Coleman DGAH056BBSB, DGAH077BBSA, DGAH077BBSB, DGAH056BBSA, DGAA090BDTA Installation Guide

...

......................................... 14 ', H', ,'1.-¢" 'l.I

HIGH EFFICIENCY SEALED COMBUSTION GAS FURNACE

MODELS: DGAA and DGAH (Single Stage Downflow Only)

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

! I

LIST OF SECTIONS

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

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

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

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

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

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

For Installation In:

1. Manufactured (Mobile) Homes

2. Recreational Vehicles & Park Models

3. Modular Homes & Buildings

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

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

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

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

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

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

ISO 9OOl

Certified Quality

Management System

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

kWARNING

[_ 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.

Johnson Controls Unitary Products 129098-UIM-H-1011

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.

129098-UIM-H-1011

SPECIFIC SAFETY

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.

RULES AND PRECAUTIONS

&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 I Duct 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.

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

]

DGAH 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.

DGAA Series

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

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.

129098-UIM-H-1011

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.

Dual trunk duct with crossover connector

I I

Dual trunk duct

_, Crossover

I J

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

Single trunk duct C

B* Transition duct

Transition Duct with Branches

U_ Branches U

'_'-3

Furnace to Closet Door Clearance --

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

250 IN.2 (161 cm 2)

FREE AREA

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.

_- 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

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

50 IN. _ (322 cm _) MINIMUM

J FREE AREA

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

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

250 IN.2(161 cm _) MINIMUM 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

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.

MINIMUM

i 0IN. _(322cm _)

FREEAREA

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

DUCT CONNECTORS

2-3/8

(6.0cm) ISEE l

--'1°"ARTF-

2-3/8 -- (6.0 cm)

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

• _ 14 (35.6 cm)_

(33.0 cm)

13 ,

(27.9 cm

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

DUCT CONNECTOR

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)

(11.1 cm)

DEPTH

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

2-3/8 -- (6.0 cm)

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

2-3/8

(6.o cm) 1 SEE l

_ _ CHART

4-3/8

1(11,1 ore)

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

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

MIN

/E I i / i/\

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

_ , ,

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

OF ENCLOSURE FOR ROOF JACK

J. _ FLOOR CUT-OUT

" " CONNECTOR

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

! i I v ._1 i / OR ELECTRIC

i _ OP NAL GAS

I _ ENTRANCE

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

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

FUTURE / I_'_'_ 9_-3/4,--I" REFRIGERANT 14 20.--I,

LINE ENTRANCE ' (5O.8 cm)

z4mcm)z4._cm) _ FLOORI

_(8.30m:

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

// J

/ _

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.

OR STAPLES

SCREWS

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

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

/ /¢ SECURETOTHE

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

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.

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.

DUCT CONNECTOR

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

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

1. Std. Blower-High Speed-No Coil.

Nominal

Air Flow I

Ext. Static Pressure

Minimum Maximum

In.W.C kPa

0.30 0.0747

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 a closet. 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

+ 19 hidden pages