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

The G961DAJ offers the following responses based on abnormal system
operation.

A pressure switch within the appliance provides proof of combustion air
flow.  During a heating cycle, the G961DAJ control responds to the state
of this switch in the following ways:

1.

If the pressure switch is not open at the beginning of the heating
cycle, the control will wait for the switch to open.

2.

If the pressure switch does not close after the inducer motor has been
energized for 60 seconds, the inducer motor will be de-energized for
300 seconds, and then re-energized.  This cycle will continue until the
pressure switch is proven closed, as long as the demand for heat
exists.

3.

If the pressure switch opens during the trial for ignition (before flame
is sensed), all outputs will be de-energized and the control will begin
another heating sequence beginning with Pressure Switch Detection.

4.

If the pressure switch opens during the run state (after flame is
sensed), the main valve will be de-energized, and the inducer and
blower will run for a 180 second purge.  Once this purge 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
inducer will be de-energized, and the blower will continue to run through a
30 second fan-off delay.  Once expired, the control will respond to the
thermostat call.

If the first ignition attempt and the first retry both fail to establish flame,
the control will activate a self-healing over-temperature correction cycle
before the next retry.  This is accomplished by running the inducer and
blower for 180 seconds, before proceeding to the third trial (second retry).

If flame is not sensed by the end of the trial for ignition period, the gas
valve is de-energized, the inducer runs through an interpurge period, and
another trial for ignition begins.  If flame is not sensed before the end of
the fourth trial, the control proceeds to a 60 minute soft lockout period
(during which all outputs are de-energized) before resetting itself.

Abnormal
System
Operation

Pressure Switch
Detection

Undesired Flame

Self Healing
Function

Failure to Sense
Flame Within
Trial Period

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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