Unitary products group DLAS, DGAT, DGAM Installation Instructions Manual

INSTALLATION

INSTRUCTIONS

MODELS DLAS, DGAT AND DGAM

SEALED COMBUSTION

DOWNFLOW GAS FURNACES

(Forced Draft with Direct HSI)

Supersedes: 1973--106/F Rev.1 (1098)

Improper installation, adjustment, service or
maintenancecancauseinjuryorpropertydam­age. Please refer to all the instructions of this
manual for proper installation procedures. Im­proper installation will void the warranty.

The furnace shall be installed so the electrical
components are protected from water.

The furnace is not to be used for temporary
heating of buildings or structures under
constructions.

1973--106/F Rev.2 (599)

DLAS MODELS
(No Coil Cabinet)

For Installation In:

1. Manufactured (Mobile) Homes

2. Recreational Vehicles & Park Models

3. Modular Homes & Buildings

DGAT & DGAM MODELS
(With Built--in Coil Cabinet)

IMPORTANT: Only individuals having proven experi-

ence with this type of equipment should attempt to per­form set--up.

Properfurnaceset--upandadjustmentis theresponsibil­ity of the retailer/homeowner and is not covered under
warranty.

FURNACE SET--UP CHECK LIST

- Has roof jack crown been correctly installed?

- Has furnace gas valve and burner orifice been cor-

rectly converted for L.P. gas where applicable?

- Has furnace gas valve been de--rated for altitudes
above 2000 feet where applicable?

- Is gas line outlet pressure properly set for fueltype?
(natural gas is 3.5” W.C.; L.P. is 10” W.C.)

- Is primary air properly adjusted per installation in­structions?

- Is cross--over duct installed per home builder and
UPG installation instructions?

- Has furnace been operated through a complete
heating cycle?

Donot testthe fuel system at morethan 14inch­es 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.

Improper installation may damage equipment, can
create a shock hazard, and will void the warranty.

NOTE: The words “Shall” or “Must” indicate a

requirement which is essential to satisfactory
and safe product performance.

The words “Should” or “May” indicate a
recommendation or advice which is not
essential and not required but which may be
useful or helpful.

IMPORTANT: These instructions are primarily in-

tended to assist qualified individuals experienced in the
proper installation of heating and/ or air conditioning ap­pliances. Some local codes require licensed installation
service personnel for this type of equipment. Read allin­structions carefully before starting the installation.

TABLE OF CONTENTS

LIST OF FIGURES

FURNACE SPECIFICATIONS 3...................

INSTALLATION STANDARDS 4...................

Code Compliance 4...........................

High Altitude Installation 4.....................

Minimum Furnace Clearance 4.................

RETURN AIR REQUIREMENTS 5.................

Closet Installations 5..........................

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

ROOF JACKS 7.................................

Existing Furnace Replacement 7...............

New Home Installation 7.......................

Installation in Snow Regions 7..................

Locating and Cutting Roof Jack Opening 7.......

Installing Roof Jack in Roof 7..................

DUCT CONNECTORS 10........................

Installation of Screw Attachment

Duct Connector 1 1............................

Installation of Tab Attachment

Duct Connector 1 1............................

Installation of Furnace 12.....................

CONNECTING ROOF JACK TO FURNACE 12.....

Ceiling Rings 13.............................

ELECTRICAL WIRING 13........................

Connect Power Supply Wires 13..............

Connect Thermostat Wires 13.................

Wall Thermostat 14..........................

WIRING DIAGRAMS 15 &16.....................

GAS PIPING 17................................

Installation and Checking of Gas Line 17........

FINAL PROCEDURE 19.........................

Install Furnace Doors 19......................

Finish and Trim 19...........................

Furnace and Air Conditioner Installations 19.....

HIGH ALTITUDE DERA TION CHART 20...........

Natural Gas 20..............................

Propane Gas 20.............................

REPAIR PARTS 21- -22..........................

FIGURE 1 — Furnace Dimensions 3............

TABLE 1 — Minimum Clearances 4.............

FIGURE 2 — Air Distribution Systems 5.........

FIGURE 3 — Closet to Door Clearance — 6” or

greater 6....................................

FIGURE 4 — Furnace to Closet Door Clearance

—1”to6” 6..................................

FIGURE 5 — Furnace to Closet Door Clearance

— Less than 1” 6............................

FIGURE 6 — Standard Roof Jack 8.............

FIGURE 7 — Roof Jack with Removable

Crowns 9....................................

FIGURE 8 — Duct Connector Dimensions 10...
FIGURE 9 — Duct Connector Screw

Attachment 11...............................

FIGURE 10 — Duct Connector Tab

Attachment 11...............................

FIGURE 1 1 — Installation of Furnace 12........

FIGURE 12 — Connecting Roof Jack to

Furnace 12.................................

FIGURE 13 — Ceiling Rings 13...............

FIGURE 14 — Field Wiring 13................

FIGURE 15 — Thermostat Wiring for DGAT and

DGAM 14..................................

FIGURE 16 — Thermostat Wiring for DLAS 14..

FIGURE 17 — Wiring Diagram for DGAT 15....

FIGURE 18 — Wiring Diagram for DGAM 16...

FIGURE 19 — Natural Gas Flame 18..........

FIGURE 20 — Propane Gas Flame 18.........

FIGURE 21 — Anti--Backflow Damper 19.......

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FURNACE SPECIFICATIONS

DGAM — Automatic ignition — with Built--in Coil Cabinet — 4 Ton -- A/C Ready

Model No. Factory Equipped for use with: Input/BTUH Output/BTUH

DGAM056BDF NA TURAL GAS 56,000 46,000
DGAM075BDF NA TURAL GAS 75,000 61,000

DGAT — Automatic Ignition — with Built--in Coil Cabinet — 3 Ton -- A/C Ready

Model No. Factory Equipped for use with: Input/BTUH Output/BTUH

DGAT056BDF NATURAL GAS 56,000 46,000
DGAT070BDF NATURAL GAS 70,000 57,000
DGAT075BDF NATURAL GAS 75,000 61,000
DGAT090BDF NATURAL GAS 90,000 72,000

DLAS — Automatic Ignition — Heating Only — No Coil Cabinet

Model No. Factory Equipped for use with: Input/BTUH Output/BTUH

DLAS056BDF PROPANE 56,000 47,000
DLAS075BDF PROPANE 75,000 62,000

Electrical Specifications

Electrical Power Supply 120Volts—60Hz—1Phase
Breaker or Fuse 15 Amp
Thermostat Circuit 24Volt—60Hz—40VA
Nominal Anticipator Setting .50
Gas Valve Inlet

1

/2”NFPT

59--1/2”

19--1/2”

9--3/4”

10--5/8”

24”

23”

76”

19--1/2”

9--3/4”

24”

23”

10--5/8”

FIGURE 1 -- DLAS, DGAT AND DGAM SERIES FURNACE DIMENSIONS

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DGAT & DGAM SeriesDLAS Series

3

INSTALLATION STANDARDS

CODE COMPLIANCE

The installer shall familiarize himself with and comply
with all local codes and regulations which govern the in­stallation of this appliance. Local codes and regulations
shall take precedent over these regulations where appli­cable. In lieu of local codes, the appliance shall be in­stalled in accordance with one or more of the following
standards.

Manufactured homes in the U.S.A.:

1. Federal Manufactured Home Construction & Safety
Standard (H.U.D. Title 24, Part 3280)

2. American National Standard (ANSI- -Z223.1,
NFPA--54) for gas fired furnaces.

3. Unit electricalwiring and groundingshallcomplywith
current CSA standard C22.2 No.148/CAN/CSA-­Z240.6.2 -- Electrical Requirements for recreational
vehicles.

Manufactured homes in Canada:

1. CAN/CGA B149 for gas fired furnaces.

2. CSA 22.1 Canadian Electrical Code part 1 for all
electrical field wiring.

Recreational Vehicles in U.S.A.:

1. American National Standard (ANSI--119--2/NFPA-­501C) for recreation vehicle installations.

2. Unit electricalwiring and groundingshallcomplywith
current CSA standard C22.2 No.148/CAN/CSA-­Z240.6.2 -- Electrical Requirements for recreational
vehicles.

Recreational Vehicles in Canada:

1. Unit installation shall comply withcurrent CSA stan­dard CAN/CGA--Z240.4.2 -- Installation Require­ments for Propane Appliances and Equipment in
Recreational Vehicles.

2. Unit electricalwiring and groundingshallcomplywith
current CSA standard C22.2 No.148/CAN/CSA-­Z240.6.2 -- Electrical Requirements for recreational
vehicles.

HIGH ALTITUDE INSTALLATION

Forelevation above2,000feet, deratefurnaceorifice4%
foreach1,000 feetof elevation above sealevel. Derating
is accomplished by reducing the orifice size. See Derat­ing Chart for orifice size.

CAUTION:

D Never attempt to alter or modify this furnace or any

of its components.

D Neverattempttorepair damagedor inoperable com-

ponents. Such action could cause unsafe operation,
explosion, fire and/or asphyxiation.

D If a malfunction has occurred, or if you feel that the

furnace is not operating as it should, contact a quali­fied service agency or gas utility for assistance.

MINIMUM FURNACE CLEARANCES

Access for servicing is animportant factor in thelocation
of any furnace. A minimum of 24 inches should be pro­videdin front ofthe furnace for access tothe heating ele­ments and controls. This access may be provided by a
closet door or by locating the furnace 24 inches from a
facing wall or partition.

These furnaces are design certified for the following
minimum clearances from combustible material in al­cove or closet installation:

TABLE 1 — Minimum Clearances

CLOSET ALCOVE

BACK 0” 0”
SIDES 0” 0”
FRONT 6” 24”
TOP 2” 2”
ROOF JACK 0” 0”
DUCT 0” 0”

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RETURN AIR REQUIREMENTS

—

A

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.

Floor or Ceiling Return Air System

Floororceiling returnairsystem forcloset installeddirect
vent forced air heating appliance.

Listed in the next paragraph are the conditions to bemet
byMobile HomeManufacturers tohave U.L.acceptance
of in--floor or ceiling return air systems of closet installed
direct vent forced air heating appliances for Mobile
Homes to be sold in the United States.

1. The return--air opening into the closet, regardless of
location, is to be sized not less than specified on the
appliance’s rating plate.

2. If the return--air opening is located in the floor of the
closet (versus the vertical front or side wall), the
opening is to be provided with means to prevent its
inadvertent closure by a flat object placed over the
opening.

3. The cross--sectional area of the return duct system
(when located in the floor or ceiling of the mobile
home) leading into the closet is to be not less than
that of the opening specified on the appliance’s rat­ing plate.

4. The total free area of openings in the floor or ceiling
registers serving the return--air duct system is tobe
not less than 150% of the size of the opening speci­fiedon theappliance’s rating plate. Atleast onesuch
register is to be located where likelihood of its being
covered by carpeting, boxes, and other objects is
minimized.

5. Materials located in the return duct system have a
flame spread classification of 200 or less.

A

Single trunk duct

B*

Dual trunk duct with crossover connector

1

6. Non--combustible pans having one--inch upturned
flanges are located beneath openings in the floor re­turn duct system.

7. Wiring materials located in the return duct system
conformtoArticle 300--22(b&c)of theNational Elec­tric Code (ANSI C1 / NFPA--70).

8. Gas piping is not run in or through the return duct
system.

9. The negative pressure in the closet as determined
by test with the air--circulating fan operating at high
heatingspeed andthe closet doorclosed is to benot
more negative than minus 0.05--inch water column.

10. For floor return systems, themobile home manufac­turer or installer shall affixa prominent marking on or
near the appliance where it is easily read when the
closet door is open. The marking shall read:

HAZARD OF ASPHYXIATION

DO NOT COVER OR RESTRICT FLOOR

OPENING, or equivalent.

AIR DISTRIBUTION SYSTEMS

For proper air distribution, the supply duct system shall
be designed sothat thestatic 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 withinthe range(s) specified onthe fur­nace rating plate.

C

Transition Duct with Branches

Transition duct

Dual trunk duct

Crossover

*B

1

D

Crossover Duct must be centered directly under furnace.

2

Use 12” Diameter Round or equivalent insulated Flex--duct only.

D

3

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

D

4

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

D

FIGURE 2

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IR DISTRIBUTION SYSTEMS

4

3

2

Branches

5

Return Air Grille Part No.
7900--286P/A — Almond
7900--287P/A — White

A

250 SQ. IN.
MINIMUM
FREEAREA

B

Furnace to Closet Door Clearance —
Greater than 6 Inches

TheclosetdoorMUSThavea minimumof250 Square Inches offreearea
in the upper half of the door.

Ifopeningforreturnairislocated inthefloor or sidewalls and below thetop
of the furnace casing:

1. 6 inches minimum clearance must be provided on side where return
is located, and

2. 6 inches minimum clearance must be maintained from the front of

50 SQ. IN.
MINIMUM
FREEAREA

250 SQ. IN.
FREEAREA

MINIMUM

furnace.

CLOSET

FURNACE

As an option to the lower grill,
an undercut of 2 1/2” will provide
50 Sq. In. of free area.

DOOR

FIGURE 3 — CLOSET TO DOOR CLEARANCE — 6” OR GREATER

Furnace to Closet Door Clearance — Greater
than 1 Inch and Less than 6 Inches

A

250 SQ. IN.
MINIMUM
FREEAREA

B

50 SQ. IN.
MINIMUM
FREEAREA

250 SQ. IN.
MINIMUM
FREEAREA

1. The closet door MUST have a minimum of 250 Square In-
ches of free area in the upper half of the door and a mini­mumof 50 Square Inches of free area in thelower area of
the door.
The lower closet door grille may be omitted if an undercut
of 2 1/2 Inches is provided in the door.

2. A fully louvered closet door MUST have a minimum of 250
Square Inches of free area in the upper half of the door.

Return Air Closet Door Part No.
7900--7771/C — White

6” or greater — Closet
to Door Clearance

As an option to the lower grill,
an undercut of 2 1/2” will provide
50 Sq. In. of free area.

FIGURE 4 — FURNACE TO CLOSET DOOR CLEARANCE — 1” to 6”

Furnace to Closet Door
Clearance — Less than 1 Inch

250 SQ. IN.
MINIMUM
FREEAREA

50 SQ. IN.
MINIMUM
FREEAREA

FIGURE 5 — FURNACE TO CLOSET DOOR CLEARANCE — LESS THAN 1”

6

Thecloset door MUST have three return air grilles. The total free
area of the two upper grilles must be a minimum of 250 Square
Inches. The total free area of the lower grille MUST be a mini­mum of 50 Sq. In.

Each grille MUST BE ALIGNED directly opposite the corre­sponding return air grille of the furnace door.

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ROOF JACKS

FAILURE TO FOLLOW ALL VENTING IN ­STRUCTION CAN RESULT IN FIRE ASPHYXI­ATION, OR EXPLOSION.

CAUTION: Only use the appropriate roof jack.

See Figures 6 & 7 for correct application.
Do not exceed the maximum height as determined

from Figures 2 & 3. Installer should allow an addi­tional 1­fully extended against the built-in stop. This pro­vides an additional safeguard against the flue as­semblybeing pulledfromtheroofjackduringtrans­portation or other stress conditions.

EXISTING FURNACE REPLACEMENT

If this furnace replaces an exciting furnace,dothefol­lowing:

1. If a 2

2. After unpacking the roof jack, check the rain caps.

3. Before inserting the roofjack into the furnace top, in-

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

5. Use only the pipes provided with the roof jack as-

6. In no case should there be a gap between sections

1

/2” travel before the flue pipe assembly is

nd

roof, roof cap or addition has been made to

the existing roof of the home, remove the old roof

jack completely!... to avoid the possibility of an
improperlyinstalledpipe or gaps in the old roof
jack, INSTALL A NEW ROOF JACK. Your ceiling
and roof height will determine the correct roof
jack to use. Refer to the vent selection table, of
the furnace installation instructions.

Insure they are not damaged, tilted or crooked. Do
not twist, crush or sit on the roof caps during
installation.Damagedroof caps will cause improp-

er furnace operation. The furnace will not heat prop­erly and could result in explosion.

spect the furnace flue and combustion air opening
for debris or insulation which might have fallen in
during pre--installation steps. Do not proceedunless
all debris have been cleaned out or removed.

tomake sure thereis nogap in backor side between
the pipe collar and the furnace casing top.

sembly. Do not add to or adapt other sheet metal
pipes.Donotcut,insertor addotherpipestothis

assembly.

of the flue pipe or the combustion air pipe. If neces­sary to prevent excessive air leakage, the installer
shouldseal joints in the combustion air tube withalu­minum type or other suitable sealant.

NEW HOME INSTALLATION

Ifthis furnaceis installedonanewhome do thefollowing:

1. Inspect the furnace top collars for signs of insulation
or ceiling debris which might have fallen in during
cutting of the ceiling and roof holes. Remove all de­bris before continuing.

2. After unpacking the roof jack, check the rain caps.
Insure they are not damaged, tilted or crooked. Do

not twist, crush or sit on the roof caps during
installation.Damagedroof caps will cause improp-

er furnace operation. The furnace will not heat prop­erly and could result in explosion.

3. Before inserting the vent pipe into the furnace top,
inspect the furnace flue and combustion air opening
for debris or insulation which have fallen in during
pre--installation steps. Do not proceed unless allde­bris have been cleaned out or removed.

4. After installing roof jack on furnace top collar,check
tomake sure thereis nogap in backor side between
the pipe collar and the furnace casing top. If neces­sary to prevent excessive air leakage, the installer
shouldseal joints in the combustion air tube withalu­minum type or other suitable sealant.

INSTALLATION IN SNOW REGIONS

Whenthe combustion airpipeinlet iscovered orblocked
with snow, the furnace will not operate properly due to
the depleted combustion air supply.

Therefore, if the furnace will be located in regions where
snow accumulation on the roof exceeds 7” 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 fur­nacefluecollar.SeeFigure8.

Mark this location on ceiling and scribe a circle with a 5”
radius (10” diameter) around this mark. Cut opening for
roof jack through ceiling and roof. (If furnace was in-

stalled during construction, cover furnace and flue
opening to prevent debris from entering flue when
hole is cut for roof jack.)

INSTALLING ROOF JACK IN ROOF

(See Figure 6 & 7 for Dimensional requirem ents .)

Insert roof jack into opening in the roof.

The roof jack should be secured to the furnace be­foreroof flange (flashing) is secured tothe roof. This

will insure a better alignment ofthe fluepipe andfurnace
fluecollar. Caulk around andunder roofflangeto provide
a water tight seal, before securing roof jack flashing to
roof.

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7

SWIVEL FLASHING

ADJUSTS FROM

0/12 TO 5/12 PITCH

4000--7101/C
4000--7121/C

4000--7141/C
4000--7151/C
4000--7171/C

SLANT
FLASHING
3/12 PITCH

4000--6101/A
4000--6121/A

4000--6141/A
4000--6151/A
4000--6171/A

DLAS & COAS Furnaces DGAT, DGAM, COAT, CGAT Furnace

Installation Dimensions Installation Dimensions

Adjustable Height

A

70” to 79”
75” to 86”

83” to 104”

90” to 116”

127” to 157”

Adjustable Height

B

86” to 95”
91” to 102”

99” to 120”
106” to 132”
143” to 173”

FLUE
GASES

COMBUSTION
AIR

CAULK
UNDER
FLASHING

19 1/2”

FLUE
GASES

COMBUSTION
AIR

CAULK
UNDER
FLASHING

CAULK CAREFULLY ALL AROUND SWIVEL JOINT WITH
SEALANT SUPPLIED BY FURNACE MANUFACTURER.

The End of Upper Portion of Roof Jack need

Not extend below the ceiling.

IMPORTANT

SEALROOFJACKFLASHINGTOTHEROOFJACK
AND ROOF.
THIS IS THE INSTALLER’S RESPONSIBILITY.

A B

76”

19 1/2”

ROOF

59--1/2”

DLAS & COAS Models

WARM AIR DUCT

DUCT CONNECTOR

FIGURE 6 -- STANDARD ROOF JACK

8

FLOOR

DGAT, DGAM, COAT & CGAT Models

DUCT CONNECTOR

WARM AIR DUCT

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