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G—Gas Combustion Combination Controls and Systems—G961DAJ Integrated Function Ignition Control    7

Check the voltage rating marked on the control or in Table 1 to be sure it
is suited to the application.  Use an NEC Class 2 transformer, such as a
Johnson Controls Y65, to provide 24 VAC under maximum load,
including the valve.

Choose a location 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 voltage
spark cable are separated from one another by a minimum of 1/4 inch, and
not wrapped around any pipe, other wiring, or accessories.

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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