York DFAA manual

107272-UIM-B-1105 HIGH EFFICIENCY SEALED COMBUSTION DRUM HEA T EXCHANGER SERIES MODEL: DF AA/DF AH (Oil and Gas Conversion Burn er/ Single St age Downflow Only) 66 - 84 MBH INPUT (19.34 - 2 4.62 KW) INPU T INSTALLATION MANUAL EFFICIENCY RA TING CERTIFIED ISO 9001 Certified Quality Management System F or Installation In: 1. Manufactured (Mobile) Hom[...]

107272-UIM-B-1105 2 Unitary Products Group SPECIFIC SAFETY RULES AND PRECAUTIONS 1. U.S..... No. 1 or No. 2 heating oil only (ASTM D396), CANADA..... No. 1 stove oil or No. 2 furnace oil only are ap proved for use and can be burned in this furnace. Refer to the furnace rat- ing plate or SECTION IV o f these instructions. 2. Install this furnace onl[...]

107272-UIM-B-1105 Unitary Products Group 3 • Provide clearances from combus tible materials as listed under Furnace Locations and Clearances. • Provide clearances for servicing, ensuring that se rvice access is allowed for both the burners and blower . • These models are ETL listed and ap proved for installation into a Modular Home or a Manuf[...]

107272-UIM-B-1105 4 Unitary Products Group CHECK CERTIFICA TIONS / APPRO V ALS • Underwriters Laboratories has certified this bur ner to comply with ANSI/UL 296 and has listed it for use with #1 or #2 fuel oil as specified in ASTM D396. Low sulfur #1 and #2 fuel oils reduce heat exchanger deposits with all burners compared to the stan- dard fuels[...]

107272-UIM-B-1105 Unitary Products Group 5 SECTION II: DUCTWORK DUCTWORK GENERAL INFORMA TION 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 NFP A (National Fire Protection As[...]

107272-UIM-B-1105 6 Unitary Products Group Use the example below to help you in calculating the duct area to deter- mine whether the ducts have sufficient area so that the furnace oper - ates at the specified external static pressure and within the air temperature rise specified on the nameplate. Example: The furnace input is 80,000 BTUH, (23.4 kW)[...]

107272-UIM-B-1105 Unitary Products Group 7 FIGURE 3: Air Distribution Systems A Single trunk duct Dual trunk duct T ransition duct 1 B* Dual trunk duct with crossover connector Crossover C T ransition Duct with Branches Branches 3 1. Crossover Duct must be centered directly under furnace. 2. Use 12” (30.5 cm) Diameter Round or insulated Flex-duct[...]

107272-UIM-B-1105 8 Unitary Products Group DUCT CONNECT ORS INST ALLA TI ON OF SCREW A TT ACHMENT DUCT CONNECT OR 1. Make flo or cut out as shown in Figure 8. 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. 3. Place locating bracket [...]

107272-UIM-B-1105 Unitary Products Group 9 INST ALLA TION OF T AB A TT ACHMENT DUCT CONNECT ORS 1. Make floor cut out as shown in Figure 8. 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. 3. Place locating bracket (supplied with the [...]

107272-UIM-B-1105 10 Unitary Products Group DF AH F urnaces: If a matching cooling coil is used, it may be placed directly on the fur- nace outlet and sealed to prevent l eakage. Follow the coil instructions for installing the supply plenum. On al l installations without a coil, a removable access panel is recommended in the outlet duct such that s[...]

107272-UIM-B-1105 Unitary Products Group 11 IMPORT ANT : Air velocity through throwaway typ e filters must not exceed 300 feet per minute (1.52 m/m). . . SECTION IV: OIL PIPING OIL SAFETY IMPORT ANT INFORMA TION: Long or oversized inlet lines may require the pump to operate dry during initial bleeding period. In such cases, the priming may be assis[...]

107272-UIM-B-1105 12 Unitary Products Group NOTICE SPECIAL REQUIREMENTS THE EFFECT OF ELEV A TION ON OIL BURNER FIRING The elevation of the installation of a modern high-speed flame r etention oil burner affects the performance of the burner . Allowance for elevation must be taken into consideration when choosing an oil burner and oper- ating it ab[...]

107272-UIM-B-1105 Unitary Products Group 13 Follow information provided with the bur ner , th e fuel pump, or the calcu- lation below to determine pipe size and length. L = Line Length in feet H = Head in feet Q = Firing rate in GPH 3/8” (0.95 cm) line L = (6 - 0.75 x H) / 0.0086 x Q) 1/2” (1.27 cm) line L = (6 - 0.75 x H) / (0.0021 8 x Q) If t[...]

107272-UIM-B-1105 14 Unitary Products Group NOTE: A burner with an electronic igni ter or a PSC motor will have a lower operating current. The actual load should be determined by a cur- rent meter . NOTE: See appliance manufacturer ’s burner specifications for required outlet pressure. Pressure is 100 psig (689 kPa) unless otherwise noted. SUPPL [...]

107272-UIM-B-1105 Unitary Products Group 15 EXTERIOR ROOF J ACK EXTENSION Application Available to comply with inst ances in which the roof jack crown needs to be raised to meet a roof clearance requirement. One extension will raise the roof jack crown by 18” 45.7 cm) . ROOF J ACK EXISTING FURNACE REPLA CEMENT If this furnace replaces an existing[...]

107272-UIM-B-1105 16 Unitary Products Group Alternate NOTE: Roof flashing, PVC pipe, PVC 90° elbows and fire stop are not supplied with the furnace. LOCA TING AND CUTTING ROOF JA CK OPENING T o 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[...]

107272-UIM-B-1105 Unitary Products Group 17 Models 4000B8161 an d 4000B8181 have r emovable crowns. If using an optional interior extensi on, place extension down on furnace top and mate with furnace flue and co mbustion air collar until it lines up with screw holes in combustion air co llar . Secure t he extension to the furnace using the pre-punc[...]

107272-UIM-B-1105 18 Unitary Products Group FIGURE 30: S tandard Roof Jack Warm Air Duct Duct Connector Roof 76" 59-1/2" Warm Air Duct Duct Connector Flue Gases 19 1/2" Flue Gases Combustion Air 19 1/2" Carefully Sealant Supplied by Furnace Manufacturer . Caulk All Around Swivel Joint with IMPORT ANT Seal Roof Jack Flashing to t[...]

107272-UIM-B-1105 Unitary Products Group 19 FIGURE 31: Roof Jack With Removable Crowns DF AH FURNACES DF AA FURNACES INST ALLA TION DIMENSIONS INST ALLA TION DIMENSIONS “A” ADJUST ABLE HEIGHT “B” ADJUST ABLE HEIGHT 85” to 101” 99” to 129” 101” to 1 17” 1 15” to 145” 4000-9161/A 4000-9181/A 4000-8161/C 4000-8181/C SWIVEL FLAS[...]

107272-UIM-B-1105 20 Unitary Products Group VENT SY STEM This furnace is a sealed combustion (direct vent) unit and is design cer- tified to use only a 4000 Series roof jack. These roof jacks are designed to exhaust flue products to the outside. INST ALLING CEILING RING The ceiling ring is to m eet fire stop requirements. Accessory Ceiling Ring may[...]

107272-UIM-B-1105 Unitary Products Group 21 † A vent shall not terminate directly above a sidewalk or pa ve d driveway that is located between t wo single family dwellings and serves both dwellings. ‡ Permitted only i f veranda, porch, deck, or b alcony is fully open on a minimum of two sides beneath th e floo r . For clearance n ot specified i[...]

107272-UIM-B-1105 22 Unitary Products Group F AN-ASSIST ED COMBUSTION SY STEM An appliance equipped with an inte gr al mechanical means to either draw or force products of combus tion through the combustion chambe r and/or heat exchanger . SECTION VII: S AFETY CO NTROLS CONTROL CIR CUIT FUSE A 3-amp fuse is provided to protect the 24-volt transform[...]

107272-UIM-B-1105 Unitary Products Group 23 SPECIFICA TIONS Models: T able 1 1 list s the major features and the applicable wiring diagram num- bers for the R7184. Tim in g: 1. Safe S tart Check: 5 seco nds (approximately) 2. V alve-on Delay: 15 seconds. 3. Burner motor-off Delay: 0, 2, 4, or 6 minutes. Field selectable using dual in-line programma[...]

107272-UIM-B-1105 24 Unitary Products Group IGNITION SY STEM SEQUENCE 1. Turn the oil supply ON at external valve on the oil pump, and/or at the oil tank. 2. Set the ther mostat above room temperature to call for heat. 3. System start-up will occur as follows: a. The burner motor will start and come up to speed. b. Shortly after the burner motor st[...]

107272-UIM-B-1105 Unitary Products Group 25 APPL YING FIL TER PRESSURE DROP TO DETERMINE SY STEM AIRFLOW Example: For a 84,000 BTUH (38.06 kW) furnace with 1 return open- ings and operating on high-speed blower , it is found that total system static is 0.30” w .c. (0 .075 kPa). T o determ ine the system airflow, com- plete the following steps: Ob[...]

107272-UIM-B-1105 26 Unitary Products Group T ABLE 15: Replacement Parts - Non Electrical DF AA MODEL ITEM NUMBER DESCRIPTION 1 Limit Switch , Manual (Upper) 2 Thermost at (Heat/Cool) 3 Exchanger , Hea t (w/Gaskets) 4 Switch, Rocker (System) 5 T ransformer (1 15 - 24V , 40 V A) 6 Filter (16 x 20 x 1) (2Requir ed) 7 Panel, Door (Upper) 8 Panel, Door[...]

107272-UIM-B-1105 Unitary Products Group 27 SECTION IX: WI RING DIAGRAM - OIL-FIRE D FURNACE FIGURE 37: Wiring Diagram for DFAA - Oil-Fired Furnace[...]

107272-UIM-B-1105 28 Unitary Products Group FIGURE 38: Wiring Diagra m for DF AH - Oil Furnac e[...]

107272-UIM-B-1105 Unitary Products Group 29 SECTION X: GAS GUN B URNER These instructions were prepared fo r the guidance of those installing this particular gas conversion burner . While they apply in principle to all installations, they should not be interpreted as meaning the only safe and economical way to install a c onversion burner . It may [...]

107272-UIM-B-1105 30 Unitary Products Group The building structure should not be weak end by installation for the gas piping. The piping should not be supported by the other piping, but should be firmly supported with pipe hooks, straps, bands, or hanger . Butt or lap welded pipe should not be bent. The gas piping should be so install ed so as to p[...]

107272-UIM-B-1105 Unitary Products Group 31 A drip leg is required by some loca l codes to trap moisture and contam- inations. Refer to Figure 39 or 40. For natural gas operation, the furnace is designed for 7" W.C. inlet gas pressure. Pressure to main burner is the n reduced to 3 1 /2" W .C at the gas valve. Refer to Figure 42 for locati[...]

107272-UIM-B-1105 32 Unitary Products Group T able shows 4% Input Reduction per 1,000 ft. (304 .8 m) Ele vation. Reference Source: NFP A No. 54, ANSI Z 223.1, Nation al Fuel Ga s Code. For Canadian high altitu de {200 0 - 4500 ft. (60 9.6 - 1,371.6)}, reduc e gas manifold pressure to 3.0” w .c. (0.75 kPa) for Natural gas and for Propa ne gas. SIZ[...]

107272-UIM-B-1105 Unitary Products Group 33 SECTION XI: ST ART -UP AND ADJUSTMENTS The initial start-up of the furnace requires the following addi tional procedures: IMPORT ANT : All electrical connections m ade in the field and in the fac- tory should be check ed for proper tightness. When the gas supply is initially connec ted to the furnace, the[...]

107272-UIM-B-1105 34 Unitary Products Group In the USA use the followin g formula to calculate the furnace input. For natural gas multiply the heat content of the gas BTU/SCF or Default 1030 BTU/SCF (38.4 MJ/m 3 ), times 2 cu bic ft. (0.056 m) of gas measured at the gas meter , times a barometric pressure and temperature corr ection factor of 0.960[...]

107272-UIM-B-1105 Unitary Products Group 35 INITIAL ST ART UP 1. Read the applicable sequence o f gas control operation in the Operation and Troubleshooting section before proceeding. 2. Move the gas va lve control switch to the “OFF” position. 3. Adjust the primary air . Set the damper to the start up settings. 4. On new gas line installations[...]

107272-UIM-B-1105 36 Unitary Products Group Observing Burner Operation 1. Observe burner to make sure it ignites. Observe colo r of flame. On natural gas the flame will burn bl ue with appreciably yellow tips. On Propane gas a yellow flame may be expe cted. If flame is not the proper color call a qualified service technician for service. 2. Let fur[...]

107272-UIM-B-1105 Unitary Products Group 37 Combustion efficiency is determined by the percent CO 2 and the tem- perature of the flue gases. These two measurements are taken on the vent. Combustion efficiency and stack loss calculators are available from several manufacturers of combustion test equipment. IMPORT ANT : DRAFT - When installing W ayne[...]

107272-UIM-B-1105 38 Unitary Products Group SECTION XII: W IRING DIAGRA M - GAS CONVERSION BU RNER FIGURE 45: Wiring Diagram for DFAA - Gas Conversion Burner[...]

107272-UIM-B-1105 Unitary Products Group 39 FIGURE 46: Wiring Diagram fo r DF AH - Gas Gun[...]

Subject to change without notice. Printed in U.S.A. 107272-UIM-B-1105 Copyright © by York International Corp. 2005. All rights reserved. Supersedes: 107272-UIM-A-0905 Unitary 5005 Norman Product Y ork OK Group Drive 73069 NOTES[...]