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INSTALLATION MANUAL
HIGH EFFICIENCY
SEALED COMBUSTION GAS FURNACE
MODELS: DGAA and DGAH
(Single Stage Downflow Only)
56 - 90 MBH INPUT
(16.41 - 26.38 KW) INPUT
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
RETURN AIR REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
GAS LINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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
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
SECTION I: SAFETY
This is a safety alert symbol. When you see this symbol on
labels or in manuals, be alert to the potential for personal
injury.
Understand and pay particular attention to the signal words DANGER,
WARNING, or CAUTION.
DANGER indicates an imminently hazardous situation, which, if not
avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation, which, if not
avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation, which, if not
avoided may result in minor or moderate injury. It is also used to
alert against unsafe practices and hazards involving only property dam-
age.
Johnson Controls Unitary Products
For Installation In:
1.
Manufactured (Mobile) Homes
2.
Recreational Vehicles & Park Models
3.
Modular Homes & Buildings
LIST OF SECTIONS
ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ROOF JACK VENT/COMBUSTION AIR SYSTEM . . . . . . . . . . . . . 13
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 20
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
LIST OF FIGURES
Wiring for Electronic Heat-Cool Thermostat . . . . . . . . . . . . . . . . . . . 13
Wiring for Standard Heat-Cool Thermostat . . . . . . . . . . . . . . . . . . . 13
Wiring for Blend Air Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Standard Roof Jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Roof Jack With Removable Crowns . . . . . . . . . . . . . . . . . . . . . . . . . 16
Roof Jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Connecting Roof Jack to Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Roof Jack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Ceiling Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Home Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Pressure Switch Tubing Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Wiring Diagram - DGAA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Wiring Diagram - DGAH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
LIST OF TABLES
Roof Jack Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Blower Performance CFM - Downflow Without Filters . . . . . . . . . . . 25
AC Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Improper installation may create a condition where the operation of
the product could cause personal injury or property damage.
Improper installation, adjustment, alteration, service or mainte-
nance can cause injury or property damage. Refer to this manual
for assistance or for additional information, consult a qualified con-
tractor, installer or service agency.
This product must be installed in strict compliance with the installa-
tion instructions and any applicable local, state, and national codes
including, but not limited to building, electrical, and mechanical
codes.
129098-UIM-G-0411
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Table of Contents
Related Manuals for Johnson Controls DGAA
Summary of Contents for Johnson Controls DGAA
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Page 1: Table Of Contents
Burner Assembly ........10 Wiring Diagram - DGAA ........26 Line Wiring Connections . -
Page 2: Safety
These instructions are required as a minimum for a safe The air temperature rise must be within the stated rise range installation. as indicated on the furnace rating plate, and the firing input rate must be set to the unit nameplate value. Johnson Controls Unitary Products... -
Page 3: Combustion Air Quality
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... -
Page 4: Ductwork
This plate must be sealed to prevent leaks. 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. Johnson Controls Unitary Products... -
Page 5: Air Distribution Systems
FREE AREA FURNACE MINIMUM FREE AREA 5 in (12.7 cm) or greater * Closet to Door Clearance Return Air Closet Door Part No. DOOR 7900-7771/C* White FIGURE 3: Closet To Door Clearance - 5” or Greater Johnson Controls Unitary Products... -
Page 6: Furnace To Closet Door Clearance - Less Than 1
7-1/2” (19.0 cm) 7990-6271 7-1/2” (19.0 cm) 7990-6081 8-1/2” (21.6 cm) 7990-6281 8-1/2” (21.6 cm) 7990-6101 10-1/4” (26.0 cm) 7990-6301 10-1/4” (26.0 cm) 7990-6121 12-1/4” (21.1 cm) 7990-6321 12-1/4” (21.1 cm) FIGURE 6: Duct Connector Dimensions Johnson Controls Unitary Products... -
Page 7: Duct Connector Screw Attachment
P/N 7900-6771, is available from furnace manufacturer. See duct. Figure 11. 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. Johnson Controls Unitary Products... -
Page 8: Anti-Backflow Damper
FLEX DUCT perature rise range and not exceed the maximum designed static pres- sure. These values are listed in Table 2. BLEND AIR DAMPER FLOOR WARM AIR DUCT DUCT CONNECTOR FIGURE 12: Floor Installation Johnson Controls Unitary Products... -
Page 9: Gas Piping
Johnson Controls Unitary Products... -
Page 10: Burner Assembly
The furnace must be isolated from the gas supply piping system by SCREWS GAS VALVE closing its individual external manual shut-off valve during any pressure testing of the gas supply piping system at pressures equal to or less FIGURE 15: Burner Assembly than 1/2 psig (3.5 kPa). Johnson Controls Unitary Products... - Page 11 Since some leak solutions including soap and water may cause corrosion or stress cracking, the piping must be rinsed with water after testing unless it has been determined that the leak test solution is non-corrosive. Johnson Controls Unitary Products...
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Page 12: High Altitude Duration Chart
Setting it higher will cause room furnace lead must be connected to neutral. Connect the green fur- temperature to exceed the set points. nace lead (equipment ground) to the power supply ground. Johnson Controls Unitary Products... -
Page 13: Roof Jack Vent/Combustion Air System
AND providing factory Roof Jack System meets all installation require- ments. Johnson Controls Unitary Products... -
Page 14: Installation In Snow Regions
Do not twist, crush or sit on the roof caps during installation. Damaged roof caps will cause improper furnace operation. The furnace will not heat properly and could result in explosion. Johnson Controls Unitary Products... -
Page 15: Standard Roof Jack
SEAL ROOF JACK FLASHING TO THE ROOF JACK AND ROOF. THIS IS THE INSTALLER'S RESPONSIBILITY. 76" 59-1/2" DGAA MODELS DGAH MODELS FLOOR WARM AIR DUCT DUCT CONNECTOR WARM AIR DUCT DUCT CONNECTOR FIGURE 21: Standard Roof Jack Johnson Controls Unitary Products... -
Page 16: Roof Jack
SEAL ROOF JACK FLASHING TO THE ROOF JACK AND ROOF. THIS IS THE INSTALLER'S RESPONSIBILITY. 76" 59-1/2" DGAA MODELS DGAH MODELS FLOOR WARM AIR DUCT DUCT CONNECTOR WARM AIR DUCT DUCT CONNECTOR FIGURE 22: Roof Jack With Removable Crowns Johnson Controls Unitary Products... -
Page 17: Connecting Roof Jack To Furnace
4000 Series roof jack. These roof jacks are designed to provide combustion air to the furnace and to exhaust flue products to the outside. No other combustion air openings or ducts are needed. FIGURE 23: Roof Jack Johnson Controls Unitary Products... -
Page 18: Roof Jack Assembly
73” to 103” 90” to 110” Models 4000B8161 and 4000B8181 have removable crowns. The vent must be installed with the minimum clearances as shown in Figure 27, and must comply with local, state, regional codes and requirements. Johnson Controls Unitary Products... -
Page 19: Home Layout
If a metal shield is used it must be a stainless steel material at a minimum dimension of 20 inches. It is recommended that a retaining type collar be used that is attached to the building surface to prevent movement of the vent pipe. Johnson Controls Unitary Products... -
Page 20: Safety Controls
Allow five minutes for any gas to dissipate before continuing with the start-up procedure. Be sure proper ventilation is available to dilute and carry away any vented gas. FIGURE 28: Pressure Switch Tubing Routing Johnson Controls Unitary Products... -
Page 21: Gas Valve
30 seconds. After this warm up, the ignition module will energize (open) the main gas valve. After flame is established, the supply air blower will start in the time set on the control board. Johnson Controls Unitary Products... - Page 22 For altitudes above 2,000 ft. (610 m) the furnace input MUST BE DERATED. Refer to the GAS CONVERSION FOR PROPANE (LP) AND HIGH ALTITUDES IN SECTION IV for information on high altitude conversions. Johnson Controls Unitary Products...
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Page 23: Inlet Gas Pressure Range
The cap for the pressure regulator must be removed entirely to gain access to the adjustment screw. Loosening or tightening the cap does not adjust the flow of gas. Johnson Controls Unitary Products... -
Page 24: Reading Gas Pressure
Then snap the bottom of the upper door into place against the casing. Finish and Trim Alcove and Closet Installations may now be finished and trimmed as necessary. Johnson Controls Unitary Products... -
Page 25: Blower Performance Cfm - Downflow Without Filters
4 TON, 2 SPEED BLOWER FOR DGPH, DGPA 7900-7751 5 TON BLOWER 5 TON, 4 SPEED BLOWER FOR ALL MODELS 1PS0166 HIGH ALTITUDE KIT FOR NATURAL GAS ALL MODELS 1PS0167 HIGH ALTITUDE KIT FOR PROPANE (LP) GAS ALL MODELS Johnson Controls Unitary Products... -
Page 26: Wiring Diagram
129098-UIM-G-0411 SECTION X: WIRING DIAGRAM FIGURE 32: Wiring Diagram - DGAA Johnson Controls Unitary Products... -
Page 27: Wiring Diagram - Dgah
129098-UIM-G-0411 FIGURE 33: Wiring Diagram - DGAH Johnson Controls Unitary Products... - Page 28 NOTES Subject to change 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...