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Johnson Controls G961DAJ, Installation Sheets Manual, Page: 11 / 12

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Johnson Controls G961DAJ Installation Sheets Manual Download Page 11

G—Gas Combustion Combination Controls and Systems—G961DAJ Integrated Function Ignition Control    11

Table 5:  Loss of Twinning Communications
(Green “OK” LED Flashing)

Possible Causes

Corrective Actions

Lack of continuity between “TWIN”
terminals and/or between the common
terminals of the two furnaces

Repair or replace wiring.

Loss of power in one of the twinned
furnaces

Refer to Table 2 for corrective actions.

The 24 VAC signal on the two controls
out of phase

Correct wiring using schematic in Figure 1.

Table 6:  Insufficient Flame Sense Current (Yellow Flame LED Off)

Possible Causes

Corrective Actions

Dirty flame sensor

Clean sensor with steel wool.

Dirty grounding surface

Clean main burner with steel wool.

Flame sensor ceramic cracked

Replace sensor.

Sense cable wrapped around spark cable

Separate cables.

Lack of continuity in sense cable

Replace sense cable.

Flame sensor not positioned in main
burner flame correctly

Correctly position flame sensor per
manufacturer’s specifications.

Defective ignition control

Replace control.

Table 7:  Marginal Flame Sense Current
(Yellow Flame LED Flashing)

Possible Causes

Corrective Actions

Dirty flame sensor

Clean sensor with steel wool.

Dirty grounding surface

Clean main burner with steel wool.

Sense cable wrapped around spark cable

Separate cables.

Flame sensor not positioned in main
burner flame correctly

Correctly position flame sensor per
manufacturer’s specifications.

!

CAUTION:

Label all wires prior to disconnection when servicing
controls.  Wiring errors can cause improper and
dangerous operation.

Do not attempt field repairs to the ignition control.  Use only an exact or
recommended replacement control.  For a replacement control or
accessories, contact the original equipment manufacturer or authorized
wholesaler.

Repairs and
Replacement

Summary of Contents for G961DAJ

Page 1: ...heem furnace application The G961DAJ responds to inputs from the thermostat limit switch es pressure switch flame sensor and power supply The G961DAJ provides outputs for timing and sequencing of the main gas valve induced draft motor indoor blower motor electronic air cleaner humidifier and spark igniter All G961DAJ applications must use redundant gas valves Any application over 400 000 Btu hr mu...

Page 2: ...Marginal Flame Good Flame 0 3 microamperes 25 Flame Current ITH ITH Flame Current 4 x ITH Flame Current 4 x ITH Prepurge Time 30 seconds Trial for Ignition Time 8 seconds Interpurge Time 30 seconds Flame Failure Response Time 0 8 seconds Postpurge Time 5 seconds Number of Trials Allowed Before Soft Lockout 4 Number of Flameouts Allowed Before Soft Lockout 5 Automatic Reset Delay Time 60 minutes Op...

Page 3: ...the blower motor is energized at heating speed 6 Postpurge Once the thermostat is satisfied the gas valve is de energized the inducer motor remains energized until the postpurge period ends and the heat fan off delay begins Once the heat fan off delay expires the blower motor is de energized Upon receiving a call for cool from the system thermostat the G961DAJ energizes the blower motor at cooling...

Page 4: ... period expires the control will begin another heating sequence beginning with Pressure Switch Detection Note If the pressure switch re closes and remains closed within 12 power line cycles forgiveness period the operating cycle will continue uninterrupted Any time flame is sensed while the gas valve is de energized the inducer and blower motors will be energized When flame is no longer sensed the...

Page 5: ... for heat is removed after the gas valve is energized but before flame has been sensed the gas valve and spark igniter are de energized and the inducer motor will run through a postpurge 3 If the call for heat is removed after flame has been sensed but before the blower comes on the gas valve is de energized the inducer will run through a 5 second purge and the blower will run through a 180 second...

Page 6: ...ity between TWIN terminals and or between the common terminals of the two furnaces 2 Loss of power in one of the twinned furnaces 3 The 24 VAC signal on the two controls out of phase A loss of communications will result in the two controls de energizing all outputs except the inducer which runs for 4 seconds and the blower which runs for 180 seconds The OK LED will flash to indicate loss of commun...

Page 7: ...ion with the shortest direct cable route to the spark igniter and flame sensor To wire the G961DAJ follow the schematic in Figure 1 All wiring should be in accordance with the National Electrical Code NEC and all other local codes and regulations The high voltage spark cable must not be in continuous contact with a metal surface Use standoff insulators Be certain the flame sensor wire and the high...

Page 8: ...S e co n d a ry 1 2 0 V A C P rim a ry M a in V a lve M a in V a lve S p a rk E le ctro d e T h e rm o sta t H ig h L im it S w itch P re ssu re S w itch Y G R W C T o se co n d fu rn a ce if tw in n e d a p p lica tio n F la m e S e n so r N C N C H N H N N C H N H N H N T W IN O p tio n a l B lo w e r C o n n e cto r 2 4 V AC 2 4 C O M L IN E N EU T R A L H U M LIN E EA C H C M 1 M 2 g961daj drw...

Page 9: ...rmostat off 4 Turn gas on and purge gas lines of all air 5 Check for gas leaks with a soap solution 6 Turn the thermostat to a high setting and verify successful ignition and a normal run condition for at least three minutes 7 Do a leak check on all pipe joints downstream of the gas valve 8 Turn the thermostat down for at least 30 seconds and then back up again Verify successful ignition at least ...

Page 10: ...stem Table 2 No Power to System Green PWR LED Off Possible Causes Corrective Actions Tripped circuit breaker Reset circuit breaker Faulty transformer Replace transformer Faulty wiring Repair or replace wiring Table 3 Internal Fault Green OK LED On Possible Causes Corrective Actions Noise problems Isolate system electrically from noise source Defective ignition control Replace ignition control Tabl...

Page 11: ...parate cables Lack of continuity in sense cable Replace sense cable Flame sensor not positioned in main burner flame correctly Correctly position flame sensor per manufacturer s specifications Defective ignition control Replace control Table 7 Marginal Flame Sense Current Yellow Flame LED Flashing Possible Causes Corrective Actions Dirty flame sensor Clean sensor with steel wool Dirty grounding su...

Page 12: ...mbustion Combination Controls and Systems G961DAJ Integrated Function Ignition Control Notes Controls Group FAN 121 507 E Michigan Street Installation Sheets Manual P O Box 423 Printed in U S A Milwaukee WI 53201 ...

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