Coleman DGAA, DGAH, DGAA Series, DGAH Series, DGAA056BDTB User's Information, Maintenance And Service Manual
...
USER’S INFORMATION,
EFFICIENCY
RATING
CERTIFIED
ISO 9001
Certified Quality
Management System
MAINTENANCE AND
SERVICE MANUAL
HIGH EFFICIENCY SEALED COMBUSTION
GAS FURNACE
MODELS: DGAA and DGAH
(Single Stage Downflow Only)
TABLE OF CONTENTS
CONTACT INFORMATION FOR USA . . . . . . . . . . . . . . . . . . . . . . .1
CONTACT INFORMATION FOR CANADA . . . . . . . . . . . . . . . . . . .1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
While you are away . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
SEASONAL SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . .2
Your Service Technician . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
WARRANTY AND RESPONSIBILITIES . . . . . . . . . . . . . . . . . . . . .2
GAS SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Natural Gas Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Propane Gas Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
INSTRUCTIONS FOR EXAMINING
THE FURNACE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Observing Burner Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
If Furnace Fails to Operate Properly . . . . . . . . . . . . . . . . . . . . . . . 4
HOW YOUR GAS FURNACE WORKS . . . . . . . . . . . . . . . . . . . . . . 4
IF FURNACE FAILS TO OPERATE PROPERLY . . . . . . . . . . . . . . 4
When You Call For Service Assistance . . . . . . . . . . . . . . . . . . . . .4
To Contact Your Serviceman (fill in) . . . . . . . . . . . . . . . . . . . . . . .4
START-UP AND SHUTDOWN INSTRUCTIONS . . . . . . . . . . . . . . .4
Read the Instructions Below Before Trying
to Start the Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Operating Instructions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
For Installation In:
1. Manufactured (Mobile) Homes
2. Recreational Vehicles & Park Models
3. Modular Homes & Buildings
To Turn Off the Appliance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
FURNACE USER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . .5
Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Removing Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Blower Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Motor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
SERVICE AND MAINTENANCE MANUAL . . . . . . . . . . . . . . . . . . . . .6
SAFETY SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
FURNACE MAINTENANCE SECTION . . . . . . . . . . . . . . . . . . . . . .6
FURNACE CLEANING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . .6
Burner Removal/Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Cleaning the Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
THE FURNACE CONTROLS AND THEIR FUNCTION . . . . . . . . . .6
SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Continuous Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Heating Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Hot Surface Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
FURNACE CONTROL DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . .8
REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
CONTACT INFORMATION FOR USA
• Contact us by mail:
DISTRIBUTED BY:
StyleCrest
801 W. 37th Street
Building #7
Wichita, Ks 67219
MANUFACTURED BY:
The manufacturer recommends that the user read all
sections of this manual and keep the manual for
future reference.
FIRE OR EXPLOSION HAZARD - Failure to follow safety warnings
exactly could result in serious injury, death, or property damage.
— Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
— WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone (including cell phone) in your building.
• Leave the building immediately.
• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire department.
— Installation and service must be performed by a qualified
installer, service agency or the gas supplier.
Johnson Controls Unitary Products 129099-UUM-G-0909
York International
5005 York Drive
Norman, OK 73069
CONTACT INFORMATION FOR CANADA
• Go to website at www.york.com click on “contact”, then click on
“contact form” and follow the instructions.
• Contact us by mail:
York International
Consumer Relations
5005 York Drive
Norman, OK 73069
SECTION I: SAFETY
1. The furnace area must be kept clear and free of combustible materials, gasoline and other flammable vapors and liquids.
2. Insulating materials may be combustible. The furnace must be
kept free and clear of insulating materials. The furnace area must
be examined when installed in an insulated space or when insulation is added to be sure that the insulation material has been kept
away from the furnace.
3. Follow the instructions exactly as shown on the OPERATING
INSTRUCTION LABEL or the Start-up and Shutdown Instructions
on Page 4 of this manual when lighting the furnace or turning the
furnace off.
4. Should the gas supply fail to shut off or if overheating occurs, shut
off the gas valve to the furnace before shutting off the electrical
supply.
5. Do not use this furnace if any part has been under water. A flooddamaged furnace is extremely dangerous. Attempts to use the furnace can result in fire or explosion. A qualified service agency
should be contacted to inspect the furnace and replace all gas
controls, control system parts, electrical parts that have been wet
or the furnace if deemed necessary.
129099-UUM-G-0909
VENT PIPE
PRESSURE
SWITCH
SILICONE
TUBE
GAS VALVE
BOOSTER DRAFT
ASSEMBLY
SAFETY SHUTOFF
SWITCH
CONTROL
BOARD
FLUE
COLLAR
BLOWER
COMBUSTION
AIR PIPE
AIR CONDITIONING
COIL PANELS
BLOWER
MOTOR
BLOWER MOTOR
CAPACITOR
GAS BURNER
ASSEMBLY
6. NEVER…Store flammable materials of any kind near your fur-
nace. Gasoline, solvents, and other volatile liquids should be
stored only in approved containers outside your home. These
materials vaporize easily and are extremely dangerous.
7. NEVER
…Store cleaning materials near your furnace. Materials
such as bleaches, detergents, powdered cleansers, etc., can
cause corrosion of the heat exchangers.
8. NEVER
…Use the area around your furnace as a storage area for
items which could block the normal flow of air. This flow of air is
required for ventilation of the various furnace components.
FIRE OR EXPLOSION HAZARD
This furnace is designed and approved for use with Natural
Gas and (LP) Propane Gas ONLY. DO NOT BURN ANY LIQUID
FUEL OR SOLID FUEL IN THIS FURNACE.
Burning any unapproved fuel will result in damage to the furnace heat exchanger, which could result in Fire, Personal
Injury, and/or Property Damage.
While you are away
Your furnace is equipped with a safety device which will shut off the
supply of gas to the burner in case of malfunction. For this reason it is
never practical to assume that the furnace will operate unattended for a
long period of time, especially if there is a possibility of damage to your
property because of freezing. So, if you plan to be away from home,
arrange for someone to check your house every day.
This furnace shall be installed in the downflow position. Figure 1 shows
a typical model in the downflow position. The furnace is equipped with
an induced-draft vent blower and atmospheric burner. Combustion air is
drawn through the roof jack and pushed into the burner box. Flue gas is
forced from the heat exchanger by the vent blower and discharged
through the flue pipe to the outside atmosphere.
This is a forced air furnace. The furnace circulating air blower draws
cool air from the house, passes it over the hot furnace heat exchanger
and circulates the warmed air through the ductwork to the house.
The furnace is equipped with the controls necessary for proper operation. The various components referred to in this manual and on the furnace rating plate are identified in Figure 1.
SEASONAL SERVICE INFORMATION
During extreme cold weather, ice may form on the furnace roof jack
crown. Small amounts of ice forming on the roof jack will present no
problem to proper furnace operation. However, excessive ice formation
could restrict the combustion air supply to the burner causing inefficient
burner operation.
When the temperature is very cold, near zero or below, it is recommended that the roof jack be inspected every day or more frequently if
required. If ice has started to collect on the roof jack crown, it should be
carefully broken off.
Y our Service Technician
Your furnace's best friend is your qualified service technician. If the unit
gives any indication of improper operation, call your service technician.
If the service technician is allowed to perform the normal routine care of
your furnace, he can many times detect potential difficulties and make
corrections before trouble develops. Preventative maintenance of this
type will allow you to operate the unit with a minimum of concern, and at
the same time will pay for itself in added years of comfort.
DESCRIPTION
FIGURE 1: Component Locations
WARRANTY AND RESPONSIBILITIES
It is the sole responsibility of the home owner to make certain that the
gas furnace has been correctly set up and converted to the proper fuel
(Propane or Natural gas) and adjusted to operate properly.
The manufacturer warrants the furnace to be free from defects in material or workmanship for the stated time in the warranty agreement (see
warranty certificate packed with the furnace).
However, the manufacturer will not be responsible for any repair costs
to correct problems due to improper set-up, improper installation, furnace adjustments, improper operating procedure by the user, etc.
It is also the sole responsibility of the home owner to make sure that the
home if located above 2,000 ft. altitude be derated.
2 Johnson Controls Unitary Products
129099-UUM-G-0909
NATURAL GAS
PROPANE GAS
LIGHT BLUE
WITH YELLOW TIPS
DARK BLUE
BLUE TIPS JUST
STARTING TO
BECOME
PRONOUNCED
WHITISH YELLOW
TO LIGHT YELLOW
LIGHT BLUE
BLUE TIPS JUST
STARTING TO
BECOME
PRONOUNCED
Some specific examples of service calls which cannot be included in
warranty payments are:
1. Converting the furnace to use another type of fuel.
2. Correcting faulty duct work in the home.
3. Correcting wiring problems in the electrical circuit to the furnace.
4. Resetting circuit breakers or other switches.
5. Adjusting the burner air shutter or service calls made to correct
problems caused by improper air adjustment.
6. Correcting problems caused by improper gas supply pressure to
the furnace.
7. Instructional training on how to light and operate furnace.
8. Furnace problems caused by installation of air conditioner, heat
pump, or other air quality device.
9. Problems caused by improper installation of the furnace flue
assembly (roof jack).
10. Adding a roof jack extension because of unusual wind condit ions
or snow conditions.
11. Adjusting thermostats.
12. Problems caused by construction debris which has fallen into the
flue or combustion air openings.
13. Replacement of fuses.
14. Problems caused by plugged or restricted orifices by any means.
You should establish a firm understanding of these responsibilities with
your manufactured housing dealer, service company or gas supplier so
there will be no misunderstanding at a later time.
GAS SUPPLY
The gas supply to your home will either be Natural Gas or Propane gas.
Your furnace will be factory equipped to operate on only one of these
two different gases.
A small metal tag secured to the furnace next to the gas valve will specify the type of gas your furnace is equipped to use.
If the gas is different from that specified on the metal tag, the furnace
can be converted by following the instructions on the furnace safety
label inside lower front panel. Parts for conversion are contained in the
small bag attached to the gas valve. Be sure the proper size orifice is
used, as specified on the furnace name plate.
The furnace must be converted by a qualified technician.
Improper conversion can cause unsafe operation, explosion,
and/or fire or asphyxiation.
Natural Gas Operation
The furnace is designed for 7" W.C. inlet pressure. Pressure is reduced
to 3 1/2" W.C. by the pressure regulator in the gas valve.
Propane Gas Operation
Inlet pressure to the gas valve must be 11" W.C. When properly converted to Propane gas, the pressure is regulated at 10" W.C.
INSTRUCTIONS FOR EXAMINING THE FURNACE
INSTALLATION
It is the owner’s responsibility to ensure that an annual inspection of the
entire heating portion of the unit is made by a qualified service agency.
Examine the furnace as outlined below in steps “1 - 6” before each
heating season.
1. Examine the heat exchanger, through an access panel located on
the supply air plenum. Visually examine the exterior sections of
the vent/combustion air piping and the vent connectors to be sure
that they are physically sound without holes or excessive corrosion.
2. Examine the vent pipe making sure it is firmly in place, and is
physically sound without holes and all of the connections are
secure.
3. Examine return connections for Modular or Manufactured (Mobile)
Homes.
4. Examine the return air filter rack connections to make sure they
are physically sound, sealed to the furnace door.
5. Examine the furnace casing making sure the physical support is
sound without sagging, cracks or gaps. Examine the furnace base
making sure it is physically sound without cracks, gaps or sagging
and has a good seal.
6. Examine the furnace casing for obvious signs of deterioration.
7. Examine the burner flames to make sure the burner look like they
are operating properly. The burner flames for natural gas should
appear blue with a few yellow tips. The burner flames for propane
gas should appear blue with moderate yellow tips. The flame
should appear cylindrical in shape and should extend from the end
of the burner into the heat exchanger.
FIGURE 2: Burner Flame Appearance
Observing Burner Operation
1. Observe burner to make sure it ignites. Observe color of flame. On
natural gas the flame will burn blue with appreciably yellow tips.
On Propane gas a yellow flame may be expected. If flame is not
the proper color call a qualified service technician for service.
2. Let furnace heat until blower cycles on.
3. Turn thermostat down.
4. Observe burner to make sure it shuts off.
5. Let the furnace cool and blower cycle off.
Should overheating occur, or the gas supply fail to shut off, shut off
the manual gas valve to the furnace and allow blower to run until
furnace cools down and blower shuts off before shutting off the
electrical supply.
Johnson Controls Unitary Products 3
If any abnormalities are observed when checking for correct operation,
such as burner failing to ignite or to turn off, sooty flame, etc., call your
nearest authorized service technician as shown in the Service Center
List included in the home owner envelope with the furnace.
129099-UUM-G-0909
1. Examine Vent Pipe
2. Examine Filter Door
3. Remove Filter
Door to Examine
Combustion Air Pipe
4. Examine Burner Door
5. Remove Burner
Door to Examine
Furnace Base and
Air Conditioning
Coil Panels
7. Remove Burner
Door to Examine
Burner Flame
If Furnace Fails to Operate Properly
1. Check setting of thermostat - and position of HEAT/COOL switch if
air conditioning is installed. If a set-back type thermostat is
employed be sure that the thermostat is in the correct operating
mode.
2. Check to see that electrical power is ON.
3. Check to see that the knob or switch on the gas control valve is in
the full ON position.
4. Make sure filters are clean, return grilles are not obstructed, and
supply registers are open.
5. Be sure that furnace flue piping is open and unobstructed.
If the cause for the failure to operate is not obvious, do not attempt to
service the furnace yourself. Call a qualified service agency or your gas
supplier.
4. Make sure filters are clean, return grilles are not obstructed, and
supply registers are open.
5. Be sure that furnace flue piping is open and unobstructed.
When You Call For Service Assistance
Very often time can be saved if you will give the service agency the
MODEL and SERIAL NUMBER of your furnace. This will enable him to
determine the specific components used, and perhaps to better identify
the possible problem and be better prepared if a service call is required.
To Contact Your Serviceman
(fill in)
COMPANY:___________________________________________
ADDRESS: __________________________________________
TELPHONE:__________________________________________
All appliances need maintenance by serviceman at the beginning of
each heating season. Call your nearest authorized service technician
to:
1. Replace filters. Clean all lint and dust from around furnace.
2. Remove fan and clean all dust and lint from unit with stiff bristle
brush.
3. Inspect combustion chamber, the transition into the blower compartment, flue collar, and roof jack.
4. Check the gas valve and line connections for leaks.
5. Make any adjustments necessary for good operation.
NOTE: The coil panel provides a good removable access for inspecting
inside the furnace casing. Smoke or reflected light inside the
casing indicates the presence of leaks in the heat exchanger.
FIGURE 3: Furnace Examination Checkpoints
HOW YOUR GAS FURNACE WORKS
Your furnace is a very easy appliance to take for granted. Season after
season, it sits there in your home, keeping you warm and comfortable.
For this reason, you may never have given much thought to the way
your furnace operates. In order to get the safest and most efficient operation from your furnace, you should understand how your furnace does
its job.
When you set your thermostat to provide more heat in your home, you
are starting the heating cycle of the furnace. First, the inducer motor
starts to purge the heat exchanger of any remaining gases. Next, the
hot surface ignitor glows and after a warm-up period the gas valve
opens and ignition occurs. A short time later, the blower starts and distributes the warm air throughout the home. When the temperature setting on your thermostat is reached, the gas valve closes, the main
burner is turned off, and the blower continues to run until the remaining
warm air in the system is distributed. When the blower stops, the heating cycle has ended.
IF FURNACE FAILS TO OPERATE PROPERLY
1. Check setting of thermostat - and position of heat/cool switch if air
conditioning is installed. If a set-back type thermostat is employed
be sure that the thermostat is in the correct operating mode.
2. Check to see that electrical power is “ON”.
3. Check to see that the lever or switch on the gas control valve is in
the full “ON” position.
START-UP AND SHUTDOWN INSTRUCTIONS
Read the Instructions Below Before Trying to Start the
Furnace
If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury,
and/or loss of life.
1. This appliance does not have a pilot. It is equipped with an ignition
device which automatically lights the burner. Do not try to light the
burner by hand.
2. BEFORE OPERATING; smell all around the appliance area for
gas. Be sure to smell next to the floor because some gas is
heavier than air and will settle on the floor.
3. Use only your hand to push the gas control switch to the “on” position. Never use tools. If the switch will not operate by hand, don’t
try to repair it, call a qualified service technician. Force or
attempted repair may result in a fire or explosion.
4. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance
and to replace any part of the control system and any gas control,
which has been under water.
Operating Instructions:
1. STOP! Read the safety information above.
2. Set the thermostat to the lowest setting.
3. Turn off all electric power to the appliance.
4. Remove furnace door.
5. Move gas control switch to the “OFF” position. Do not force. See
Figure 4.
4 Johnson Controls Unitary Products
129099-UUM-G-0909
INLET
ON/OFF SWITCH
(shown in OFF position)
OUTLET
SUPPLY
PRESSURE
TAP
OUTLET (MANIFOLD)
PRESSURE TAP
ELECTRICAL
CONNECTIONS
MAIN REGULATOR
ADJUSTMENT
90°
FLANGE
MANUAL
SHUT-OFF
VALV E
GAS
PIPE
GAS
PIPE
MANUAL
SHUT-OFF
VALV E
GAS
VALV E
GAS
BURNER
DRIP
LEG
DRIP
LEG
6. Wait five (5) minutes to clear out any gas. If you then smell gas,
STOP! Follow “B” in the safety information above. If you don’t
smell gas, go to next step.
7. Move gas control switch to the “ON” position. Do not force. See
Figure 4.
8. Replace burner door.
9. Turn on all electric power to the appliance.
10. Set thermostat to the desired setting. Burner will light, which may
take 30-60 seconds.
11. After three (3) trials for ignition, if the appliance will not operate follow the instructions, “TO TURN OFF THE APPLIANCE” and call
your service technician or gas supplier.
To Turn Off the Appliance:
1. Set the thermostat to lowest setting.
2. Turn off all electric power to the appliance if service is to be performed.
3. Remove burner access panel.
4. Move gas control switch to the “OFF” position. See Figure 4.
5. Replace burner access panel.
Should overheating occur, or the gas valve fail to shut off,
turn the external manual gas valve in the gas supply line to
the furnace to the “off” position and let the furnace cool off
before shutting off the electrical power supply. Refer to Figure 5.
FIGURE 4: Gas Valve
FIGURE 5: Gas Piping
Johnson Controls Unitary Products 5
FURNACE USER MAINTENANCE
Before proceeding, be sure the area is well ventilated. Turn
the thermostat OFF . If the blower is running, wait until it stops
automatically. Turn OFF the gas and electrical power supplies
to the furnace. Check all metal parts and surfaces to be sure
they have cooled to room temperature before you begin.
Every time the filters are changed the following items should be visually
inspected:
• Check roof jack assembly for blockage or leakage.
• Check all components to be sure they are in good condition and
that there are no obvious signs of deterioration.
• Check the evaporator coil drain lines to make sure there are no
cracks or leaks.
• Check for dirt or lint on any surfaces or on components. Do not try
to clean any of the surfaces or components. Cleaning of the furnace and its components must be done by a qualified service professional.
If, during the inspection of your furnace, you find any of the following
conditions:
• Excessive amounts of dust and lint on components.
• Damaged or deteriorated components or surfaces.
• Leaks or blockage in the vent pipe passages.
• Water on any surface inside or outside of the furnace.
Do not operate the furnace, and call a certified dealer / servicing contractor to check and / or clean your furnace, or for more information if
you have questions about the operation of your furnace.
If all components appear to be in good operating condition, replace the
front panels. Follow the operating instructions to place the furnace in
operation.
Air Filters
Dirty filters greatly restrict the flow of air and may cause damage to the
moving parts of the furnace. If the filters become clogged the heat
exchangers and blower motor could overheat resulting in a potentially
dangerous situation.
The filters should be checked every 3 months (DO NOT USE PLEATED
FILTER in this furnace). On new construction, check the filters every
week for the first four weeks and every three weeks after that, especially if the indoor fan is running continuously. When replacing the filter(s) you must use filters that are the same size and type as those in
the furnace (2 - 16 x 20 x1).
Removing Filters
Internally Mounted Air Filters
The air filter is in a rack that is attached to the door of the furnace.
To remove the filter you must do the following:
1. Before proceeding, be sure the area is well ventilated. Follow
instruction “To turn off the appliance”. Check all metal parts and
surfaces to be sure they have cooled to room temperature before
you begin.
2. Remove the filter door.
3. Remove the air filter by sliding it down the track. The air filter will
slide out of the rack.
4. Replace throw away filter(s)) with the same size new filter(s).
Throw away filter(s)) may be replaced with cleanable filter(s) at
this time. Cleanable filter(s) may be cleaned as described in the
manufacturer instructions or as described in these instructions.
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