Installation Instructions - dms.hvacpartners.comdms.hvacpartners.com/docs/1009/Public/0C/AG-CBBA-01.pdf · 7900/D, 7956/D, 7995C, DGRT and DLRS series, ... The installation instruction

NOTE: Read the entire instruction manual before starting the installation.

INTRODUCTION

When upgrading a Coleman, Intertherm, or Miller gas furnace for use with an outdoor heat pump or air conditioner, the blower motor assemblymust always be changed out. Two kits cover this change out conversion. Kit KCBBA02013TG covers the conversion of Coleman 7900B, 7900C,7900/D, 7956/D, 7995C, DGRT and DLRS series, Intertherm MGHA, and Miller MMHA in 2-1/2-, 3-, 3-1/2-, and 4-ton gas furnaces. KitKCBBA01015TG covers the conversion of Coleman 7900B, 7900C, 7900/D, 7956/D, 7995C, DGRT and DLRS series, Intertherm MGHA, andMiller MMHA in gas furnaces above 4 tons.

SAFETY CONSIDERATIONS

Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified personnel shouldinstall, repair, or service heating equipment.

Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations must be performedby trained service personnel. When working on heating equipment, observe precautions in the literature, tags, and labels attached to or shippedwith the unit and other safety precautions that may apply.

Follow all safety codes. In the United States, follow all safety codes including the National Fuel Gas Code NFPA No. 54-1992/ANSI Z223.1-1992.In Canada, refer to the current edition of the National Standard of Canada CAN/CGA- B149.1- and .2-M91 Natural Gas and Propane GasInstallation Codes. Wear safety glasses and work gloves. Have fire extinguisher available during start-up, adjustment, and service call procedures.

Recognize safety information. This is the safety-alert symbol. When you see this symbol on the furnace and in instructions or manuals, bealert to the potential for personal injury.

Understand the signal word DANGER, WARNING, or CAUTION. These words are used with the safety-alert symbol. DANGER identifies themost serious hazards whichwill result in severe personal injury or death. WARNING signifies a hazard thatcould result in personal injury ordeath. CAUTION is used to identify unsafe practices whichwould result in minor personal injury or product and property damage.

WARNING: Before installing or servicing system, always turn off main power to system. There may be more than 1disconnect switch. Turn off accessory heater power if applicable. Electrical shock can cause personal injury or death.

DESCRIPTION AND USAGE

Kits KCABBA02013TG and KCABB01015TG are comprehensive kits containing a blower motor assembly, control box assembly, adapter frame,and a parts bag. Installation of components is determined by unit of application. The installation instruction is composed of 3 sections coveringspecific units and sizes.

1. Section 1 covers the installation of KCBBA02013TG into Coleman 7900B, 7900C, 7900/D, 7956/D, 7995C, DGRT and DLRS series2-1/2-, 3-, 3-1/2-, and 4-ton gas furnaces.

2. Section 2 covers the installation of KCBBA01015TG into Coleman 7900B, 7900C, 7900/D, 7956/D, 7995C, DGRT and DLRS series gasfurnaces above 4 tons.

3. Section 3 covers the conversion of 2-1/2-, 3-, 3-1/2-, and 4-ton Intertherm MGHA and Miller MMHA Series Gas Furnaces using kitKCBBA02013TG and the conversion of units above 4-ton using kit KCBBA01015TG.

INSTALLATION SECTION 1

This section covers the installation of KCBBA02013TG into Coleman 7900B, 7900C, 7900/D, 7956/D, 7995C, DGRT and DLRS series 2-1/2-,3-, 3-1/2-, and 4-ton gas furnaces.

PROCEDURE 1—REMOVE BLOWER FROM CARTON

1. Remove blower from carton. Unit is heavy so exercise care when handling.

2. Straighten any flanges bent during shipment.

3. Remove cardboard packing from blower wheel.

Installation Instructions

KCBBA02013TGKCBBA01015TG

Blower Packages ForGas Furnaces

Form: AG-CBBA-01 Cancels: AG-CABA-04, AG-CAWH-01 Printed in U.S.A. 10-93 Catalog No. 92-33CB-BA1

4. Check rotation of blower wheel in housing. If any rubbing occurs between blower wheel and housing, adjust blower wheel on motor shaftby loosening blower wheel setscrew and sliding wheel along shaft until rubbing stops.

5. Check blower wheel setscrew for tightness. When tightening setscrew, be sure screw is on flat side of motor shaft.

6. Check control box and wiring harnesses for shipping damage. File claim with shipper if shipment is damaged or incomplete.

PROCEDURE 2—REMOVE EXISTING BLOWER FROM FURNACE

1. Turn electrical power at main electrical service entrance to OFF position.

2. Remove furnace door.

3. Unplug motor connector plug from receptacle on furnace control box by pinching clasping tabs on sides of plug and pulling plug straightup from receptacle.

4. Remove blower mounting screws, then remove blower from front of furnace. Retain screws for new blower installation.

PROCEDURE 3—INSTALL KCBBA02013TG BLOWER ASSEMBLY AND CONTROL BOX

A. Mount Control Box and Adapter Frame to Blower

1. Remove cover from blower control box by removing screw. Retain screw for reinstallation.

2. Mount control box cover on blower wrapper using 3 No. 10 X 1/2-in. screws. (See Fig. 1.)

3. Install adapter frame to blower housing using 4 No. 10 X 1/2-in. screws. (See Fig. 1.)

4. Mount control box to cover on blower with screw removed in Step 1 above. (See Fig. 2.) Make sure bottom of cover engages inside ofcontrol box flange.

B. Install Blower Into Unit

1. Start blower rail flanges into blower slots and push blower into furnace until mounting bracket flange is against furnace. (See Fig. 2.)

2. Secure blower with 2 screws removed earlier in Procedure 2, Step 4. Attach blower ground lead under screw in blower compartment thatcontacts an unpainted surface.

C. Connect Wiring Harnesses

1. Connect 15-pin plug of 33-in. wiring harness (supplied) to blower control box receptacle. (See Fig. 3.)

2. Connect 9-pin plug of 6-in. harness to furnace control box receptacle. (See Fig. 3.)

3. Connect 9-pin receptacle of 6-in. harness to 9-pin plug of 33-in. wiring harness. (See Fig. 3.)

4. Connect 6-pin plug of blower wiring harness to blower control box receptacle. (See Fig. 3.)

PROCEDURE 4—MODIFY FURNACE CONTROL BOX WIRING

A. 7900B Series Furnace

1. Remove 5/8-in. knockout on furnace control box.

2. Remove furnace control box cover.

3. Run loose red wire (supplied) from R of low-voltage terminal board on blower control box through knockout hole in furnace control box.(See Fig. 3 and 5.)

4. Run loose blue wire from 9-pin receptacle of 6-in. wiring harness through knockout hole in furnace control box.

5. Install strain relief to wires and snap into knockout hole of furnace control box.

6. Remove 2 gray wires from low-voltage connection of transformer. Cut terminals off and strip wires 1/2 in. Twist ends of gray wires andred wire together and secure with wire nut provided. (See Fig. 5.)

7. Remove 2 yellow wires from low-voltage connection of transformer. Cut terminals off and strip wires 1/2 in. Twist ends of yellow wiresand blue wire (of 9-pin receptacle through knockout) together and secure with wire nut provided. (See Fig. 5.)

8. Replace furnace control box cover.

B. 7900C, 7995C, 7900/D, 7956/D, DLRS, and DGRT Series Furnace



3. Run loose blue wire from 9-pin receptacle of 6-in. wiring harness through knockout hole in furnace control box. (See Fig. 4 and Fig. 6, 7,8, or 9.)

4. Install strain relief to wire and snap into knockout hole of furnace control box.

5. For 7900C, 7995C, 7900/D, and 7956/D remove yellow wires from low-voltage connection of transformer. Cut terminals off and strip wires1/2 in. Twist ends of yellow wires and blue wire (or 9-pin receptacle through knockout) together and secure with wire nut provided. (SeeFig. 6, 8, or 9.)

—2—

Fig. 1—Blower AssemblyA92247

BLOWER ASSY

ADAPTER FRAME

CONTROL BOX COVER

Fig. 2—Blower Assembly InstallationA92248

BLOWER ASSY

ADAPTER FRAME

CONTROL BOX ASSY

—3—

6. For DLRS and DGRT series furnaces, remove 2 of the 3 low-voltage connections of transformer. A gray and a yellow wire should beremoved leaving the third yellow wire connected to the transformer. That is the yellow wire that goes to the reignitor module. Cut terminalsoff and strip the 2 wires 1/2 in. Twist ends of yellow, gray and blue wire (or 9-pin receptacle through knockout) together and secure withwire nut provided. (See Fig. 7.)


PROCEDURE 5—CONNECT THERMOSTAT

A. Heating Only Thermostat (2 wire)

1. Connect thermostat wires W to W of low-voltage terminal board on blower control box.

2. Series variation

a. For 7900B Series: connect thermostat R terminal to loose red wire from 9-pin plug of 6-in. harness. (See Fig. 3.)

b. For 7900C, 7995C, 7900/D, 7956/D, DLRS, and DGRT Series: tape loose end of red wire from 9-pin plug of 6-in. harness, and connectthermostat wire R to R on low-voltage terminal board. (See Fig. 4.)

3. Remove locking clip on HEAT/COOL switch on blower control box. (See Fig. 3 or 4.)

4. Explain to homeowner that HEAT/COOL switch must be manually set in appropriate position for heating or cooling.

5. Turn ON-OFF switch on furnace junction box to ON position.

B. Heat/Cool Thermostat (3 wire)

1. Connect thermostat wires W and Y to W and Y, respectively, of low-voltage terminal board on blower control box.

2. Series variation



NOTE: Do not remove locking clip from HEAT/COOL switch.


C. Heat/Cool Thermostat (4 wire)

1. Remove external jumper wire from G and Y of low-voltage terminal board on blower control box.

2. Connect thermostat wires W, Y, and G to W, Y, and G, respectively, of low-voltage terminal board on blower control box.

3. Series variation





PROCEDURE 6—CONNECT CONDENSING UNIT

Connect condensing unit control relay or contactor to Y and C on blower low-voltage terminal board on blower control box.

PROCEDURE 7—COMPLETE UNIT INFORMATION PLATE

Using ballpoint pen, complete information requested on information plate. Peel backing off plate and affix in upper right-hand corner of vestibulepanel.

PROCEDURE 8—COMPLETE UNIT INSTALLATION

1. For 2-wire thermostats only: Remember to explain to homeowner that HEAT/COOL switch must be manually set to appropriate position.

2. Replace furnace door.

3. Restore power to unit.

4. Cycle furnace in both heating and cooling modes to ensure proper operation.

PROCEDURE 9—SERVICE

A qualified service person should clean and lubricate the blower unit each heating and cooling season. Clean the blower unit when cooling coilis cleaned. Lubricate motor every 5 years if motor is used intermittently, or every 2 years if motor is in continuous operation. Remove motor tolubricate. Place approximately 8 drops of SAE 20 non-detergent oil in oil port. Plug port securely.

Check electrical connections for tightness and controls for proper operation each heating and cooling season. Service as necessary.

—4—

INSTALLATION SECTION 2This section covers the installation of KCBBA01015TG into Coleman 7900B, 7900C, 7900/D, 7956/D, 7995C, DGRT and DLRS series gasfurnaces above 4 tons.


1. Remove blower from carton. Unit is heavy so exercise care when handling.



4. Check rotation of blower wheel in housing. If any rubbing occurs between wheel and housing, adjust blower wheel on motor shaft byloosening blower wheel setscrew and sliding wheel along shaft until rubbing stops.

5. Check blower wheel setscrew for tightness. When tightening setscrew, be sure screw is on the flat side of motor shaft.

6. Check control box and wiring harnesses for shipping damage. File claim with shipper if shipment is damaged or incomplete.




3. Unplug motor connector plug from receptacle on furnace wiring box by pinching clasping tabs on sides of plug and pulling plug straightup from receptacle.

4. Remove blower mounting screws, then remove blower from front of furnace. Retain screws for new blower installation.

PROCEDURE 3—INSTALL KCBBA01015TG BLOWER ASSEMBLY AND CONNECT WIRING

A. Install Blower Into Unit



B. Connect Wiring Harnesses

1. Connect 15-pin plug of 33-in. wiring harness, supplied in kit, to blower control box receptacle. (See Fig. 3.)

2. Connect 9-pin plug of 6-in. harness to furnace control box receptacle. (See Fig. 3.)

3. Connect 9-pin receptacle of 6-in. harness to 9-pin plug of 33-in. wiring harness. (See Fig. 3.)

Fig. 3—Coleman 7900B Wiring LayoutA92252

LOCKING CLIPHEAT/COOL SWITCH

BLOWER CONTROL BOX

15 PIN

6 PIN

33-IN. WIRING HARNESS

RED


9 PIN

BLUE

“R” OF THERMOSTAT

STRAIN RELIEF

9 PIN EXISTING CONTROL BOX

RWGYC

BLOWER ASSY

LOW VOLTAGE TERMINAL BOARD

GRN/YEL GND

RED

—5—

4. Connect 6-pin plug of blower wiring harness to blower control box receptacle. (See Fig. 3.)


A. 7900B Series Furnace



3. Run loose red wire (supplied) from R of low-voltage terminal board on blower control box through knockout hole in furnace control box.(See Fig. 3 and 5.)

4. Run loose blue wire from 9-pin receptacle of 6-in. wiring harness through knockout hole in furnace control box.

5. Install strain relief to wires and snap into knockout hole of furnace control box.

6. Remove 2 gray wires from low-voltage connection of transformer. Cut terminals off and strip wires 1/2 in. Twist ends of gray wires andred wire together and secure with wire nut provided. (See Fig. 3 and 5.)

7. Remove 2 yellow wires from low-voltage connection of transformer. Cut terminals off and strip wires 1/2 in. Twist ends of yellow wiresand blue wire (of 9-pin receptacle through knockout) together and secure with wire nut provided. (See Fig. 5.)


B. 7900C, 7995C, 7900/D, 7956/D, DLRS, and DGRT Series Furnace



3. Run loose blue wire from 9-pin receptacle of 6-in. wiring harness through knockout hole in furnace control box. (See Fig. 4 and Fig. 6, 7,8, or 9.)

4. Install strain relief to wire and snap into knockout hole of furnace control box.

5. For 7900C, 7995C, 7900/D, and 7956/D remove yellow wires from low-voltage connection of transformer. Cut terminals off and strip wires1/2 in. Twist ends of yellow wires and blue wire (or 9-pin receptacle through knockout) together and secure with wire nut provided. (SeeFig. 6, 8, or 9.)

Fig. 4—Coleman 7900C, 7995C, 7956/D, DLRS, and DGRT Wiring LayoutA92253

LOCKING CLIPHEAT/COOL SWITCH

BLOWER CONTROL BOX

15 PIN

6 PIN



9 PIN

BLUE

ELECTRICAL TAPE

STRAIN RELIEF

9 PIN EXISTING CONTROL BOX

RWGYC

BLOWER ASSY


GRN/YEL GND

RED

—6—

6. For DLRS and DGRT series furnaces, remove 2 of the 3 low-voltage connections of transformer. A gray and a yellow wire should beremoved leaving the third yellow wire connected to the transformer. That is the yellow wire that goes to the reignitor module. Cut terminalsoff and strip the 2 wires 1/2 in. Twist ends of yellow, gray and blue wire (or 9-pin receptacle through knockout) together and secure withwire nut provided. (See Fig. 7.)



A. Heating Only Thermostat (2 wire)

1. Connect thermostat wires W to W of the low-voltage terminal board on blower control box.

2. Series Variation



3. Remove locking clip on HEAT/COOL switch on blower control box. (See Fig. 3 or 4.)



B. Heat/Cool Thermostat (3 wire)

1. Connect thermostat wires W and Y to W and Y, respectively, of low-voltage terminal board on blower control box.

2. Series Variation





C. Heat/Cool Thermostat (4 wire)


2. Connect thermostat wires W, Y, and G to W, Y, and G, respectively, of low-voltage terminal board in blower control box.

3. Series Variation

Fig. 5—Coleman 7900B Wiring From TransformerA92254

3GRAYLIMIT

SWITCH 1 GRAY TO LIMIT SWICH

MANUAL RESET GRAY

RED

TO BLOWER CONTROL (MARKED 24VAC)FROM BLOWER CONTROL BOX LVTB MARKED “R”

LOAD 24VLINE 120V

LINE 120VLOAD 24V

BLKBLKWHTWHT

PIN 7PIN 8

TO POWER CORD

(L2) BLU

FROM 9 PIN

6 INCH WIRING

HARNESS

YEL

TO GAS

VALVE (TR)

YEL

TO BLOWER CONTROL (COMMON)

TO (2) ON

FURNACE CONTROL

BOX SYSTEM SWITCH

(L1)

7900B SERIES

—7—






Connect condensing unit control relay or contactor to Y and C on blower low-voltage terminal board on blower control box.


Using ballpoint pen, complete information requested on information plate. Peel backing off plate and affix in upper right-hand corner of vestibulepanel.


1. For 2-wire thermostats only: Remember to explain to homeowner that HEAT/COOL switch must be manually set to appropriate position.





A qualified service person should clean and lubricate the blower unit every heating and cooling season. Clean cooling coil when blower unit iscleaned. Lubricate motor every 5 years if motor is used intermittently, or every 2 years if motor is in continuous operation. Remove motor tolubricate. Place approximately 8 drops of SAE 20 non-detergent oil in oil port. Plug port securely.


Fig. 6—Coleman 7900C Direct Spark Ignition Wiring From TransformerA92255

LOAD 24V

LINE 120V

LINE 120V

LOAD 24V

BLK

BLK

WHT

WHT

PIN 7

PIN 8

TO POWER CORD

(L2)

BLU

FROM 9 PIN

6 INCH WIRING

HARNESS

YEL

TO GAS

VALVE (TR)

YEL

TO DAMPER MOTOR

TO (2) ON

FURNACE CONTROL

BOX SYSTEM SWITCH

(L1)

7900C SERIES

TO PIN 1

RED

DIRECT SPARK IGNITION

—8—

INSTALLATION SECTION 3

This section covers the conversion of 2-1/2-, 3-, 3-1/2-, and 4-ton Intertherm MGHA and Miller MMHA Series Gas Furnaces using kitKCBBA02013TG and the conversion of units above 4-ton using kit KCBBA01015TG.


1. Remove blower from carton of kit KCBBA02013TG or KCBBA01015TG. Unit is heavy so exercise care when handling.



4. Check rotation of blower wheel in housing. If any rubbing occurs between blower wheel and housing, adjust blower wheel position on motorshaft by loosing blower wheel setscrew and adjusting along shaft until rubbing stops.

5. Check blower wheel setscrew for tightness. When tightening setscrew, be sure screw is on the flat side of motor shaft.

6. Check control box for shipping damage. File claim with shipper if shipment is damaged or incomplete.

NOTE: Use adapter frame and wiring harness supplied.




3. Unplug motor connecter plug from receptacle on furnace control box by pinching clasping tabs on sides of plug and pulling plug straightup from receptacle.

4. Remove blower mounting screws then remove blower from front of furnace. Retain screws for new blower installation.

PROCEDURE 3—INSTALL KCBBA02013TG OR KCBBA01015TG BLOWER ASSEMBLY AND CONTROL BOX

A. Mount Control Box and Adapter Frame to Blower

1. Remove cover from blower control box by removing screw. Retain screw for reinstallation.

2. Mount control box cover on blower wrapper using 3 No. 10 X 1/2-in. screws. (See Fig. 1.)

Fig. 7—Coleman DLRS and DGRT Standing Pilot Wiring From TransformerA92256

LOAD 24V

LINE 120V

LINE 120V

LOAD 24V

BLK

BLK

WHT

WHT

PIN 7

PIN 8

TO POWER CORD

(L2)

BLU

FROM 9 PIN

6 INCH WIRING

HARNESS

GRAY

TO LIMIT

SWICH

YEL

TO DAMPER MOTOR

TO (2) ON

FURNACE CONTROL

BOX SYSTEM SWITCH

(L1)

DLRS AND DGRT

TO PIN 1

RED

STANDING PILOT WITH REIGNITOR

—9—

3. Mount control box to cover on blower with screw removed in Step 1. (See Fig. 2.) Make sure bottom of cover engages inside of controlbox flange.

4. Install adapter frame to blower housing using 4 No. 10 X 1/2-in. screws supplied in kit KCBBA02013TG or KCBBA01015TG. (See Fig.1.)

B. Install Blower into Unit



C. Connect Wiring Harnesses

1. Connect 15-pin plug of 15- to 6-pin wiring harness to blower control box. (See Fig. 17.)

2. Connect 6-pin plug of 15- to 6-pin wiring harness to furnace control box receptacle. (See Fig. 17.)

3. Connect 6-pin plug of blower wiring harnesses to blower control box. (See Fig. 17.)



2. Remove red wire from low-voltage connection of transformer and cut off terminal.

3. Clip brown wire from low-voltage side of transformer. (See Fig. 18.)

4. Strip 1/2 in. of brown and red wires.

5. Twist end of brown and red wires together and secure with wire nut provided. (See Fig. 18.)

6. Remove black wire from high-voltage side of transformer and cut off terminal.

7. Locate black wire at fan switch that goes to 6-pin receptacle of furnace control box and clip at fan switch.

8. Strip ends 1/2 in. each of black wire just removed and black wire removed in Step 6.

9. Twist ends of black wires together and secure with a wire nut provided. (See Fig. 18.)

Fig. 8—Coleman 7956/D Standing Pilot Wiring From TransformerA93459

LOAD 24V

LINE 120V

LINE 120V

LOAD 24V

BLK

BLK

WHT

WHT

PIN 7

PIN 8

TO POWER CORD

(L2)

BLU

FROM 9 PIN

6 INCH WIRING

HARNESS

YEL

TO LIMIT

SWICH

TO (2) ON

FURNACE CONTROL

BOX SYSTEM SWITCH

(L1)

7956/D SERIES

TO PIN 1

RED

STANDING PILOT

—10—

10. Tape exposed ends of black and brown clipped wires with electrical tape.

11. Connect red and white wires of 28-in. wiring harness to red and white wires of furnace control box, respectively.



A. Heating Only Thermostat (2 Wire)

1. Connect thermostat wire R and W to R and W, respectively, of low-voltage terminal board on blower control box.

2. Remove locking clip on HEAT/COOL switch of blower control box. (See Fig. 17.)



B. Heat/Cool Thermostat (3 Wire)

1. Connect thermostat wires R, W, and Y to R, W and Y, respectively, of low-voltage terminal board on blower control box.



C. Heat/Cool Thermostat (4 Wire)


2. Connect thermostat wires R, W, Y, and G to R, W, Y, and G, respectively, of low-voltage terminal board on blower control box.




Connect condensing unit control relay or contactor to Y and C of blower low-voltage terminal board on blower control box.


Using a ballpoint pen, complete information requested on information plate. Peel backing off plate and affix in upper right-hand corner of vestibulepanel.

Fig. 9—Coleman 7995C Standing Pilot Wiring From TransformerA92257

LOAD 24V

LINE 120V

LINE 120V

LOAD 24V

BLK

BLK

WHT

WHT

PIN 7

PIN 8

TO POWER CORD

(L2)

BLU

FROM 9 PIN

6 INCH WIRING

HARNESS

YEL

TO BOOSTER

RELAY (3)

YEL

TO DAMPER MOTOR

TO (2) ON

FURNACE CONTROL

BOX SYSTEM SWITCH

(L1)

7995C SERIES

TO PIN 1

RED

STANDING PILOT

—11—

Fig.10—Colem

an7900BWiring

Diagram

A92258

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7900

B

1

1

3 3 1

R W G Y C

12 5

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5 4

2 4

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2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6

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LOA

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120V

PR

I

BLU

120V

WH

T

RE

D

GR

OU

ND

S

CR

EW

24V

YEL

RR

BLOWER CONTROL

BLOWER

LIN

24V

SE

C

QV

CO

M

24V

OR

N

BLU

BLK

WH

T

BRN

ORG

YEL

BLU

YE

L

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N

GRY

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WIR

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UT

TR

AN

S

LIM

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SW

ITC

H

LIM

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SW

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H

—12—

Fig.11—Colem

an7900CDirectSparkIgnitionWiring

Diagram

A92259

120V

7900

C D

IRE

CT

SP

AR

K IG

NIT

ION

If an

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NO

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:

1

1

3 3 1

R W G Y C

12 5

3 4 6

5 4

2 4

5 6

2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6

1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9

2 4

3 1

RE

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WH

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N

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N

SW

ITC

H

ELE

CT

RIC

AL

TA

PE

LIM

IT

SW

ITC

HLI

MIT

S

WIT

CH

WHT

GR

Y

GR

Y

BLKYELYEL

YEL

YE

L

WH

TB

LUB

LUY

EL

GR

Y

BLU

BLU

BLK

GR

Y

BLU

WHT

BO

OS

T

RE

LAY

BLK

BO

OS

TE

R

MO

TO

R

CO

ND

EN

SA

TE

C

OIL

SW

ITC

H

DA

MP

ER

M

OT

OR

SW

ITC

H

GRY

BLU

GR

Y

BLK

WIR

E N

UT

S

SY

ST

EM

S

WIT

CH

WHT

BLKBLK

WH

T

BLK

120V

24V

TR

AN

POWER

VALVEGROUND

GROUND

GRN

1 2

YEL

BRN

YEL

GA

S C

ON

TR

OL

ON

LE

WH

T

24V

RR

YEL

—13—

Fig.12—Colem

an7900CStandingPilotWiring

Diagram

A92260

TR

AN

S.

If an

y of

the

wire

sup

plie

d w

ith th

e fu

rnac

e m

ust b

e re

plac

ed, i

t mus

t be

repl

aced

with

ty

pe 9

0˚C

min

. the

rmop

last

ic o

r it'

s eq

uiva

lent

.

NO

TE

:

7900

C S

TA

ND

ING

PIL

OT

1

1

3 3 1

R W G Y C

12 5

3 4 6

5 4

2 4

5 6

2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6

1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9

RE

D

WH

T

GR

N

YE

L

BLU

BLU

RE

D

RE

D

RE

D RE

D

WH

T

WH

T

YE

L

RE

D

YE

LW

HT

BLKBR

RE

DYE

L

RE

D

BLO

WE

R

RE

LAY

RE

VE

RS

ING

R

ELA

Y

BLU

BLU

YE

L

BLU

GR

NR

ED

TR

AN

BLK

BLU

WH

TB

LKB

LUB

LUW

HT

BLU

BLK

BLK

WH

TR

ED

RE

D

WH

T

WHT

WHT

RED

BLKBLU

WH

TR

ED

BLU

BLK

WH

TW

HT

WH

TR

ED

BLU

BLK

WH

TW

HT

BLK

BLK

FM

CA

P

GR

N

ALS

BLU

WH

TB

LU

BLK

BLK

OR

NR

ED

WH

TB

LK

BLK

WH

TR

ED

ORG

ORG

WHT

BLK

FA

N

SW

ITC

H

ELE

CT

RIC

AL

TA

PE

LIM

IT

SW

ITC

H

GR

Y

DA

MP

ER

M

OT

OR

SW

ITC

H

WIR

E N

UT

SY

ST

EM

S

WIT

CH

WHT

BLKBLK

LIN

E

24V

SE

C

120V

PR

I1 2

GRY

GRY

GA

S C

ON

TR

OL

BLU

120V

WH

T

RE

D LIM

IT

SW

ITC

H

RE

D

GR

YLO

AD

GR

OU

ND

S

CR

EW

BLU

BLU

YE

LB

LU

24V

BLU

RR

—14—

Fig.13—Colem

anDLR

SandDGRTStandingPilotwith

IgnitorWiring

Diagram

A93462

TR

AN

S.

If an

y of

the

wire

sup

plie

d w

ith th

e fu

rnac

e m

ust b

e re

plac

ed, i

t mus

t be

repl

aced

with

ty

pe 9

0˚C

min

. the

rmop

last

ic o

r it'

s eq

uiva

lent

.

NO

TE

: DL

RS

AN

D D

GR

T S

TA

ND

ING

P

ILO

T W

ITH

IGN

ITO

R

1

1

3 3 1

R W G Y C

12 5

3 4 6

5 4

2 4

5 6

2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6

1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9

RE

D

WH

T

GR

N

YE

L

BLU

BLU

RE

D

RE

D

RE

D RE

D

WH

T

WH

T

YE

L

RE

D

YE

LW

HT

BLKBR

RE

DYE

L

RE

D

BLO

WE

R

RE

LAY

RE

VE

RS

ING

R

ELA

Y

BLU

BLU

YE

L

BLU

GR

NR

ED

TR

AN

BLK

BLU

WH

TB

LKB

LUB

LUW

HT

BLU

BLK

BLK

WH

TR

ED

RE

D

WH

T

WHT

WHT

RED

BLKBLU

WH

TR

ED

BLU

BLK

WH

TW

HT

WH

TR

ED

BLU

BLK

WH

TW

HT

BLK

BLK

FM

CA

P

GR

N

ALS

BLU

WH

TB

LU

BLK

BLK

OR

NR

ED

WH

TB

LK

BLK

WH

TR

ED

ORG

ORG

WHT

BLK

FA

N

SW

ITC

H

ELE

CT

RIC

AL

TA

PE

LIM

IT

SW

ITC

H

GR

Y

DA

MP

ER

M

OT

OR

SW

ITC

H

WIR

E N

UT

SY

ST

EM

S

WIT

CH

WHT

BLKBLK

LIN

E

24V

SE

C

120V

PR

I

GRY

GRY

BLU

120V

WH

T

RE

D LIM

IT

SW

ITC

H

RE

D

GR

YLO

AD

GR

OU

ND

S

CR

EW

BLU

BLU

YE

LB

LU

24V

BLU

RR

Rem

ove

jum

per

acro

ss th

e G

and

Y

term

inal

s fo

r a

4-w

ire th

erm

osta

t.N

OT

E:

GA

S

CO

NT

RO

L

PIL

OT

B

UR

NE

R

ELE

CT

RO

DE

RE

IGN

ITO

R

MO

DU

LE

YE

LR

ED

24 V

BLU

BLU

BLU

GR

Y

—15—

Fig.14—Colem

an7956/D

StandingPilotWiring

Diagram

A93461

TR

AN

S.

If an

y of

the

wire

sup

plie

d w

ith th

e fu

rnac

e m

ust b

e re

plac

ed, i

t mus

t be

repl

aced

with

ty

pe 9

0˚C

min

. the

rmop

last

ic o

r it'

s eq

uiva

lent

.

NO

TE

:

7956

/D S

TA

ND

ING

PIL

OT

1

1

3 3 1

R W G Y C

12 5

3 4 6

5 4

2 4

5 6

2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6

1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9

RE

D

WH

T

GR

N

YE

L

BLU

BLU

RE

D

RE

D

RE

D RE

D

WH

T

WH

T

YE

L

RE

D

YE

LW

HT

BLKBR

RE

DYE

L

RE

D

BLO

WE

R

RE

LAY

RE

VE

RS

ING

R

ELA

Y

BLU

BLU

YE

L

BLU

GR

NR

ED

TR

AN

BLK

BLU

WH

TB

LKB

LUB

LUW

HT

BLU

BLK

BLK

WH

TR

ED

RE

D

WH

T

WHT

WHT

RED

BLKBLU

WH

TR

ED

BLU

BLK

WH

TW

HT

WH

TR

ED

BLU

BLK

WH

TW

HT

BLK

BLK

FM

CA

P

GR

N

ALS

BLU

WH

TB

LU

BLK

BLK

OR

NR

ED

WH

TB

LK

BLK

WH

TR

ED

ORG

ORG

WHT

BLK

FA

N

SW

ITC

H

ELE

CT

RIC

AL

TA

PE

LIM

IT

SW

ITC

H

GR

Y

WIR

E N

UT

SY

ST

EM

S

WIT

CH

WHT

BLKBLK

LIN

E

24V

SE

C

120V

PR

I1 2 BLU

GRY

GA

S C

ON

TR

OL

BLU

120V

WH

T

RE

D LIM

IT

SW

ITC

H

RE

D

GR

YLO

AD

GR

OU

ND

S

CR

EW

BLU

24V

BLU

RR

—16—

Fig.15—Colem

an7900/D

HotSurface

IgnitionWiring

Diagram

A93460

NEUTRAL

LIN

E L

OA

D

24V

SE

C

120V

PR

I

120V

7900

/D H

OT

SU

RF

AC

E IG

NIT

ION

If an

y of

the

wire

sup

plie

d w

ith th

e fu

rnac

e m

ust b

e re

plac

ed, i

t mus

t be

repl

aced

with

ty

pe 9

0˚C

min

. the

rmop

last

ic o

r it'

s eq

uiva

lent

.

NO

TE

:

1

1

3 3 1

R W G Y C

12 5

3 4 6

5 4

2 4

5 6

2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6

1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9

2 4

3 1

RE

D

WH

T

GR

N

YE

L

BLU

BLU

RE

D

RE

D

RE

D RE

D

WH

T

WH

T

YE

L

RE

D

YE

LW

HT

BLKBR

RE

DYE

L

RE

D

BLO

WE

R

RE

LAY

RE

VE

RS

ING

R

ELA

Y

BLU

BLU

YE

L

BLU

GR

NR

ED

TR

AN

BLK

BLU

WH

TB

LKB

LUB

LUW

HT

BLU

BLK

BLK

WH

TR

ED

RE

D

WH

T

WHT

WHT

RED

BLKBLU

WH

TR

ED

BLU

BLK

WH

TW

HT

WH

TR

ED

BLU

BLK

WH

TW

HT

BLK

BLK

FM

CA

P

GR

N

ALS

BLU

WH

TB

LU

BLK

BLK

GR

NR

ED

BLU

WH

TB

LK

BLK

WH

TR

ED

RE

D

BLU

WHT

BLK

RED

FA

N

SW

ITC

H

ELE

CT

RIC

AL

TA

PE

LIM

IT

SW

ITC

HM

AN

UA

L R

ES

ET

LI

MIT

SW

ITC

H

WHT

GR

Y

GR

Y

YELYEL

YELY

EL

BLU

BLU

YE

LG

RY

BLU

BLU

BLK

BLU

WHT

BO

OS

T

RE

LAY

BLK

BO

OS

TE

R

MO

TO

R

CE

NT

RIF

UG

AL

SW

ITC

H

DA

MP

ER

M

OT

OR

SW

ITC

H

GRY

BLU

GR

Y

BLK

SYSTEM SWITCH

WHT

WH

T

BLK

GRN1 2

WH

T

24V

RR

YEL

GROUND SCREW

321

WH

T

BLK GR

Y

TR TH GA

S

CO

NT

RO

L

L2S2 OR IGNS1 OR IGNL1WV2 OR TRWV1 OR VALVETH

IGN

ITIO

N M

OD

ULE

HO

T

SU

RF

AC

E

IGN

ITO

R

Inco

min

g po

wer

mus

t be

pola

rized

. O

bser

ve c

olor

coo

ling.

NO

TE

:

GRYBRNYELBLK

WHT

BR

N

GR

D

SC

RE

W

ORG

BRN

BLU

—17—

Fig.16—Colem

an7995CStandingPilotWiring

Diagram

A92261

TR

AN

S.

If an

y of

the

wire

sup

plie

d w

ith th

e fu

rnac

e m

ust b

e re

plac

ed, i

t mus

t be

repl

aced

with

ty

pe 9

0˚C

min

. the

rmop

last

ic o

r it'

s eq

uiva

lent

.

NO

TE

:

7995

ST

AN

DIN

G P

ILO

T

1

1

3 3 1

R W G Y C

12 5

3 4 6

5 4

2 4

5 6

2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6

1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9

RE

D

WH

T

GR

N

YE

L

BLU

BLU

RE

D

RE

D

RE

D RE

D

WH

T

WH

T

YE

L

RE

D

YE

LW

HT

BLKBR

RE

DYE

L

RE

D

BLO

WE

R

RE

LAY

RE

VE

RS

ING

R

ELA

Y

BLU

BLU

YE

L

BLU

GR

NR

ED

TR

AN

BLK

BLU

WH

TB

LKB

LUB

LUW

HT

BLU

BLK

BLK

WH

TR

ED

RE

D

WH

T

WHT

WHT

RED

BLKBLU

WH

TR

ED

BLU

BLK

WH

TW

HT

WH

TR

ED

BLU

BLK

WH

TW

HT

BLK

BLK

FM

CA

P

GR

N

ALS

BLU

WH

TB

LU

BLK

BLK

OR

NR

ED

WH

TB

LK

BLK

WH

TR

ED

ORG

ORG

WHT

BLK

FA

N

SW

ITC

H

ELE

CT

RIC

AL

TA

PE

LIM

IT

SW

ITC

H

DA

MP

ER

M

OT

OR

SW

ITC

H

WIR

E

NU

T

SY

ST

EM

S

WIT

CH

WHT

BLKBLK

LIN

E

24V

SE

C

120V

PR

I

1 2

GRY

GRY

GA

S

CO

NT

RO

L

BLU

120V

WH

T

RE

DR

ED

GR

Y

LIM

IT

SW

ITC

H

LOA

D

GR

OU

ND

S

CR

EW

BLU

BLU

YE

LB

LU

2 4

3 1BLU

BO

OS

TE

R

MO

TO

R

CO

ND

EN

SA

TE

C

OIL

SW

ITC

HLIM

IT

SW

ITC

H

BLK

BLK

BO

OS

T

RE

LAY

YELYEL

BLU

BLU

BLU

BLK

GR

Y

24V

YEL

RR

—18—


1. For 2-wire thermostat, position HEAT/COOL switch to appropriate mode. Explain to homeowner that HEAT/COOL switch must bemanually set to appropriate position.

2. For 3- or 4-wire thermostats, locking clip should not be removed from HEAT/COOL switch since modes are automatically selected.





A qualified service person should perform cleaning and lubricating of the blower unit each heating and cooling season. Clean cooling coil whenblower unit is cleaned. Lubricate motor every 5 years if motor is used intermittently, or every 2 years if motor is in continuous operation. Removemotor to lubricate. Place approximately 8 drops of SAE 20 non-detergent oil in oil port. Plug port securely.


Fig. 17—Intertherm MGHA and Miller MMHA Wiring LayoutA92249

6 PIN

EXISTING FURNACE CONTROL BOX

RWGYC

LOCKING CLIP


BLOWER ASSY

AUTO/FAN/ON SWITCH

BLOWER CONTROL BOX

HEAT/COOL SWITCH

15 PIN

6 PIN

Fig. 18—Furnace Control Box ModificationA92250

15 PIN

6 PIN1 2 3 4 5 6

NEUTRAL

L1

3 2 1B

LU

BLK

BLK

OR

G

WHITEWHITE

RED REDRED

RED

AUX LIMIT

BLU

BLK

WH

TRED

WHTBLUBLK

WHT

WHT

BLK

RE

D

TAPE

BR

N GRN

TRANS

BLK WHT

WH

TB

RN

BR

N

WH

T

GAS VALVE

EXISTING FURNACE CONTROL BOX

LIMIT SWITCH

FAN SWITCH

TAPEBLK

BLKORG

BLU

BLUORG

BLK

GROUND SCREW

FAN ON/OFF SWITCH

—19—

Fig.19—Wiring

Diagram

A92251

INT

ER

TH

ER

M M

GH

A A

ND

MIL

LER

MM

HA

S

ER

IES

GA

S F

UR

NA

CE

S

1

1

3 3 1

R W G Y C

12 5

3 4 6

5 4

2 4

5 6

2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6

RE

D

WH

T

GR

N

YE

L

BLU

BLU R

ED

RE

D

RE

D RE

D

WH

T

WH

T

YE

L

RE

D

YE

LW

HT

BLKBR

RE

DYE

L

RE

D

BLU

BLU

YE

L

BLU

GR

NR

ED

TR

AN

BLK

BLU

WH

TB

LKB

LUB

LUW

HT

BLU

BLK

BLK

WH

TR

ED

RE

D

WH

T

WHT

WHT

RED

BLKBLU

WH

TR

ED

BLU

BLK

WH

TW

HT

WH

TR

ED

BLU

BLK

WH

TW

HT

BLK

BLK

FM

CA

P

GR

N

SLS

BLK

WH

TR

ED

BLU

120V

WH

T

3

NE

UT

RA

L

L1

1

BLU

BLK

BLK

OR

G

WHITEWHITE

RED REDRED

RED

BLU

BLK

WH

TREDWHT

BLU BLK

BLK

RE

D

TAPEB

RN GRN

BLK

WH

T

BR

NB

RN

WH

T

TA

PE

BLK

BLKORG

BLU

BLUORG

BLK

GROUND SCREW

FA

N O

N/O

FF

S

WIT

CH

32

WH

T

WH

T

21 4 5 6

GA

S V

ALV

E

EX

IST

ING

FU

RN

AC

E C

ON

TR

OL

BO

X

LS

FS

S

LS

FM

LIM

IT S

WIT

CH

F

AN

SW

ITC

H

SE

CO

ND

AR

Y L

IMIT

SW

ITC

H

FA

N M

OT

OR

CA

P

TR

AN

B

R

RR

CA

PA

CIT

OR

T

RA

NS

FO

RM

ER

B

LOW

ER

RE

LAY

R

EV

ER

SIN

G R

ELA

Y

NO

TE

S:

1. I

ncom

ing

pow

er m

ust b

e po

lariz

ed. O

bser

ve c

olor

cod

ing.

(S

ee fu

rnac

e da

ta la

bel f

or e

lect

rical

dat

a.)

2. I

f any

of t

he o

rigin

al w

ire, a

s su

pplie

d, m

ust b

e re

plac

ed,

u

se 1

05˚C

ther

mop

last

ic ty

pe w

ire o

r it'

s eq

uiva

lent

.2-

0608

1

SLS

RR

BR

FS

LS

YEL YE

L

RE

D

GR

N

RE

D

RR

24V

—20—

Fig.20—Intertherm/Miller

Wiring

Diagram

A92246

EX

IST

ING

FU

RN

AC

E C

ON

TR

OL

BO

XIN

TE

RT

HE

M M

GH

A A

ND

MIL

LE

R M

MH

A

1

1

3 3 1

R W G Y C

12 5

3 4 6

5 4

2 4

5 6

2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6

1 2 3 4 5 6 7 8 9

RE

D

WH

T

GR

N

YE

L

BLU

BLU

RE

D

RE

D

RE

D RE

D

WH

T

WH

T

YE

L

RE

D

YE

LW

HT

BLKBR

RE

DYE

L

RE

D

BLO

WE

R

RE

LAY

RE

VE

RS

ING

R

ELA

Y

BLU

BLU

YE

L

BLU

GR

NR

ED

TR

AN

BLK

BLU

WH

TB

LKB

LUB

LUW

HT

BLU

BLK

BLK

WH

TR

ED

RE

D

WH

T

WHT

WHT

RED

BLKBLU

WH

TR

ED

BLU

BLK

WH

TW

HT

WH

TR

ED

BLU

BLK

WH

TW

HT

BLK

BLK

FM

CA

P

GR

N

ALS

BLU

WH

TB

LU

BLK

BLK

OR

NR

ED

BLU

120V

WH

T

24V

YEL

RR

1 2 3

RE

D T

RA

NS

BLK TRANS

WHT TRANS

WHT TRANS

TRANSFORMER

RED TRANS

REDRED TRANS

BLK

EXISTING WHT

EXISTING WHT

RE

D T

RA

NS

BLU

BLK

WHT

FAN RELAY

BLU

YEL

EXISTING WHT

BLK

OR

G

FA

N/O

N/O

FF

SW

ITC

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BLU

—21—

© 1993 RESCO P.O. Box 1667, Indianapolis, IN 46206 14025c —22— Book/Tab: 1/3d 4/2d Catalog No. 92-33CB-BA1

Documents

Installation Instructions - dms.hvacpartners.comdms.hvacpartners.com/docs/1009/Public/0C/AG-CBBA-01.pdf · 7900/D, 7956/D, 7995C, DGRT and DLRS series, ... The installation instruction