Coleman DGAA070BDTB User Manual FURNACE Manuals And Guides 1302277L

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HIGH EFFICIENCY

SEALED COMBUSTION GAS FURNACE

MODELS: DGAA and DGAH

(Single Stage Downflow Only)

56-90 MBH INPUT

(16.41 -26.38 KW)INPUT

ISO 9OOl

Certified Quality

Management System

For Installation In:

1. Manufactured (Mobile) Homes

2. Recreational Vehicles & Park Models

3. Modular Homes & Buildings

! I

LIST OF SECTIONS

SAFETY ................................................ 1

DUCTWORK ............................................ 4

RETURN AIR REQUIREMENTS ............................. 8

FILTE RS ............................................... 9

GAS LINE INSTALLATION ................................. 9

ELECTRICAL POWER .................................. 12

ROOF JACK VENT/COMBUSTION AIR SYSTEM ............. 13

SAFETY CONTROLS ................................... 20

START-UP AND ADJUSTMENTS .......................... 20

WIRING DIAGRAM ..................................... 26

LIST OF FIGURES

Furnace Dimensions ...................................... 4

Air Distribution Systems .................................... 5

Closet To Door Clearance - 5" or Greater ...................... 5

Furnace To Closet Door Clearance - 1" To 5" . .................. 6

Furnace To Closet Door Clearance - Less Than 1" . .............. 6

Duct Connector Dimensions ................................ 6

Recommended Floor Cut-out ................................ 7

Duct Connector Depth ..................................... 7

Duct Connector Screw Attachment ........................... 7

Duct Connector Tab Attachment ............................. 7

Anti-Backflow Damper ..................................... 8

Floor Installation .......................................... 8

Furnace Air Filters ........................................ 9

Gas Piping ............................................. 10

Burner Assembly ........................................ 10

Line Wiring Connections .................................. 12

Wiring for Heat Only Thermostat ............................ 13

Wiring for Electronic Heat-Cool Thermostat ................... 13

Wiring for Standard Heat-Cool Thermostat ................... 13

Wiring for Blend Air Accessory ............................. 13

Standard Roof Jack ..................................... 15

Roof Jack With Removable Crowns ......................... 16

Roof Jack ............................................. 17

Connecting Roof Jack to Furnace .......................... 17

Roof Jack Assembly ..................................... 18

Ceiling Rings ........................................... 18

Home Layout .......................................... 19

Pressure Switch Tubing Routing ........................... 20

Gas Valve ............................................. 23

Reading Gas Pressure ................................... 24

Furnace Control Board ................................... 24

Wiring Diagram - DGAA .................................. 26

Wiring Diagram - DGAH .................................. 27

LIST OF TABLES

Unit Clearances to Combustibles ............................. 4 Roof Jack Options ...................................... 18

External Static Pressure Range .............................. 8 Inlet Gas Pressure Range ................................ 23

Filter Sizes - All Models .................................... 9 Nominal Manifold Pressure ................................ 23

High Altitude Duration Chart ............................... 12 Blower Performance CFM - Downflow Without Filters ........... 25

Ratings & Physical /Electrical Data .......................... 13 AC Accessories ........................................ 25

SECTION I: SAFETY

[_ This is a safety alert symbol. When you see this symbol on

labels or in manuals, be alert to the potential for personal

injury.

Understand and pay particular attention to the signal words DANGER,

WARNING, or CAUTION.

DANGER indicates an imminently hazardous situation, which, if not

avoided, will result in death or serious iniurv.

WARNING indicates a potentially hazardous situation, which, if not

avoided, could result in death or serious iniurv.

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-

age.

kWARNING

Improper installation may create a condition where the operation of

the product could cause personal injury or property damage.

Improper installation, adjustment, alteration, service or mainte-

nance can cause injury or property damage. Refer to this manual

for assistance or for additional information, consult a qualified con-

tractor, installer or service agency.

CAUTION

This product must be installed in strict compliance with the installa-

tion instructions and any applicable local, state, and national codes

including, but not limited to building, electrical, and mechanical

codes.

Johnson Controls Unitary Products 129098-UIM-H-1011

129098-UIM-H-1011

SPECIFIC SAFETY

1.

2.

3.

RULES AND PRECAUTIONS

Only Natural gas or Propane (LP) gas are approved for use with

this furnace. Refer to the furnace rating plate or Section IV of

these instructions.

Install this furnace only in a location and position as specified in

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.

4.

5.

6.

&WARNING

FIRE OR EXPLOSION 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 prop-

erty damage, personal injury or loss of life.

Test for gas leaks as specified in SECTION IX of these instruc-

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.

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 manufac-

turer provided the combustion air and vent system have been

installed and maintained as a Sealed Combustion Direct Vent Sys-

tem and provided a return air duct system and return air plenum

are not required by state, local, or regional codes.

kWARNING

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 pro-

tected from water.

The furnace is not to be used for temporary heating of buildings or

structures under construction.

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 requirements to be met:

a. 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.

b. 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.

c. 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.

d. 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.

e. 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.

f. The furnace and ductwork should be thoroughly and com-

pletely cleaned prior to occupancy of the dwelling to insure

the proper operation of the furnace and to avoid potential

health concerns.

7. In Canada refer to the Natural Gas and Propane Installation code,

section on Central Furnaces. When installed in a Manufactured

(Mobile) Home, combustion air shall not be supplied from occu-

pied spaces.

8. 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.

9. Manufactured (Mobile) Home and Modular Home Installation:

This appliance must be installed in a (sealed combustion) configu-

ration using a roof jack vent system. A roof jack is only approved

vent system that can be used to vent this appliance.

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.

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 non-

removable chassis.

SAFETY REQUIREMENTS

Provide clearances from combustible materials as listed under

Furnace Locations and Clearances.

Provide clearances for servicing ensuring that service access is

allowed for both the burners and blower.

• These models are CSA listed and approved for installation into a

Modular Home, Manufactured (Mobile) Home, or Recreational

Vehicles.

• Failure to carefully read and follow all instructions in this

manual can result in furnace malfunction, death, personal

injury and/or property damage.

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 elec-

trical characteristics match. All models use nominal 115 VAC, 1

Phase, 60-Hertz power supply. DO NOT CONNECT THIS APPLI-

ANCE TO A 50 HZ POWER SUPPLY OR A VOLTAGE ABOVE

130 VOLTS.

Furnace shall be installed so the electrical components are pro-

tected from water.

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 precau-

tions 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 prac-

tices. These instructions are required as a minimum for a safe

installation.

2 Johnson Controls Unitary Products

129098-UIM-H-1011

Manufactured homes in the U.S.A.:

Federal Manufactured Home Construction & Safety Standard

(H.U.D. Title 24, Part 3280).

National Fuel Gas Code (ANSI-Z223.1, NFPA-54).

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 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 Appli-

ances 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 for recreational vehicles.

COMBUSTION AIR QUALITY

(LIST OF CONTAMINANTS)

The furnace will require OUTDOOR AIR for combustion AT ALL TIMES,

INCLUDING any of the following environments.

Restricted Environments

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 sub-

stances and /or chemicals.

Permanent wave solutions

Chlorinated waxes and cleaners

Chlorine based swimming pool chemicals

Water softening chemicals

De-icing salts or chemicals

Carbon tetrachloride

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

When outdoor air is used for combustion, the combustion 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 fur-

nace.

1. Spray or aerosol cans, rags, brooms, dust mops, vacuum

cleaners or other cleaning tools.

2. Soap powders, bleaches, waxes or other cleaning com-

pounds; 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.

INSPECTION

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.

FURNACE LOCATION AND CLEARANCES

The furnace shall be located usinq the followinq quidelines:

1. The furnace should be located where the roof jack can be installed

with out major modifications to the roof of the structure.

2. As centralized with the air distribution as possible.

3. Where there is access to fresh air particularly when the blend air

accessory will be installed.

4. Where it will not interfere with proper air circulation in the confined

space.

5. 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.

6. 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 in freezina temoeratures:

1. Furnace shall be installed in an area where ventilation facilities

provide for safe limits of ambient temperature under normal oper-

ating 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.

2. 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.

AWARNING

Installation in an ambient below 32°F (0,0 °C) could create a haz-

ard, resulting in damage, injury or death,

3. 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:

1. 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.

2. 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 clear-

ances for combustible materials where accessibility clearances are

greater. See Table 1.

AWARNING

Check the rating plate and power supply to be sure that the electri-

cal characteristics match. All models use nominal 115 VAC, 1

Phase 60Hz power supply.

Furnace shall be installed so the electrical components are pro-

tected 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.

Johnson Controls Unitary Products 3

129098-UIM-H-1011

TABLE 1: Unit Clearances to Combustibles

Top Front Rear Sides Roof Jack Flue Floor IDuct 1

Application Closet Alcove Closet Alcove Closet Alcove Closet Alcove Closet Alcove Closet Alcove Closet Alcove

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

Downflow 2(50.8) 2(50.8) 6(15.24) 24(60.96) 0 0 0 0 0 0 0 0 0 0

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

A

]

DGAH Series

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 ]

B

DGAA Series

FIGURE 1: Furnace Dimensions

SECTION I1: DUCTWORK

DUCTWORK GENERAL INFORMATION

The duct system's design and installation must:

1. Handle an air volume appropriate for the served space and within

the operating parameters of the furnace specifications.

2. 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.

3. 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.

4. Complete a path for heated or cooled air to circulate through the

air conditioning and heating equipment and to and from the condi-

tioned space.

CAUTION

The cooling coil must be installed in the supply air duct, down-

stream 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 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 pre-

vent the furnace or the air conditioner from operating unless the damper

is in full heat or cool position.

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 pres-

sures 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, DO NOT COVER OR RESTRICT

FLOOR OPENING.

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.

IIMPORTANT

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.

2. A sheet metal plate can be made that completely covers the open-

ing in the base.

3. The plate must be secured with screws.

4. This plate must be sealed to prevent leaks.

4 Johnson Controls Unitary Products

129098-UIM-H-1011

AWARNING

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 informa-

tion on correcting the problem.

DUCTWGRK INSTALLATION

Air Distribution 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 systems are illustrated 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 rise

within the range(s) specified on the furnace rating plate.

DUCT DESIGN - CANADA

Supply duct design shall be in accordance with the latest HRA Digest,

the ASHRAE Handbook Fundamentals, or other good engineering prin-

ciples.

NOTE: Refer to HRA Digest Residential Air System Design Manual,

Sections 5 and 6, the requirements of which are summarized as fol-

lows:

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

2. 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 neces-

sary to maintain a maximum air temperature rise of 50° C as the

air passes over the furnace heat exchanger.

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

4. 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 bath-

rooms or kitchens where this might not be practical.

5. Where practical, outlets shall be provided near the exterior doors

of the home.

CLEARANCE REQUIREMENTS - CANADA

Supply air ducts from warm air furnaces having a specified minimum

plenum clearance shall maintain this clearance from combustible mate-

rial 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* Transition duct

Dual trunk duct with crossover connector

U_ Branches U

I I

_r

Dual trunk duct

_, Crossover

I J

'_'-3

1. Crossover Duct must be centered directly under furnace.

2. Use 12" (30.5 cm) Diameter Round or insulated Flex-duct only.

3. Terminate Flex-duct (opposite furnace) in the center of the trunk duct.

4. Flex-duct material must be pulled tight No Loops or unnecessary dips Air Flow may be impeded.

FIGURE 2: Air Distribution Systems

Return Air Grille Part No.

7900-287P/A * White

250 IN.2 (161 cm 2)

MINIMUM

FREE AREA

/50 IN. _(322 cm _)

_ MINIMUM

J FREE AREA

Furnace to Closet Door Clearance --

5 ranches (12.7 cm) or more

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)

FREE AREA

_- 5 in (12.7 cm) or greater * Closet

_ _o Door C, .......

, , Return Air Closet Door Part No.

DOOR 7900-7771/C* White

FIGURE 3: Closet To Door Clearance - 5" or Greater

Johnson Controls Unitary Products 5

129098-UIM-H-1011

As an option to the lower grill,

an undercut of 2-1/2" will provide

50 inches 2 (322 cm 2)of free area.

250 IN.2(161 cm 2)

MINIMUM

FREE AREA

50 IN. _ (322 cm _)

MINIMUM

J FREE AREA

Furnace to Closet Door Cmearance i

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 cm2) 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._(161cm _)

MINIMUM

FREE AREA

FIGURE 4: Furnace To Closet Door Clearance - 1" To 5"

250 IN.2(161 cm _)

MINIMUM

FREE AREA

Furnace to Closet Door Clearance --

Less than 1 ranch (2.54 cm)

The closet door MUST have three return air grilles. The total free area of the

two upper grilles must be minimum of 250 ranches2(1613 cm2) . 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.

i 0IN. _(322cm _)

MINIMUM

FREE AREA

FIGURE 5: Furnace To Closet Door Clearance - Less Than 1"

DUCT CONNECTORS

2-3/8 --

(6.0 cm)

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

• _ 14 (35.6 cm)_

13 ,

(33.0 cm)

11

(27.9 cm

2-3/8

(6.0cm) ISEE l

--'1°"ARTF-

t ?"

4-3/8

DUCT CONNECTOR DIMENSIONS

DUCTCONNECTOR

PART NUMBER

7990-6011

7990-6021

7990-6041

7990-6061

7990-6071

7990-6081

7990-6101

7990-6121

(11.1 cm)

DUCT CONNECTOR

DEPTH

1" (2.5 cm)

2" (5.7 cm)

4-1/2" (11.4 cm

6-1-2" (16.5 cm)

7-1/2" (19.0 cm)

8-1/2" (21.6 cm)

10-1/4" (26.0 cm)

12-1/4" (21.1 cm)

2-3/8 --

(6.0 cm)

2-3/8

(6.o cm) 1 SEE l

_ _ CHART

4-3/8

1(11,1 ore)

DUCT CONNECTOR DIMENSIONS

DUCT CONNECTOR

PART NUMBER

7990-6211

7990-6221

7990-6241

7990-6261

7990-6271

7990-6281

7990-6301

7990-6321

DUCT CONNECTOR

DEPTH

1" (2.5 cm)

2" (5.7 cm)

4-1/2" (11.4 cm

6-1-2" (16.5 cm)

7-1/2" (19.0 cm)

8-1/2" (21.6 cm)

10-1/4" (26.0 cm)

12-1/4" (21.1 cm)

FIGURE 6: Duct Connector Dimensions

6 Johnson Controls Unitary Products

129098-UIM-H-1011

REAR WALL CEILING CUT-OUT

OF ENCLOSURE FOR ROOF JACK

2-3/4 (7,0 cm) I/

MIN

J. _ FLOOR CUT-OUT

IT • v _/"1 ............ _//"_,'_-- FOR DUCT

" " CONNECTOR

/E I i /i/\

_ , ,

-_l_/'t I I I f-'_ VI 1 FURNACE

_ __/__..__ r I_-1 L_oUTL,NE

i _ OP NAL GAS

! i I v ._1 i /OR ELECTRIC

/

tI|

I _ ENTRANCE

2-1/8 (5,4,cm)I,I I[_" / jFRONTPANEL

t t (31 '\ _----1"- ---- -- OF FURNACE

_(8.30m:

FUTURE /I_'_'_ 9_-3/4,--I"

z4mcm)z4._cm) _ FLOORI

REFRIGERANT 14 20.--I,

LINE ENTRANCE ' (5O.8 cm)

FIGURE 7: Recommended Floor Cut-out

S FLOOR

II _' II (" FLOOR

DUCT COpNTNHECTOR [,_ ..................JOIST

u ; u

SUPPLY DUCT

FIGURE 8: Duct Connector Depth

/LOCATORBRACKET

/

/' ...............NAILS, FLATHEAD SCREWS

]/ OR STAPLES

// J

/_

/SCREWS

/

/

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

SUPPLY DUCT

FIGURE 9: Duct Connector Screw Attachment

INSTALLATION OF SCREW ATTACHMENT DUCT

CONNECTOR

1. Make floor cut out as shown in Figure 7.

2. 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.

3. Place locating bracket (supplied with the duct connector) to the

back edge of the floor opening. See Figure 9.

4. Apply a water based duct sealant to the 1!2" supply duct attach-

ment flange of the duct connector.

5. Determine which of the four positions the duct connector best cen-

ters over the supply duct and insert it through the floor cut-out.

6. When properly aligned with the supply duct, secure the duct con-

nector to the floor with nails, flat head screws or staples.

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

duct.

8. 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.

NOTE: Duct sealant and tape must be classified as meeting HUD Stan-

dard 3280.715, U.L. Standard 181A.

If tape is used to provide a better air seal, it should be a type approved

by the applicable national or local codes.

/-- LOCATOR BRACKET

/NAILS,FLATHEAD SCREWS

/ / ...........OR STAPLES

/ / BEND TABS UNDER

/_ _ DUCT OPENING TO

/ /¢ SECURETO THE

IP" i' SUPPLYDUCT,

FLOOR

SUPPLY DUCT

FIGURE 10: Duct Connector Tab Attachment

INSTALLATION OF TAB ATTACHMENT DUCT

CONNECTORS

1. Make floor cut out as shown in Figure 7.

2. 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.

3. Place locating bracket (supplied with the duct connector) to the

rear of the floor area for the furnace. See Figure 10.

4. Determine which of the four positions the duct connector best cen-

ters over the supply duct and insert it through the floor cut-out.

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

nector.

6. Cut out the opening to the supply duct.

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

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

or staples.

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 suffi-

cient clearance to bend the tabs on two sides of the duct connector.

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 fas-

tened to the duct with screws after drilling the required screw hole.

Furnace and Air Conditioner Installations

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

tribution and operates completely independent of the furnace, the ther-

mostat system must have an interlock to prevent the furnace and air

conditioner from operating at the same time. This interlock system usu-

ally 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.

Johnson Controls Unitary Products 7

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.

AUTOMATIC

DAMPER

FURNACE

BASE DUCT

CONNECTOR

NOTE: FOR BEST AIR DELIVERY INSTALL DAMPER

WITH BLADES PARALLEL TO SUPPLY DUCT.

FIGURE 11: Anti-Backflow Damper

INSTALLATION RECOMMENDATIONS

1. Remove the front panels and set the furnace onto the duct con-

nector. Slide it back until the rear of the unit engages the Iocator

bracket.

2. Secure the front of the furnace with two screws at the mounting

holes provided.

3. Secure the top of the furnace to a structural member using screw

through the strap at the back of the furnace. Strap may be moved

to any of the holes located along the top back of the furnace.

Installer may provide an equivalent method, such as screws

through 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 follow-

ing may result:

1. Short cycling of the furnace.

2. Wide temperature fluctuations from the thermostat setting.

3. Reduced overall operating efficiency of the furnace.

The supply and return duct system must be of adequate size and

designed such that the furnace will operate within the designed air tem-

perature rise range and not exceed the maximum designed static pres-

sure. These values are listed in Table 2.

SECTION II1: RETURN AIR

REQUIREMENTS

CLOSET INSTALLATIONS

Additional Requirements

Additional requirements for floor and ceiling return system for closet

installed sealed combustion heating appliance are given in the next

paragraph.

kWARNING

HAZARD OF ASPHYXIATION, DO NOT COVER OR RESTRICT

FLOOR OPENING

TABLE 2: External Static Pressure Range

Input Output Nominal

Air Flow I

MBH kW MBH kW CFM cmm In.W.C kPa

56 16.4 45 12.9 1305 36.9 0.10 0.0249

70 20.5 56 16.4 1305 36.9 0.10 0.0249

77 22.5 62 18.0 1305 36.9 0.10 0.0249

90 26.3 72 21.1 1305 36.9 0.10 0.0249

Ext. Static Pressure

Minimum Maximum

In.W.C kPa

0.30 0.0747

0.30 0.0747

0.30 0.0747

0.30 0.0747

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 Iou-

vered 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 Installa-

tion Manual to complete the installation.

BLEND AIR

FLEX DUCT

BLEND AIR

DAMPER

FLOOR

FIGURE 12: Floor Installation

8 Johnson Controls Unitary Products

129098-UIM-H-1011

SECTION IV: FILTERS

FILTER 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.

[CAUTION

All installations 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. EXTERNAL RETURN FILTER GRILLE: The second type is an

external return air filter grille that can only be used in applica-

tions where the furnace is installed in acloset. This type of fil-

ter 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 fur-

nace. There must be a minimum clearance of 6" (15.2 cm)

between the front of the furnace and the closet door and!or the fur-

nace 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.

a. 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.

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

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.

c. Consideration should be given when locating the return filter

grille for maintenance.

d. Any filter that has a large pressure drop should be checked to

be sure the pressure drop caused by the air filter will not pre-

vent the furnace from operating within the rise range, speci-

fied 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.

Air Filters Can Be

Found On The Inside

Of This Panel

FIGURE 13: Furnace Air Filters

TABLE 3: Filter Sizes - All Models

Input Output Air Flow Cabinet Width Door Filter 1

MBH kW MBH kW CFM cmm In In cm

56 16.4 44.8 13.1 1305 34.0 193/4 2-16x20x1 2x41 x51

70 20.5 56 16.4 1305 34.0 193!4 2-16x20x1 2x41 x51

77 22.5 62 18.1 1305 34.0 193!4 2-16x20x1 2x41 x51

90 26.3 72 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 V: GAS LINE INSTALLATION

GAS SAFETY

ADANGER

This furnace is designed to operate on NATURAL GAS or PRO-

PANE 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, prop-

erty 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.

GAS PIPING

Installation and Checking of Gas Line

Gas Supply piping must be sized in accordance with the recommenda-

tions 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 com-

ply with requirements contained in Manufactured Homes Al19.1, Rec-

reational 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.

Johnson Controls Unitary Products 9

129098-UIM-H-1011

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 heat-

ing, 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 installa-

tion, 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 solu-

tion.

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

occur.

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.

A drip leg is recommended in the gas supply line to trap moisture and

contaminations. 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 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

use of a flexible gas appliance connection, always use a new listed con-

nector. Do not use a connector that has previously serviced another gas

appliance.

Some utility companies or local codes require pipe sizes larger than the

minimum sizes listed in these instructions and in the codes. The furnace

rating plate and the instructions in this section specify the type of gas

approved for this furnace - only use those approved gases.

MANUAL_[_:::_'/_]'_ GAS GAS DRIP

SHUT'OFF I] IDR_lP BURNER VALVE LEG

I'_-MANUAL

SHUT-OFF

VALVE

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 by

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).

CAUTION

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 CONVERSION FOR PROPANE (LP)

AWARNING

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 ser-

vice agency is responsible for the proper installation. The installa-

tion is not proper and complete until the operation of the converted

appliance is checked as specified in the manufacturer's instruc-

tions.

_WARNING

Improper installation may damage equipment, can create a shock

hazard, and will void the warranty.

IMPORTANT

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 ser-

vice personnel are required by some states to be licensed. Persons

not qualified shaft not install this equipment nor interpret these

instructions.

NOTE: The words "Shall" or "Must" indicate a requirement, which is

essential to satisfactory 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

1. Burner orifices for LP (propane) gas are located in bag attached to

the gas valve. Size is marked on orifice.

2. Conversion plate.

SCREWS _----_ ..............

FIGURE 15: Burner Assembly

GAS VALVE

10 Johnson Controls Unitary Products

129098-UIM-H-1011

CONVERSION PROCEDURE

CAUTION

The gas supply must be shut off prior to disconnecting the electrical

power, before proceeding with the conversion.

AWARNING

SHOCK HAZARD -Turn off electrical supply to furnace.

1. Shut off gas supply at valve upstream from furnace or at meter as

required. Refer to Figure 14.

2. Disconnect gas supply piping from gas valve on furnace.

3. Disconnect electrical wires from gas valve, noting which wires are

connected to which terminals.

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

CAUTION

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.

5. Remove the four screws that attach the gas manifold to the burner

support box. See Figure 15.

6. Remove and discard natural gas orifices.

7. Remove LP (propane) orifices from the bag attached to the gas

valve.

8. Install the LP (propane) gas orifices supplied with the furnace.

Tighten to 15 - 25 inch - pounds of torque.

9. Reinstall the manifold in the assembly by reversing the removal

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 pro-

pane tag supplied in the orifice bag.

13. Remove the blue conversion label on the furnace door after the

furnace has been converted.

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 with

suitable leak detector.

AWARNING

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.

[IMPORTANT

When converting gas valve from or to Propane gas, it will be neces-

sary to change main burner orifice to prevent an underfired or over-

fired condition. See label inside lower furnace door for complete

instructions.

HIGH ALTITUDE GAS ORIFICE CONVERSION

This furnace is constructed at the factory for natural gas-fired operation

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

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.

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.

The unit may also be converted 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 CAN/CGA-B149.1-00 Natural Gas and Propane Installation

Code.

&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 con-

verted will create an extremely dangerous condition resulting in pre-

mature 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.

Johnson Controls Unitary Products 11

129098-UIM-H-1011

TABLE 4: High Altitude Duration Chart

NATURAL GAS

56,000 -- Input 70,000 -- Input 77,000 -- Input 90,000 -- Input

Elevation Orifice Drill Orifice Drill Orifice Drill Orifice Drill

Feet Meters Part # Part # Part # Part #

Dia. Size Dia. Size Dia. Size Dia. Size

Sea Level 0.136 29 9951-1361 0.154 23 9951-1541 0.161 20 9951-1611 0.180 15 9951-1801

2,000 618 0.136 29 9951-1361 0.149 25 9951-1491 0.157 22 9951-1571 0.177 16 9951-1771

3,000 914 0.128 30 9951-1281 0.149 25 9951-1491 0.157 22 9951-1571 0.173 17 9951-1731

4,000 1219 0.128 30 9951-1281 0.147 26 9951-1471 0.154 23 9951-1541 0.173 17 9951-1731

5,000 1524 0.128 30 9951-1281 0.144 27 9951-1441 0.152 24 9951-1521 0.169 18 9951-1691

6,000 1829 0.128 30 9951-1281 0.144 27 9951-1441 0.149 25 9951-1491 0.166 19 9951-1661

7,000 2134 0.120 31 9951-1201 0.140 28 9951-1401 0.147 26 9951-1471 0.161 20 9951-1611

8,000 2438 0.120 31 9951-1201 0.136 29 9951-1361 0.144 27 9951-1441 0.161 20 9951-1611

9,000 2743 0.120 31 9951-1201 0.136 29 9951-1361 0.140 28 9951-1401 0.157 22 9951-1571

10,000 3048 0.116 32 9951-1161 0.128 30 9951-1281 0.136 29 9951-1361 0.152 24 9951-1521

PROPANE GAS

56,000 -- Input 70,000 -- Input 77,000 -- Input 90,000 -- Input

Elevation Orifice Drill Orifice Drill Orifice Drill Orifice Drill

Feet Meters Part # Part # Part # Part #

Dia. Size Dia. Size Dia. Size Dia. Size

Sea Level 0.082 45 9951-0821 0.093 42 9951-0931 0.098 40 9951-0981 0.106 36 9951-1061

2,000 618 0.081 46 9951-0811 0.093 42 9951-0931 0.096 41 9951-0961 0.104 37 9951-1041

3,000 914 0.078 47 9951-0781 0.089 43 9951-0891 0.093 42 9951-0931 0.101 38 9951-1011

4,000 1219 0.078 47 9951-0781 0.089 43 9951-0891 0.093 42 9951-0931 0.101 38 9951-1011

5,000 1524 0.078 47 9951-0781 0.089 43 9951-0891 0.093 42 9951-0931 0.099 39 9951-0991

6,000 1829 0.076 48 9951-0761 0.086 44 9951-0861 0.089 43 9951-0891 0.098 40 9951-0981

7,000 2134 0.076 48 9951-0761 0.086 44 9951-0861 0.089 43 9951-0891 0.096 41 9951-0961

8,000 2438 0.073 49 9951-0731 0.082 45 9951-0821 0.086 44 9951-0861 0.096 41 9951-0961

9,000 2743 0.073 49 9951-0731 0.081 46 9951-0811 0.086 44 9951-0861 0.093 42 9951-0931

10,000 3048 0.070 50 9951-0700 0.078 47 9951-0781 0.082 45 9951-0821 0.089 43 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 VI: ELECTRICAL POWER

Electrical Power 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

these instructions for specific furnace electrical data.

CAUTION]

Use copperconductorsonly.

SUPPLY VOLTAGE CONNECTIONS

2,

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-

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.

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-wir-

ing label on the inside of the blower compartment door or the wir-

ing 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 fur-

nace lead (equipment ground) to the power supply ground.

3. The furnace's control system requires correct polarity of the power

supply and a proper ground connection. Refer to Figure 16.

l_ BLK (HOT) l NOMINAL 1

W.T <NEUTRAL) f 120VOLT

GRN a GRN

FIGURE 16: Line Wiring Connections

LOW VOLTAGE CONTROL WIRING CONNECTIONS

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

the control panel.

2. Connect the thermostat wires to the furnace low voltage pigtails.

See Figure 17 (heating only) and Figure 18 or 19 (heating and

cooling).

3. Connect thermostat wires to the furnace when installing blend air

accessory as shown in Figure 20.

4. Connect low-voltage circuit to the wall thermostat pigtails.

NOTE: Five-conductor thermostat cable is recommended for all instal-

lations to allow easy installation of an air conditioning system at a later

time.

IMPORTANT

Set the heat anticipator in the room thermostat to 0.40 amps. Set-

ting it lower will cause short cycles. Setting it higher will cause room

temperature to exceed the set points.

12 Johnson Controls Unitary Products

129098-UIM-H-1011

Eighteen gauge thermostat wire is highly recommended,

Smaller gauge thermostat wire may be used only if the guideline below

is followed.

Thermostat Wire Length Thermostat Wire Gauge

(Furnace to Thermostat)

0 - 45 feet 22

0 - 70 feet 20

Do not use the thermostat wire smaller than 22 gauge. If thermostat

wire small than 18 gauge is used, pay particular attention that the con-

nections between the different wire sizes are tight.

Operational problems may be caused by loose connections or by the

use of thermostat wire that is too small to carry the required load. Any

such problems are the responsibility of the installer.

A separate 115 V.A.C. supply circuit must be used for the furnace. The

circuit should be protected by a 15 amp fuse or circuit breaker.

Avoid locations where the thermostat could be subject to drafts from

outside, or exposed to direct light from lamps, sun, fireplaces, etc., or

affected by air from a duct register blowing directly on the thermostat.

The wall thermostat should be located 52 to 66 inches above the floor.

The preferred location is on an inside wall situated in an area with good

air circulation, and where the temperature will be reasonably represen-

tative of other living areas the thermostat is controlling.

ROOM FURNACE

THERMOSTAT CONTROL il

FIGURE 17: Wiring for Heat Only Thermostat

ROOM FURNACE CONDENSING

THERMOSTAT CONTROL UNIT

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

FIGURE 18: Wiring for Electronic Heat-Cool Thermostat

ROOM FURNACE CONDENSING

THERMOSTAT PIGTAILS UNIT

FIGURE 19: Wiring for Standard Heat-Cool Thermostat

UN,TCONDENS'NG

TO AIR CONDITIONER

CONTROLS

[ BLENDAIR ICONTROL BOX

FIGURE 20: Wiring for Blend Air Accessory

TABLE 5: Ratings & Physical /Electrical Data

Input

MBH I kW

DGAA SERIES

56 16

70 21

77 23

90 26

DGAH SERIES

56 16

77 23

Output

MBH I kW

Nominal 1

CFM(m3/min)

CFM I cmm

Cabinet Width

In. I cm

Air Temp, Rise

AFUE

°F I°C

Operation

Wgt.

LBS IKg

45 13 1305 37 19-1/2 49.5 80.0 45 - 75 25 - 41.7 163 73.9

56 16 1305 37 19-1/2 49.5 80.0 45 - 75 25 - 41.7 163 73.9

62 18 1305 37 19-1/2 49.5 80.0 45 - 75 25 - 41.7 163 73.9

72 21 1305 37 19-1/2 49.5 80.0 45 - 75 25 - 41.7 163 73.9

45 13 1050 30 19-1/2 49.5 80.0 45 - 75 25 - 41.7 146 66.2

62 18 1050 30 19-1/2 49.5 80.0 45 - 75 25 - 41.7 146 66.2

Max. Outlet Booster Motor Max Min, wire Size

Input Air Temp Blower Blower Size Total Unit Ignitor & Gas Valve Over-Current (awg) @ 75 ft

MBHI kW °F I °C Hp lAmps In. I cm Amps Amps Amps Protect one way

DGAA SERIES

56 16 165 73.9 1/3 7.3 10x8 25.4 x 20.3 12.0 4.1 0.6 15 14

70 21 165 73.9 1/3 7.3 10 x 8 25.4 x 20.3 12.0 4.1 0.6 15 14

77 23 165 73.9 1/3 7.3 10 x 8 25.4 x 20.3 12.0 4.1 0.6 15 14

90 26 165 73.9 1/3 7.3 10 x 8 25.4 x 20.3 12.0 4.1 0.6 15 14

DGAH SERIES

56 16 165 73.9 1/6 7.8 10x8 25.4 x 20.3 12.4 4.1 0.6 15 14

77 23 165 73.9 1/6 7.8 10 x 8 25.4 x 20.3 12.4 4.1 0.6 15 14

Slower - High Speed

1. 0.3" Ext. Static Duct Pressure - No Coil - Std.

SECTION VII: ROOF JACK VENT/

COMBUSTION AIR SYSTEM

VENT AND COMBUSTION AIR SAFETY

The venting system must be installed in accordance with Section 5.3,Air

for Combustion and Ventilation, of the National Fuel Gas CodeZ223.1/

NFPA 54 (latest edition), or Sections 7.2, 7.3 or 7.4 of CAN/CGA

B149.1-00, National Gas and Propane Codes (latest edition) or applica-

ble provisions of the local building code and these instructions. The fur-

nace shall not be connected to any chimney, a flue serving a separate

appliance, or any appliance designed to burn solid fuel. The furnace rat-

ing plate lists the maximum vent gas temperature.

This Category I, furnace is designed for Manufactured (Mobile) Home

and Modular Home application. It may be installed without modification

in a garage, equipment room, alcove or any other indoor location where

all required clearance to combustibles and other restrictions are met,

AND providing factory Roof Jack System meets all installation require-

ments.

Johnson Controls Unitary Products 13

129098-UIM-H-1011

It is recommended that the appliance is installed in a location where the

space temperature is 32 °F (0°C) or higher. If the appliance is installed

in a location where the ambient temperature is below 32 °F (0°C), the

combustion by-products could condense causing damage to the appli-

ance heat exchanger and!or the Roof Jack.

[IMPORTANT

The "VENT SYSTEM" must be installed as specified in these

instructions for Manufactured (Mobile) Home and Modular Homes.

This appliance must be vented with an approved roof jack may not

be common vented with another gas appliance.

Modular Homes must be vented with an approved roof jack and may

not be common vented with other appliances.

kWARNING

Failure to follow all venting instructions can result in fire, asphyxi-

ation, or explosion.

CAUTION]

Only use the appropriate roof jack. See Figures 21 and 22 for

correct application.

Do not exceed the maximum height as determined from Figures

21 and 22. Installer should allow an additional 1-1/2" 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 during transportation or

other stress conditions.

EXISTING FURNACE REPLACEMENT

If this furnace replaces an existing furnace, do the following:

1. If a 2rid roof, roof cap or addition has been made to the existing

roof of the home, remove the old roof jack completely! To avoid the

possibility of an improperly installed pipe or gaps in the old roof

jack, INSTALL A NEW ROOF JACK. Your ceiling and roof height

will determine the correct roof jack to use. Refer to the vent selec-

tion table, of the furnace installation instructions.

2. After unpacking the roof jack, check the rain caps. Insure they are

not damaged, tilted or crooked. Do not twist, crush or sit on the

roof caps during installation. Damaged roof caps will cause

improper furnace operation. The furnace will not heat properly and

could result in explosion.

3. Before inserting the roof jack into the furnace top, inspect the fur-

nace flue and combustion air opening for debris or insulation

which might have fallen in during pre-installation steps. Do not pro-

ceed unless all debris has been cleaned out or removed.

4. After installing roof jack on furnace top collar, check to make sure

there is no gap in back or side between the pipe collar and the fur-

nace casing top.

5. Use only the pipes provided with the roof jack assembly. Do not

add to or adapt other sheet metal pipes. Do not cut, insert or add

other pipes to this assembly.

6. In no case should there be a gap between sections of the flue pipe

or the combustion air pipe.

NEW HOME INSTALLATION

If this furnace is installed in a new home do the following:

1. Inspect the furnace top collars for signs of insulation or ceiling

debris which might have fallen in during cutting of the ceiling and

roof holes. Remove all debris before continuing.

2. After unpacking the roof jack, check the rain caps. Insure they are

not damaged, tilted or crooked. Do not twist, crush or sit on the

roof caps during installation. Damaged roof caps will cause

improper furnace operation. The furnace will not heat properly and

could result in explosion.

3. Before inserting the vent pipe into the furnace top, inspect the fur-

nace flue and combustion air opening for debris or insulation

which have fallen in during pre-installation steps. Do not proceed

unless all debris have been cleaned out or removed.

4. After installing roof jack on furnace top collar, check to make sure

there is no gap in back or side between the pipe collar and the fur-

nace casing top.

INSTALLATION IN SNOW REGIONS

When the combustion air pipe inlet is covered or blocked with snow, the

furnace will not operate properly due to the depleted combustion air

supply.

Therefore, if the furnace will be located in regions where snow accumu-

lation on the roof exceeds 4" or in H.U.D. Snow Load Zones, a roof jack

extension (Part No. 7680B6541 ) is recommended.

LOCATING AND CUTTING ROOF JACK OPENING

To facilitate the proper installation of the roof jack, it is very important

that the roof jack opening in the ceiling and roof be on the same vertical

center line as the furnace flue collar. See Figure 21 or 22.

Mark this location on ceiling and scribe a circle with a 5" radius (10"

diameter) around this mark. Cut opening for roof jack through ceiling

and roof. (If furnace was installed during construction, cover furnace

and flue opening to prevent debris from entering flue when hole is cut

for roof jack.)

INSTALLING ROOF JACK IN THE ROOF

(See Figures 21 and 22 for Dimensional requirements.)

Insert roof jack into opening in the roof.

The roof jack should be secured to the furnace before roof flange (flash-

ing) is secured to the roof. This will insure a better alignment of the flue

pipe and furnace flue collar. Caulk around and under roof flange to pro-

vide a water tight seal, before securing roof jack flashing to roof.

1. Provide protection for Vent Connector and Air-Intake Connector

from damage and debris.

2. Mark Roof Jack center line on ceiling. Cut a 5" radius (10" diame-

ter) hole through ceiling.

3. Mark Roof Jack center line on roof. Cut oblong hole through roof.

4. Insert Roof Jack through roof opening. Do not secure Roof Jack to

roof.

Connect Roof Jack to Furnace

1. Verify gasket is around outside of Air-Intake Connector. Install new

gasket if missing or damaged.

2. Pull the Roof Jack's telescoping section down onto furnace. Fully

engage Roof Jack onto Vent Connector and Air-Intake Connector

and compress gasket. See Figure 24. Refer to Interior Roof Jack

Extension installation instructions, if applicable.

3. Align holes in Roof Jack and Air-Intake Connector. Secure Roof

Jack to furnace using #10 x 1/2 - 1-1/2" Type AB or Type B sheet

metal screw.

Secure Roof Jack to Roof

1. Apply caulk or other sealant to underside of Roof Jack flashing.

2. Locate Roof Jack such that pipes are plumb.

3. Secure Roof Jack flashing with nails, screws or staples.

4. Install roofing material over Roof Jack flashing.

5. Seal Roof Jack swivel joint with Chemcaulk 900 Sealant. Not

required for Roof Jacks with fixed slant flashing.

Complete Installation, as required

1. Install Exterior Roof Jack Extension, if applicable. Refer to installa-

tion instructions provided with Exterior Roof Jack Extension. Refer

to Figure 23.

14 Johnson Controls Unitary Products

129098-UIM-H-1011

SWIVEL FLASHING

ADJUSTS FROM

0/12 TO 5/12 PITCH

SLANT

FLASHING

3/12 PITCH

4000-7101/C 4000-6101/A

4000-7121/C 4000-6121/A

4000-7141/C 4000-6141/A

4000-7151/C 4000-6151/A

4000-7171/C 4000-6171/A

DGAH FURNACES

INSTALLATION DIMENSIONS

,,A,_

ADJUSTABLE HEIGHT

70" to 79"

75" to 86"

83" to 104"

90" to 116"

127" to 157"

DGAA FURNACES

INSTALLATION DIMENSIONS

,,a,_

ADJUSTABLE HEIGHT

86" to 95"

91" to 102"

99" to 120"

106" to 132"

143" to 173 ....

The 4084-7141 is dimensionally the same as 4000-7141/C and is available only in Canada.

2 The 4084-7151 is dimensionally the same as 4000-7151/C and is available only in Canada.

t FLUE

GASES

19 1/2"

COMBUSTION

AIR

CAULK

UNDER

FLASHING

CAREFULLY CAULKALLAROUND SWIVEL JOINT WITH

SEALANT SUPPLIED BY FURNACE MANUFACTURER.

_ _ COMBUSTION

A,R

_ FLASHING

The End of Upper Portion of Roof Jack need ____

Not extend below the ceiling. _ __

_MPORTANT I--

SEAL ROOF JACK FLASHING TO THE ROOF JACK

AND ROOF,

THIS ISTHE INSTALLER'S RESPONSIBILITY.

FLUEGASES

19 1/2"

r

ROOF

A

76"

59-1/2"

DGAA MODELS

DGAH MODELS

_r '_ FLOOR #_--..................

\ \ \ \ \ \ \ / / / / / / / / / P/ / /

f

WARM AIR DUCT DUCT CONNECTOR DUCT CONNECTOR WARM AIR DUCT

FIGURE 21: Standard Roof Jack

Johnson Controls Unitary Products 15

129098-UIM-H-1011

SWIVEL FLASHING

ADJUSTS FROM

0/12 TO 5/12 PITCH

SLANT

FLASHING

3/12 PITCH

4000-8161/C 4000-9161/A

4000-8181/C 4000-9181/A

DGAH FURNACES

INSTALLATION DIMENSIONS

,,A,_

ADJUSTABLE HEIGHT

85" to 101"

99" to 129"

DGAA FURNACES

INSTALLATION DIMENSIONS

,,B,_

ADJUSTABLE HEIGHT

101" to 117"

115" to 145"

CAREFULLY CAULKALLAROUND SWIVEL JOINT WITH

SEALANT SUPPLIED BY FURNACE MANUFACTURER.

CAULK

Not extend below the ceiling.

IMPORTANT

AND ROOF.

CAULK

UNDER

FLASHING

ROOF

A

59-1/2"

DGAA MODELS

DGAH MODELS __

__ ........................_ FLOOR ................

B

76"

\ \ I k \ \ \ \ \ \ \ // / /// /HI ///_/ / / /

WARM AIR DUCT DUCT CONNECTOR DUCT CONNECTOR WARM AIR DUCT

x x > x x x x x > x > x x x x x x > >4 x x x x x x > x x x > >4 x >4 >4 x m x x x >4 x x x x

FIGURE 22: Roof Jack With Removable Crowns

16 Johnson Controls Unitary Products

129098-UIM-H-1011

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.

STEP 2:

Place the roof jack extension on top of the

crown assembly base, pushing down firmly

to assure a snug fit.

IMPORTANT: Make sure that the pipes are

connected.

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.

Extension

Crown

Y

Base

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. Installthe 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.

/

UPPER

CAP

LOWER

CAP

EXTENSION

-- BRACKET

CROWN

ASSEMBLY

BASE

STEP 4:

Complete assembly.

Place these instructions in the customer

packet provided with the furnace.

FIGURE 23: Roof Jack

EXTERIOR ROOF JACK EXTENSION

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.

CONNECTING ROOF JACK TO FURNACE

CAUTION]

The inner flue pipe must be present.

It is mandatory that the combustion air pipe and flue pipe assem-

bly be fully engaged. The combustion air pipe MUST be securely

fastened to the furnace with a sheet metal screw in the hole pro-

vided.

Use a 1/2" blunt or sharp end sheet metal screw to fasten roof

jack combustion air pipe to furnace combustion air collar. Screw

hole is provided in the pipe and collar. Excessively long screws

may extend to flue pipe and puncture it. Screws are not to

exceed I i/2" in length.

NOTE: Combustion air tube and flue pipe are part of the same assem-

bly. Only the combustion air tube need be fastened to the furnace.

1. Check to be certain that the flue pipe and combustion air tube are

present.

2. 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).

COMBUSTION

AIR TUBE _

TSoECwURL_STRAP ,

#8 OR #10 SCREW

RECOMMENDED

COMBUSTION

AIR TUBE COLLAR

/

/

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.

FIGURE 24: Connecting Roof Jack to Furnace

COMBUSTION AND VENTILATION AIR

This furnace is a sealed combustion (direct vent) unit and is design cer-

tified 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.

Johnson Controls Unitary Products 17

129098-UIM-H-1011

COM_INT

AIR PIPE AND "_t_---_ MUST BE

FLUE ASSEMBLY _ BELOW CEILING

INTERIOR

EXTENSION

(OPTIONAL)

FURNACE COMBUSTION

AIR COLLAR

FIGURE 25: Roof Jack Assembly

INTERIOR EXTENSIONS

To choose the proper length roof jack with or without the optional exten-

sion see Figure 25 and Table 8. More than one interior extension may

be used to accommodate A "dimensions up to 110" (284.5 cm).

WARNING

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 adjust-

able heights by the amount of the interior extension height. If the fur-

nace 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 assem-

bly 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.

TABLE 6: Roof Jack Options

Roof Jack Adjustable Height with Adjustable Height with

Model Number no Interior Extension on 17" Interior Extension

4000B7141 14" to 78" 64" to 95"

4000B7151 66" to 90" 83" to 107"

4000B8161 59" to 79" 76" to 96"

4000B8181 73" to 103" 90" to 110"

Models 4000B8161 and 4000B8181 have removable crowns.

CAUTION

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 fur-

nace combustion air collar. Screw holes are provided in pipe and collar.

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

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

Under no circumstances shaft the connection between the flue and

combustion air pipe assembly of the roof jack and the interior exten-

sion 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.

FIGURE 26: Ceiling Rings

VENT 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.

18 Johnson Controls Unitary Products

129098-UIM-H-1011

\

[] VENT TERMINAL

FIXED _ AIR SUPPLY

CLOSED

"' [] AREA WHERE TERMINAL IS NOT PERMITTED

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

j CLOSED

OPERABLE

FIGURE 27: Home Layout

Canadian Installations IUS Installation 2

A.Clearance above grade, veranda, porch, deck, or balcony 12 inches (30 cm) 12 inches (30 cm)

12 inches (30 cm) for models <100,000 BTUH

B.Clearance to window or door that may be opened (30 kW), 36 inches (91 cm) for models > 100,000 4 Feet

BTUH (30 kW)

C.Clearance to permanently closed window 4 Feet 4 Feet

D.Vertical clearance to ventilated soffit located

above the terminal within a horizontal distance 4 Feet 4 Feet

of 2 feet (61 cm) from the center line of the terminal

E.Clearance to unventilated soffit 12 Inches 12 Inches

F. Clearance to outside corner 12 Inches 12 Inches

G.Clearance to inside corner 6 Feet 6 Feet

H.Clearance to each side of center line extended 3 feet (91 cm) within a height 15 feet (4.5 m) 3 feet (91 cm) within a height 15 feet (4.5 m)

above the above the meter/regulator assembly

above meter/regulator assembly meter/regulator assembly

I. Clearance to service regulator vent outlet 3 feet (91 cm) 3 feet (91 cm)

12 inches (30 cm) for models <100,000 BTUH

J. Clearance to nonmechanical air supply inlet to building (30 kW), 35 inches (91 cm) for models >100,000 4 Feet

or the combustion air inlet to any other appliance BTUH (30 kW)

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

6 feet (1.83 m) zontally

K.Clearance to a mechanical supply inlet

_.Clearance above paved sidewalk or paved driveway located on

public property

M.Clearance under veranda, porch, deck, or balcony

Vent Termination from any Building Surface

Above anticipated snow depth

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

2. In accordance with the current ANSI Z223.1 /NFPA 54, National

tured Homes and Recreational Vehicles.

7 feet (2.13 m) 1-

12 inches (30.4 cm)

12" (30.4 cm)

12" (30.4 cm)

Propane Installation Code.

7 _et(2.13 m) t

12inches(30.4 cm)

12"(30.4 cm)

12"(30.4 cm)

Gas Code. In accordance with the current UL 311 Standard for Safety for Roof Jacks for Manufac-

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 of the gas supplier and the manufacturer's Installation Manual.

Any fresh air or make up inlet for dryer or furnace area is considered to be forced air inlet.

Avoid areas where condensate drippage may cause problems such as above planters, patios, or adjacent to windows where steam may cause fogging.

A terminus of a vent shall be either:

Fitted with a cap in accordance with the vent manufacturer's installation instructions, 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 19

129098-UIM-H-1011

CARBON MONOXIDE POISONING HAZARD

AWARNING

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, restriction, leakage, corrosion or other

deficiencies, which could cause an unsafe condition

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. Place the appliance being inspected in operation. Adjust thermostat so the appliance shall operate contin-

uously.

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, fire-

place 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 VIII: SAFETY CONTROLS

CONTROL CIRCUIT FUSE

A 3-amp fuse is provided on the control circuit board to protect the 24-

volt 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-ener-

gizes the ignition control module and the gas valve if any of the follow-

ing conditions are present. Refer to Figure 28 for tubing connections.

1. Blockage of combustion air piping or terminal.

2. Blockage of vent piping or terminal.

3. Failure of combustion air blower motor.

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 pro-

vides 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 AND

ADJUSTMENTS

The initial start-up of the furnace requires the following additional

procedures:

IMPORTANT

All electrical connections made in the field and in the factory should

be checked for proper tightness.

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.

FIGURE 28: Pressure Switch Tubing Routing

20 Johnson Controls Unitary Products

129098-UIM-H-1011

TOOLS AND INFORMATION THAT WILL BE

REQUIRED IN ORDER TO PROPERLY PERFORM THE

FURNACE START-UP PROCECURE.

1. 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 !

m3).

2. You will need a thermometer or portable digital thermometer to

read the supply and return air temperatures.

3. 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.

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

the gas valve.

5. 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 U-

tube manometer or the digital pressure measuring equipment to

the gas valve pressure ports.

There is an accessory kit (1PK0601) available from Source 1, which

has the following items:

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

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

the following items:

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

1 - 5!16" (0.8 cm) x 1!8" (0.3 cm) reducing coupling

1 - 1!8" (0.3 cm) adapter

1 - Dwyer- Manometer

These items are required in order to properly perform the required start-

up procedure.

IGNITION SYSTEM SEQUENCE

1,

2.

3.

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

Set the thermostat above room temperature to call for heat.

System start-up will occur as follows:

a. 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.

b. After this warm up, the ignition module will energize (open)

the main gas valve.

c. After flame is established, the supply air blower will start in

the time set on the control board.

AWARNING

FIRE OR EXPLOSION 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 the detection of leaks

to check all connections. A fire or explosion may result causing

property damage, personal injury or loss of life.

[IMPORTANT

Burner ignition may not be satisfactory on first start-up due to resid-

ual air in the gas line or until gas manifold pressure is adjusted. The

ignition control will make 3attempts to light before locking out.

With furnace in operation, check all of the pipe joints, gas valve connec-

tions 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.

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

gas supply piping system.

CALCULATING THE FURNACE INPUT

(NATURAL GAS)

NOTE: Burner orifices are sized to provide proper input rate using natu-

ral gas with a heating value of 1030 BTU/Ft 3. If the heating value of

your gas is significantly different, it may be necessary to replace the ori-

fices.

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

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

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

3. Calculate the furnace input by using one of the following equa-

tions.

Johnson Controls Unitary Products 21

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 mea-

sured 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 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

= BTU/H

= 78,666.90

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

BTU/H

80.000.00

In Canada you will use the following formula to calculate the furnace 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 MJim 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 correction factor of 0.960; times 3600, then divided by the time it

took to measure 1 cubic ft. (0.028 m) of gas from the gas meter.

The formula for metric input calculation using a cubic foot gas meter:

0.2777 = kW x 3412.14 = BTU/H

= 77,796.80

0.2777 = 22.80 x 3412.14

MJ/m 3 x 2 cu.ft, x 0.028 x 0.960 x 3600 = MJ/H x

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 = 82.12 x

90.5

Natural Gas

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 = 83.46 x

108

Propane Gas

2500 BTU/SCF = 93.15 MJ/m 3

0.2777 = 23.18 x 3412.14 = 79,093.4

In Canada use the following 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 MJim 3 (or Default 93.15), times 0.10 m 3 of gas measured at the gas meter, times a baro-

metric 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:

0.2777 = kW x 3412.14 = BTU/H

= 78,581.60

0.2777 = 23.03 x 3412.14

MJ/m 3 x m3 x 0.960 x 3600 = MJ/H x

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 = 82.94 x

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 = 83.19 x

387

Propane Gas

2500 BTU/SCF = 93.15 M Jim 3

0.2777 = 23.10 x 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 input specified on the rating plate then replace the gas orifices with the gas orifices

of the proper size for the type of gas you are using.

For altitudes above 2,000 ft. (610 m) the furnace input MUST BE DERATED. Refer to the GAS CONVERSION FOR PROPANE (LP) AND HIGH

ALTITUDES IN SECTION IV for information on high altitude conversions.

22 Johnson Controls Unitary Products

129098-UIM-H-1011

,& CAUTION

Be sure to relight any gas appliances that were turned off at the

start of this input check.

CHECKING THE GAS PRESSURES

1. The pressure ports on the gas valve are marked OUT PRESSURE

TAP and INLET PRESSURE TAR

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

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

R

4. Using a 3/32" (0.2 cm) Allen wrench, loosen the set screw by turn-

ing it 1 turn counter clockwise. DO NOT REMOVE THE SET

SCREW FROM THE PRESSURE PORT.

5. Push one end of the 3/8" (0.9 cm) ID flexible tubing over the pres-

sure port so that the body of the port is inside the tubing.

6. 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.

TABLE 7: Inlet Gas Pressure Range

Minimum

Maximum

INLET GAS PRESSURE RANGE

Natural Gas Propane (LP)

4,5" W,C, (1,12 kPa) 8,0" W,C, (1,99 kPa)

10,5" W,C. (2.61 kPa) 13,0" (3,24 kPa) W.C.

IMPORTANT

The inlet gas pressure operating range table specifies the minimum

and maximum gas line pressures required for safe furnace opera-

tion.

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

fied on the rating plate and in these instructions is shown below:

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

11.0" W.C. (2.74 kPA)for Propane (LP) Gas

ADJUSTMENT 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 line

before the gas valve. Find the pressure ports on the gas

valve marked OUT P and IN R

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

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

3. 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 posi-

tive side of the manometer to the gas valve pressure reference port.

Refer to Figure 30 for connection details.

IMPORTANT

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.

1. Refer to Figure 29 for location of pressure regulator adjustment

cap and adjustment screw on main gas valve.

2. Turn gas and electrical supplies on and follow the operating

instructions to place the unit back in operation.

3. Adjust manifold pressure by adjusting gas valve regulator screw

for the appropriate gas per the following:

TABLE 8: Nominal Manifold Pressure

NOMINAL MANIFOLD PRESSURE

Natural Gas 3.5" w.c. (0.87 kPa)

Propane (LP) Gas 10.0" w.c. (2.488 kPa)

CONNECTIONS

FIGURE 29: Gas Valve

(shown in OFF position) OUTLET

[IMPORTANT

If gas valve regulator is turned in (clockwise), manifold pressure is

increased. If screw is turned out (counter clockwise), manifold pres-

sure will decrease.

4. After the manifold pressure has been adjusted, re-calculate the

furnace input to make sure you have not exceeded the specified

input on the rating plate. Refer to "CALCULATING THE FURNACE

INPUT (NATURAL GAS)".

5. 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.

6. Turn the electrical and gas supplies back on, and with the burners

in operation, check for gas leakage around the gas valve pressure

port for leakage using an approved gas detector, a non-corrosive

leak detection fluid, or 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 pres-

sure setting could result in an over-fire condition. A high manifold

pressure will cause an over-fire condition, which could cause pre-

mature 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.

Johnson Controls Unitary Products 23

129098-UIM-H-1011

MANIFOLD PRESSURE "U" TUBE CONNECTION

[]

TUBING

3.5 IN (0.87 kPa)

WATER

COLUMN

T AS

PRESSURE

SHOWN

GAS VALVE

FIGURE 30: Reading Gas Pressure

ADJUSTMENT OF TEMPERATURE RISE

_DANGER

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 fur-

nace 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.

The temperature rise, or temperature difference between the return air

and the heated supply air from the furnace, must be within the range

shown on the furnace rating plate and within the application limitations

as shown in Table 7.

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.

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.

FAN OFF

JUMPER

FAN ON I_

ADJUSTMENT

JUMPER ]

÷

TRANSFORMER

LINEVOLTAGE

BLACK-HIGH SPEED

RED-LOW SPEED

÷

I II I

FUSE 3A

FIGURE 31: Furnace Control Board

FILTER PERFORMANCE

The airflow capacity data published in Table 9 represents blower perfor-

mance WITHOUT filters.

APPLYING FILTER PRESSURE DROP TO

DETERMINE SYSTEM AIRFLOW

Example: For a 90,000 BTUH (26.4 kW) furnace operating on high-

speed 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)

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

Subtract the airflow @ 0.10 w.c. (0.02 Pa) from the airflow @ 0.20 w.c.

(0.05 Pa) to obtain airflow difference.

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)

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 PROCEDURE

Install 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.

24 Johnson Controls Unitary Products

129098-UIM-H-1011

TABLE 9: Blower Performance CFM - Downflow Without Filters

STANDARD HEATING BLOWERS

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, INCHES WC (kPa)

Nominal Cabinet

CFM(m3/min) Size

1305 (37)

1305 (37)

1305 (37)

1305 (37)

Speed 0.1 (0.025) 0.2 (0.050) 0.3 (0.075) 0.4 (0.099) 0.5 (0.124)

Tap cfm cm/m cfm 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

7900 - 7751 AC/ACCESSORY BLOWER

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)

Nominal Cabinet

CFM(m3/min) Size

1725 (48.9) A

1725 (48.9) A

1725 (48.9) A

1725 (48.9) A

EXTERNAL STATIC PRESSURE, INCHES WC (kPa)

Speed 0.1 (0.025) 0.2 (0.050) 0.3 (0.075) 0.4 (0.099) 0.5 (0.124)

Tap cfm cm/m cfm cm/m cfm cm/m cfm 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 NO. DESCRIPTION USED WITH

7900-7761 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 HIGH ALTITUDE KIT FOR NATURAL GAS ALL MODELS

1PS0167 HIGH ALTITUDE KIT FOR PROPANE (LP) GAS ALL MODELS

Johnson Controls Unitary Products 25

'11

r-

m

5"

_3

B

i

E3

©

>

>

BLOWER SPEED CHART

(CHARTE DE VITESSE

DE LA SOUFFLERIE)

INPUT CFM CeOL

(ENTREE) (PCM) HIGH HEAT

(CL[MA) (CHAU)

BLK REO

O56 1200 (NOIRJ (ROUG)

&K REO

070 1200 (NOIR) (RO(JG}

BLK RED

077 1200 {NOIR) (ROUG)

BLK RED

O9O 1200 (NOLO) (ROUG)

WIRE COLOR KEY

(CODE DE COULEUR

DU FILAGE}

BLK 8LACK

(OIR) {NOIR)

!_LU BLUE

(BLEU) (BLEUJ

RED REO

(ROUG) (qOUGE)

YEL YELLOW

{,AUN (AUNE)

WHT WHITE

(BLANC) (BLANC]

_RN eqo_x

?f'4N GREE

(VERT (VERT)

PRP PURPLE

:POURPRE} [POURPRE

O'RN OftANGE

(ORA) (O'_ANOE)

CAUTION

OPEN ALL DISCONNECTS BEFORE

SERVICING THIS NIT

PRE_CAUTION

OUVREZ LES DISJQNCTE RS AVANT

DE PR!?CEOER AVEC LE BERV[CE

80X DOWNFLOW FURNACE

(FOURNAISE 80X

VENTILEE FAR LE BAS)

LADDER DIAGRAM

DIAGRAMME ELEMENTAIRE

NOTES:

I. ALL FIELD WIRING PER_ (A) NATIONA

(B) CANADIA

(C) LOCAL 0

?IF A Y OF THE ORIGINAL WIRE AS SU

REPLACED, IT MUST BE REPLACED WIT

TEMRERAT RE RATIG OF AT LEAST 22

5. CONNECTORS SUITABLE FOR COPPER CO

4. ALL REPLACEME T COMPONE TS MUST B

5, PROVIDE ISCONNECTS FOR ALL POWER

MOTORS AqE INHERENTLY PROTE! TE_},

7. SSI IS IN SERIES WITH LSI AND LS2

NOTES:

I. TOUT FILAGE EN CHANTIER SELON: (A

(B

',C

2. SI bE FILAGE DOIT ET_E REMPLACE

L'ETRE AVEC UN MATERIAUX POUVANT

O'AU MOINS 221_F (105_8).

5 SEULEME T DES MARETTES POUR FIL D

4 TQUTE COMPOSANTE DE REMPLACEME T

'_ FOURNI'}SEZ LEC_ OISJONCTE RS _tOq

#_ LES MOTE qS SONT PROTE.OES DE PAR

7 S?_I [}E SE_IE AVEC LSI ET L_}

L ELEC CODE (NEC) AND/OR/

N ELEC CODE (DEC) AND/OR/

R CITY CODES.

PPLIED WITH THE FURNACE MUST BE

HWIRING MATERIAL HAVING A

I_F (I05_C).

NDUCTORS ONLY

E PROPERLY GROUNDED.

SUPPLIES

) CODE ELEC NATIONAL (CEN') ET/OU/

) CODE ELEC CANAD[EN (CEC) ET/OU/

) CODES LOCAUX ET MUNICIPAUX.

NPATRIE OU EN TOUT, IL DOlT

RESISTER A DES TEMPERATURES

E CUIVRE.

DOlT [ETRE BIEN MISE EN TERRE.

L'ALIMENTA[TON

LEUR CONCEPTION

CONNECTION DIAGRAM

(DIAGRAMME DE RACCORDEMENT)

DE SURCHARGE

DE TIR}

LEGEND

09 ©ISCON ECT SWITCH

V A_ VALVE

ION HOT SURFACE IG [TER

PI/SI 9 PIN PLG & SOCKET ON F_RNA CE CONTROL BOARD

P2/$2 6 PI PLUG & SOCKET ON FRNAC E CO TROL BOARD

°5/S:_ 2 ¢_I _>LU{"& SOCKET AT HOT SURFACE IGNITOR

_/54 9 PIN Pk, & SOCKET

LSI,2 AUXILIAqY LINIT SWITCH ON _LO WE_R INLET

ILP PRESSURE S/'TITCH

IRC RU CAPACITOR

IT TRANSFORMER, #OVA

{9 I_}ENTIFIED RJN CAPACITOR

24V CONNECT[O r. ROOM THERMOSTAT

0 FIELD CONNECTION

FACTORY WIRIN AO DEVICES

FIELD WIRING AND DEVICES

• • RELAY CONTACTS 0 IGNITION

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

L£GENDE

D9 C@A4UTATE R DE OlSJO CTON

GV £OU*>A>E DE OAZ

IGN IG_,ITION DE SURFACE CHAUDE

PI/SI PRISE & RECEPTACLE A 9 PTS S R LA ;LAD ETTE }E CONT'_OLE }'[GNIT[ ON

P2/$2 PRISE & RECEPTACLE A 6 PTS SU R LA PLAOUETTE DE CO TROLE O'IGNIT[O N

PS/SS PRISE ET ftECE°TACLE A 2 ;_TS D 'IGNITION 8E r_URFACE CHAUDE

P4/$4 PRISE ET RECE:_TACLE A 9PTS

LSI, COMM_TATEUR A XILIAIRE DE PqE SSlON SR _30I_IER ;}E SOLFFLERIE

ILP COM_,_TATEUR DE PRESS[ON

IRD CAPAC[TEUR DE FONCTIONNE_¢ENT ID ENTIFIE

IT TRANBFORMEUR, 4OVA

CAPAC[TEUR DE FONCT[ONNEMENT IOENTIF IE

Z_l 24V RACCORDEMENT ©U THERMOSTAT OE PIECE

0 RACCOR©E_ENT DE CHANTIER

FILAGE DE L'USI_.E ET APPAREILS

FILAGE DE CHA TIER ET APPARE[L S

L_ _ CO TACTE9 DES RELAIS SUR LA PLAQUETT E t;E CONTROLE 9'1 NITION

155887 UWD A 0705

¢o

(.o

O

(.o

T

i

o

"11

r-

m

5"

_3

B

B

i

E3

©

>

-I-

WIRE COLOR KEY

(CODE DE COULEUR

DU FILAGE)

BLK BLACK

(NOIR} (NOIR)

BLU BLUE

(BLEU) (BLEU}

RED RED

{ROUG) (ROUGE_

YEL YELLOW

_JAUN) (JAUNE)

WHT WHITE

(BLANC) (BLANC)

BRN BROW\

(SPUN) (SPUN)

GRN GREEN

(VERT) (VERT}

PRP PURPLE

(POURPRE} (POURPRE}

ORN ORANGE

(ORA) _RANGE)

CAUTION

OPEN ALL DISCO NECTS BEFORE

SERVICI G THIS NIT

RECAUTION

OUVREZ LES DIS ONCTEURS AVAT

©E PROCE'DER AVEC LE SERVICE

80X DOWNFLOW FURNACE

(FOURNAISE BOX

VENTILEE PAR LE BAS)

LADDER DIAGRAM

DIAGRAMME E[EMENTAIRE CONNECTION DIAGRAM

(DIAGRAMME DE RACCORDEMENT)

POWER SUPPLY 115160 SEE NOTE I

_ (AL[MENTATION 115 160 VOiR NOTE I)

HEAT/COOL

RELAY

I (........ /_ _ED_) TRELAY D'l DUCT)

S

i (RELA[ S

RELAY '}HG [TIO II'_pRitOM__._

ON

I ..... {__ _©_ J......

I COOL_;> -- _0

HEAT/COOL THERMOSTAT

',THERMOSTAT CLIMA/CHAUFJ

NOTES:

I. ALL FIELD WIRING PER: (A) NATIONA

(_) CANA[]IA

',C LOCAL

2. IF ANY OF THE ORIGINAL WIRE AS SU

REPLACED, IT VUST #E REPLACED WIT

TEM'_ERATUHE RATING OF AT LEAST 22

3 CONNECTORS SUITA_3LE FOR COPPER CO

4. ALL REPLACEMENT COMP ENTS MUST

B. PR VIDE DISCONNECTS FOR ALL POWER

I

T

(EN TERRE)

I GRN GRN

qGND,

(EN TERRE}

FLAME SENSOR

YEL YEL

IT (4OVA) {CAPTEUR DE

FLAMME) BRN

GAS VALVE R_

RELAy

•HOT su

• (IGNITION OE

SURFACE CHAUDE)

©E GAZI BLK

BLK

DE SURCHARGE

DE TIR)

L ELEC CODE (NEC) AND/OR/

N ELEC CODE (CEC) AND/OR/

R CITY CODES

PPLIED WITH THE FURNACE MUST BE

H WIRING _ATER[AL HAVING A

PF (105"C),

N©UCT©RS ONLYI

E PROPERLY GROUNDEO.

SUPPLIES

(EN TEqRE)

6 MOTORS ARE iNHERENTLY PROTECTED

7 SSI IS IN SERIES WITH LSI AND LS2

NOTES:

I. TOT FILAGE EN CHANTIER SELONt !A

{D

',C

2 SI LE FILAGE DOIT ETRE REMPLACE

L'EtRE AVEC UN MATERIAUX POUVANT

'AU MOINS 22PF (lOb'C)

5 SEULEMENT DES MARETTES POUR FIL O

4 TOUTE COMPOSANTE E REMPLACEMENT

5. FOURN[SSEZ LES DISJONCTEU;_S POUR

6 LES MOTEURS SONT PROTEGES DE PAR

7 SSI DE SERIE AVEC LSI ET LS

CODE ELEC. NATIONAL (CEN) ET/OU/

CODE ELEC CANADIEN (CEC ET/OU/

} CODES LOCAUX ET MUNICIPAUX.

N PATRIE OU EN TOUT, IL OOIT

RESISTER A DES TEMPERATURES

E CU[VRE.

OOIT [ETRE 6IEN MISE EN TERRE

L'ALIMENTAITON

LEUR CONCEPTION

LEGEND

i)5 DISCONNECT SWITCH

Gv GAS VALVE

IGN HOT SURFACE IGNITER

PI/SI 9 PIN PLUG & SOCKET ON FURNACE CONTROL BOAR

*>2/9 6 _I PLuG &SOCKET ON FU_NAC E CO TROL !_OA_O

P3/$3 8 PIN PL.G & SOCKET AT HOT SURFACE IGNITOR

R4/$4 9 PIN PLUG & SOCKET

LSI, AUXILIA_y LIMIT SWITCH ON 5LO WER INLET

ILP PRESSURE SWITCH

IqC f_uN OA_AC/TO_

IT TRANSFORMER, 4OVA

IDENTIFIED RUN CA_ACITOR

24v CO ECT[ON ROO_ THERMOSTAT

0 FIEL© CONNECTI©_,

FACTORy WIRI_,G AND EVICES

FIELD WIRING AND DEVICES

• • RELAY CONTACTS ON IGNITION

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

BLU I

BLU

8RY

FOURNAISE)

WHT

_HT RED

I

RE© 24V SEC _LU J

BLK _ ....... WHT

115V PR[ COM

_LLKKWHT BLKBLK

COMMUTATEUR

(IISVCA NEUT.',

LEGENDE

°S COMMUTATEUR DE O[SJONCTON

GV SOUPAPE DE GAZ

ION IGNITION DE SURFACE CHAUDE

Pl/Sl PRISE & RECEPTACLE A 9 PTS S UR LA PLAOUETTE DE CONTROLE I]HGNITI ON

P@/S2 PRISE & RECEPTACLE A 6 PTS SU R LA PLAQUETTE DE CONTROLE D'IGNITIO N

P3/$5 PRISE ET RECEPTACLE A 2PTS 0 'IGNITION DE SURFACE CHAUOE

P4/S¢ PRISE ET RECEPTACLE A 9 PTS

LSI,2 COMMUTATEUR AUXILIAIRE DE PRE SS[ON SUR BOITIER DE SOUFFLERIE

ILP COMMUTATEUR DE PRESSION

IRC CAPACITEUR DE FONCT[ONNE_ENT l° ENT[FIE

IT TRANSFORMEUR, €OVA

®CAPACITEUR DE FONCTIONNE_ENT I©ENTIF IE

2@V RACCORDEMENT ©U THERMOSTAT DE PIECE

RACCOROEMENT DE CHANTIER

FILAGE DE L'USINE ET APPARE[LS

FILAGE DE CHANTIER ET APPAREIL S

157953 UWD A 0705 ¢o

(o

0

(o

c

Ii

o

NOTES

Subject to change without notice. Published in U.S.A.

Copyright _>2011 by Johnson Controls, Inc. All rights reserved.

Johnson Controls Unitary Products

P.O. Box 19014

Wichita, KS 67204-9014

129098-UIM-H-1011

Supersedes:129098-UIM-G-0411