dgat program kit 37323712001 installation instructions
Contents
1. 2 Allow burner to operate 5 minutes Measure time required in seconds for gas meter 2 cubic foot dial to rotate one complete turn or 1 2 cubic foot dial to rotate 4 complete turns Calculate input Gas Heating Valuef x 7200 Time Assume 1030 BTU per cubic foot for natural gas if gas supplier cannot provide exact value C Measure Static Pressure 1 FIGURE 52 Measuring supply static pressure Verify upper door is installed and furnace burner and blower are operating in heating speed Supply Static Pressure a Remove top screws from coil cabinet cover plates 3 total b Connect manometer positive pressure hose fitting to Static Pressure Probe c Insert static pressure probe into each screw hole Insert probe straight into hole 6 Probe must be level horizontal for proper measurement See Figure 52 i e Y 7 Part 6 Submit Claim A Mail Documentation 1 Submit original DGAT Program Claim to York International Attn Warranty Dept P O Box 385 Norman OK 73070 Unitary Products Group 035 20530 001 Rev B 0804 NOTES 14 Unitary Products Group Unitary Products Group NOTES 035 20530 001 Rev B 0804 15 NOTES Subject to change without notice Printed in U S A 035 20530 001 Rev B 0804 Copyright by York International Corp 2004 All rights reserved Supersedes 035 20530 001 Rev A 0804 Unitary P O Wichita Products Box KS Group 190142. igniter and flame sen sor 3 Turn off gas supply to furnace by closing manual shut off valve Disconnect gas supply piping 4 Remove gas valve See Figure 3 Unitary Products Group g i 7 i j F ns _ a DAER 7 FIGURE 3 Gas valve removal 5 Remove the burner assembly See Figure 4 When burner is removed check the ribbon porting located in the end of the burner to insure it is concentric and square Reference Figure 5 Check the seams between the burner halves to insure that they are completely closed and tight The flame spreader needs to be checked for proper align ment and to insure that it is not distorted and the burner mounting legs should also be checked for distortion If any of these items are found to be out of alignment the burner should be replaced FIGURE 5 Burner inspection Unitary Products Group 035 20530 001 Rev B 0804 C Inspect Heat Exchanger 1 Insert inspection mirror through burner opening Use flashlight or droplight to illuminate surface Inspect entire interior perimeter of heat exchanger Note con dition per following guidelines a Typical Discoloration Pattern Surface must be smooth shape with no bumps or indentations li Normal heat pattern may include light to dark gray discoloration See Figure 6 If visual inspection does not reveal any defor mation crack or burn through of the heat exchanger surface then you nee
3. 38 Compress stainless loop in middle to slide up with holes in blower shelf support bracket past heat exchanger Do not skin or scrape foil from Cut away view insulation while sliding switch down side of heat exchanger FIGURE 42 Reinstall blower shelf Pass wires up through back slot of blower shelf before locating to final position FIGURE 39 Remove shoe horn Unitary Products Group 035 20530 001 Rev B 0804 ELECTRIC SHOCK HAZARD Cal injury or death INCOMING POWER MUST BE POLARIZED OBSERVE COLOR CODING DIAGNOSTIC FLASH CODES Steady On Normal operation One Flash Ignition failure Two Flashes si Three Flashes fail Four Flashes Limit swi Five Flashes Gas Valve Energized with no call for heat Rapid Flash Reversed polarity See installation instructions for more information 035 19636 001 Rev A 1003 FIGURE 43 Install new wire clamp in blower shelf hole on rear left hand side of shelf Reinstall 7 screws to FIGURE 46 Install new wiring diagram over existing secure blower shelf diagram Oe not remove oF by pass Auuiiry Lit Switch connected ts Vetiow wires adjacent te hest exchange see Wirny Dagrami Rerneving or by pessing Auniiary Lirit
4. 67204 901
5. Switch wil cause Serious nyay death oF property ttamnege Srenedistety contact an Authori ed Bervice Centar the 4 Flesh FIGURE 44 Install new auxiliary limit switch leads in DISCONNECT THe EL rerainan mra eee series with upper limit per wiring diagram FIGURE 47 Install danger label on vestibule panel just below upper limit switch FIGURE 45 Install and secure blower on shelf Plug FIGURE 48 Turn gas supply back on and leak check blower motor into control box gas valve piping connection 10 Unitary Products Group 035 20530 001 Rev B 0804 FIGURE 50 Install Consumer Notice on top front furnace door and instruct the consumer on how to DGAT Field Inspection Program Gas Orifice Selection Chart LP Propane ___NaturaGas i Propane Diameter DrilSize PartNo Diameter Dril Size PartNo 4 000 1470 9951 1471 0890 9951 0891 5 000 1440 9951 1441 0890 9951 0891 6 000 1440 9951 1441 0860 9951 0861 035 20530 001 Rev B 0804 Part 4 Checkout Data A Furnace Checkout an overfired furnace Once again you will need to make sure that your gas pressure is set properly If found to be okay you should then also clock the meter to determine the units firing rate and if AWARNING needed check the supply duct system static pres sure Refer to Part 5 for information on how to mea sure gas pressure determine the firing rate and measure supply static pressure If any items tested resu
6. 1 2 Wrench b 11 32 Nut driver c High temperature RTV Silicone Source 1 Part Number MA HTSS R B To Turn Off Gas to Appliance These instructions will direct you To Turn Off Gas to Appli ance during the inspection A label with these instructions is located inside the lower door The instructions are as follows 1 Set the thermostat to lowest setting 2 Turn off all power to the appliance 3 Remove control access panel 4 Move gas control switch to OFF position C Operating Instructions These instructions will direct you to follow the Operating Instructions to place the appliance in operation A label with the Operating Instructions is located inside the lower door The Operating Instructions are as follows 1 Set the thermostat to lowest setting 2 Turn off all electric power to the appliance 3 This appliance is equipped with an ignition device which automatically lights the burner Do NOT try to light the burner by hand 4 Remove control access panel 5 Move gas control switch to OFF position Do not force 6 Wait five 5 minutes to clear out any gas If you smell gas determine source and repair as necessary 7 Move gas control to ON position Do not force 035 20530 001 Rev B 0804 8 Replace control access panel 9 Turn on all electrical power to the appliance 10 Set thermostat to the desired setting Burner will light which may take 30 60 seconds 11 After three
7. 3 trials if the appliance will not operate follow the instructions TO TURN OFF GAS TO APPLIANCE and refer to troubleshooting guide in the Installation Instructions or Owner s Manual D Product Specifications Model No DGAT070 DGATO075 70 000 Btu hr 75 000 Btu hr 57 000 Btu hr 61 000 Btu hr Air Temperature 45 75 F Rise Range Maximum Outlet eee Temperature Maximum External Part 1 Basic Information Record the following on the DGAT Program Claim Form Record information clearly and legibly Most of this information should be available before travelling to the job site A Rating Plate Data 1 Model Number 2 Serial Number B Customer Data 1 Customer name street address city state and zip code 2 Customer telephone number Part 2 Inspection A Inspect Roof Jack 1 Verify the proper Roof Jack is being used The DGAT is approved for use with the 4000 Series roof jack only See Figure 1 4000 SERIES 7900 SERIES FIGURE 1 Roof Jack NOTE The 7900 Series Roof Jack can be converted to a 4000 Series Roof Jack by replacing crown Use p n 4000 6941 C 2 Inspect Roof Jack Replace if damaged tilted crooked or shows deterioration 3 Remove bird screens or other obstructions to com bustion air inlet B Remove Assembly Burner ane formation FIGURE 2 Turn power switch to off position 1 Follow instructions TO TURN OFF GAS TO APPLI ANCE 2 Disconnect wires to gas valve
8. DGAT PROGRAM KIT 37323712001 INSTALLATION INSTRUCTIONS 035 20530 001 Rev B 0804 Heating Air Conditioning FOR MODELS AWARNING Use of this instruction is intended for qualified individuals experienced in the proper installation and service of manu factured housing heating appliances Fire or explosion hazard Failure to properly inspect and restore appliance to proper operation may cause property damage personal injury or loss of life General Information A Before You Start Once you have read this instruction view the video tape 1 Thoroughly review this instruction Contact DGAT Program at 1 888 665 4640 or on line at dgatpro gram york com if you have any questions 2 Inspect kit contents a Three 3 piece heat exchanger liner assembly i Part A has two 2 curved hooks and four 4 stainless steel bolts ii Parts B and C have slotted holes b Auxiliary limit switch assembly c Customer Packet with instructions and labels d Card board shoehorn for auxiliary limit switch assembly installation e Natural gas orifice bag assembly LP Propane gas orifice bag assembly and hardware bag assembly f Wire clamps 3 Gather test equipment Digital Thermometer 5 16 Hex head driver Flashlight or droplight Inspection mirror D 2 0 oF 2 Phillipshead screwdriver f Two 2 crescent wrenches 4 Tools needed to install DGAT Program Kit Unitary Products Group a
9. d to check the entire inside surface of the heat exchanger by feel If you feel any roughness deformation crack or burn through proceed with replacing the heat exchanger with 37323713001 FIGURE 6 Typical discoloration pattern b Cracked See Figure 7 FIGURE 7 Cracked heat exchanger c Deformed See Figure 8 035 20530 001 Rev B 0804 FIGURE 8 Deformed heat exchanger d Burn Through See Figure 9 FIGURE 9 Burned through heat exchanger While you are feeling the inside surface you should also check the integrity of the rivets that secure the overflame baf fle to the heat exchanger drum You can check the rivets by pushing against each of the four 4 mounting legs If any of the rivets are missing the heat exchanger will need to be FIGURE 10 Overflame baffle located in top of heat exchanger assembly cut away view replaced D Corrective Actions 1 Heat Exchanger cracked deformed or burned through or 1 or more overflame baffle pop rivets are missing Replace heat exchanger with 37323713001 Replacement Heat Exchanger Follow instructions provided with kit If heat exchanger burn through has resulted in dam age to the furnace casing insulation and or a breach in the furnace casing you will need to contact the DGAT program at 1 888 665 4640 or on line at dgat program york com to receive authorization to replace furnace Heat Exchanger exhibits normal discoloration pattern with no
10. defects a Install DGAT Program Kit 37323712001 Follow instructions in Part 3 Part 3 DGAT Program Kit Installation A Install Heat Exchanger Liner FIGURE 12 Remove burner inlet pan 12 screws as FIGURE 11 Remove pressure switch tube marked and remove burner inlet pan Unitary Products Group 035 20530 001 Rev B 0804 FIGURE 13 Remove bottom screw from air vane FIGURE 16 Rotate liner upward to hook on overflame loosen top screw and rotate air vane counterclockwise baffle Use caution when rotating air vane so that foil faced insulation is not damaged FIGURE 17 Make sure the hooks on Part A straddle the rear right hand leg of overflame baffle FIGURE 14 Remove burner chute mounting screws 4 and remove burner chute FIGURE 18 Push Part A of liner as far forward as leg FIGURE 15 Insert stainless steel liner piece Part A will allow with clips first Unitary Products Group 5 035 20530 001 Rev B 0804 Insert Part C and rotate upwards Place Part C over stud bolts in Part A Install stainless steel nuts FIGURE 22 Again push assembled liner as far to front as possible and tighten all 4 stainless steel nuts al FIGURE 23 Inspect with light to make sure Part A B and C are pushed outward against drum gt FIGURE 21 Install stainless steel nuts found in 7 p hardware bag Do not tighten FIGURE 24 Reinstall burner chute to original position 6 Un
11. itary Products Group 035 20530 001 Rev B 0804 FIGURE 25 Reposition air vane to original position Reinstall bottom screw and tighten top screw FIGURE 28 Reinstall burner 4 al FIGURE 26 Install burner inlet pan with 12 screws If FIGURE 29 Reinstall gas valve and gas piping needed re seal pan with high temperature RTV silicone FIGURE 27 Remove old gas orifice install new per FIGURE 30 Reconnect pressure tube to pressure chart switch and wiring connectors to gas valve igniter and sensor 7 Unitary Products Group 035 20530 001 Rev B 0804 FIGURE 31 Install warning label directly below rating FIGURE 34 Remove blower support shelf 7 screws plate on vestibule panel B Install Auxiliary Limit Switch Assembly FIGURE 32 Remove Blower Assembly Mounting Screws 4 Unplug blower motor from control box Remove wire clamp Remove blower assembly FIGURE 36 To protect side wall insulation insert cardboard sheet as a shoe horn to insert auxiliary limit switch assembly between insulation and heat exchanger FIGURE 33 Remove wires from upper limit Unitary Products Group 035 20530 001 Rev B 0804 lt a FIGURE 37 Bow back plate of auxiliary limit switch FIGURE 40 Outer plate should compress against side assembly to insert on right hand side of blower casing foil Cut away view compartment FIGURE 41 Push flange in until clearance holes line FIGURE
12. lt in findings outside the design 1 Verify Cardboard Pad Shoehorn was removed Remove Cardboard Pad Shoehorn before operat ing furnace Fire Hazard parameters listed on the units rating plate it is an indication Failure to remove may cause property damage per of application installation problems that must be addressed sonal injury or loss of life Since application installation problems are not covered under the warranty you will need to discuss this situation with the 2 Check Air Temperature Rise ATR homeowner as they will be responsible for covering any a Make sure furnace has operated for at least 5 Charges to correct any problems found minutes 4 If measured ATR is within design parameters pro b Measure return air temperature at top louver ceed to step B and complete your on site visit openings of top furnace door B Complete On Site Visit c Measure supply air temperature at the closet reg 1 Verify all gas fueled appliances are returned to nor ister grille mal operation Follow instructions provided by the d Subtract the return air temperature from the sup epplanice manUacIUren oly air temperature to obtain the ATR 2 Complete the DGAT Program Claim Form 3 If measured ATR is outside parameters shown on the a Record your name and company information furnace rating plate then you will need to determine b Obtain homeowner s signature why unit is operating beyond its desig
13. n parameters If the ATR is too low it is an indication of an underfired furnace Make sure that your gas pressure is set properly If the ATR is too high it is an indication of 3 Review the Consumer Notice with the customer c Sign claim form to certify the furnace has been properly upgraded 12 Unitary Products Group 035 20530 001 Rev B 0804 Part 5 Additional Testing Procedures A Measure Gas Pressure a Remove gas valve OUT PRESS TAP plug using 3 16 Allen wrench Install 1 8 NPT hose barb fit ting See Figure 51 FIGURE 51 Pressure tap b Connect manometer positive pressure hose fitting to OUT PRESS TAP hose barb fitting c Follow OPERATING INSTRUCTIONS to place furnace in operation d Allow burner to operate 30 60 seconds Measure Outlet Manifold Gas Pressure Adjust pressure to 3 5 0 2 w c for natural gas or 10 0 0 2 w c for LP propane e Follow instructions TO TURN OFF GAS TO APPLIANCE f Remove hose barb from gas valve Install plug Follow OPERATING INSTRUCTIONS to place fur nace in operation Operate furnace through at least one 1 complete heating cycle to confirm proper operation B Measure Input Rate d Adjust controls on all other gas fired appliances to prevent operation Extinguish pilot s if applicable Follow instructions provided by the appliance manu facturer Follow OPERATING INSTRUCTIONS to place fur nace in operation Input
Download Pdf Manuals
Related Search