:
I.

ALL

FIELD

WIRING

PER:

(A)
NATIONA
(_) CANA[]IA
',C LOCAL

L ELEC
N ELEC
R CITY

CODE
CODE
CODES

(NEC)
(CEC)

AND/OR/
AND/OR/

2. IF ANY OF THE
ORIGINAL
WIRE
AS SU
REPLACED,
IT VUST
#E REPLACED
WIT
TEM'_ERATUHE
RATING
OF AT LEAST 22

PPLIED
WITH THE
FURNACE
H WIRING
_ATER[AL
HAVING
PF (105"C),

N©UCT©RS

CONNECTORS

4. ALL

SUITA_3LE

REPLACEMENT

B. PR

VIDE

MOTORS

SSI

COMP

COPPER

ENTS

DISCONNECTS
ARE

FOR

iNHERENTLY

SERIES

POWER

LSI

AND

DISCONNECT

GAS

PI/SI

GROUNDEO.

LS2

(FOURNAISE
VENTILEE

PAR

TOT

FILAGE

SELONt

CHANTIER

BOX

SOCKET

ON FU_NAC

P3/$3

PL.G

SOCKET

AT HOT

R4/$4

PLUG

SOCKET

AUXILIA_y

BAS)

N PATRIE
RESISTER

SEULEMENT

E CU[VRE.

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129098-UIM-H-1011
Supersedes:129098-UIM-G-0411

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Coleman DGAA070BDTB User Manual FURNACE Manuals And Guides 1302277L

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