Johnson Controls DGAA, Installation Manual

Page 1: ...ol 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 Th...

Page 2: ...ome 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 ...

Page 3: ...S 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 freezing temperatures 1 Furnace shall be installed in an area where ventilation facilities p...

Page 4: ...e 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 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 mus...

Page 5: ...imum 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 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 causi...

Page 6: ...MUST have three return air grilles The total free area of the two upper grilles must be minimum of 1613 cm The total free area of the lower grille MUST be a minimum of 250 Inches 50 Inches 322 cm 2 2 2 2 The grilles MUST BE ALIGNED directly opposite the return air grille of the furnace door 250 IN 161 cm MINIMUM FREE AREA 2 2 50 IN 322 cm MINIMUM FREE AREA 2 2 FIGURE 6 Duct Connector Dimensions 2 ...

Page 7: ... 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 aft...

Page 8: ... the maximum designed static pres sure These values are listed in Table 2 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 BLEND AIR INSTALLATIONS If a blend air ventilation system is installed the 5 12 7 cm diameter kn...

Page 9: ... an air filter that has a lower pressure drop must be installed SECTION V GAS LINE INSTALLATION GAS SAFETY 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...

Page 10: ...on 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 shall be installed externally of furnace casing After piping has been installed turn gas on and check all connections with a leak detector or soap solu tion Never use open flame to t...

Page 11: ... 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 The gas supply must be shut off prior to disconnecting the electrical power before proceeding with the conversion SHOCK ...

Page 12: ...an air conditioning system at a later time TABLE 4 High Altitude Duration Chart NATURAL GAS Elevation Feet 56 000 Input 70 000 Input 77 000 Input 90 000 Input Meters Orifice Dia Drill Size Part Orifice Dia Drill Size Part Orifice Dia Drill Size Part Orifice Dia Drill Size Part 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 2...

Page 13: ...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 Thermostat Wire Length Furnace to Thermostat Thermostat Wire Gauge 0 45 feet 22 0 70 feet 20 FIGURE 17 Wiring for Heat Only Thermostat FIGURE ...

Page 14: ...herefore 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 fl...

Page 15: ...ion of Roof Jack need Not extend below the ceiling A B 1 2 The 4084 7141 is dimensionally the same as 4000 7141 C and is available only in Canada The 4084 7151 is dimensionally the same as 4000 7151 C and is available only in Canada DGAH FURNACES DGAA FURNACES INSTALLATION DIMENSIONS INSTALLATION DIMENSIONS A ADJUSTABLE HEIGHT B ADJUSTABLE HEIGHT 70 to 79 75 to 86 83 to 104 90 to 116 127 to 157 86...

Page 16: ... 4000 8181 C SWIVEL FLASHING ADJUSTS FROM 0 12 TO 5 12 PITCH SLANT FLASHING 3 12 PITCH 76 59 1 2 IMPORTANT SEAL ROOF JACK FLASHING TO THE ROOF JACK AND ROOF THIS IS THE INSTALLER S RESPONSIBILITY A B CAREFULLY CAULK ALL AROUND SWIVEL JOINT WITH SEALANT SUPPLIED BY FURNACE MANUFACTURER The End of Upper Portion of Roof Jack need Not extend below the ceiling CAULK UNDER FLASHING CAULK UNDER FLASHING ...

Page 17: ...own 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...

Page 18: ...s 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 VENT CLEARANCES FIGURE 25 Roof Jack Assembly 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 asphyxiati...

Page 19: ...ance of 2 feet 61 cm from the center line of the terminal 4 Feet 4 Feet 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 above meter regulator assembly 3 feet 91 cm within a height 15 feet 4 5 m above the meter regulator assembly 3 feet 91 cm within a ...

Page 20: ...h 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 T...

Page 21: ...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 With furnace in operation check all of the pipe joints gas valve connec t...

Page 22: ... 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 MJ m3 or Default 93 15 times 0 10 m3 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 ...

Page 23: ... 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 t...

Page 24: ...in 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 ESP 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...

Page 25: ...SORY BLOWER Speed Tap EXTERNAL STATIC PRESSURE INCHES WC kPa BTU H kW Input Output Nominal CFM m min Cabinet Size 0 1 0 025 0 2 0 050 0 3 0 075 0 4 0 099 0 5 0 124 cfm cm m cfm cm m cfm cm m cfm cm m cfm cm m 56 45 16 4 13 1 1725 48 9 A 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 Low w Coil 1270 36 0 1240 35 1 ...

Page 26: ...129098 UIM G 0411 26 Johnson Controls Unitary Products SECTION X WIRING DIAGRAM FIGURE 32 Wiring Diagram DGAA ...

Page 27: ...129098 UIM G 0411 Johnson Controls Unitary Products 27 FIGURE 33 Wiring Diagram DGAH ...

Page 28: ...e without notice Published in U S A 129098 UIM G 0411 Copyright 2011 by Johnson Controls Inc All rights reserved Supersedes 129098 UIM F 0909 Johnson Controls Unitary Products P O Box 19014 Wichita KS 67204 9014 NOTES ...