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

The controls are connected to a two stage thermostat.  When the first stage
calls for heat (or cool), the blower motors are simultaneously energized,
but the ignition sequence (or cooling sequence) only takes place in the first
furnace.  When the second stage calls for heat (or cool), the ignition
sequence (or cooling sequence) starts in the second furnace without
interrupting the operation of the blowers.

In any of the safety functions, soft lockout, or abnormal operation modes,
if only one furnace is affected, the other furnace will continue its normal
operating cycle and maintain control of the affected furnace’s blower.
The affected furnace will initiate its abnormal operating sequence, with
the exception of interrupting blower operation.

If the abnormal condition still exists after the demand for heat (or cool) is
satisfied, the safety function or abnormal operation sequence will take
over the operation of both blowers.

Twinning communications can be lost due to:

1.

Lack of continuity 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
communication between furnaces while in twinning mode.  Once the
purge period expires, the controls attempt to restore communications
before returning to normal operation.

!

WARNING: Shock Hazard.  Disconnect power supply before

wiring to prevent electrical shock or equipment
damage.

Fire or Explosion Hazard.  If the control is installed
in an area that is exposed to water (dripping, spraying,
rain, etc.) it must be protected.  If the control has been
exposed to water in any way, do not use it.

This instruction sheet is intended as a guide for qualified personnel installing
or servicing Johnson Controls ignition controls.  Carefully follow all
instructions on this sheet and all instructions on the appliance.  Limit repairs,
adjustments, and servicing to the operations listed in this sheet or on the
appliance.

Two Stage
Operation

Abnormal
Operation

Loss of
Communications

Installation and
Wiring

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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