Installation manual

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Johnson Controls Unitary Products 129098-UIM-G-0411

For Installation In:

1. Manufactured (Mobile) Homes

2. Recreational Vehicles & Park Models

3. Modular Homes & Buildings

HIGH EFFICIENCY

SEALED COMBUSTION GAS FURNACE

MODELS: DGAA and DGAH

(Single Stage Downflow Only)

56 - 90 MBH INPUT

(16.41 - 26.38 KW) INPUT

INSTALLATION MANUAL

LIST OF SECTIONS

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

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

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

FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

External Static Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Filter Sizes - All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

High Altitude Duration Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Ratings & Physical / Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Roof Jack Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Blower Performance CFM - Downflow Without Filters . . . . . . . . . . . 25

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 injury

WARNING indicates a potentially hazardous situation, which, if not

avoided, could result in death or serious injury

CAUTION indicates a potentially hazardous situation, which, if not

avoided may result in minor or moderate injury.

It is also used to

alert against unsafe practices and hazards involving only property dam-

age.

Improper installation may create a condition where the operation of

the product could cause personal injury or property damage.

Improper installation, adjustment, alteration, service or mainte-

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

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

tractor, installer or service agency.

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.

Summary of content (28 pages)

PAGE 1
INSTALLATION MANUAL HIGH EFFICIENCY SEALED COMBUSTION GAS FURNACE MODELS: DGAA and DGAH (Single Stage Downflow Only) For Installation In: 1. 2. 3. 56 - 90 MBH INPUT (16.41 - 26.38 KW) INPUT Manufactured (Mobile) Homes Recreational Vehicles & Park Models Modular Homes & Buildings LIST OF SECTIONS SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 2
129098-UIM-G-0411 SPECIFIC SAFETY RULES AND PRECAUTIONS 1. 2. 3. 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.
PAGE 3
129098-UIM-G-0411 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).
PAGE 4
129098-UIM-G-0411 TABLE 1: Unit Clearances to Combustibles Top Front Application Closet Alcove Closet In. (cm) In. (cm) In. (cm) Downflow Alcove Rear Sides Floor1 Roof Jack Flue Duct1 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) 2(50.8) 2(50.8) 6(15.24) 24(60.96) 0 0 0 0 Inches 59-1/2” 76” 24.3/4” 23” 19-1/2” 9-3/4” 12” c.m. 151.0 193.0 62.9 58.4 49.5 24.8 30.
PAGE 5
129098-UIM-G-0411 DUCT DESIGN - CANADA Supply duct design shall be in accordance with the latest HRA Digest, the ASHRAE Handbook Fundamentals, or other good engineering principles. The supply air temperature MUST NEVER exceed the Maximum Supply Air Temperature, specified on the nameplate. Operating the furnace above the maximum supply air temperature will cause the heat exchanger to overheat, causing premature heat exchanger failure.
PAGE 6
129098-UIM-G-0411 Furnace to Closet Door Clearance — Greater than 1 Inch (2.54 cm) and Up to 5 (12.7 cm) Inches 2 1. The closet door MUST have a minimum of 250 Inches2 (1613 cm2) of free 2 2 area in the upper half of the door and a minimum of 50 Inches (322 cm ) 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.
PAGE 7
129098-UIM-G-0411 2-3/4 (7.0 cm) MIN. REAR WALL OF ENCLOSURE CEILING CUT-OUT FOR ROOF JACK 9-7/8 (25.1 cm 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, FLAT HEAD SCREWS OR STAPLES BEND TABS UNDER DUCT OPENING TO SECURE TO THE SUPPLY DUCT. FURNACE OUTLINE 15 (38.1 cm) 20-1/2 (52.1 cm) 23-1/4 (59.
PAGE 8
129098-UIM-G-0411 NOTE: See label on coil panel for conversion and lighting instructions. Obtain a temperature rise within the ranges specified on the name plate. SECTION III: 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. AUTOMATIC DAMPER HAZARD OF ASPHYXIATION, DO NOT COVER OR RESTRICT FLOOR OPENING.
PAGE 9
129098-UIM-G-0411 SECTION IV: FILTERS 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 external 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.
PAGE 10
129098-UIM-G-0411 To install gas line and to connect it to the gas valve, care must be taken to hold gas valve firmly to prevent misalignment of the burner orifice, or to damage gas valve which could result in improper heating, explosion, fire or asphyxiation. DO NOT USE EXCESSIVE PIPE SEALANT ON PIPE JOINTS.
PAGE 11
129098-UIM-G-0411 CONVERSION PROCEDURE The gas supply must be shut off prior to disconnecting the electrical power, before proceeding with the conversion. When converting gas valve from or to Propane gas, it will be necessary to change main burner orifice to prevent an underfired or overfired condition. See label inside lower furnace door for complete instructions. HIGH ALTITUDE GAS ORIFICE CONVERSION SHOCK HAZARD - Turn off electrical supply to furnace. 1.
PAGE 12
9098-UIM-G-0411 TABLE 4: High Altitude Duration Chart NATURAL GAS 56,000 — Input Elevation Orifice Drill Feet Part # Meters Dia. Size Sea Level 0.136 29 9951-1361 2,000 618 0.136 29 9951-1361 3,000 914 0.128 30 9951-1281 4,000 1219 0.128 30 9951-1281 5,000 1524 0.128 30 9951-1281 6,000 1829 0.128 30 9951-1281 7,000 2134 0.120 31 9951-1201 8,000 2438 0.120 31 9951-1201 9,000 2743 0.120 31 9951-1201 10,000 3048 0.116 32 9951-1161 70,000 — Input Orifice Drill Part # Dia. Size 0.154 23 9951-1541 0.
PAGE 13
129098-UIM-G-0411 Eighteen gauge thermostat wire is highly recommended. Smaller gauge thermostat wire may be used only if the guideline below is followed. Thermostat Wire Length (Furnace to Thermostat) 0 - 45 feet 0 - 70 feet ROOM THERMOSTAT R W FURNACE CONTROL R W Thermostat Wire Gauge 22 20 FIGURE 17: Wiring for Heat Only Thermostat ROOM THERMOSTAT Do not use the thermostat wire smaller than 22 gauge.
PAGE 14
129098-UIM-G-0411 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 appliance heat exchanger and/or the Roof Jack. The “VENT SYSTEM” must be installed as specified in these instructions for Manufactured (Mobile) Home and Modular Homes.
PAGE 15
129098-UIM-G-0411 SWIVEL FLASHING ADJUSTS FROM 0/12 TO 5/12 PITCH 1 2 SLANT FLASHING 3/12 PITCH DGAH FURNACES DGAA FURNACES INSTALLATION DIMENSIONS INSTALLATION DIMENSIONS “A” ADJUSTABLE HEIGHT “B” ADJUSTABLE HEIGHT 4000-7101/C 4000-6101/A 70” to 79” 86” to 95” 4000-7121/C 4000-6121/A 75” to 86” 91” to 102” 4000-7141/C 4000-6141/A 83” to 104” 99” to 120” 4000-7151/C 4000-6151/A 90” to 116” 106” to 132” 4000-7171/C 4000-6171/A 127” to 157” 143” to 173”” The 4084-7141 is dimensio
PAGE 16
129098-UIM-G-0411 SWIVEL FLASHING ADJUSTS FROM 0/12 TO 5/12 PITCH SLANT FLASHING 3/12 PITCH DGAH FURNACES DGAA FURNACES INSTALLATION DIMENSIONS INSTALLATION DIMENSIONS “B” ADJUSTABLE HEIGHT “A” ADJUSTABLE HEIGHT 4000-8161/C 4000-9161/A 85” to 101” 101” to 117” 4000-8181/C 4000-9181/A 99” to 129” 115” to 145” CAREFULLY CAULK ALL AROUND SWIVEL JOINT WITH SEALANT SUPPLIED BY FURNACE MANUFACTURER.
PAGE 17
129098-UIM-G-0411 EXTERIOR ROOF JACK EXTENSION UPPER CAP 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. LOWER CAP CONNECTING ROOF JACK TO FURNACE CROWN ASSEMBLY BASE STEP 2: Place the roof jack extension on top of the crown assembly base, pushing down firmly to assure a snug fit.
PAGE 18
129098-UIM-G-0411 CEILING COMBUSTION AIR PIPE AND FLUE ASSEMBLY THIS JOINT MUST BE 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 extension see Figure 25 and Table 8. More than one interior extension may be used to accommodate A “dimensions up to 110” (284.5 cm).
PAGE 19
129098-UIM-G-0411 G V A D V E FIXED CLOSED B L V B I V C V V B VENT TERMINAL X AIR SUPPLY B B F V H V V B M X V AREA WHERE TERMINAL IS NOT PERMITTED K X J FIXED CLOSED OPERABLE FIGURE 27: Home Layout Canadian Installations1 US Installation2 A.Clearance above grade, veranda, porch, deck, or balcony 12 inches (30 cm) 12 inches (30 cm) B.
PAGE 20
129098-UIM-G-0411 CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death. The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation: 1. Inspect the venting system for proper size and horizontal pitch.
PAGE 21
129098-UIM-G-0411 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.
PAGE 22
129098-UIM-G-0411 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.
PAGE 23
129098-UIM-G-0411 Be sure to relight any gas appliances that were turned off at the start of this input check. CHECKING THE GAS PRESSURES 1. 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.
PAGE 24
129098-UIM-G-0411 MANIFOLD PRESSURE “U” TUBE CONNECTION TRANSFORMER LINE VOLTAGE GAS VALVE 3.5 IN (0.
PAGE 25
129098-UIM-G-0411 TABLE 9: Blower Performance CFM - Downflow Without Filters EXTERNAL STATIC PRESSURE, INCHES WC (kPa) 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) Nominal Cabinet CFM(m³/min) Size 1305 (37) A 1305 (37) A 1305 (37) A 1305 (37) A Speed Tap 0.1 (0.025) 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) 1725 (48.9) 1725 (48.
PAGE 26
129098-UIM-G-0411 SECTION X: WIRING DIAGRAM FIGURE 32: Wiring Diagram - DGAA 26 Johnson Controls Unitary Products
PAGE 27
129098-UIM-G-0411 FIGURE 33: Wiring Diagram - DGAH Johnson Controls Unitary Products 27